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Grounding and overfill protection system for Top Loading

A grounding and overfill protection system for top loading is a critical safety setup used in operations where flammable liquids or hazardous materials are transferred into tank trucks, railcars, or containers. Such systems prevent accidents caused by static electricity buildup, overfilling, and spills, ensuring safety for personnel, equipment, and the environment.

Here’s how such a system is designed and operates:

1. Grounding System

Grounding is essential to discharge static electricity and prevent ignition.

Key Components

  • Grounding Clamp: A high-quality, conductive clamp is used to establish a reliable connection between the tank truck/railcar and the grounding system.
  • Ground Verification Monitor: This device checks for a proper connection between the tank and the ground before loading begins. If the connection is not secure, the system prevents the transfer operation.
  • Static Discharge Reel: Provides a retractable grounding cable that ensures continuous grounding throughout the operation.
  • Grounding Rod or Earth Bond: Connects the grounding system to the earth to dissipate static charges safely.

How It Works

  • Before loading starts, the operator attaches the grounding clamp to a designated grounding point on the vehicle or container.
  • The ground verification monitor ensures the connection is secure. If the grounding fails, an alarm is triggered, and the loading process is halted.

Safety Standards

  • Systems typically comply with standards such as API RP 2003, NFPA 77, and IEC 60079-32 for static electricity control.

2. Overfill Protection System

Overfill protection prevents spills and ensures the safety of personnel and the surrounding area.

Key Components

  • Overfill Sensors/Probes: Installed in the tank or container to detect liquid levels. These can include:
    • Float Sensors
    • Capacitance Sensors
    • Optical Sensors
  • Control Unit: Monitors the signals from the overfill sensors. If the liquid reaches a critical level, it triggers alarms and automatically stops the loading process.
  • Emergency Shutoff Valve: Activated when the overfill protection system detects a high-level condition. This valve halts the flow of liquid into the tank.
  • Visual and Audible Alarms: Alerts operators when the liquid level approaches or exceeds the safe limit.

3. Integration of Grounding and Overfill Protection

Many systems integrate grounding and overfill protection into a single solution for convenience and enhanced safety.

  • Interlocking Mechanism: The loading process cannot begin unless both the grounding and overfill systems are properly engaged.
  • Automatic Cutoff: If either grounding is lost or the liquid reaches the high-level limit, the system stops the loading operation.
  • Centralized Control Panel: Operators can monitor both grounding status and liquid levels from a single interface.

4. Advantages

  • Prevents Static Discharge: Reduces the risk of fire or explosions.
  • Minimizes Spills and Environmental Impact: Ensures compliance with environmental regulations.
  • Increases Operational Safety: Protects personnel and equipment.
  • Regulatory Compliance: Helps meet safety standards like API 2350 and OSHA requirements.

5. Typical Applications

  • Loading flammable or combustible liquids like fuel, chemicals, or solvents.
  • Tank truck and railcar loading facilities.
  • Bulk storage terminals and distribution hubs.

By implementing a robust grounding and overfill protection system, facilities can ensure safe and efficient top-loading operations while complying with industry regulations.

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LNG tank gauging system combined with high measuring performance

A LNG  tank gauging system with high measuring performance is critical for ensuring accurate inventory management, safety, and operational efficiency in LNG storage and transport facilities. Combining advanced technologies, such systems provide reliable measurements of critical parameters like liquid level, density, temperature, and pressure in LNG tanks.

Key Components of a High-Performance LNG Tank Gauging System

Level Measurement:

  • Servo Tank Gauges: Highly precise, capable of measuring the liquid level, interface level, and density by utilizing a servo-driven displacer.
  • Radar Gauges (Guided Wave Radar or FMCW): Non-contact measurement, unaffected by temperature, pressure, or vapor conditions in LNG tanks.

Temperature Measurement:

  • Multiple-Point Temperature Probes: Measure temperature at various levels in the tank to account for stratification and provide accurate average temperatures.

Density Measurement:

  • Float-Based Density Measurement: Measures the density of LNG at specific levels for accurate mass calculations.
  • Thermal Density Probes: Combine temperature and density measurements for enhanced accuracy.

Pressure Sensors:

  • Measure vapor pressure and assist in calculating mass and volume using tank pressure and liquid density.

Tank Management Software:

  • Integrates measurements of level, temperature, and pressure.
  • Calculates critical values like gross and net volume, density, and mass.
  • Provides real-time monitoring and inventory management.

Safety Systems:

  • Integrated alarms for high/low level and temperature.
  • Overfill protection devices to ensure operational safety.

Features of High-Performance LNG Tank Gauging Systems

High Accuracy:

  • Systems achieve accuracies within ±1 mm for level measurement and ±0.1°C for temperature measurement, ensuring precise inventory control.

Cryogenic Compatibility:

  • Designed to function reliably in extreme low-temperature environments (below -160°C) common in LNG applications.

Real-Time Data Transmission:

  • Provides continuous and instantaneous updates on tank conditions, crucial for safe operation and decision-making.

Redundancy and Reliability:

  • Use of redundant sensors ensures reliability in case of equipment failure.
  • Advanced diagnostics to predict and prevent system malfunctions.

Remote Monitoring:

  • Supports integration with remote monitoring systems, allowing operators to oversee multiple tanks or facilities from a central location.

Compliance with Industry Standards:

  • Adheres to standards like API 625, ISO 20519, and OIML R85 for LNG measurement and storage.

Advantages

Optimized Inventory Management:

  • Accurate data on LNG levels and mass ensures proper inventory control, reducing losses and discrepancies.

Improved Safety:

  • Precise measurement reduces the risk of overfilling, spillage, or dangerous pressure buildups.

Cost Efficiency:

  • Accurate gauging minimizes waste and maximizes the value of stored LNG.
  • Reduced downtime through predictive maintenance and real-time monitoring.

Flexibility:

  • Suitable for fixed storage tanks, floating LNG (FLNG) facilities, and LNG carriers.

Leading LNG Tank Gauging Systems

Emerson Rosemount Tank Gauging System:

  • Features high-accuracy radar level gauges and multiple-spot temperature sensors.
  • Provides integrated solutions with inventory management software.

Honeywell Enraf LNG Tank Gauging:

  • Offers servo and radar level gauges with advanced diagnostic capabilities.
  • Integrated safety features for overfill prevention.

Kongsberg Marine Automation:

  • Combines level, pressure, and temperature sensors with high-performance software.
  • Designed for marine and shore-based LNG operations.

Endress+Hauser Proservo NMS80:

  • High-precision servo gauges designed specifically for cryogenic LNG storage tanks.
  • Combines density profiling with advanced data analytics.

Integration with Automation Systems

Modern LNG tank gauging systems often integrate with distributed control systems (DCS) and SCADA platforms, allowing for centralized monitoring, data analysis, and process control.

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Servo tank gauge inventory management applications

Servo Tank Gauges are highly accurate instruments widely used in inventory management applications for liquid storage tanks. They are especially valuable in industries like oil and gas, chemicals, petrochemicals, and food processing. Here’s an overview of their applications and benefits:

Applications of Servo Tank Gauges in Inventory Management

High-Accuracy Level Measurement

  • Purpose: Monitors liquid levels in storage tanks with high precision.
  • Use Case: Tracking inventory for crude oil, refined products, LNG, chemicals, and edible liquids.

Density Profiling

  • Purpose: Measures liquid density at different tank levels.
  • Use Case: Identifying product stratification or detecting contamination layers.

Temperature Monitoring

  • Purpose: Measures product temperature at multiple points in the tank using integrated temperature probes.
  • Use Case: Maintaining product integrity and ensuring accurate volume calculations.

Volume and Mass Calculation

  • Purpose: Converts level measurements into volume and mass using tank strapping data.
  • Use Case: Facilitates real-time inventory reconciliation and prevents discrepancies in supply chain operations.

Interface Detection

  • Purpose: Identifies interfaces between two immiscible liquids (e.g., oil and water).
  • Use Case: Critical in ensuring product purity during transfers and storage.

Overfill Prevention and Safety Systems

  • Purpose: Alerts operators of potential overfill situations to avoid spills and accidents.
  • Use Case: Regulatory compliance for hazardous material storage.

Remote Monitoring and Control

  • Purpose: Integrates with Distributed Control Systems (DCS) or SCADA for remote operation.
  • Use Case: Centralized inventory management across multiple tank farms or terminals.

Custody Transfer Operations

  • Purpose: Ensures highly accurate measurements for buying/selling liquid products.
  • Use Case: Certified for legal metrology standards to prevent disputes.

Key Advantages of Using Servo Tank Gauges

  • High Accuracy: Measures liquid levels with millimeter precision.
  • Reliability: Operates under challenging conditions (extreme temperatures, corrosive environments).
  • Automation Ready: Seamless integration with inventory management systems for real-time data.
  • Compliance: Meets international standards (e.g., API, ISO) for custody transfer and safety.
  • Cost Efficiency: Reduces manual intervention and improves inventory visibility, avoiding losses.

Why Use Servo Gauges for Inventory Management?

  • Minimizes product loss with real-time insights.
  • Enhances operational efficiency by integrating with ERP systems.
  • Ensures regulatory compliance with accurate reporting.
  • Prevents tank downtime with predictive maintenance alerts.
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Simplify your LNG Tank Gauging System from Field Control Room

Simplifying an LNG tank gauging system from the field to the control room can enhance usability and efficiency. Here’s how it can be done:

1. Integrated System Design

  • Guided Wave Radar: Use guided wave radar gauges for precise level measurements and reduce maintenance complexity.
  • Servo Tank Gauges: Implement servo gauges for accurate density, level, and mass measurements.

2. Centralized Data Processing

  • Smart Transmitters: Deploy transmitters that communicate directly with the control room via digital protocols like HART or Modbus.
  • Single Software Interface: Use integrated software that consolidates all measurement data in one dashboard.

3. Wireless Communication

  • Replace hard-wired systems with wireless communication for reduced installation complexity and enhanced scalability.

4. Automated Alarms and Alerts

  • Configure the system to send automatic alerts to operators for deviations like overfill risks, leaks, or sensor malfunctions.

5. Standardized Protocols

  • Use industry-standard communication protocols (e.g., OPC UA, MQTT) to ensure seamless integration with existing systems.

6. Real-Time Data Access

  • Equip the control room with real-time visualization tools for continuous monitoring of LNG levels, temperature, and pressure.
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A servo tank gauge is a device used to measure the level

A servo tank gauge is a precise measuring instrument used primarily in the oil, gas, and chemical industries to determine the level of liquids within storage tanks. This device operates based on servo mechanisms, providing highly accurate and continuous measurements of tank levels.

How It Works

  1. Suspended Displacer: A small displacer (a weighted object) is attached to a measuring wire or tape that is lowered into the tank.
  2. Servo Motor: The servo motor controls the movement of the displacer, lowering or raising it until it reaches the liquid’s surface.
  3. Balance Point: When the buoyant force of the liquid equals the weight of the displacer, the system identifies this as the liquid level.
  4. Measurement Signals: The position of the displacer is tracked, and the data is converted into electronic signals for precise level measurement.

Key Features

  • High Accuracy: Can measure liquid levels with millimeter-level precision.
  • Multi-parameter Measurement: Besides level, many servo tank gauges also measure temperature, density, and interface levels (e.g., between oil and water layers).
  • Remote Monitoring: Modern servo gauges can transmit data to a central control system for real-time monitoring and data analysis.

Applications

  1. Inventory Management: Used for precise liquid inventory in storage tanks.
  2. Custody Transfer: Ensures accurate measurement of liquids during transactions between parties.
  3. Tank Farm Operations: Tracks levels in multiple tanks for operational efficiency.
  4. Safety Monitoring: Prevents overfilling and reduces spill risks in tanks containing hazardous substances.

Advantages

  • Non-invasive: The gauge does not require immersion into the liquid for functionality.
  • Durability: Works effectively in harsh environments, including extreme temperatures and corrosive substances.
  • Integration: Compatible with other tank gauging systems like radar or ultrasonic for redundancy or comprehensive monitoring.

Servo tank gauges are crucial in industries that require accurate and reliable liquid level measurement for safety, compliance, and operational efficiency.

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The grounding and overfill protection system is designed for bottom loading of tank trucks

The grounding and overfill protection system is a critical safety mechanism designed for bottom loading of tank trucks, ensuring safe and efficient fuel or chemical transfer operations. Here’s how it works and its importance:

Key Features of the Grounding and Overfill Protection System

Grounding Protection

  • Prevents static electricity buildup during the transfer process, which could otherwise lead to dangerous sparks or fires.
  • The system typically includes a grounding clamp and cable connected to the tank truck and loading station.
  • Continuously monitors the connection to ensure proper grounding before and during loading.

Overfill Protection

  • Equipped with sensors to detect when the tank is nearing its maximum capacity.
  • Automatically shuts off the flow of liquid if the set fill level is exceeded, preventing spills and environmental contamination.

Integrated Monitoring and Control

  • Advanced systems often include indicator lights, alarms, and interlock features to ensure the process halts if grounding or overfill conditions are not met.
  • Centralized control systems allow operators to monitor multiple trucks simultaneously.

Compatibility with Bottom Loading

  • Specifically designed to integrate with bottom loading configurations, where the liquid is loaded into the tank from its lower sections.
  • Enhances safety and speed, as bottom loading reduces turbulence and vapor generation compared to top loading.

Advantages

Enhanced Safety

  • Mitigates risks of fire, explosion, and spills during transfer.
  • Ensures compliance with safety standards like NFPA, API RP 1004, or local regulations.

Environmental Protection

  • Prevents overfills that could lead to hazardous material spills, protecting soil and water from contamination.

Efficiency

  • Automation reduces human error and streamlines the loading process.
  • Real-time feedback ensures any issues are addressed immediately.

Regulatory Compliance

  • Many jurisdictions mandate grounding and overfill protection for hazardous liquid transfers, making this system essential for legal operations.

Components of the System

  • Ground Verification Monitor: Confirms the tank truck is properly grounded.
  • Overfill Sensors: Installed in the truck tank to detect high liquid levels.
  • Control Panel: Displays status indicators and activates alarms or interlocks.
  • Emergency Shutoff Valve: Automatically halts the flow of liquid if overfill or grounding issues are detected.
  • Interlock System: Prevents loading if grounding or sensor connection is incomplete.

Best Practices for Use

  • Regularly inspect and test the grounding and overfill system to ensure proper operation.
  • Train operators in the system’s use and maintenance.
  • Ensure compatibility between the truck and loading station systems to avoid connection issues.
  • Use in conjunction with vapor recovery systems to minimize emissions during transfer.

By integrating a grounding and overfill protection system, tank truck loading operations achieve a higher standard of safety, efficiency, and environmental stewardship.

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LNG tank gauging system for the oil and gas industry

An LNG tank gauging system is a specialized technology used in the oil and gas industry to monitor and measure the levels of liquefied natural gas (LNG) stored in cryogenic tanks. These LNG tank gauging systems are critical for ensuring operational efficiency, safety, and accurate inventory management. Here’s an overview of their functionality and applications:

Key Components of LNG Tank Gauging Systems

  1. Level Measurement Devices:

    Typically use radar gauges or servo gauges for precise, non-contact measurements in cryogenic and pressurized environments.

  2. Examples:

    Guided Wave Radar (GWR): Effective in measuring liquid levels and interfaces (e.g., LNG and vapor).

    Servo Tank Gauges: Measure levels with high precision using a float and servo mechanism.

  3. Temperature Measurement:

    LNG requires precise temperature monitoring to remain in its liquid state. Multiple temperature sensors are placed at different levels to track thermal gradients.

  4. Pressure Sensors:

    Measure the pressure within the tank, especially in pressurized LNG tanks, to maintain stability and detect anomalies.

  5. Density Measurement:

    Real-time density profiling ensures the accurate calculation of LNG mass and volume.

  6. Tank Management Software:

    Provides a comprehensive view of inventory, temperature profiles, and tank integrity.

  7. Offers remote monitoring and integrates with broader enterprise systems for logistical and safety planning.

Functions of LNG Tank Gauging Systems

  1. Inventory Management:

    Accurately calculate the LNG volume, mass, and energy content using level, temperature, and density data.

  2. Leak Detection:

    Early detection of leaks through pressure, temperature, and level inconsistencies ensures safety and reduces product loss.

  3. Tank Integrity Monitoring:

    Continuous assessment of tank conditions to detect structural issues or thermal stress.

  4. Operational Safety:

    Monitors parameters to prevent overfill, underfill, or sudden temperature/pressure changes that could lead to accidents.

  5. Transfer Management:

    Used during LNG transfer operations (loading and unloading) to ensure accurate accounting of transferred quantities.

Advantages of LNG Tank Gauging Systems

  • High Precision: Advanced sensors provide highly accurate level, temperature, and density data.
  • Non-Intrusive Technology: Radar and other non-contact gauges reduce the risk of contamination and maintenance needs.
  • Real-Time Data: Ensures continuous monitoring for operational efficiency and safety.
  • Integration: Easily integrates with plant management and SCADA systems for centralized control.
  • Regulatory Compliance: Helps meet stringent industry and environmental regulations.

Applications in the Oil and Gas Industry

  1. LNG Storage Facilities:

    Cryogenic tanks in terminals, refineries, and power generation plants.

  2. LNG Carrier Ships:

    Provides real-time gauging data for safe transportation.

  3. Regasification Terminals:

    Monitors LNG volumes and conditions before conversion back to gaseous form.

  4. Pipeline Operations:

    Tracks LNG quantities for billing and operational purposes during pipeline transfers.

  5. Floating Storage and Regasification Units (FSRUs):

    Used for offshore LNG storage and regasification systems.

Leading Technologies

  • Rosemount Tank Gauging System (Emerson)
  • Honeywell Enraf Tanksystem
  • Kongsberg Radar Gauging
  • Saab TankRadar

LNG tank gauging systems ensure precise and safe management of LNG assets, making them indispensable in the highly regulated and safety-conscious oil and gas industry.

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Servo Tank Gauge & Flowmeters

Servo tank gauges and flowmeters are essential instruments in liquid inventory management, offering precise measurement and monitoring of liquid levels, density, and flow rates within tanks and pipelines. Here’s an overview of their functions, applications, and advantages:

Servo Tank Gauge

Functionality:
Servo tank gauges operate using a servo-driven mechanism that accurately measures the level and density of liquids in storage tanks. The gauge’s weight, typically suspended by a cable, is lowered into the tank until it detects the liquid surface, then retracts slightly to ensure a stable reading. This precise control allows servo gauges to measure even slight changes in liquid level and density.

Applications:

  • Oil and Gas Industry: Monitoring crude oil, refined products, and other liquid hydrocarbons in tank farms and refineries.
  • Chemical Industry: Measuring levels of chemicals in tanks, ensuring safe storage and handling of hazardous substances.
  • LNG and Cryogenic Storage: Accurate measurement in low-temperature environments for liquefied natural gas (LNG) and other cryogenic applications.

Advantages:

  • High Accuracy: Offers very precise level and density readings, crucial for inventory control and loss prevention.
  • Density Measurement: Some models provide density measurement by sampling at various depths, aiding in identifying stratification or contamination within the tank.
  • Remote Monitoring: Many servo gauges integrate with remote monitoring systems, allowing operators to track levels in real time.
  • Compatibility with Inventory Management Systems: Easily integrates with modern automation and inventory management systems for efficient data handling.

Flowmeters

Functionality:
Flowmeters measure the rate of fluid flow within pipelines or process streams, with various types available for different fluids, pressures, and environments. Common flowmeters include ultrasonic, magnetic, turbine, and Coriolis flowmeters, each suited to specific fluid types and conditions.

Applications:

  • Water and Wastewater Treatment: Measuring flow rates of water and treated effluent in municipal and industrial treatment plants.
  • Oil and Gas: Monitoring oil and gas production and pipeline transport.
  • Chemical Processing: Ensuring precise flow rates in chemical production processes to maintain consistent product quality.
  • Pharmaceutical and Food Industries: Ensuring accurate measurements for quality control in production processes involving fluids.

Advantages:

  • Versatility: Flowmeters are available for various flow conditions, from low-viscosity liquids like water to dense and viscous fluids like crude oil.
  • Real-Time Data: Provides real-time monitoring, which is essential for process control and operational efficiency.
  • High Accuracy: Flowmeters such as Coriolis and ultrasonic types offer precise measurements, ideal for applications where flow consistency is critical.
  • Energy Efficiency: Many modern flowmeters are designed to minimize energy consumption, which can be important in large-scale applications.

Integration of Servo Tank Gauges and Flowmeters

Together, servo tank gauges and flowmeters offer a comprehensive approach to inventory and process management by accurately monitoring both the stored volume and the transferred flow rates of liquids. Integrated into automated inventory systems, they provide valuable real-time data, essential for optimizing production, preventing overflows, and ensuring safety in industrial operations.

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Portable density meter measures the density within seconds

A portable density meter is an efficient tool for quickly measuring the density of liquids, solids, or slurries in just seconds. These devices are commonly used in industries like manufacturing, pharmaceuticals, and food processing, where fast and accurate density measurements are required for quality control and product consistency.

Features of a Portable Density Meter:

  1. Fast Measurements: These meters deliver density results within seconds, providing immediate feedback.
  2. Compact and Lightweight: Their portability makes them ideal for on-site use or field testing without needing a laboratory setup.
  3. Ease of Use: They typically feature user-friendly interfaces, such as touchscreens or simple button operations, for quick deployment and readings.
  4. Versatility: Some models can measure a wide range of substances, from liquids to solid materials, depending on the design.
  5. Accuracy: High-precision models can measure density with great accuracy, ensuring quality standards are met.

These meters are ideal for applications where rapid testing is crucial, such as in:

  • Quality control of liquids and chemicals.
  • Density-based sorting of raw materials.
  • Field testing in environmental or industrial settings.
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Grounding and Overfill Protection System for Top Loading

A grounding and overfill protection system for top loading is critical in industries that handle flammable or hazardous liquids, such as oil, chemicals, and petrochemicals. These systems ensure safety during loading operations by preventing static discharge and overfilling, which can lead to spills, fires, or explosions.

Key Components and Functions:

  1. Grounding System
    • Purpose: Prevents static electricity buildup by safely grounding the tank or vehicle receiving the liquid.
    • Operation: When a truck or container is top-loaded, the grounding system provides a secure connection between the loading equipment and the grounded earth point. This dissipates any static electricity generated during filling, preventing sparks.
    • Monitoring: Modern grounding systems often include continuous monitoring, confirming a secure ground connection before and during the entire loading process. If the ground is lost, the system typically halts loading, ensuring safety.
  2. Overfill Protection System
    • Purpose: Prevents spills by shutting off the filling process when the tank reaches a predetermined capacity.
    • Sensors: Uses high-level sensors or probes installed in the tank to detect liquid levels. Once the level approaches a safe limit, the system signals to either alert the operator or automatically halt the flow.
    • Automatic Shutoff: In some systems, the overfill protection can engage an automatic shutoff valve or pump cutoff, stopping the flow immediately when the maximum level is detected.
  3. Interlock Mechanism
    • Purpose: Ensures that loading will not begin unless grounding is properly established.
    • Process: The grounding system is interlocked with the loading equipment, requiring confirmation of proper grounding before valves open or pumps start. This prevents accidental ungrounded loading and reduces the risk of static-induced incidents.

Benefits of a Grounding and Overfill Protection System for Top Loading:

  • Enhanced Safety: Mitigates risks associated with static discharge and overfilling, protecting both personnel and infrastructure.
  • Environmental Protection: Prevents spills and leaks, reducing environmental contamination and the potential for costly cleanup.
  • Regulatory Compliance: Helps meet safety standards and regulations for handling and transporting hazardous liquids.
  • Operational Efficiency: Reduces downtime and potential incident response, providing a safe, efficient loading process.

Applications

These systems are commonly used in:

  • Oil and Gas Refineries: For safely loading tanker trucks and railcars.
  • Chemical Processing Plants: In top-loading operations with volatile or corrosive chemicals.
  • Fuel Depots and Terminals: For handling gasoline, diesel, and other fuels in bulk.

This combination of grounding and overfill protection provides a complete safety solution for top-loading operations in hazardous environments.