EN 13616
Overfill prevention devices for static tanks for liquid fuels
Requirements and assessment methods for overfill prevention devices used with non-pressurised static fuel tanks.
Stop overfills before they become spills
Overfill protection for stations, depots, and mobile tanks
Overfill protection that fits everyday fuel logistics. Certified components, clear operator feedback, and a safety chain designed for filling stations, depots, and mobile tank systems.
Prevent overfill at delivery by monitoring the level limit and triggering a controlled shutoff of the loading or unloading process. Designed to integrate with common overfill probes and European interfaces for fuel logistics.
Fail-safe shutoffStops on limit, fault, or signal loss
The permissive chain is continuously monitored. If the signal chain breaks, the system transitions to a safe state.
EX-ready optionsHardware for hazardous areas
Selected system components are available in ATEX-certified variants for operation in hazardous areas.
Multi-tank workflowsSupport for parallel filling tasks
Implementations can support deliveries to multiple tanks with clear status feedback per channel.
Where overfills happen
Overfills are rarely one single mistake. They are usually a chain of small issues: missing tank data on site, unclear hose routing, parallel unloading, time pressure, and limited visibility in hazardous areas.
- Multiple tanks and compartments in one stop
- Night deliveries and limited visibility
- Manual checks and reliance on local experience
- Costly clean-up and reporting after an incident
Risk and cost exposure
Spills can trigger clean-up, downtime, and liability. Public case studies and regulator reports show that costs can scale from thousands per spill to very large losses in major incidents. Actual impact depends on location, product, and response time.
What changes with overfill protection
The operator gets a clear permissive status before pumping, continuous monitoring during unloading, and a defined shutoff on limit reach or fault. The result is a repeatable process that reduces reliance on ad-hoc judgement.
- Clear status feedback per channel
- Shutoff on overfill, fault, or connection loss
- Supports standard workflows at stations and depots
- Operational documentation via a defined safety chain
How it works
A certified safety chain from probe to shutoff valve ensures reliable overfill prevention in three steps.
- 1
Connect the safety chain
Connect the tank overfill probe interface (cable or radio system depending on configuration) and confirm readiness on the receiver or display unit.
- 2
Automatic permissive check
Before product transfer, the system verifies the signal chain. Only a valid chain enables the transfer process.
- 3
Continuous monitoring
During unloading, the level limit and signal integrity are monitored. Faults, disconnects, or radio loss are treated as unsafe conditions.
- 4
Controlled stop
If the level limit is reached or the safety chain fails, the system triggers a controlled stop of the transfer and shows the status for the operator.
Standards & Certifications
EN 13922
Overfill prevention systems for liquid fuels on tank vehicles
Minimum requirements for overfill prevention systems on tank vehicles for liquid fuels.
ATEX
Equipment for use in potentially explosive atmospheres
Depending on configuration and zone, components are available with appropriate hazardous-area certification.
Proof & success stories
Key metrics
- Buncefield incident: reported costs close to £1bn
- “≈ £1bn”
- Average cost per diesel spill incident (road diesel spills)
- “≈ $15k”
- EPA-reported median clean-up costs (selected states, sample)
- “$27k–$266k”
UK Major Incident Investigation Board reporting on the 2005 UK fuel depot incident.
Spill Center data cited by TruckingInfo, context is diesel spill incidents from trucks.
EPA study on leaking underground storage tank cleanup costs in selected US states.
“A defined safety chain helps standardise operations and makes it easier to demonstrate preventive controls during audits.”
Schedule a loading safety assessment
Our engineering team maps your loading racks, marine berths, and truck gantries to deliver a tailored retrofit plan.
