Document Title: Technical Bulletin Revision No: 1

Description: Installation and Inspection Issue Date: 06/01

Guidelines for the AUS25
Quick-Fill Tank Vents

The objective of this technical bulletin is to detail key information on the correct
installation, operation and maintenance of the Banlaw Quick-Fill Tank Vent.

NOTE: Please refer to the dedicated Banlaw Pipeline vent brochure for part
numbers and other specific product information.

1. Key Advantages of the Banlaw Vent

The Banlaw vent has a number of key advantages over equivalent competitors
products i.e. the Wiggins ZV10. The Banlaw vent has:

• A ¾” bore breather tube – the ZV10 has only a ½” bore. This enables
a single Banlaw vent to be used at flowrates up to 800LPM (210GPM)
without appreciable tank pressurisation, whilst flowrates between 800
and 1100LPM require 2 vents per tank
• Splash tube to provide protection against excessive turbulence or
splashing affecting the correct operation and orientation of the float
balls.
• All parts of the vent are manufactured from high quality cast
aluminium, machined aluminium, and zinc plated mild steel – selected
vent models
• All Banlaw vents incorporate o’ring seals, thus providing an extended
and a more reliable service life. Other manufacturers use flat “gasket”
style seals, prone to leakage and premature failure
• Banlaw manufacture a wide range of standard vent models to cater for
most tank designs and applications, including CAT and Komatsu
manual fill necks. Banlaw also offer custom designed vents to suit
unique installations
• Banlaw vents are available with a choice of 2 emergency relief
pressures; 110kPa (16psi) and 49kPa (7psi), to suit a variety of tank
designs. The relief setting of each vent is clearly identified by the
colour of the anodised aluminium vent cap; 49kPa (GREEN) and
110kPa (RED).
• A number of vent accessories are available to ensure the correct
installation of the vent is achieved easily

2. Function of the Quick-Fill Vent

The Quick-Fill tank vent was designed to be installed onto fuel and oil tanks fitted
with Dry-Break (or quick-fill) pressurised refuelling equipment. Its primary
functions are to:

1. exhaust air from the tank during normal filling, whilst creating minimal
back-pressure and thus tank pressurisation during filling

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 2. provide an air-tight seal within the tank once the fuel level has reached the
required level, thus creating pressurisation of the tank and upstream
delivery line in order to cause the refuelling nozzle to terminate the flow of
fuel into the tank
3. gradually allow the tank pressure to return to atmospheric pressure, by
passage of air through the 1/16” bleed hole
4. the emergency relief facility provides protection against overpressurisation
of the tank due to excess vapour pressure
NOTE: A Banlaw quick-fill tank vent is designed only as a partial relief device for
the range of flowrates used. It is designed to exhaust excess vapour pressure
from the tank, due to thermal expansion or otherwise. If required to exhaust
liquid fuel, the pressure within the tank will increase substantially . A full relief
device must be installed if comprehensive protection is required i.e. exhausting of
liquid fuel without a substantial rise in tank pressure. The Banlaw vent will begin
to open at the stated relief pressure, and will remain open until the tank pressure
decreases to a level below the vent relief pressure.

Options available with the vent include:

• a ¾” male nipple threaded into the vent exhaust port. This enables a
breather hose to be attached and thus route the discharge of tank
vapour to a safe or more convenient location = see also Section 5.2
• a 2” NPT female socket (or half coupling) which can be welded into the
tank top plate to securely locate the vent
• a vent box, so that the vent can be mounted on the side wall of a tank,
in instances where insufficient space exists on the top surface of the
tank, or when ready access to the vent is required
• a small Ryco air filter cartridge with a serviceable filter element, which
conveniently screws into the vent exhaust port. This filter prevents the
ingress of dust and other contamination into the vent and thus tank
through the otherwise open vent exhaust

3. Components of the Banlaw Vent

Figure 3.1 below details the components and essential features of the vent. Note
the 1/16” breather hole in the top flange of the valve.

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 Figure 3.1: Components of the Banlaw Quick-Fill Vent

The vent is fully assembled and tested at the Banlaw factory prior to sale. As with
all Banlaw products, each vent is covered by a 3 month manufacturers’ warranty
and is manufactured in accordance with Banlaw Pipeline company Quality
Assurance procedures, accredited by Lloyd’s Register of Quality Assurance
Australia (AS/NZS ISO 9001-1994).

4. Application of the Banlaw Vent

The vent is designed to accompany the Banlaw (or equivalent) refuelling nozzle
and the Banlaw (or equivalent) dry-break fuel receiver. The vents primary function
is to support the operation of the quick-fill refuelling system. It is distinct from
traditional “free-to-air vents” and other vent designs, and thus cannot be replaced
with other vent types or used for other purposes outside the scope of this
document without the express permission of Banlaw Pipeline. It can only be
classed as a “free-to-air” vent whilst ever the fuel level and thus float balls remain
at a low level so as to ensure the free passage of air through the vent valve. If the
fuel is at such a level so as to raise the float balls against the o’ring seal at the
base of the vent valve, thus effectively sealing the tank, the only unrestricted
passage of air from or into the tank will pass through the 1/16” bleed hole in the
top flange of the valve. This is to ensure any further filling of the tank is
discouraged by the resistance of air through the vent bleed hole and thus
pressurisation of the tank contents.

If additional fuel is forced into the tank i.e. if the automatic shut-off of the nozzle
is manually over-ridden, the emergency relief facility of the vent may be activated.
Sustained filling of the tank and thus relief of excess vapour will eventually
eliminate the ullage within the tank and hence cause overfilling. Once the ullage
in the vicinity of the vent has been eliminated, the vent will be forced to exhaust
liquid fuel. As mentioned earlier, such a task will increase the pressurisation of
the tank substantially creating the risk of tank rupture or some other catastrophic
failure.

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If in any doubt, contact your nearest authorised Banlaw distributor or Banlaw
Pipeline direct for confirmation of the correct vent application, prior to
installation.

5. Correct Installation Guidelines

The correct installation of the tank vent is crucial to the proper operation of the
Banlaw refuelling system. Incorrect or otherwise poor installation practice will
jeopardise the safety and reliability of the system. The Banlaw Quick-Fill refuelling
system is a “pressurised” system, and thus its inherent safety relies on the
installation being in accordance with the manufacturers’ guidelines.

Following are guidelines on the correct location and installation of the vent within
a tank.

NB: Refer also to Banlaw technical bulletins on multi-compartment tanks and

dual tank configurations for additional vent installation information.

5.1 Positioning the Vent in the Tank

The correct location of the vent can best be determined by considering the factors
affecting the vents operation:

a) Action of float balls: once the fluid level within the tank reaches a level
approximately equal with the second vent float ball (from the top), the
buoyancy force generated by the 3 hollow float balls force the solid ball
upwards onto the o-ring seal at the base of the vent valve. This effectively
seals the vent and thus subsequent flow of fuel into the tank will pressurise
the tanks’ contents. The solid ball remains against the seal whilst ever the
fluid level remains above a level approximately equal to that of the second
ball. Whilst the vent valve is sealed, air or fuel can only bypass the valve in 2
ways:
• Through the 1/16” breather hole
• Activating the emergency relief function of the vent, by overcoming the
force provided by the relief spring and thus lifting the valve flange from
its sealed “home” position. This will occur at any time the pressure
within the tank exceeds the emergency relief pressure of the vent.

b) generation of tank ullage: the tank ullage is the volume within the top of the
tank occupied by air/vapour. Whilst the value does vary, it is generally
required to maintain an ullage of 3-5% of the tank volume to account for
thermal expansion and the difference in time taken to both pressurise the
tank and create sufficient back pressure to close the refuelling nozzle. Due to
the standard range of quick-fill vents available and the vast array of tank
designs, delivery systems, flowrates etc., the proportion of ullage will vary.
The standard length of vent available does cater for the majority of tank
designs, although end-users must be aware that ullage will vary. Selection of
the correct vent model for an application is important if the required ullage is
to be maintained.
c) ullage and it’s role in the quick-fill system: as mentioned in point (b), the
generation of ullage depends upon the fluid level at which the vent closes, the

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 rate at which that level is rising, and the amount of back pressure required to
turn the nozzle off – see Technical Bulletin on Quick-Fill Nozzle Theory. If
these factors are too high, the risk of overfilling the tank is a real threat. Such
a problem leads to leakage from the vent – even after the nozzle has shut-off
– and the rapid overpressurisation of the tank due to the elimination of the
compressible air “cushion” normally within the ullage. The overpressurisation
of the tank is partially compensated for by the release of excess pressure
through the vent’s emergency relief facility, although forcing liquid fuel –
rather than air – through the vent relief requires significantly more force,
which must be provided by the rapid pressurisation of the tank. ELIMINATION
OF ULLAGE CAN CAUSE TANK RUPTURE OR OTHER SIGNIFICANT
DAMAGE. To minimise this risk, a number of key points needs to be
considered:

1. the position of the vent with respect to the highest point of the tank
volume is critical – many examples are shown in the following
drawings. In essence, some ullage must be maintained in the region
surrounding the vent. Allowing the fuel level reach the underside of the
vent body (top of the vent valve) will cause leakage from the vent bleed
hole and perhaps exhausting of fuel from the emergency relief valve.
To minimise this risk, the vent should be installed in the uppermost
section of the tank – see also point 3
2. ensure all manual fill caps, flanges, threaded fittings, and all other
fittings either mounted on the tank or hydraulically linked with the
tank, are air-tight. ANY SUCH LEAKS WILL DELAY THE
PRESSURISATION OF THE TANK AND HENCE DELAY THE SHUT-OFF
OF THE NOZZLE. Such faults will cause overfilling of the tank and
perhaps leakage of fuel from either the vent breather hole or relief
valve. NB: this also includes fuel supply or return lines from the
engine(s) linked to the fuel tank. In extreme circumstances, the engine
fuel circuit may delay the pressurisation of the tank due to fuel
bypassing the diesel pump etc. Low flowrates and high levels of tank
pressurisation further exacerbate this problem. Evidence of this
problem occurring is the engine revving or flooding once the tank
becomes pressurised.
NOTE: Banlaw manufacture a ¾” ball check valve which can be installed in the
fuel return line from the engine. This will prevent the pressurisation of the tank
forcing fuel back through the return line.
3. There is an inherent time delay between the vent closing and the
nozzle turning off. If the rate of fuel level increase surrounding the vent
is high (high ratio of flowrate : fluid surface area), then the level at
which the vent closes relative to the top surface of the tank is critical to
ensure ullage is maintained. Such examples are cylindrical tanks and
tall, narrow tank designs, Also, installing a vent into a manual fill tube
rising from the top of the tank will certainly cause problems. NB: The
vent may be installed in a manual fill tube provided the top of the tube
does not rise above the top of the tank – see Figure 5.6. For
applications such as tall narrow tanks and cylindrical tanks, Banlaw do
manufacture vents with an extended vent valve to ensure the
premature closing of the vent does maintain the correct tank ullage.

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Detailed below are various tank designs. Shown also are the correct and incorrect
locations for the installation of the Banlaw vent.

IMPORTANT: Each Figure is accompanied by text explaining the relationship

between the tank design and corresponding vent placement. The critical factors of
each application are mentioned, in addition to any comments regarding
limitations or restrictions for each case. It is important this text is read
carefully, as minor variations to tank design from that shown in an example
can alter the correct placement of the vent. To confirm the correct installation
of the vent prior to installation, contact your nearest authorised Banlaw
distributor or Banlaw Pipeline direct for assistance.

Figure 5.1: Bi-level Tank (1)

Figure 5.1 shows a tank design commonly used in vehicles where the fuel tank is
located beneath the engine. The scale of the tank may vary, but generally the
correct and incorrect vent locations shown do apply. The only exception to this is
when the width (and hence volume) of the upper region(s) at each side of the tank
are relatively insignificant compared to the width of the lower (central) level. Such
circumstances permit the installation of the vent onto the lower level, provided
the key points of this document are considered. NOTE: If minor spillage is
detected from the vent bleed hole at the completion of refuelling, an extended
series vent may be installed to create earlier vent shut-off and thus a slightly
reduced fuel level within the tank. Again, this will depend upon the relationship
between the volume differential between the upper and lower regions. Comments
on both Figures 5.2 and 5.4 should also be considered.

The purpose of the hose linking both upper regions of the tank is to equalise the
ullage pressure and thus fluid level between each region during pressurisation of
the tank after the vent has closed. This will become of increasing importance at
high flowrates and high levels of tank pressurisation.

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 Figure 5.2: Bi-level Tank (2)

Figure 5.2 illustrates a similar point to that described in Figure 5.1, and
subsequently carries the same precautions. Most importantly, the rate of fuel
level increase surrounding the vent must not be excessively high such that the
rate of tank pressurisation is rapid. Such events will lead to overfilling of the tank
and subsequent spillage of fuel from the vent bleed hole or relief valve if the tank
is overpressurised prior to nozzle shut-off.

Figure 5.3: Cylindrical Tanks

Banlaw manufacture a vent specifically for cylindrical tanks, or other tanks where
the rate of fuel level increase at the vent is high – see also Figure 5.4 below.

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 Figure 5.4: Tall Narrow Tank Designs

The purpose of the extended vent is to create an otherwise premature closure of

the vent and hence pressurisation of the tank contents. Such a need exists in
cylindrical tanks (Fig. 5.3), thin narrow tanks (Fig. 5.4), or other applications
where the standard length of vent is insufficient to create the correct tank ullage.
In essence, a rapid rate of fuel level increase in the upper region of the tank – in
which the vent is installed – will reduce the length of time between vent closure
and elimination of tank ullage (overfilling). This time is increased to that required
by extending the length of the vent valve and thus causing the vent to close
earlier. Sufficient ullage is created at the completion of refuelling, which would
otherwise not have been possible.

Figure 5.5: Short / Wide Tanks and the Effect of Gradient

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Figure 5.5 demonstrates an application typically encountered with lighting plants,
drilling rigs, and dewatering pumps. Wide tanks are particularly susceptible to
changes in gradient (slope) adversely affecting the quick-fill system.

Figure 5.5B will cause spillage from the vent, as the vent will close prematurely
and the relatively high percentage of ullage will take a longer period of time to
pressurise. By the time sufficient back pressure has been generated and thus
forced the nozzle into the off position, fuel has already begun to leak from the
vent breather hole.

The success of the situation depicted in Figure 5.5C depends upon the same
considerations given to cylindrical and tall, narrow tanks. The vent will not close
until the fluid level has reached the float balls, which in this situation is after what
would normally be the case with the tank level i.e. Figure 5.5A. Thus the tank will
be overfilled, and spillage may occur from the vent if the ullage is eliminated.

Locating the vent in the middle of the tank may negate the effect of gradient to
some extent, although the objective remains to maintain the tank in a level
position whilst refuelling.

Figure 5.6: Manual Fill Pipes

The installation of a quick-fill vent into the manual fill pipe of a tank is a
convenient option. The function of the vent and thus the quick-fill system will not
be adversely affected provided a simple factor is considered. When installing the
vent into the pipe, care must be taken to ensure the level of the float balls, with
respect to the main volume of the tank, is approximately the same as if the vent
was installed directly into the tank itself. To achieve this Figure 5.6A incorporates
the use of an extended vent valve, whilst Figure 5.6B illustrates a truncated
(shortened) fill pipe and a standard length vent. Either installation will work,
although for the purposes of simplicity, option B is preferred if space permits. NB:
Note the downward facing vent exhaust port to minimise the ingress of dust and
other foreign material into the vent cap.

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5.2 Routing the Discharge of Vent Exhaust

Regardless of where the vent is installed, care must be taken to ensure the
discharge of tank vapour – and liquid fuel in the case of a problem – is directed
away from heat and other ignition sources, and humans. Such a task is made
easier by the attachment of a breather tube onto the exhaust port to allow
routing of the discharge point to a convenient and safe location. Such a location
should also be clearly visible to the refuelling operator to ensure prompt
termination of fuel flow if the discharge of fuel is detected.

A length of breather hose or tube may be attached to the vent exhaust port using
either the optional ¾” male hosetail fitting, or directly over the 33mm diameter
“olive” at the end of the port. Ideally 1” hose should be used for longer distances,
and a minimum of ¾” hose for shorter distances. NB: For flowrates in excess of
say 600LPM per vent, a minimum of 1” hose is recommended to minimise the
restriction of air flow from the tank.

The free and unrestricted passage of air through the vent and the vent breather
hose (if attached) is critical to the proper operation of the quick-fill system. Any
excessive or abnormal restriction is analogous to the partial sealing of the vent
and hence partial pressurisation of the tank. Such pressurisation, although
appearing minimal, may be sufficient to cause premature shut-off of the
refuelling nozzle, thus only partial filling of the tank . Such restriction often
comes from dirt and mud built up in the end of the vent exhaust / breather hose,
commonly found on rail locomotives and mining vehicles where the breather hose
terminates behind a bogey or wheel. Other sources include kinks, small diameter
hose, and blocked filters (if fitted).

6. Vent Maintenance
The Banlaw vent is virtually maintenance free. The only regular maintenance an
end-user should perform is the inspection and clearing of the vent exhaust port or
breather hose – see section 5.2, and a general inspection to detect any damage
to the vent. To do this, the vent may be removed from the tank during prescribed
vehicle servicing and inspected for any noticeable defects, in particular damage to
the o’ring seal at the base of the vent valve, and the ingress of liquid fuel into any
of the hollow float balls. If these defects are detected, the vent must be replaced.
Removing the vent for inspection may only be necessary if a refuelling problem
associated with the vent is suspected – see section 7.

Based on market research recently conducted, Banlaw have derived a

“preventative maintenance plan” for its refuelling equipment. For the quick-fill
vent, it is recommended the vent be replaced every 3-4 years for mining use, and
every 5-6 years for railway use. These figures represent the recommended
exchange period, and will obviously vary according to the nature of the operating
environment.

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7. Troubleshooting

This section is designed to assist the end-user in identifying and rectifying

common problems associated with the Banlaw vent – in particular leakage of fuel
from the vent breather.

Most problems associated with quick-fill refuelling are incorrectly attributed to

the nozzle. Such problems as leakage from the vent exhaust are blamed on the
nozzle failing to shut-off at the correct pressure. Although in some cases the
nozzle is at fault, the majority of the time the cause of the problem is tank
related. For example, overfilling of the tank and subsequent leakage from the
vent breather is usually due to either incorrect vent placement or air leaks in the
tank i.e. welds, tank flanges, manual fill caps or threaded fittings, delaying the
pressurisation of the tank and subsequent nozzle shut-off. Such delays in nozzle
shut-off can also lead to rapid overpressurisation of the tank and subsequent
venting of vapour or liquid fuel through the emergency relief valve in the vent.

Performing a few simple checks may resolve the problem of a leaking vent

1. Check for diesel and air leaks in the tank and associated fittings
(particularly manual fill caps) – this is best done during tank
pressurisation prior to nozzle shut-off. Rectify any leaks found.
2. If the vent was installed by someone other than the OEM, an
authorised Banlaw agent or Banlaw Pipeline itself, confirm the vent is
installed in the correct location, as per section 5.1– consult Banlaw
Pipeline or an authorised distributor for assistance

NOTE: Refer also to Banlaw technical bulletins on multi-compartment tanks and

dual tank configurations for further information on those applications.

3. If manufacturing or modifying a tank, confirm the changes with Banlaw

prior to commencing work to ensure the quick-fill system will operate
correctly
4. Confirm the vent does effectively seal the tank prior to nozzle shut-off.
This is best done by placing your hand over the vent exhaust port or
breather and detecting the exhaust air from the tank whilst refuelling.
Once the fuel level has reached the required level, the float balls
should seal the vent thus terminating the flow of exhaust air. Once the
vent has sealed, a slight hissing sound will be heard indicating the
pressurisation of the tank and subsequent discharge of pressurised air
through the 1/16” vent breather hole. The nozzle should shut-off within
approximately 5-10 seconds after the vent has sealed – this value may
vary according to tank volume, flowrate, and the spring setting of the
nozzle. At no stage either prior to or after nozzle shut-off should
any leakage be detected from the vent

NOTE: If the nozzle fails to remain in the open (on) position until the tank is
pressurised by the sealing of the vent valve, check for excessive flow restriction in
the fuel delivery line between the fuel receiver and the tank i.e. partially closed
valve or a recently installed check valve etc. If no cause can be detected, Banlaw

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Pipeline or your nearest authorised Banlaw distributor agent should be informed
promptly and the details of the refuelling application explained.

NOTE: For information on the Banlaw refuelling nozzle, refer to the relevant
technical bulletin

5. Confirm the flowrate of fuel is within the range recommended for the
refuelling nozzle:
• Banlaw 21 and 800 series nozzles: 170-800LPM (45-210GPM)
• Banlaw 22 and 1000 series nozzles: 400-1000LPM (105-265GPM)

6. Confirm the recommended number of vents is installed on the tank:

• 80-200LPM (21-53GPM): single vent recommended
• 200-800LPM (53-210GPM): single vent recommended (4 max.)
• 800-1000LPM (210-265GPM): 2 vents recommended (4 max.)

NOTES: 1. The maximum number quoted in brackets should not be required,

unless either minimal (near zero) tank pressurisation is permitted
during refuelling, or the tank compartments / baffling has been
incorrectly designed – refer to technical bulletin on multi-compartment
tanks
2. These recommendations apply to Banlaw quick-fill vents only

Contact your nearest authorised Banlaw distributor or Banlaw Pipeline direct

should problems persist.

8 The Banlaw FillSafe System

The Banlaw FillSafe System is an electronic level sensing system, used in

applications where zero tank pressure is required. Once installed, FillSafe
becomes the primary system responsible for termination of fuel flow into the tank.
The refuelling equipment used is identical to that used in the standard Banlaw
refuelling system – the FillSafe equipment complements existing refuelling
equipment. In the vent of a failure to the FillSafe system, or if the system is
overridden, the tank will be pressurised thus causing the nozzle to shut-off as
would normally occur.

The FillSafe System has three key components:

• Float switch installed into tank (optic sensor or other switch types are
optional)
• Transmitter unit installed on vehicle
• Receiver unit installed at refuelling depot

To terminate fuel flow, the receiver unit may be connected to an in-line solenoid
valve or the pump control relay.

Additional information is available from the Banlaw Pipeline webpage

(www.banlaw.com) or from Banlaw Pipeline direct.

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Kind Regards

Adam Peattie
Product & Design Engineer
BANLAW PIPELINE Pty Ltd
Email: adam@banlaw.com.au

Disclaimer: The information supplied in this document is meant as a guide only.

Banlaw Pipeline Pty Ltd accepts no liability for any damage or event resulting
from the implementation of any content of this document. To confirm the correct
advice has been received, all details should be checked with an authorised Banlaw
distributor or Banlaw Pipeline direct prior to installation.

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