Petroleum Tank Truck Industry

Bottom-Loading and
Vapor Recovery
An overview on the development of bottom-loading and
vapor recovery in the petroleum tank truck industry.

By: Robert Koeninger, General Manager of Dixon Bayco Division

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 1

CONTENTS
Introduction.................................................................................................................... 3

Petroleum Tank Truck Bottom-Loading and Vapor Recover........................................... 6

Traditional Top-Loading ................................................................................................. 7

Problems Associated with Top-Loading......................................................................... 7

The Bottom-Loading Process......................................................................................... 8

Vapor Recovery............................................................................................................ 11

Overfill Protection......................................................................................................... 15

Vapor Processing at the Terminal................................................................................ 16

Bottom-Loading and Vapor Recovery Equipment......................................................... 16

2 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

INTRODUCTION
In the drive to improve workplace safety and lower operating costs, North American
oil companies partnered with the transportation industry to develop the concept of
bottom-loading petroleum tank trucks. Starting in the 1950s, the concept led to an
industry-wide adoption of a new tanker product: a valve that permitted both loading
and unloading through a common valve located at the bottom of the tanker. This
valve has a special nose design, which, along with a mating dry break coupler (on the
terminal loading arm), allows for the fast, safe connection, and transfer of petroleum
from the terminal to the tank truck.

The advent of bottom-loading, combined with other tank truck improvements, made
possible entirely new systems for the containment and collection of petroleum vapors.
Petroleum vapors were previously exhausted to the atmosphere when loading and
unloading tank trucks. This vapor recovery ability became vital as the U.S. Clean Air Act
and similar legislation worldwide demanded lowering of airborne pollutants to protect
the environment.

Petroleum
PetroleumTank
TankTruck
TruckIndustry
IndustryBottom-Loading
Bottom-Loadingand
andVapor
VaporRecovery
Recovery 3
PETROLEUM TANK TRUCK
BOTTOM-LOADING AND
VAPOR RECOVERY

Illustration A illustrates typical tank truck Manholes at the top of each compartment
construction. Petroleum tankers are usually typically include a hatch for inspections or
divided into compartments, each of which can top-loading, and a compartment vent, which is
carry a different grade of fuel. An emergency connected to the vapor plumbing.
valve at the bottom of each compartment
controls the entry and exit of petroleum to/
from the compartment. Piping connects the
emergency valve to the bottom-loading API valve
(for loading and unloading).

Illustration A: Typical Petroleum Tank Truck Construction

Compartment Manhole to compartment Hollow rail to transfer vapor

Vapor piping

SIDE
VIEW Rubber Ti
res

50
P SI/
19
76
Rubber Ti
res

50
P SI/
19
76
Rubber Ti
res

50
P SI/
19
76
Rubber Ti
res

50
P SI/
19
76
Rubber Ti
res

50
PS
I/1
9 76

Vapor valve
API load/unload valves

Manhole assembly

Vent
TOP Hatch Hollow rollover rail
VIEW API Valves

Gasoline piping to compartments API valves Vapor valve Vapor piping

BOTTOM
VIEW

Emergency valves, control entry/exit to compartments

4 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

TRADITIONAL TOP-LOADING

Many parts of the world still employ traditional

top-loading technology to fill petroleum tank
trucks. These loading terminals typically have an
elevated gantry, which allow operators to walk dynamically generated sparks are extremely
on top of the tank to open the manhole and drop dangerous, and, when combined with gasoline
fuel into each compartment (see Illustration B on vapors, can cause catastrophic explosions.
page 6).
2. Operator safety: Operators have fallen from the
When unloading at the service station, drivers are top of tankers with grave consequences. Top-
often required to climb on top of the tanker and loading operators are also exposed to gasoline
open the compartment manholes to: fumes, which can cause health problems. Today
1. Measure the drop with a dip stick some jurisdictions have prohibited or restricted
2. Assure the station operator of a full load the operators’ presence on the top of the tank
3. Allow air into the compartment when truck during loading and unloading.
dropping fuel
3. Product contamination: With compartment
The manholes are subsequently closed once manholes open during top-loading, the
the discharge is completed. Manholes with opportunity exists for rain, snow, and wind-
pneumatic vents or use of mechanical vents are blown dirt to contaminate the product. Aircraft
often employed to eliminate the need to have fuels are particularly sensitive to minute forms
operators on top of tankers opening and closing of contamination. Pens, screwdrivers, and
manholes. cigarettes are items that have accidentally been
dropped into manhole compartments causing
PROBLEMS ASSOCIATED WITH contamination, damage, and malfunction of
TOP-LOADING emergency valves and downline equipment.

As shown in Illustration B (page 6), top-loading 4. Time loss: Typically, top-loading permits only
of gasoline generates considerable turbulence one compartment to be filled at a time. With
as well as venting of fumes to the atmosphere. bottom-loading, multiple compartments are
The following list of problems associated with loaded simultaneously. Faster loading reduces
top-loading may be minimized by bottom-loading the time the tank truck is waiting at the terminal
systems. and greatly improves loading and delivery
efficiency.
1. Static/dynamic sparks: Top-loading is prone to
excessive turbulence. Splashing and the turbulent
flow of petroleum can cause static electricity
build-up (even when tankers are grounded). In
addition, operators scrambling or walking on
tankers can accidentally scrape or strike the
tanker and discharge a spark. Both static or
Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 5
Illustration B: Petroleum Tank Truck Top-Loading at Terminal

Fuel from storage terminal

Terminal platform Closed manhole Vapor out Open manhole

Fuel in
Turbulence

Rubber Rubber Rubber

Rubber Tires Tires Tires
Rubber Tires
Tires

50 50 50
50 50

PS

PS
PS
PS

I/1

I/1
PS

I/1

97
I/1

97
97
I/1

97

6
97

6
6
6
6

Unloading valves

Illustration C: Petroleum Tank Truck Bottom-Loading at Terminal (no vapor recovery)

Terminal loading arm

Vapor out
(vapor can exit through installed vent, not shown)

Liquid in

Rubber Ti Rubber Ti Rubber Ti

Rubber Ti res res res
Rubber Ti res
res
50 50 50
50 PS PS PS
50 PS I/1 I/1 I/1
PS I/1 97 97 97
I/1 97 6 6 6
97 6
6

API valves

Fuel from storage terminal API terminal coupler

THE BOTTOM-LOADING PROCESS

Illustration C (above) shows the typical bottom- Petroleum Institute (APl). This cooperative effort
loading systems which were commonly applied has resulted in a common specification for
prior to the introduction of vapor recovery. loading valves, as well as a standardization of
coupling equipment at the petroleum terminals
The key to bottom-loading is the API valve, which (see Illustration E on page 8). The API valves are
was developed by the oil and transportation placed low on the tanker and connected by piping
industry through participation in the American to each compartment. There is one API valve

6 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

Illustration D: Petroleum Tank Truck Droppping Fuel at Service Station
(no vapor recovery)
Vent to atmosphere

Air in (air can enter through installed vent, not shown)

Vent stack

Liquid out

Rubber Rubber Rubber

Rubber Tires Tires Tires
Rubber Tires
Tires

50 50 50
50 50

PS

PS
PS
PS

I/1

I/1
PS

I/1

97
I/1

97
97
I/1

97

6
97

6
6
6
6

API valves

Vapor out

Liquid in

per compartment. Petroleum is pumped through terminal coupler is designed to minimize leakage
the loading arm system at the terminal, via the of petroleum when connecting or disconnecting
API valve, piping, and emergency valve, and into (see Illustration E on page 8).
the tanker compartment. An emergency valve
is located at the bottom of each compartment, By far the most popular style of API coupler is
which controls the entry and exit of petroleum. the load/unload model, which has a handle.
Bottom-loading results in fast, smooth flow filling The handle opens the API poppet at the service
of the compartment, with minimum turbulence. station and allows for gravity unloading of the
Gravity unloading of each compartment is compartment.
accomplished by connecting a drop hose from
the API valve to the underground tank collar, then The second style (no handle) is activated only
manually opening the emergency valve and API at the terminal by the dry break API coupler
valve to drain the compartment. during loading (this load-only valve is passive
when unloading). Unloading will typically be
The API valve is a spring-loaded poppet valve done through a second valve such as a faucet
with a special coupling nose design and a or butterfly valve, in conjunction with ''Y'' shaped
mounting flange. At the terminal, a loading plumbing or a special ''Y'' valve. Load-only APls
arm with a special mating coupler attaches to are also used with manifold systems.
and opens the API valve. This ‘’dry break’’ style

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 7

Illustration E: API Valve and API Coupler Mate at Terminal
API valve and API coupler mate and lock together, allowing terminal to pump petroleum through the valve into the tank
truck

Handle operates plunger,

which opens API valve poppet

Petroleum Poppet
to compartment

Attached Attaches to
to piping on loading arm
tanker at terminal

Poppet
Petroleum
Sight glass from terminal

API valve API coupler

(load/unload model)

Illustration F: API Valve Connection to Drop Hose at Service Station

Petroleum
to compartment
API handle shown
in open position

Hose coupler
and hose
Poppet
API valve is open
Drop adapter

Hose connects
to drop elbow

8 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

Illustration G: Application of Load-Only API Valve
Typical “Y” plumbing with load only API

API coupler
''Y'' plumbing is sometimes API valve (load only)
available with a built-in
control valve. This item is
called a ''Y'' valve

Attaches to
Attach
loading arm at
loadin
Y plumbing terminal
termin

Unload adapter where various

configurations are possible and will
include a valve to control flow and an
Attaches adapter/coupler for connection of
to tanker plumbing discharge hose to service station tanks

Butterfly valve

VAPOR RECOVERY vapors be collected from underground service

station tanks and transported to the terminal for
processing. The introduction of stage 1 vapor
The U.S. Clean Air Act legislated major reductions recovery requires modifications to the service
of atmospheric hydrocarbon pollution. Studies station, tank trailer, and terminal equipment.
have shown that up to 95% of emissions from the Modifications include a separate vapor transfer
transportation of petroleum could be contained port to the underground tank. This two-point
for recycling. As a result, the petroleum industry vapor recovery system requires both a vapor and
began to seriously examine gasoline vapor a fill port. A single-point vapor recovery system
emissions and controls. Although attempts uses the drop piping to transport using a special
have been made to develop top-loading vapor coaxial elbow. Two-point systems are preferable
recovery systems, the advent of bottom-loading due to faster unloading.
provided superior vapor recovery technology.
Today, bottom-loading vapor recovery technology Stage 2 vapor recovery involves the prevention
dominates and has been applied worldwide. of automobile tank vapors from escaping using
special nozzles and additional modification
Vapor recovery involves the prevention of to service stations. This whitepaper will deal
gasoline vapors escaping to the atmosphere only with stage 1 vapor recovery. However, an
during the loading and unloading process. This illustration of stage 2 vapor recovery is provided
is called ''stage 1 vapor recovery''. It requires that (see illustration J on page 12).

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 9

Illustration H: Stage 1: Vapor Recovery at the Terminal Service Station
Petroleum tank truck bottom-loading at terminal (with vapor recovery)

Terminal loading arm

Vapor out (through vent)

Vapor
Liquid in
piping

Rubber Ti Rubber Ti Rubber Ti

Rubber Ti res res res
Rubber Ti res
res
50 50 50
50 P PS PS
50 P SI/ I/1 I/1
P SI/ SI/ 19 9 76 9
19 19 76 76
76 76

Vapor valve

API valves

Fuel from storage API terminal coupler

terminal

Petroleum Tank Truck Dropping Fuel at Service Station (two-point vapor recovery system)

Air in (through vent)

Vent stack

Vapor
Liquid out piping

Rubber Rubber Rubber

Rubber Tires Tires Tires
Rubber Tires
Tires

50 50 50
50 50
PS

PS
PS
PS

I/1

I/1
PS

I/1

97
I/1

97
97
I/1

97

6
97

6
6
6
6

API valves Vapor valve

Vapor out

Liquid in

10 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

Petroleum Tank Truck Dropping Fuel at Service Station (single-point
vapor recovery system)

Vent stack Air in (through vent)

Vapor
Liquid out
piping

Rubber Rubber Rubber

Rubber Tires Tires Tires
Rubber Tires
Tires

API
50 50 50
50 50

PS

PS
PS
PS

I/1

I/1
PS

I/1

97
I/1

97
97
I/1

97

6
97

6
6
6
6

valves Vapor valve

Coaxial
elbow

Vapor out

Liquid in

Illustration I: Tank Truck with Hook-up at Service Station with Vapor Recovery

Compartment manhole and vent

Safety vents

V
A
P
O
R APIs
Vapor return valve
Vapor hose coupler

Hose
Drop coupler Elbow inlets
adapters Hose
coupler

OR
VAP EL
Vapor hose FU
coupler

Vapor elbow Drop elbow

Vapor cap Locking fill cap

Vapor adapter Fill adapter

Vapor from underground tank Fuel to underground

tank
Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 11
Illustration J: Stage Two Vapor Recovery
Air in

Vapor to
atmosphere

Liquid out

Without stage two: vapors from auto gasoline tank escape to atmosphere when filling at service station.

Coaxial nozzle Coaxial hose

Vapor in

Liquid out

With stage two: vapors from auto gasoline tank are collected and returned to underground service.

12 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

OVERFILL PROTECTION

Overfill protection has evolved and become

more complex, especially with the adoption of
sealed transportation systems that do not allow
for visual inspection. Bottom-loading and vapor Early mechanical overfill protection systems,
recovery applications are two examples of sealed such as floating ball cut-off devices and
systems. As automation increases, so too does pneumatic Venturi cut-offs, could not easily be
the danger of overfilling compartments. This can checked and were found inconsistent. Today
occur when: the only reliable and verifiable performing
• Incorrect information is given to the pump/ equipment is electronic monitoring systems.
metering device at the terminal These electronic overfill protection systems work
• There is a failure of the pump/metering device in conjunction with terminal equipment to serve
• Operators attempt to fill an already full as a secondary shut-off mechanism should the
compartment terminal loading equipment fail, or when operator
• Tankers return to the terminal with an error results in an overfill situation.
undelivered partial load

Illustration K: Tank Truck with Overfill Protection

Top view

Overfill protection
sensor mounts on
manhole cover.
Sensors can be
mounted on bottom
of compartments to
indicate when
empty.
Vapor rail

Electronic socket transfers Terminal

sensor information to control panel
terminal control panel

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 13

Electronic overfill systems typically consist of:

• An electronic sensor located at the interior top

of each compartment, usually mounted on
manhole covers. The sensor signals if it is wet
or dry.
• Bottom sensors, which are sometimes In some locations, gasoline vapors are collected
installed to check if the compartment is but not processed. They are simply burned
empty. (flared) into the atmosphere.
• An electronic socket on the bottom exterior
of the tanker, which is electronically
connected to each sensor. The socket BOTTOM-LOADING AND VAPOR
includes physical grounding. RECOVERY EQUIPMENT
• The Dixon FT7000 rack overfill monitor
at the terminal loading rack, which is
connected by cable to the tanker socket. Manholes and Manhole Accessories
The monitor continuously checks each Manholes provide personnel entry to the
sensor to permit the pumping of petroleum. petroleum tanker compartment. Manholes
If a sensor becomes wet, the signal is typically come in diameters of 16” and 20”.
interrupted and immediately shuts down They consist of a ring welded to the top of the
the rack pumping equipment. A shut-off signal compartment onto which the manhole cover is
can result from the top sensor changing from mounted. The cover is typically manufactured
a dry to a wet signal signifying the with mounting locations for ancillary items, such
compartment is overfilled. At the terminal, as an inspection hatch, vapor vents, and overfill
if the bottom sensor is wet (signifying a protection sensors.
compartment is not empty), loading will be
prevented. There are several accessories that can be
mounted on manholes. The most important
VAPOR PROCESSING AT THE is the emergency vent, which is designed as a
surge suppression relief valve. It will open in case
TERMINAL
of an emergency, such as the overfilling of the
compartment (preventing excessive pressure
Petroleum vapors collected at the terminal are buildup), or for pressure relief in case of a fire,
typically processed through large reactors filled which can cause tanker pressure buildup. These
with activated carbon. The activated carbon acts vents open when pressure exceeds approximately
as a filter, trapping the hydrocarbon molecules. 3.6 PSI. This 10” vent is also a hatch, which can
When saturated, the molecules are drawn off be manually opened for filling the compartment
the carbon by vacuum, and the resulting product or for inspections. The emergency surge vent is a
is condensed and reintroduced to the gasoline mandatory requirement for North American (DOT
manufacturing process. There are typically 406) petroleum tank trucks and has a very high
two reactors. As one reactor is collecting the venting capacity.
hydrocarbons, the other is under vacuum,
discharging the vapor by product.
14 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery
Another required accessory is a “normal” or
PV vent, which is usually thread mounted and
protrudes to the underside of the cover. This
small, limited capacity vent compensates for
ambient-temperature-generated pressure or
vacuum build­ups. This in-and-out breathing vent
moderates compartment conditions close to Tank trucks equipped for vapor recovery will have
exterior atmospheric pressures. the vapor vent adapter connected to the vapor
piping systems using a short length of hose.
Other accessories mounted on manhole covers Some mechanical vents may need special hoods
can include a vapor vent (described below) and (metal or rubber) with spouts to connect to the
overfill protection sensor. vapor plumbing.

Pneumatic vapor vents

Manhole shown
with typical Hatch/emergency vent
accessories

Overfill Sequential vapor vent-threaded

protection VR6030SQ
sensor

Vapor vent
with attached hose
Sequential vapor vent-TTMA flange
VR6035SQ
VAPOR VENTS
Vapor vents are required to allow air/vapor into
or out of the compartment during loading and EMERGENCY VALVES
unloading. They prevent a vacuum or pressure The emergency valve (sometimes called a foot
buildup in the compartment and allow for smooth valve) controls the entry and exit of petroleum
and rapid filling or unloading. from the tanker compartment. Located at the
bottom of each compartment, the emergency
Today, vapor vents are generally mounted onto valve is connected to the API valve by piping
the manhole and are pneumatically operated. and can be either mechanically or pneumatically
Pneumatic manhole mounted vents are popular operated. The emergency valve is designed to
because they can be controlled by air valves and minimize turbulence and spray of petroleum and
are normally operated with the emergency valve therefore reduce the possibility of generating
by a pneumatic control box on the tanker. The static electricity.
operator simply pulls the control knob for the
required compartment. Pneumatic vents can also The emergency valve remains shut and prevents
have a built-in sequencing feature to verify all compartment discharge should a vehicular
vents are open prior to loading. collision occur. For example, if an automobile
Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 15
Dixon as a Solution
Did you know that Dixon Bayco offers
solutions to your bottom-loading and collides with the tank truck undercarriage,
vapor recovery challenges? the emergency valve will automatically close
or remain shut, preventing the product in the
API drop adapters: compartment from escaping. A shear groove on
• Materials: the exterior of the emergency valve is designed
body - aluminum, to break away along with the piping leading to
seals - Baylast, FKM, the API valve. However, the main poppet (valve)
Buna-N is designed to remain closed and intact on
• Sizes: 3” and 4” the inside of the compartment. The danger of
• Options include product discharge is therefore limited to the short
models with built-in length of plumbing between the shear section
sight glass and the API. The breakaway design prevents the
compartment contents from being discharged
Vapor recovery elbows: and causing a more dangerous situation.
• Materials:
body - aluminum, Typical Pneumatic Emergency Valve
seals - Baylast, Buna Attachment for rod connecting
• Options include handle to vapor vent (if required)

styles such as D, push- Valve (spring-loaded, normally closed)

on, ball lever, and elbows Tanker compartment bottom

with or without a poppet Flange mounting to

bottom of tanker (bolt on)

Shear groove
Vapor recovery Groove pipe connection
couplers: for plumbing to API (flange
mounting models also available)
• Materials: Pneumatic cylinder
body - 356T6 AL, which activates valve

seal - Buna-N A. In an emergency, this section with closed valve

• Size: 4” x 3” inside the compartment remains with tanker.
• Options include a
probe connected B. In an emergency, this section (outside the
compartment) is designed to break away at the shear
to a spring-loaded groove, along with the piping to the API valve.
poppet or couplers
only with a probe
The trend is to pneumatically operate emergency
valves. However, mechanically activated
emergency valves (controlled by cable operated
levers) are still in use. Mechanical emergency

16 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

valves often control vapor vents via a metal rod
connected to both. The emergency valve and
vapor vent operate simultaneously. Both items
are opened during the loading and unloading
process. Both remain closed at all other times.

AIR INTERLOCK VALVES

Air interlock valves are simple, plunger-activated
air valves that are linked to the truck airline
system and used to direct pressurized air to
activate other pneumatic devices on the tanker.
There are many variations of air-activated
Standard air interlock model
systems used by transporters. Emergency valves, 5000AIHD
vapor vents, and trailer air brakes are commonly
controlled devices. Air interlocks are often
mounted on API valves, vapor valves and safety
bars and can be activated by coupling of hose,
or terminal dry breaks, or by operating the safety
bar. Air interlocks allow for improved safety,
reduced operator error and improved automation Air interlock with valve paddle plunger
when loading and unloading petroleum. Several 5000AIVHD
air interlocks are often found on petroleum
trailers.
At the service station, a drop hose is connected
API VALVES to the handle model API valve. The other
There are two basic styles of API valves: those hose end is connected to the drop elbow
that can be opened with a handle and those with and the underground tank pipe. Gasoline is
no handle. By far the most popular product is gravity transferred from the tank truck to the
the handle model; it allows for both loading and underground tank when the API valve is opened
unloading of the tanker through this common by use of its handle (see illustration F on page 8).
valve.
Load-only APls (no handle) are not utilized during
Both API models are spring-loaded, 4” poppet service station drops. Flow is controlled by a
valves, which at the terminal mate with a separate “Y” valve or “Y” plumbing with a faucet
specially designed API dry break coupling. or butterfly valve (see illustration G on page 9).
The nose/coupler geometry of the API valve is Older style manifold systems can also employ
made to a specific standard (API recommended load-only API valves.
practice API RP1004:2003). The two items, the
API valve (on the tank truck) and the API coupler GRAVITY DROP ADAPTERS
(at the terminal) are designed for the fast, easy, Drop adapters are part of the service station
and drip-free connection and transfer of gasoline unloading system when using API valves that
from the terminal to the road tank truck. are opened manually. Gravity drop adapters are

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 17

simple couplers designed to attach and lock onto
the API nose geometry on one end and allow
attachment to a standard cam and groove hose
couplings at the other end. They permit the drop
hose, which uses standard cam and groove hose
couplers, to link the API valve to the drop elbow
and the underground tank. Gravity drop adapters typically come in two sizes
for use with either 3” or 4” hose.

DROP HOSE
The drop hose is used to transport gasoline
between the tank truck and the underground tank
during unloading at the service station. Standard
cam and groove aluminum hose couplings
are used on each end. Using 4” diameter hose
provides fast unloading; however, 3” diameter
hose is common because of reduced weight and
API load-only valve API load/unload valve
5204L 5204NG cost.

DROP ELBOWS
Drop elbows are typically carried on the tanker
and connect the underground tank collar to
the drop hose. Elbows are used extensively
throughout North America, Mexico, and parts of
API dust cap
South America. They are not common in Europe
5205
and Asia. Elbows protect drop hose from damage
due to kinking. They also make hose connection
Ring
to the underground tank more convenient. It
Outlet
should be noted that drop elbows are designed
for use with a special underground tank collar.

By far the most common elbows are for 4”

top seal collars. Most service stations have
standardized on 4” fill piping.

Sight glass models require assembly of ring to outlet. UNDERGROUND TANK COLLARS
4540SG The style and size of tank coupling will vary
Drop adapters are sometimes stored in the tool depending upon the country and whether vapor
compartment of the tank truck until required recovery is being used.
during unloading at the service station. In some
cases, they are left on the API and removed only In North America, stations are usually equipped
when loading at the terminal. to use 4” drop elbows, which attach to 4” top

18 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

seal couplings (a few older stations have 3”
piping). In some locations 4” side seal elbows
and couplings are employed. Elsewhere in the
world standard cam and groove hose fittings are
common in addition to special regional designs.
Service stations equipped with vapor recovery
have a second outlet on the underground tank to
allow vapor to escape and be transferred to the
INLETS 3” and 4”
tanker during the unloading cycle. These outlets
use a standard 4” quick coupler adapter but with
a built-in, spring-loaded poppet (valve).

Where vapor elbows are employed, the elbow

contains a bottom probe, which opens the valve
6000-16 6000-14
when coupled to the collar. The adapter profiles
for 4” top seal fill and vapor couplings are
different to prevent drop elbows from attaching
TOP SEAL ELBOWS onto vapor collars and vapor elbows from
attaching to fill collars.

VAPOR ELBOWS
Vapor elbows are similar in design to drop elbows
and function to make the vapor hose connection
convenient for operators and to the hose from
splitting due to kinks. When mounting, a probe on
6500A 6200A the bottom end automatically opens the poppet
on the vapor collar, allowing vapors from the
underground tank to escape. The vapor hose
connects to the 3” adapter outlet on the elbow.
SIDE SEAL ELBOWS

Vapor elbows are typically designed with 3”

diameter bodies and with a 3” male adapter
outlet. However, note that vapor service station
piping and vapor collars are 4”.

6000ASA

4” top seal 4” vapor 4” side seal

collar/adapter collar/adapter tank adapter
BZ4051 VR4086 BSS4051

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 19

For stations that do not have a separate vapor
outlet, a special co-axial elbow can be used. This
elbow (6400X, bottom photo) allows for both
the drop of gasoline and the escape of fumes
through a standard 4” top seal drop collar. A tube-
within-a-tube design allows fuel to be dropped
through the inside tube, while vapors escape VAPOR HOSE AND FITTINGS
around the outside. This is called a “single-point The vapor hose is typically 3” diameter (4”
delivery system”, compared to the two-point common at terminals). For connection to the
system, which has separate dedicated vapor and vapor elbow, the hose can be equipped with a
drop fittings. Two-point systems are preferred standard 3” shanked quick coupler. However,
due to faster delivery drop-off. should the Dixon Bayco VR6200 vapor elbow be
employed (with exit poppet) then the VR3000AL
(with probe) is required. The probe is needed to
open the exit end poppet on this vapor elbow
model.

At the tank truck end a special 4” x 3” probed

hose coupler is needed. The coupler connects
to the vapor valve on the tank truck. The coupler
probe is required to open the poppet in the vapor
valve.
Dual-point vapor Heavy duty dual-point
recovery elbow vapor recovery elbow
VR6200ANP VR6500
(available with and without poppet)

3” with probe
VRC3000AL

Single point coaxial drop elbow

6400X
(3” and 4” male and female inlet models available) 4” x 3” with poppet and probe 4” x 3” without poppet
VR4030CS-AL with probe
VR4030CS-SH

20 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

VAPOR VALVES
The 4” vapor valve allows entry of displaced
gasoline fumes from the underground tank to
the 4” vapor piping system on the road tanker.
The vapor hose coupler probe automatically
depresses (opens) the poppet in the vapor valve
when coupled.

Dixon Bayco provides two models: VR4000, high

flow design with sight glass and drain plug and
VR4100, standard model. The high flow design
provides low resistance to vapor flow for fast
loading of tank truck compartments at terminals.
However, the VR4100 is more popular as a
standard in the industry.

Vapor return valve Vapor return valve

TTMA flange female thread
VR4000 VR4100

Vapor cap
VR4050PL

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 21

 Dust Caps & Plugs with
Safety Vapor Vents Tank Vapor Vents
Handles for Hose Tubes

Tube Doors

Elbow Extension Kits

Grounding
Studs

VAPOR

Vapor Hose Couplers

VAPOR

Vapor Valves Single-Point Vapor Recovery/

Fuel Drop Co-Axial Elbow

(vapor outlet)

(fuel inlet)

VAPOR
FLOW

Vapor Elbows
Vapor
Adapter

Vapor Caps

VAPOR
From Underground Tank

22 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

 Aluminum TTMA Flanges, Flange Gaskets, FloTech™ Overfill Detection
Flange Adapters
Monitors
Sensors

Ground Bolt
Sockets
Air Interlocks

API Valve Caps Dust Caps Drop Hose Fittings

API Valves Drop Adapters

Sight Glass

Load Only

FUEL
FLOW

Load/Unload Drop Elbows

Locking Fill Caps

Top Seal Adapters

FUEL
To Underground Tank

23 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery

Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery 23
Robert Koeninger has 32 years experience in Founded in 1916, Dixon is a premier U.S.- based
the petroleum cargo tank industry with a total of worldwide manufacturer and supplier of hose
41 years experience in commercial and military couplings, valves, dry disconnects, swivels,
electronic packaging and design. Robert holds and other fluid transfer and control products.
seven U.S. patents on various liquid level and Dixon’s products and services support a
control designs. He started FloTech Inc, which wide range of industries, including chemical
is part of the Dixon Bayco Division of Dixon processing, petroleum exploration, refining and
Valve and Coupling Company and a leading transportation, steelmaking, construction, mining,
manufacturer of liquid level sensing and control manufacturing, and processing.
systems for the petroleum bottom-loading
industry. Robert is a graduate of Cincinnati State dixonvalve.com • 877.963.4966
in electrical engineering technology.

24 Petroleum Tank Truck Industry Bottom-Loading and Vapor Recovery