PEI/RP300-09 - - - - - - - - - - - - -

Recomrinended Practices
for lnst,allation and
Testing of Vapor-
Recove1ry Systems at
Vehicle-·Fueling Sites
 Other Recommended Practices available from PEI
Order online at www.pei.org/shopping

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Systems

• PEI/RP200, Recommended Practices for Installation of Aboveground Storage Systems

for Motor-Vehicle Fueling

• PEI/RP400, Recommended Procedure for Testing Electrical Continuity of Fuel-

Dispensing Hanging Hardware

• PEI1RP500, Recommended Practices for Inspection and Maintenance of Motor Fuel

Dispensing Equipment

• PEI/RP600, Recommended Practices for Overfill Prevention for Shop-Fabricated

Aboveground Tanks

• PEI/RP700, Recommended Practices for the Design and Maintenance of Fluid-

Distribution Systems at Vehicle Maintenance Facilities

• PEI/RP800, Recommended Practices for Installation of Bulk Storage Plants

• PEI/RP900, Recommended Practices for the Inspection and Maintenance of UST

Systems

• PEI/RPI 000, Recommended Practices for the Installation of Marina Fueling Systems

• PEI/RPllOO, Recommended Practices for the Storage and Dispensing of Diesel Exhaust
Fluid (DEF)
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

FCJtREWORD
These Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-
Fueling Sites have been prepared as an industry service by the Petroleum Equipment Institute. The text
represents the consensus views of the PEI Vapor-Recovery Installation Cornmittee, comprised of the
following members:

B. J. Benton, POE, Chairman Pete Delderfield

United Pump and Controls, Inc. Delta Petroleum & Industrial Inc.
Suwanee. Georgia West Palm Beach. Florida

Victor Ayala Larry R. Gregory

D & H Pump Service, Inc. ExxonMobil Fuels Marketing Co.
El Paso, Texas Fairfax, Virginia

Scott C. Boorse Stephen A. Purpora

Wawa lnc. Protanic, Inc.
Wawa, Pennsylvania Milwaukee, Wisconsin

John Bracknell Dennis Rethmeier

CROMPCO, LLC Western Pump, inc.
Duluth, Georgia San Diego, California

Jason S. Carr Jeffrey Underland

Stantec Consulting Services. Inc. Petroleum Services, lnc.
Portland. Maine Baltimore, Maryland

Serving as consultant to the committe:e was Marcel Moreau, POE, Marcel Moreau Associates,
73 Bell Street, Portland, Maine 04103.
The PEI Vapor-Recovery Installation Committee acknowledges the contributions to past
editions of this document by the following people: John P. Hartmann, Brian E. Hurley. Frank X.
Singleton, James A. Spiros, James H. Spiros and James A. Wynne. UI.
This document supersedes and replaces the previous recommended practice entitled,
Recommended Practices for Installation and Testing of Vapor-Recove,y Systems at Vehicle-Fueling
Sites. PEVRP300-04.
All questions and other communications relating to this document should be sent only to
PEI Headquarters, addressed to the attention of the PEI Vapor-Recovery Installation Committee.
Petroleum Equipment Institute
P.O. Box 2380
Tulsa. Oklahoma 74 101-2380
(918) 494-9696
Fax: (9 I 8) 491-9895
E mail: info@pei.org
www.pei.org
© 2009 Petroleum Equipment institute
DISCLAIMER

Every effort has been made by the PEI Vapor-Recovery Installation Committee to ensure the accuracy and
reliability of the information contained in this document. However, neither the Committee, its consultant,
nor the Petroleum Equipment Institute makes any representation, warranty, or guarantee in connection with
the publication of these recommended practices. The Institute hereby expressly disclaims any liability or
responsibility for loss or damage resulting from their use; for the violation of any federal, state, or municipal
regulation with which these recommended practices may conflict: or for the infringement of any patent
resulting from the use of these recommended practices.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

CtDNTENTS
Foreword ............................................................................................................................................... iii

SECTIONS

1 . lntroduction ................................................................................................................................... 1
1.1 Origin
1.2 Background ......................... ................... ................................................................................................................. I
I .3 Purpose .................... ........... .................................................................................................................................... I
1.4 Scope ................................................................................................................................................................... 1
1.5 Sources ................................................................................................................................................................... I
1.6 Use of Other PEI Recommended Practices ............................................................................................................ I
1.7 Importance of Competent Personnel ........................................... ........................................................................... 2
1.8 Written Plans and Specifications ................................................................................................................. ........... 2
1.9 Regulations ............................................................................................................................................................. 2

2. Definitions ..................................................................................................................................... 2
2.1 Air to Liquid (AIL) Volume Ratio Test .................................................................................................................. 2
2.2 Bond ..... ................................................................................... ................. ............................................................... 2
2.3 Breakaway ........................ ....................................................................................................................................... 2
2.4 California Alr Resources Board (CARB ) ............................................................................................................... 2
2.5 Coaxial Drop Tube ......................................................................................... ......................................................... 2
2.6 Coaxial Hose ........................................................................................................................................................... 3
2.7 Combustible-Gas Detector ..................................................................................................................................... 3
2.8 Cubic Feet Per Minute (CMF), Cubic Feet Per Hour (CFH) ................................................................................. 3
2.9 Digital Manometer ........ .......................................................... .................................... ............................................ 3
2.10 Dispenser. ........................................................ ........................................................................................................ 3
2.11 Dispenser Sump ...................................................................... ................................................................................ 3
2.12 Drive-Off................................................................................. ............................................................................. ... 3
2.1 3 Drop Tube ............................... ................................................ ......................................:......................................... 3
2.14 Dynamic Backpressure Test. ........................... ........................................................................................................ 3
2.1 5 Enhanced Vapor-Recovery (EVR) ............................................................. ............................................................. 3
2.16 Extractor Fitting ...................... ....................................................................................................... ......................... 3
2.17 Face Seal ....................................... .......................................... ................................................................................ 3
2.18 Fuel Outlet Fitting ................................................................... ...................................... .......................................... 3
2. I 9 FuelNapor Splitter .................................................................................................................................................. 3
2.20 Ground .............. ...................................................................................................................................................... 4
2.21 Hanging Hardware .............................................................................................................. .................................... 4
2.22 Hose ....................................................................................................... ............. .................................... ................ 4
2.23 Hose Retractor ........................................................................................................................................................ 4
2.24 Inches Water Column (Inches WC) .................................................................................................................... .... 4
2.25 Incline Manometer .................................................................................................................................................. 4
2.26 Liquid Collection Point. .......................................................................................................................................... 4
2.27 Listed ............................................... ............................................................................................ ............. ............... 4
2.28 Manifold ............................................................ ......................................................................................................4
2.29 Manometer .............................................................. ................................................................................................ 4
2.30 National Pipe Thread (NPT) ....................... ............. ............ ...................................... ............................................. 4
2.3 1 Nozzle ....................... .................................. ............................................ ................................................................ 5
2.32 Nozzle, Bellowless.................................................................................................................................................. 5
2.33 Nozzle Bellows .......................................................................................................................................................5
2.34 Nozzle Boot ......................................................................... .......................................................................... ......... 5
2.35 Nozzle Spout ............................................... ..................................................................................................... ....... 5
2.36 Personal Protective Equipment (PPE) ............ ........................................................................................................ 5
2.37 Poppeted Coaxial Drop Tube ........................................................................... ....................................................... 5
PEI Recommended Practices 300-09

2.38 Pressure Decay Test .............. ......................... ........................................................... .............................................. 5

2.39 Pressure Regulator ................................... ............................................................................................................... 5
2.40 PressureNacuum (PN) Vent Cap ............................................................ ............................................................... 5
2.41 Reference Gauge ................................................................................................................................. .................... 5
2.42 Riser ......................................................................................................... ............................................................... 5
2.43 Spill-Containment Manhole .................................................................................................................................... 5
2.44 Stage I Vapor Recovery ................................................................................................. ......................................... 6
2.45 Stage II Vapor Recovery .................................................:....................................................................................... 6
2.46 Stage II Vapor-Recovery Nozzle ............................................................................................................................ 6
2.47 Swivel ..................................................................................................................... ................................................ 6
2.48 Tank-Top Sump ..................................................................... ................. ................................................................. 6
2.49 Top Off .............................................................................................................. ...................................................... 6
2.50 Transition Sump ................................................................................................ ...................................................... 6
2.51 Ullage ............................................................................................... ...... ........... ............................ .......................... 6
2.52 Vapor-Emission Guard .................................................................................................................. ..........................6
2.53 Vapor/Fuel Splitter .................................................................................................. ........................... .....................7
2.54 Vapor-Recovery Adapter........................................................................ ................................................................. 7
2.55 Vapor-Recovery System ......................................................................................................................................... .7
2.56 Vapor Shear Valve ................................................... .......................................................................................... ...... 7
2.57 Vapor Valve ............................ ................... .................................................................................. ............................ 7
2.58 Vent Cap .................. .......................................... ...................................................................................................... 7
2.59 Volatile Organic Compound (VOC) ....................................................................................................................... 7
2.60 Whip Hose .................................................. ............................................................................................................ 7

3. Stage I Vapor-Recovery Systems .................................................................................................... 7

3. l Stage l Vapor Recovery .. ........................................... ............................................................................................. 7
3.2 Vapor-Recovery Adapters ..................................................... ....................... ............................ ..............................7
3.3 Types of Stage I Vapor-Recovery Systems ............................................. ................................................................ 7
3.3.1 Two-Point (Dual Point) Stage I Vapor-Recovery Systems .............................................. ......................... 8
3.3.2 Coaxial Stage I Vapor-Recovery Systems ................................................................................................ 8
3.3.3 Manifolded Stage I Vapor-Recovery Systems .......................................................................................... 9
3.4 Aboveground Tanks .................................... .......................................................................................................... l 0

4. Stage II Vapor-Recovery Systems ................................................................................................. 10

4.1 Stage II Vapor-Recovery ........... ................................................................................................... ..... .................... IO
4.2 Balance Systems ............................................................................................... ..... ............................................... 1O
4.3 Vacuum-Assist Systems ......................................... ..................................................... .......................................... I 0
4.4 Aboveground Tanks ......................................... ..................................................................................................... 13

5. Stage II Vapor-Recovery System Components ............................................................................... 13

5.1 General ............................ ..................................................................................................................................... 13
5.2 Nozzles ............................................................................................... .................................................................. 13
5.3 Hoses ................................................................................................................................................................. 13
5.4 Swivels ................ ................................................................................................................................................. 14
5.5 Breakaways ........................................................................................................................................................... 14
5.6 Hose Retrac;tors ................................. ....... ................................................ .................................................. ........... 14
5.7 Vapor Valves ......................................................................................................................................................... 14
5.8 Dispensers ......................................................................................... .................................................................... 14
5.9 Vacuum-Assist Devices ...... .................................................................................................................................. 15
5.10 Ball Valves ............................................................................................................................................................ 15
5.11 Vapor Shear Valves ............. ...................................... ........................ ...................... .............................................. 15
5.12 PressureNacuum Vent Valves ................ ............................................................................................................... 15
5.1 3 Vapor-Return Piping ...................................................... ........................ ............................................. .................. 16
5.14 Liquid-Collection Point ........................................................................................................................................ 16
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

6. Aboveground Vapor-Recovery Piping Conne,cted To Aboveground Tanks ......................................... 18

7. Underground Piping and Fittings .................................................................................................. 18

7.1 General Require ments for Underground Vapor-Recovery Piping ........................................................................ 18
7.2 Underground Piping Materials.............................................................................................................................. 18
7.3 Underground Piping Practices .............................................................................................................................. 18
7.4 Underground Piping Layout and Tre nches ........................................................................................................... 18
7.5 Underground Piping Backfill and Compaction .................................................................................................... 19
7.6 Flex._ible Connectors .............................................................................................................................................. I 9
7.7 Underground Fiberglass Piping ............................................................................................................................ 19
7.8 Underground Flexible Piping...................... .......................................................................................................... 19
7.9 Containment Sumps .................................... .......................................................................... ................................ 20
7.1 0 Riser Piping ............................................... ........ ................ .................................................................................... 20
7 .11 Testing of Underground Primary-Vapor Piping .................................................................................................... 20
7.1 1.1 Initial Piping Test .................................................................................................................................... 20
7. I I .2 lnitial System Test .................................................................................................................................. 20
7. I L.3 Dynamic Backpressure Test.. .................................................................................................................. 21
7 .11.4 Monitoring During Construction .................................................................................... ........................ 21
7. I 1.5 Post-Construction Testing ....................................................................................................................... 2 1
7. 12 Testing of Underground Secondary-Vapor IPiping............................................... ................................................. 2 1
7.12. J lnitial Test for Underground Secondary Piping ................................................................................. ..... 2 1
7. 12.2 Monitoring During Construction ............................................................................................................ 21
7. 12.3 Final Integrity Test for Secondary Piping ............................................................................................... 21
7.12.4 C leaning Up ................................................................ ...................................... ................... ................... 21

8 . Pressure Decay Test ................................ .,. .................................................................................. 22

8.1 General ............. ...................................................................... .............................................................................. 22
8.2 Test Equipment ............ ......................................................................................................................................... 22
8.2. I Nitrogen Cylinder and Regulator ........................................................................................................... 22
8.2.2 Provision for Bonding and Grounding ................................................................................................... 22
8.2.3 Pressure-Relief Valve ..................... ..................................................................................................... .... 22
8.2.4 Pressure-Measuring Equipment .............................................................................................................. 22
8.2.4.1 Digital Manometer ................................................................................................................... 22
8.2.4.2 Mechanical Pressure Gauge ............... ...................................................................................... 23
8.2.4.3 Manometer ...................... ........................................................................... ............. .................. 23
8.2.5 Vent Plug ....................................... ........................................................................... ................... ............ 23
8.2.6 Flow Meter .............. ................................................................... ............................................................. 23
8.2.7 Stopwatch ................................................................................................................................................ 23
8.2.8 Shut-Off Valve ........................................................... ............................................................................. 23
8.2.9 Isolation Valve ............. ........................................................................................................................... 23
8.2. IO Test Assembly ......................................................................................................................................... 23
8.2.11 PN Vent Valve Test Assembly ............................................................................................................... 24
8.2.1 2 Leak-Locating Methods and Devices ........................................... .......................................................... 24
8.3 Preparing for the Test. ........................................................................................................................................... 24
8.3.1 Safety ... ................................................................................................................................................... 24
8.3.2 Delay After Deliveries ............................................................................................................................ 24
8.3.3 Delay After AIL Testing ............................ .............................................................................................. 24
8.3.4 Delay After Dispensing .................................................................................... ....................................... 24
8.3.5 Place Dispensing Equipment in No rmal Operati ng Position ....... .......................................................... 24
8.3.6 Remove Fill Adapter Caps and Vapor Adapter Dust Caps ......... ............................................................ 24
8.3.7 Check Product Level................................................................................................................ ............... 24
8.3.8 Check Drains in Spill-Contain ment Manholes ....................................................................................... 24
8.3.9 Check Ullage Volume ........................................................................................... .................................. 25
8.3. 10 Drain Liquid-Collection Points ............................................................................................................... 25
8.3. 11 Connect Test Assembly ................. .................................................................................... ...................... 25
PEI Recommended Practices 300-09

8.3.12 Bond and Ground the Test Equipment ................................................................................................... 25

8.3.13 Calculate Pressurization Time ................................................................................................................ 25
8.3. l4 Turn Off Vapor Processors ................................................................................................ ...................... 25
8.4 Test Procedure ............................................................. .......................................................................................... 25
8.4.1 Initiate Safety Procedures ....................................................................................................................... 25
8.4.2 Warm Up the Digital Manometer ...........................................................................................................25
8.4.3 Pre-Test the Stage I Vapor-Recovery Adapter ........................................................................................ 25
8.4.4 Close the Valve Between the Vacuum Pump and the Storage Tanlc ...................................................... 26
8.4.5 Stop Dispensing and Monitor Pressure .................................................................................................. 26
8.4.6 Pressurize the Ullage Space of the Storage System ............................................................................... 26
8.4.7 Monitor the Time Required to Pressurize the Storage System .............................................................. 26
8.4.8 Pressurize the Ullage to 2.2 Inches WC ................................................................................................. 26
8.4.9 Conduct the Test .................................................................................................................................. ... 27
8.4.10 If the Storage System Fails the Test ....................................................................................................... 27
8.4.11 If the Vapor Return Lines Are Not Manifolded...................................................................................... 27
8.4. 12 If the Vapor Piping Was Isolated from the Tank(s) ................................................................................ 27
8.4.13 Test the P/V Vent Valve .......................................................................................................................... 27
8.4.14 Reporting Results ...................... ........................................... ...................... ............................................. 27
8.4.15 Cleaning Up ............................................................................................................................................ 28
8.5 Testing Aboveground Tanks ...................................... ........................................................................................... 28

9. Dynamic Backpressure Test ......................................................................................................... 28

9.1 General ................................................................................................................................................................. 28
9.2 Dynamic Backpressure Test Methods .................................................................................................................. 28
9.3 Dynamic Backpressure Test Equipment ............................................................................................................... 29
9.3. l Nitrogen Cylinder and Regulator ........................................................................................................... 29
9.3.2 Provision for Bonding and Grounding ................................................................................................... 29
9.3.3 Pressure-Relief Valve .............................................................................................................................. 29
9.3.4 Pressure-Measuring Equipment .............................................................................................................. 29
9.3.4.1 Digital Manometer ................................................................................................................... 29
9.3.4.2 Mechanical Pressure Gauge ..................................................................................................... 29
9.3.5 Flow Meter .............................................................................................................................................. 30
9.3.6 Shut-Off Valve ....................................................................................................................... ............... .. 30
9.3.7 Simulated Fill Pipe ................................................................................................................................. 30
9.3.8 Gasket ..................................................................................................................................................... 30
9.3.9 "T" Assembly .......................................................................................................................................... 30
9.3.10 Pump ...................................................................................................................................................... 30
9.3.11 Portable Gasoline Tank ........................................................................................................................... 30
9.3.12 Stopwatch ................................................................................................................................................ 30
9.3. l 3 Vapor-Adapter Opener ....................................... ..................................................................................... 30
9.4 Preparing for the Test.. .......................................................................................................................................... 30
9.4. l Initiate Safety Procedures .......................................................................................................................30
9.4.2 Verify the Integrity of the Storage System ............................................................................................. 30
9.4.3 Flow Liquid Through the Vapor Piping .................................................................................................. 31
9.4.4 Drain Liquid-Collection Point .............................................. .................................................................. 31
9.4.5 Bond and Ground lhe Test Equipment .................................................................... ............................... 31
9.4.6 Check Test Equipment for Leaks .................................................................. .......................................... 31
9.4.7 Check Method I Test Equipment for Backpressure ...................................................... ......................... 31
9.4.8 Check Method 4 Test Equipment for Backpressure ............... ................................................................ 31
9.4.9 Connect "T' Assembly ........................................................................................................................... 31
9.5 Test Procedure ...................................................................................................................................................... 3 1
9.5. 1 Initiate Safety Procedures ....................................................................................................................... 3 1
9.5.2 Vent the Storage System ......................................................................................................................... 3 1
9.5.3 Insert Nozzle in Simulated Fill Pipe ...................................................................................................... .32
9.5.4 Close the Nitrogen Flow-Control Valve ................................................................................................. 32
9.5.5 Close the Inlet Valve of the Low-Pressure Mechanical Gauge .............................................................. 32
 Recommended Practices for Installation and Testing of Vapor-Recove1y Systems at Vehicle-Fueling Sites

9.5.6 Set the Nitrogen Delivery Pressure ....................................................................................................... 32

9.5.7 Adjust the Nitrogen Flow Rate ................................................................................................................ 32
9.5.8 Record Backpressure ............................................................................................................................... 32
9.5.9 Compare Measured Backpressure to Acceptable Backpressure Level .................................................. 32
9 .5.10 ff the Backpressure Exceeds the Acceptable Level ................................................................................ 32
9.5.11 Record Results ........................................................................................................................................ 32
9.5.12 Increase Nitrogen Flow Rates ................................................................................................................. 33
9.5.13 Repeat Test for All Other Nozzles./Dispensers ....................................................................................... 33
9.5.14 CleanUp ......................................... ........................................................................................................ 33
9.6 Aboveground Tanks .............................................................................................................................................. 33

10. Air-to-Liquid (A/ L) Volume Ratio Test ............................................................................................. 33

I0.1 General ............... .................................................................................................................................................. 33
l 0.2 Test Equipment ... ................. ............................................................................................................................. .... 33
10.2.1 Air-Volume Meter ............................................................................................................................ ....... 33
I0.2.2 Nozzle Vapor Adapter .............................................. ............................................................................... 34
10.2.3 Portable Gasoline Tank ..................................................................................................... ...................... 34
I0.2.4 Air-Volume Meter Air Intake.................................................................................................................. 35
I0.2.5 Liquid-Volume Meter. ............................................................................................................................. 35
I0.2.6 Stopwatch ................................................................................................................................................ 35
I0.2. 7 Lubricant .................................. .... ........................................................................................................... 35
10.3 Preparing for the Test ............................................................................................................................................ 35
I0.3. I Initiate Safety Procedures ....................................................................................................................... 36
10.3.2 Determine Whether the Test Is to be Conducted with the Pressure/Vacuum Vent Valve lnstalled ....... 36
10.3.3 Determine lf the Test Is to be Conducted with the Vapor Processor On or Off .................................... 36
I0.3.4 Determine the Volume to be Dispensed During the AIL Test ................................................................ 36
10.3.5 Determine the Fuel-Dispensing Rate Required by the Equipment Certification ................................... 36
I0.3.6 Check to See If the Air-Meter Calibration Is Current ............................................................................ 36
10.3.7 Verify that the Spouts of the Nozzles to be Tested are in Good Condition ........................................... 36
10.3.8 Check that the Nozzle Vapor Adapter is Compatible with the Nozzle Spout.. ...................................... 36
I0.3.9 Check the Condition of the Nozzle-Vapor-Adapter Seals ...................................................................... 36
I 0.4 Test Procedures ..................................................................................................................................................... 36
I0.4. l Initiate Safety Procedures ........................................................................................................................ 36
10.4.2 Ground the Portable Test Tank ................................................................................................................ 36
10.4.3 Ensure that There Is No Gasoline in the Test-Equipment Tubing ........................................................... 36
10.4.4 Install the Nozzle Vapor Adapter ............................................................................................................. 36
10.4.5 Record the Initial Air-Volume Meter Reading ......................................................................................... 37
10.4.6 Reset the Dispenser Meter Display .......................................................................................................... 37
10.4.7 Reset the Stopwatch ................................................................................................................................. 37
I0.4.8 Insert Nozzle in Test Tank and Start the Test .......................................................................................... 37
I0.4.9 Dispense Fuel and Time the Test ............................................................................................................. 37
I0.4.10 Calculate the Fuel Dispensing Rate and Verify that it is Acceptable ...................................................... 37
10.4.11 Calculate AIL Ratio .................................................................................................................................. 37
10.4.12 lf a Nozzle Fails by a Narrow Margin ..................................................................................................... 38
10.4.13 Record Data............................................................................................................................................... 38
I 0.4.14 Testing Uni hose Dispensers ...................................................................................................................... 38
I 0.5 Troubleshooting .................................................................................................................................................... .38
10.5.1 Test the Nozzle Vapor Adapter Seal ....................................................................................................... 38
I0.5.1.1 Nozzle-Vapor-Adapter Test Equipment ................................................................................... 38
10.5.1.2 Nozzle-Vapor-Adapter Test Procedure ..................................................................................... 39
10.6 Post-Test Procedures .............................................................................................................................................. 39
10.6. l Replace P/V Vent Valve ........................................................................................................................... 39
I 0.6.2 Empty Portable Tank ...................................................... ........................................................................ 39
10.6.3 Carefully Seal the lnlet and the Outlet of the Air-Volume Meter .......................................................... 39
10.7 Aboveground Storage Tanks .............................................. ................................................................................... 39
PEI Recommended Practices 300-09

U . Electrical Installation ............................................ .................................................... ............... .... 39

11.1 General Requirements ........................................................................................................................................... 39
11.2 Classifications .................................................................................................... ................................................... 39
1 J.3 Electrical Equipment. ................................... ......................................................................................................... 41

12. Testing and Inspection ................................................ ............................................... .................. 42

12.1 General ......... ................... ..................................................................................................................................... 42
12.2 Test Results ......................................................................................... .................................................................. 42
12.3 Other Testing ............................................................................................ ............................................................. 42

13 . Documentation and Training ................... ....... .......... ..................................................................... 42

13.1 As-Built Drawings .................................................... ...... ...................................................................................... 42
13.2 Compone nt Documentation .................................................................................................................................. 42
13.3 Scheduled Maintenance ........................................................................................................................................ 43
13.4 Tra ining ................................................................... .............................................................................................. 43

1 4 . Decommissioning Stage II Vapor-Recovery Piping ......................................................................... 43

14.1 lntroduction .................................................................. .............................................. ........................................... 43
14.2 Nature of the Procedure ............................ ............ ................................................................................................ 43
14.3 Qualifications ..................................... ................................................................................................................... 44
14.4 Paperwork ................................................................................................................................................. ............ 44
14.5 Applicability ......................................................................................................................................................... 44
14.6 Decommissioning Procedure ................................................................................................................................ 44
14.6.1 lnitiate Safety Procedures ....................................................... ................................................................ 44
14.6.2 Relieve Pressure in the Tank Ullage .................................................................................................... ...44
14 .6.3 Drain Liquid-Collection Points ............................................................................................................... 44
14.6.4 Vaccum-Assist Systems with Vapor Pumps for Each Fueling Position ................................................. 45
14 .6.5 Vacuum Assist Systems with a Centrally Located Vapor Pump .......................................................... ..45
14.6.6 Isolate the Below-Grade Vapor Piping at the Base of the Dispenser.. .................................................. .45
14.6.7 Disconnect the Vapor Piping at the Tank Top ............................................................. ........................... 45
14.6.8 Seal the Dispenser Cabinet Vapor Piping ............................................................................................... 46
14.6.9 Replace Hangi ng Hardware ............................................................................................................. ....... 46
14.6.10 Replace the Pressure/Vacuum Vent Valve(s) ................. .................................. ....................................... 46
14.6.11 Remove Stage lJ Operating [nstructions from Dispensers .................................................................... .46
14.6. J2 Conduct Pressure Decay Test and Tie-Tank Test ........................................................... ....................... .46
14.6. 13 Conduct a Final Visual Check ................................................................................................................46
14.6. 14 Complete the Checklist in Appendix C of this document. ................................... .............................. .... 46

APPENDICES

Appendix A: Pressure Decay Test Tables ................................................................................. ............. 4 7

Appendix B: Sample Forms for Test Data Recording ............................................................................. 49

Appendix C: Stage II Decommissioning Checklist ................................................................................. 52

Appendix D: Publication Reference ...................................................................................................... 53

 Recommended Practices for lnsrallation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
1. INTRODUCTION
1.1 Origin. The Petroleum Equipment Institute !(PEI)
has produced this document as an indusu·y service. The
recommended practices described herein represent a
synthesis of industry procedures, manufacturers' recom-
mendations, and regulatory standards relating to gaso-
line vapor-recovery equipment. These practices are the
consensus recommendations of the PEI Vapor-Recovery
Installation Committee. The Committee is made ILIP of
representatives from petroleum marketing, equipment
manufacturing, service, testing, and installation con-
tracting comparues. In addition. the Committee has had
the benefit of reasoned comments submitted by parties
interested in the vapor-recovery-equipment industry.
1.2 Background. Large quantities of volatile organic
compounds (VOCs) can be released into the atmosphere
when gasoline is transferred between bulk tanks , fuel
delivery trucks, underground and aboveground storage
tanks, and vehicle fuel tanks. These compounds are
significant contributors to air pollution. Vapor recovery
is a genera] term describing methods for preventi ng the
emission of VOCs into the atmosphere in o rder to pre-
serve air quality and protect human health. In this docu-
ment, vapor recovery refers specifically to the processes
used to capture VOCs during gasoline de livery to storage
tanks and vehicles at sites such as convenience stores
and automotive service stations.
1.3 Purpose. The purpose of this document is to
provide concise recommended practices for the installa-
tion, testing, and decommissioning of Stage I and Stage
U vapor-recovery systems at vehicle-fueling sites. T he
recommendations are intended to:
• conform to sound engineering and construction
practices
• meet e nvironmental requirements
• minimize system failures
• ensure reliability
• avoid unnecessary installation and decommission-
ing costs.
1.4 Scope. T he recommended practices in this pub-
lication are limited to those re lating to the installation.
testing, and decommissioning of Stage I and Stage II
motor-fuel vapor-recovery systems located at retail,
commercial, and government vehicle-fueling faci1lities.
The storage tanks at these facilities may be located
underground or aboveground. Tbjs document does not
address practices associated w ith the installation, test-
ing, or decommissioning of vapor-recovery systems at
terminals or bulk plants. nor does it address marina- or
aircraft-fueling faci Iities.
Operation and maintenance procedures fo r vapor-recov-
ery systems are also outside the scope of this document.
Refer to American Peu·oleum Institute Publication #1639,
Owner/Operator '.s Guide to Operation and Maintenance
of Vapor Recove,y Systems at Gasoline Dispensing
Facilities for information concerrung the operation and
maintenance of vapor-recovery systems.
This document is NOT intended to:
• provide interpretation of regulatory or legislati ve
requirements re lated to vapor-recovery systems
• endorse or recommend particular materials, equip-
ment, suppliers, or manufacturers
• discourage the development a nd implementation
of new equipment or procedures.
The inc lusion of procedures for the installation of equip-
ment or dev ices does not imply that such equipment or
procedures should always be used. Alternative proce-
dures not described in this document may be equally
effective.
This document addresses established vapor-recovery
technologies that are c uri-ently in use throughout most of
the United States. These recommended practices do not
address CARB enhanced vapor-recovery (EVR) require-
ments.
1.5 Sources. The procedures outUned in this docu-
ment constitute a synthesis of regulations and recom-
mendations published by federal and state e nvironmental
agencies, particularly CARB. Io instances where the re
were disparities or omissions in the material available,
the PEI Vapor-Recovery Installation Committee has
included its own consensus recommendations, based
on practical experience in the installation, testing, and
decommissioning of Stage II vapor-recovery systems.
1 .6 Use of Other PEI Recommended Practices.
Vapor-recovery systems are only a part of unde rground
or aboveground storage tank and piping installations.
There are many other aspects of fue l-storage and dis-
pensing syste ms that are not described in this document.
Refer to the following PEI documents for additional rec-
ommended practices and procedures related to storage
systems for motor vehicle fuels:
• PEI/RP 100, Recommended Practices for Installa-
tion of Underground Liquid Storage Systems
PEI Recommended Practices 300-09
• PEVRP200, Recommended Practices for Installa-
tion of Aboveground Storage Systems for Motor-
Vehicle Fueling
• PEI/RP400, Recommended Procedure for Testing
Electrical Continuity of Fuel-Dispensing Hanging
Hardware
• PEI/RP500, Recommended Practices for Inspec-
tion and Maintenance of Motor Fuel Dispensing
Equipment
• PEI/RP900, Recommended Practices for the
Inspection and Maintenance of UST Systems
1.7 Importance of Competent Personnel. The instal-
lation, testing, and decommissioning of vapor-recovery
systems is a technically sophisticated field and requires
a wide range of knowledge, experience. and specialized
equipment. Reliance on professional vapor-recovery-
system installers, service personnel, and testers who pos-
sess the tools, experience. and integrity to insist on doing
the job right provides the system owner with the most
effective protection against system failure and liability
exposure.
1.8 Written Plans and Specifications. To properly
solicit bids, obtain required permits, and provide guid-
ance for installers, facility owners who contemplate
vapor-recovery projects should provide a written scope
of the proposed work, together with concise specifica-
tions and construction plans. These documents should
accurately describe the property where the work is to
be done, indicate the size and location of system com-
ponents, and clearly specify all material and equipment
to be used as weU as appropriate construction details.
Installation checklists may be developed from the plans
and specifications. Checklists provide a convenient and
effective tool for planning, implementing. and docu-
menting the required work.
1.9 Regulations. The vapor-recovery systems dis-
cussed in this recommended practice are typically installed
in response to state or local air-quality regulations. While
the general requirements of the regulations are similar, the
specific requirements can vary from jurisdiction to juris-
diction. The PEI Vapor-Recovery Installation Committee
has not attempted to describe or interpret specific vapor-
recovery regulations in this document.
The suitability and effectiveness of vapor-recovery sys-
tems are usually certified by a governmental agency. The
certification process typical ly requires testing the indi-
vidual system components and the system as a whole.
An evaluation of the installation materials, installation
instructions, and test procedures may also be required.
2
Verify that the equipment to be installed meets all appli-
cable requirements before beginning an installation.
Consult the local authority having jurisdiction before
vapor-recovery plans are finalized or construction is
initiated. Approvals may also be required from building-
code officials, environmental agencies, zoning boards. or
similar authorities.
2. DEFINITIONS
When used in this document, the terms listed below have
the following meanings:
2 .1 Air to Liquid (A/L) Volume Ratio Test. A test
procedure that measures the volume of air returned to
a storage tank when a specified volume of gasoline is
dispensed from a vacuum-assist vapor-recovery nozzle.
The ratio of the volume of air returned to the tank and the
volume of gasobne dispensed is a measure or the effec-
tiveness of the vapor-recovery system. The AIL ratio
measured during a test is compared with the specifica-
tions for a specific vacuum-assist system to determine if
the equipment is operating properly.
2.2 Bond. An electrical connection between two or
more conductive objects such that they are at the same
electrical potential, but not necessarily at the same
potential as the earth.
2.3 Breakaway. A valve installed in a motor-vehicle-
fueling hose designed to separate with little or no prod-
uct spillage when excessive pulling force is placed on
the hose. A breakaway is intended to prevent the release
of flammable liquids and vapors and to protect dispens-
ers from damage when vehicl.e s leave the dispenser area
with the nozzle still in the vehicle fill pipe.
2.4 California Air Resources Board (CARB). This
agency is responsible for regulating gasoline vapor-
recovery systems in California. Historically, Californ ia
vapor-recovery regulations have frequently formed the
basis of regulations adopted by government agencies in
other states.
2.5 Coaxial Drop Tube. A drop tube designed to allow
the flow of both product and vapors through a single fill-
pipe riser. The diameter of a standard drop tube is just
slightly smaller than the inside diameter of the fill-pipe
riser. The diameter of a coaxial drop tube is about an
inch smaller than the diameter of the fi ll-pipe riser. Small
tabs on the outside of the coaxial drop tube keep the tube
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
centered in the fill pipe, allowing vapors to flow upward
between the drop tube and the fill pipe while product
flows downward through the drop tube. (See also "drop
tube" and ·'poppeted coaxial drop tube.")
2.6 Coaxial Hose. A combination fuel- and vapor-
dispenser hose commonly used for Stage II vapor-recov-
ery installations. When installed, it appears to be a single
hose, but it is actually a hose within a hose. In a coaxjal
dispenser hose that is typically used with balance vapor-
recovery systems, the product flows through the inner
hose and the vapors flow through ttie outer hose. In an
inverted coaxial dispenser hose that is commonly used
on vacuum-assist vapor-recovery systems, the vapor
flows through the inner hose and the product flows
through the outer hose. (See also "hose.")
2.7 Combustible-Gas Detector. An instrument used
to detect the presence of combustible vapors in air.
2.8 Cubic Feet Per Minute (CFM) , Cubic Feet Per
Hour (CFH). Units of measurement typically appliied to
the flow of liquids or gases in a pipe or tube. A cubic
foot is the volume contained in a cube that measures I
foot on each of its sides. A flow rate of 2 cubic feiet per
minute means that a volume of 2 cubic feet is passi ng by
a given point in a pipe or tube each minute. A flow rate of
2 cubic feet per hour means that a volume of 2 cubic feet
is passing by a given point in a pipe or tube each hour.
2.9 Digital Manometer. A band-held pressure--mea-
suring device that uses a transducer to convert pres-
sure to a corresponding voltage. A digital manometer
typically indicates pressure measurements using a digital
display.
2.10 Dispenser. A device that transfers liquid fuel via
pressure or suction from a storage system into a motor
vehicle.
2.11 Dispenser Sump. A Jjquid-tight container installed
beneath a dispenser designed to contain leaks and spills
from ilispenser components and to isolate metallic pip-
ing .and fittings from the corrosive underground envi-
ronment. (See also " tank-top sump" and "transition
sump.")
2.12 Drive-Off. A fueling incident where a vehicle is
driven away from the dispenser while the fueling-nozzle
spout is still in the vehicle fill pipe.
2 .13 Drop Tube. A tube, usually made of thin a lurru-
num. positioned inside an underground storage tank
fill-pipe riser and extending to a point near the bottom of
the tank. The bottom operung of the drop tube should be
entirely submerged when the liquid level is 4 to 6 inches
above the bottom of the tank. By introducing product
into a storage tank during a delivery at a point below
the liquid level. the creation of vapors is minirruzed and
the rate of delivery is increased. (See also "coaxial drop
tube" and "poppeted coaxial drop tube.")
2 .14 Dynamic Backpressure Test. A test of Stage lJ
vapor-recovery piping that measures the resistance to
flow in the vapor path between the nozzle or dispenser
riser and the storage tank. The purpose of the test is
to verify that there are no physical or liquid blockages
obstructing the flow of vapors in the piping system.
2.15 Enhanced Vapor Recovery (EVR). A general
term used to describe relatively new vapor-recovery
requirements developed by CARB for implementation
in California.
2.16 Extractor Fitting. An underground storage sy. -
tern component that allows a tank-top fitting, such as
a float vent valve or isolation plug, to be installed or
removed without the necessity of breaking concrete or
excavating to the tank top. (See Figure 5-4.) The remov-
able part of the extractor fitting is a type of bushing.
The external threads of the bushing screw into a mating,
permanently installed fitting at the tank top, and the
internal threads of the bushing hold the float vent valve
or isolation plug. A riser extends from the pe1manently
installed portion of the extractor to just below grade. A
special, long-handled wrench is inserted down the riser
and engages the extractor bushing so it can be unscrewed
and lifted out of the riser, bringing with it the float vent
valve or isolation plug.
2.17 Face Seal. In a balance Stage Il vapor-recovery
system, the part of a nozzle bellows that presses against
the fil l pipe of a motor vehicle to produce a vapor-tight
connection between the vehicle fill pipe and the nozzle.
The face seal is usually constructed of soft, fl exible
material shaped like a donut.
2.18 Fuel Outlet Fitting. The component of a dis-
penser from which fuel exits the dispenser cabinet. The
outlet fitting typically includes a threaded portion that
provides the connection point for the hanging hardware
to the ilispenser.
2.19 FueljVapor Splitter. A device that separates coax-
ial fuel and vapor pathways into separate connections for
fuel and vapor piping. In a typical app]jcation, a coaxial
hose is screwed into one side of a fuel/vapor splitter, and
separate fuel and vapor piping is installed on the other
side. (See Figure 4-2 for a schematic illustration.)
PEI Recommended Practices 300-09
2.20 Ground. A bond between one or more electrically
conductive objects and the earth, so that all objects are
at zero (0) e lectrical potential.
2.21 Hanging Hardware. A generic term used to refer
to all of the fuel- and/or vapor-containing components
from the fuel outlet fitting of the dispenser cabinet to the
nozzle. Typical hanging hardware components include
whip hoses, breakaways, dispensing hoses, swivels, and
nozzles.
2.22 Hose. A flexible tube attached to the fuel outlet
of a motor-fuel-dispensing device intended to conduct
liquid fuel from the dispenser cabinet to a nozzle. (See
also "coaxial hose.")
2.23 Hose Retractor. A device that pulls a fuel-dis-
pensing hose back to a storage position after it has been
used. (See Figure 5-1.) A spring-operated hose retractor
utilizes a rope or wire cable clamped to the dispensing
hose at one end and wound on a spring-tensioned reel at
the other end. The reel unwinds to allow the nozzle to be
brought to the fill pipe of a vehicle and rewinds to pick
up the slack in the hose when the nozzle is returned to
the dispenser. In a counterweight-operated hose retrac-
tor, the rope or wire cable clamped to the hose is led
over a pulley and fastened to a counterweight at the other
end. The counterweight rises and falJs in response to the
movement of the dispensing hose, minimizing the slack
in the hose at all times.
2.24 Inches Water Column (Inches WC). Vapor-
recovery systems are designed for minimal operating
pressures. As a result, integrity tests for these systems,
such as pressure decay tests (See Chapter 8), must be
conducted at very low pressures. These low pressures
are typically measured in inches of water column, which
is the pressure produced by a column of water, 1 inch
square, with a specified height. One inch of water col-
umn is equal to a pressure of approximately 1/28 pound
per square inch (psi). Stating this another way, a column
of water 28 inches high produces a pressure that is
approximately equal to I psi.
2.25 Incline Manometer. (See "manometer.")
2.26 Liquid Collection Point. A liquid collection point
(also referred to as a drop-out tank, condensate trap, or
vapor pot) is a small-capacity reservoir that is placed
lower than the vapor piping, providing a place for liq-
uid gasoline that may travel down the vapor piping to
accumulate without obstructing the vapor pathway. (See
Figure 5-5.)
2.27 Listed. Equipment or materials included on a list
published by a nationally recognized testing laboratory.
inspection agency, or other organization concerned with
product evaluation that conducts periodic inspections of
the production facilities where listed equipment or mate-
rials are manufactured. The listing states that equ ipment
or materials meet nationally recognized standards and
have been tested and found suitable for use in a specified
manner.
2.28 Manifold. With regard to underground petroleum
storage systems, a manifold is a piping arrangement that
interconnects two or more storage-system components.
The term may be applied to any of the following:
• Manifolded Stage Il Vapor Piping - Individual
piping runs from dispensers (sometimes called
branch piping) that connect to a larger-diameter
piping run (sometimes called trunk piping) located
in the vicinity of the dispenser islands. A single
run of trunk piping then carries gasoline vapors
gathered from several dispensers back to an under-
ground storage tank or tanks. (See Figure 5-3.)
• Manifolded Stage I Vapor Piping - Piping that
connects the ullage spaces of two or more tanks
together and provides one or more grade-level fit-
tings for Stage I vapor collection. (See Figure 3-4.)
• Manifolded Product Piping - A single piping run
that carries fuel from a tank to a dispenser area
where the piping then branches out to bring fuel
to individual dispensers.
• Manifolded Vent Piping - Piping that connects
the ullage spaces of two or more tanks together.
In some cases, a single vent line and vent riser
used for all the tanks. In other cases, the vent ris-
ers are connected together above ground so that
there is a single vent opening to the atmosphere.
Manifolded vent piping and manifolded Stage I
vapor piping can be combined into a single vapor-
handling system. (See Figure 5-3.)
2.29 Manometer. A manometer is a pressure-measur-
ing device consisting of a clear tube connected to a liquid
reservoir. When pressure is applied to the reservoir, the
liquid rises in the tube to a height that is proportional to
the pressure applied. The sensitivity of a manometer can
be increased by placing the tube in a nearly horizontal
position so that a small change in pressure produces a
large, mostly horizontal movement of the liquid inside
lhe tube. This more sensitive type of manometer is called
an "incline manometer." (See also "digital manometer.")
2.30 National Pipe Thread (NPT). A United States
standard for screw threads cut in piping and fittings for
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
general use. The NPT standard calls for the diameter of
the threads to taper so that as the piping is screwed into
a mating fitting, the fit of the male and female threads
becomes increasingly tight. A sealant must be used with
NPT joints to make them liquid-tight or airtight.
2.31 Nozzle. A device consisting of a spout, a handle,
and a control valve attached to the end of a hose and used
for controlling the flow of a liquid.
2.32 Nozzle, Bellowless. A fuel-dispensing nozzle
designed for use with vacuum-assist Stage JI vapor-
recovery systems that does not have a bellows. (See
also "nozzle bellows.") Vacuum-assist nozzles may be
equipped with a vapor emission guard (see also "vapor
emission guard") to enhance the vapor-collection effi-
ciency of the vapor-recovery system.
2 .33 Nozzle Bellows. A flexible, compressible, corru-
gated tube (often called a boot) around the spout of Stage
TI balance vapor-recovery nozzles. The bellows enables
both an airtight seal between the nozzle bellows face
seal and the vehicle fill pipe and a pathway for vapors
from the motor-vehicle fuel tank to travel into the vapor-
recovery system.
2.34 Nozzle Boot. A common term for a nozzle bellows.
(See "nozzle bel1ows."') This term is also used to describe
the receptacle on the side or front of a dispenser caibinet
where the nozzle is placed between dispensing events.
2.35 Nozzle Spout. The tube at the end of a nozzle that
is inserted into the fill pipe of a vehicle tank during fuel-
ing operations.
2.36 Personal Protective Equipment (PPE). Personal
protective equipment is designed to protect workers from
serious workplace injuries or illnesses resulting from
contact with chemical, physical, electrical, mechanical, or
other workplace hazards. Examples of personal protective
equipment include safety shoes, hard hats, safety glasses,
coveraHs, gloves, high-visibility vests, and respirators.
2.37 Poppeted Coaxial Drop Tube. A coaxial drop
tube that has a spring-operated, ring-shaped poppet at the
top of the vapor path between the fi ll-pipe riser and the
drop tube. This poppet seals the vapor path so that fuel
vapors cannot escape from the storage tank unless a. mat-
ing coaxial fuel-delivery elbow is connected to the fi_ll
pipe. (See also "drop tube" and "coaxial drop tube.")
2.38 Pressure Decay Test. An integrity test of the
ullage portion of a gasoline storage system equ:ipped
with Stage 11 vapor recovery. To conduct the test, all the
vapor-containing portions of the storage system, includ-
ing the vent lines, vapor manifold, vapor piping, and
riser pipes, are pressurized slightly by adding nitrogen
gas. Pressure changes in the system are monitored for a
specified period of time, and the final pressure is com-
pared to an alJowable value.
2.39 Pressure Regulator. 1n Stage II vapor-recovery
testing applications, a pressure regulator is used to reduce
the very high pressures present in the nitrogen source
bottle to the very low pressures required to conduct
various Stage II tests. Because of the large difference in
inlet and outlet pressures involved and the accuracy with
which the outlet pressure must be controlled, a pressure
regulator that steps down the pressure in two stages is
generally required. Alternatively. two pressure regula-
tors, one with a high inlet pressure and one with a low
inlet pressure. may be used in series to accurately control
the nitrogen pressure.
2 .40 Pressure/ Vacuum (P/ V) Vent Valve. Like a
standard vent cap, a pressure/vacuum vent va]ve pre-
vents precipitation from entering the vent pipe and dis-
perses flammable vapors. Unlike a standard vent cap. a
pressure/vacuum vent valve seals the vent-pipe opening
so that air does not enter and vapors do not escape unless
a pressure or vacuum condition that exceeds the design
opening pressure or vacuum limi t of the vent valve is
present in the storage tank. (See also "vent cap.")
2.41 Reference Gauge. A gauge of known accuracy
used as a standard against which other gauges may be
calibrated.
2.42 Riser. A generic term for several types of vertical
pipes typically found in fuel-storage systems. Types of
risers include:
• The length of pipe that is connected to the top of
an underground tank and extends upward to a short
distance below finished grade. Exan1ples of this
type of riser include fill, Stage I vapor recovery,
automatic tank-gauge probe, interstitial, submers-
ible pump, and extractor risers.
• The vertical section of product or vapor piping
located between the dispenser shear valve and the
horizontal run of piping that serves a dispenser.
• The vertical portion of storage-tank vent pipes.
2 .43 Spill-Containment Manhole. A liquid-tight,
cylindrical container, commonly referred to as a "spill
bucket," placed around the fill pipe of a storage tank that
is designed to captme incidental spills that might occur
during a delivery. Typically, spill-containment manholes
are equipped with a drain valve that leads into the ullage
5
PEI Recommended Practices 300-09
space of tbe storage tank below. When spilled product
collects in the manhole, the valve can be opened to allow
the product to drain into the tank.
2.44 Stage I Vapor Recovery. A system for exchang-
ing gasoline vapors in a storage tank and product in a
fuel-delivery truck so that no vapors are released to the
environment. Stage I vapor recovery is typically accom-
plished using one of the following piping arrangements:
• Two-Point (Dual-Point) Vapor Recovery - Two
tank risers are used, one to move Liquid into the
tank and one to move vapors into the truck. There
is a separate vapor-recovery riser for each storage
tank at the facility. (See Figure 3-2.)
• Coaxial Vapor Recovery - A single tank ri ser
is equipped with a coaxial drop tube. A special
delivery elbow connects to the combined fill/vapor
ri ser on the tank and provides separate connection
points for the product and vapor hoses. (See Figure
3-3.)
• Manifolded Vapor Recovery - One or more
vapor collection points are connected via under-
ground piping to all the gasoline storage tanks at
a facility. (See Figure 3-4 and the definition of
"manifold.")
2.45 Stage II Vapor Recovery. A system for exchang-
ing gasoline vapors in a vehicle fuel tank and fuel in a
storage tank so that vapor emissions to the environment
during refueling are significantly reduced. There are two
types of Stage U vapor-recovery systems - balance and
vacuum-assist:
• Balance Stage Il vapor recovery creates an airtight
connection between the motor-vehicle fuel tank,
the storage-system tank, and the vapor piping
between them. (See Figure 4-2.) In a properly
operating balance Stage IT vapor-recovery system,
the movement of a given volume of fuel from the
storage tank to the vehicle tank is balanced by
the flow of an equal volume of vapors from the
vehicle tank to the storage tank. The addition of
fuel to the motor-vehicle tank pushes vapors out of
the vehicle tank while the removal of fuel from the
storage tank helps to draw the vapors back to the
storage tank. There is no external force involved in
moving the gasoline vapors from the vehicle tank
to the storage tank.
• Vacuum-assist Stage II vapor recovery uses an
external vacuum source to help move gasoline
vapors through the Stage II vapor-recovery piping
from the nozzle to the storage tank. (See Figure
6
4-3.) The vacuum source is typically an electrically
driven pump, located in the dispenser cabinet. or a
jet pump, located in the vapor piping near the stor-
age tank. In some cases, the vacuum source may
be combined with a vapor-processing unit that
may be located some distance from the dispensers
or tanks. Because of the external vacuum source,
an airtight connection between the nozzle and the
vehicle fuel tank is not required.
2.46 Stage II Vapor-Recovery Nozzle. A nozzle used
to dispense gasoline that has an internal pathway for
conducting gasoline vapors from the spout through the
handle to the fuel-inlet fitting of the nozzle. Stage II
vapor-recovery nozzles may be either "balance•· or
"vacuum-assist" types.
2 .47 Swivel. A device that facilitates the handling of a
nozzle by reducing the twisting or torsional stress on the
hose. Swivels allow different components of the hanging
hardware to rotate relative to one another. Swivels may
allow rotation along an axis that is parallel to the length
of the hose, perpendicular to the hose, or at about a 45-
degree angle to the hose.
2.48 Tank-Top Sump. A liquid-tight container designed
to contain leaks and spills from tank-top fittings or
equipment and to isolate metallic piping and fittings
from the corrosive underground environment. (See also
"dispenser sump" and "transition sump.")
2.49 Top Off. An attempt to dispense gasoline to a
motor-vehicle fuel tank after the dispensing nozzle's
primary automatic shutoff mechanism has engaged.
2 .50 Transition Sump. A liquid-tight container installed
at a point where product piping from an aboveground stor-
age tank transitions to underground piping. The transition
sump is designed to contain leaks and spills from the pip-
ing and fittings within it and to isolate metallic piping and
fittings from the corrosive underground environment. (See
also "dispenser sump" and "tank-top sump.")
2.51 Ullage. The empty space above the liquid in a
storage tank. The ullage volume is calculated by sub-
tracting the gross volume of liquid in a tank from the
maximum capacity of the tank, as listed on the appli-
cable tank chart.
2.52 Vapor-Emission Guard. A small, flexible, cone-
shaped bellows (also called a "min i-boot") installed at
the base of certain vacuum-assist vapor-recovery nozzle
spouts to enhance the effectiveness of vapor collection.
Although similar in function to a nozzle bellows (see
also "nozzle bellows"), a vapor-emission guard is much
 Recommended Practices for Installation and Tesiing of Vapor-Recovery Systems at Vehicle-Fueling Sites
smaJJer and does not provide an airtight seal widh the
motor-vehicle fil l pipe.
2.53 Vapor/ Fuel Splitter. See ·'fuel/vapor splitter."
2 .54 Vapor-Recovery Adapter. A special fitting in a
Stage I vapor-recovery system that is installed at th.e top
of the vapor-recovery riser in two-point and manifolded
Stage I vapor-recovery systems. The vapor-recovery
adapter mates to the vapor-recovery elbow attached by
the fuel-delivery driver prior to a deli very. Some adapters
incorporate a swivel feature that allows the vapor-recov-
ery elbow to rotate on a vertical axis, thus preventing
the loosening or over-tightening of the adapter because
of movement of the vapor-recovery hose. The adlapter
includes a spring-loaded poppet that remains closed until
the driver attaches the vapor-recovery elbow. An oirange
dust cap is placed on the adapter between fuel deliveries
to keep the poppet clean and identify dhe adapter as a
vapor-recovery fitting.
2.55 Vapor-Recovery System. A general term used
to refer to the equipment and procedures for captur-
ing hydrocarbon vapors during the transfer of gasoline
between bulk tanks, fuel-delivery trucks, storage tanks,
and motor-vehicle fuel tanks.
2.56 Vapor Shear Valve. A fitting installed in dhe
vapor piping at the base of a dispenser dhat is designed
to ·'shear" or break off if the dispenser cabinet is dis-
lodged from its base. (See Figure 5-2.) The vapor shear
valve may incorporate a test port dhat can be used to
introduce nitrogen or product into the vapor piping:. The
vapor shear valve may also include poppets that cap off
dhe vapor piping to the tank and the vapor piping im the
dispenser when dhe shear section separates.
2.57 Vapor Valve. A valve in dhe vapor padhway of a
vapor-recovery system that opens to allow vapor to flow
back to dhe storage tank and closes whenever product is
not being dispensed.
2.58 Vent Cap. A device installed at the top of a stor-
age-tank vent pipe to prevent precipitation from e nter-
ing the vent pipe, while allowing air to freely ente:r and
vapors to freely ex.it the vent pipe. Vent caps intended
for use with flammable liquids must direct vapors exit-
ing dhe vent pipe horizontally or vertically to promote
the dispersion of flammable vapors so they do not accu-
mulate at the base of the vent pipe. (See also "pressure/
vacuum vent valve.")
2.59 Volatile Organic Compound (VOC). Chemical
compounds consisting of hydrogen and carbon atoms
dhat evaporate rapidly.
2.60 Whip Hose. A sho11 length of hose with dhreaded
fittings at both ends that is usually installed adjacent
to a breakaway valve. (See Figure 5-1.) The whip hose
ensures dhat the forces exerted during a drive-off are
aligned widh the axis of the breakaway valve.
3. STAGE I VAPOR-
RECOVERY SYSTEMS
3.1 Stage I Vapor Recovery. The capture of gaso-
line vapors displaced during dhe filling of underground
or aboveground storage tanks is referred to as Stage I
vapor recovery. Captured vapors are transferred to dhe
fuel-delivery truck and transported back to a terminal or
bulk plant where dhey can be processed by condensation,
absorption, or incineration .
During a Stage I delivery, both fuel-delivery and vapor-
recovery hoses must provide airtight connections between
dhe fuel-delivery truck piping and the storage-tank risers.
As fuel flows from the fuel-delivery truck to the storage
tank, vapors from the storage tank are displaced and
drawn into the trnck tank via the vapor-recovery hose.
(See Figures 3-1 A and 3- lB.)
3.2 Vapor-Recovery Adapters. A common feature
of two-point and manifolded Stage I vapor-recovery
systems is a vapor-recovery adapter. The vapor-recovery
adapter is installed at the top of the vapor-recovery riser
and mates to the vapor-recovery elbow attached by the
fuel-delivery driver prior to a delivery.
Some jurisdictions require installation of fill and vapor-
recovery adapters that include a swivel feature. The
swivel facilitates the connection of the vapor hose to
the delivery elbow by allowing dhe deUvery elbow to
rotate. The swivel feature also keeps the vapor-recovery
adapter from becoming loosened or over-tightened when
dhe vapor hose is adjusted, thus maintaining a vapor-tight
seal between the vapor adapter and dhe riser pipe.
Some jurisdictions require dhe installation of spill-con-
tainment manholes around vapor-recovery risers.
3 .3 Types of Stage I Vapor-Recovery Systems. There
are dhree common types of fuel- and vapor-hose arrange-
ments between dhe fuel-delivery truck and dhe facility
storage tank: two-point, coaxial, and manifolded. Each
type is described in the sections that fol low.
PEI Recommended Practices 300-09
Vapor Out
Air In
,D.
Fuel In
Fuel - +
Vapor
c::::::::::J Ai r ¢
FIGURE 3-1A. Without Stage I vapor recove,y, vapors
displaced from the storage tank during a fuel delivery
are released to the atmosphere via the storage tank vent.
As fuel drains from the fuel-delive,y truck, fresh air is
drawn in to the tanker compartment.
Vent
Va or In
Fuel In
FIGURE 3-18. With Stage I vapor recove,y, vapors
displaced from the storage tank during a delivery flow
through the vapor piping and the vapor-recove,y hose
into the fuel-delivery truck. There should be no flow of
air or vapor through the storage tank vent pipe.
3.3.1 Two-Point (Dual-Point) Stage I Vapor-
Recovery Systems. Two-point Stage I vapor-
recovery systems consist of a tank-fill riser
equipped with a drop tube and a separate vapor-
Typically
2 to 6 feet
Fuel a+
Vapor
FIGURE 3-2. Two-point Stage I vapor recovery uses two
separate tank risers, one for fuel delivery into the tank
and one for vapor transfer to the .fuel-delivery truck.
Each tank is equipped with its own vapor riser.
recovery riser, usually located within a few feet of
the fill pipe. (See Figure 3-2.)
Two-point systems require that a separate vapor-
recovery hose be connected for each storage tank
that is to receive product. The fuel- and vapor path-
ways are relatively unrestricted and do not slow
down the rate of fuel delivery into the storage tank.
3.3.2 Coaxial Stage I Vapor-Recovery Sys-
tems. Coaxial Stage I vapor-recovery systems
consist of a tank-fill riser equipped with a smaller-
diameter drop tube. In the United States, the fill
riser is typically 4 inches in diameter while the
coaxial drop tube is typically 3 inches in diameter.
During a fuel delivery, fuel flows into the tank
through the drop tube while vapors flow to the
truck via the narrow space created between the
drop tube and the fill riser. (See Figure 3-3.)
A special fue l-delivery elbow mates to the top
of the fill pipe, sealing the liquid and the vapor
pathways from each other and the atmosphere.
The coaxial delivery elbow separates the product
and vapor pathways so that separate product and
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

than the correspondi ng pathways in a two-point

Vapor Hose system. During a delivery, coaxial vapor-recovery
systems require that a separate vapor-recovery

...
Fuel Hose hose be connected for each storage tank that is to
receive product.

NOTE: Determine local requirements before usi ng

coaxial Stage I vapor recovery. Regulations may
I> t>
limit the use of coaxial Stage I vapor recovery.

Coaxial \, , Ball-float vent valves used for

Fill Pipe
Adapter
overfill prevention will not work when coaxial
Stage I vapor recovery is installed. For more
information concerning overfill prevention,
Tank
see PEI/RPlOO, Recommended Practices f or
Installation of Underground Liquid Storage
Systems.
Coaxial~
Drop Tube 3 .3 .3 Manifolded Stage I Vapor-Recovery Sys-
tems. In manifolded Stage I vapor-recovery sys-
tems, the vent piping from two or more gasoline
tanks is manifolded, and a single vapor-hose con-
nection point is typically provided. (See Figure
3-4.) Some manifolded Stage I vapor-recovery

Fuel -+ l
4to 6 Inches
Vapor
!
FIGURE 3-3 . Coaxial Stage I vapor recovery uses a
drop tube with a narrow top section to create a vapor
pathway between the drop tube and the fill pipe. A spt!.-
cial coaxial delivery elbow must be used to complete the
foe/ and vapor pathways to the fuel-delive,y truck.

vapor hoses can be connected between the dleliv-

ery elbow and the fuel-delivery truck.
Where pressure decay testing of the tank ullage is
required, the top of the coaxial drop tube should
include a spring-loaded poppet mechanism that
automatically seals the vapor pathway to prevent
the release of vapors, except when the delivery
elbow is connected.
Coaxial Stage I vapor recovery can be easily retro-
Fuel -+
fitted on an existing storage tank with a direct-fill Vapor -+
pipe by replacing the existing drop tube with a
coaxial drop tube and fill/vapor adapter. F uel-
delivery rates thro ugh coaxial vapor-recovery FIGURE 3-4. Man~folded Stage l vapor recovery allows
systems are reduced because the cross-sectional a single vapor hose connection point to be used for all
areas of the liquid and vapor pathways are smaller the gasoline tanks at a facility.
PEI Recommended Practices 300-09
systems may utilize multiple vapor-hose connec-
tion points. Stage 11 vapor-recovery piping from the
dispensers is often connected directly to the vent
manifold. Three-inch diameter piping is typically
used to construct the vent manifold.
h. I ( : Only gasoline tanks may share a
common vent manifold. Diesel, kerosene, as
well as other non-gasoline tank vents must
not be manifolded with gasoline vents.
With manifolded Stage I vapor-recovery piping,
product can be delivered into all tanks that share a
vent manifold using one or more vapor-hose con-
nections.
3.4 Aboveground Tanks. Stage I vapor recovery for
aboveground tanks is typically accomplished using two-
point or manifolded connections in the same manner as
with underground tanks. (See Figure 3-5.)
Spill
Container
\ or Adapter
- DropTube
" q
___,__
c,4.o</dp~f/J <rq,cDdD, fl~ ,df/
~ ,qt> <J4
,__ ~4",.q 4
FIGURE 3-5. Two-point Stage I vapor recovery is most
often used with aboveground storage tanks. The fill and
vapor connection points may be located at the tank top
as shown in this figure, or fuel and vapor piping may be
run to a location that is remote from the tank.
4. STAGE II VAPOR·
RECOVERY SYSTEMS
4.1 Stage II Vapor Recovery. Stage II vapor recov-
ery is a system for exchanging gasoline vapors between
a vehicle fuel tank and a fuel storage tank during the
vehicle-fueling process so that the volume of vapor
released to the environment is greatly reduced. Stage II
vapor-recovery system s are generally classified as either
balance or vacuum-assist systems. (See Figures 4- 1A
and 4-lB.) The characteristics of these two types of sys-
tems are described in the following sections.
4 .2 Balance Systems. Balance Stage II systems rely
o n c reating a vapor-tight network so that the transfer of
fuel from the storage tank to the vehicle tank forces the
vapors in the vehicle tank back into the storage tank. The
movement of liquid fuel from the storage tank into the
vehicle creates the forces necessary to move fuel vapors
from the vehicle to the storage tank without the need for
additional pumps. (See Figure 4-2.)
Because the forces moving the vapor are relatively weak
and the distances the vapor must travel are sometimes
long, it is essential that a balance system present as little
resistance as possible to the vapor flow. In addition, the
entire system, especially the inte rface between the fuel-
ing nozzle and the vehicle-fill opening, must be vapor
tight.
Balance vapor-recovery systems can be easily identified
by the large bellows (also known as a boot) that sur-
rounds the nozzle spout. A soft, flexible seal on the end
of the bellows mechanism, called a face seal, is designed
to mate effectively with all types of vehicle fill pipes
to create a vapor-tight seal. The bellows mechanism is
compressed when the nozzle is pushed into the vehicle
fi ll pipe. The compression of the bellows opens a vapor
valve in the nozzle so that vapors can flow back to the
tank. The pressure required to compress the bellows cre-
ates the seal between the vehicle and the vapor pathway
in the dispensing hose. The bellows mechanism includes
an interlock device that prevents fuel dispensing unless
the bellows is compressed sufficiently to ensure an effec-
tive seal.
4.3 Vacuum-Assist Systems. Vacuum-assist systems
e mploy a pump to help move vapors out of the vehicle
fuel tank through the vapor-piping system to the storage
tank. Vacuum-assist systems do not require a vapor-tight
seal between the nozzle spout and the vehicle fill pipe
and do not have the bellows mechanism required on bal-
ance systems. (See F igure 4-3.)
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

Air In
FuelNapor
,0, Splitter

Fuel Out

Fuel -+
Vapor
FIGURE 4-2. In a balance Stage II vapor-recovery sys-
D Air ¢
tem, the nozzle is equipped with a flexible bellows that
seals around the automobile fill pipe. Vapors typically
FIGURE 4-1A. Without Siage If vapor recove,y, vapors
fl.ow in the outside pathway of the coaxial hose, and
displaced from the vehicle tank during fueling are move from the vehicle fuel tank to the storage tank solely
released to the atomosphere. As fuel is pumped out of the because of the transfer offuel from the storage tank to
storage tank, fresh air is drawn in via the vent pipe and the vehicle tank.
becomes saturated with·f uel vapors.

FueWapor
Splitter

Inverted
/ Coaxial Hose

t
Vapor
Pump

Fuel Out

Fuel -+
Vapor
FIGURE 4-3. In a vacuum-assist Stage fl vapor-recovery
system, the nozzle spout contains a vapor pathway,
FIGURE 4-1B. With Stage If vapor recovery, vapors dis-
vapors typically flow in the inside pathway of the coaxial
placed from the vehicle tank during fueling flow through
hose, and a pump is used to move vapors from the
the vapor-recovery hose and piping into the storage tank.
vehicle fuel tank to the storage tank.
There should be no .fl.ow of air or vapor through the stor-
age tank vent pipe.
PEI Recommended Practices 300-09
Most vacuum-assist nozzle spouts are coaxial. with a
central fuel passage and an outer vapor passage. A series
of small holes near the tip of the nozzle spout provide the
entry point for vapors into the recovery system. In some
vacuum-assist nozzles the entry point for the vapors is
near the base of the nozzle spout. These nozzles typicaJiy
have a vapor emission guard to improve the effective-
ness of the vacuum-assist system.
Because vacuum-assist systems are not closed, some air
is drawn into the vapor-recovery system in addition to
the gasoline vapors. As a result, vacuum-assist systems
typicaJiy return slightly more of the vapor/air mixture
to the storage tank than the vol ume of liquid fuel that
is removed from the storage tank. This imbalance may
create a positive pressure in the storage tank. Some
vacuum-assist systems incorporate a remote burner that
automatically burns off excess vapors from the storage
tank. Technology that uses a membrane to separate the
vapors from the air and exhausts the clean air to the
atmosphere has also been developed.
There are two basic types of vacuum-assist systems.
One type uses a vane pump, usually located in the dis-
Exhaust
Vapor Shear
Valve
Emergency
Shutoff Valve
Fuel -+
Vapor
...
FIGURE 4-4. A vacuum-assist Stage II vapor-recovery system operating with an aboveground storage tank fre-
quently requires a vapor pump to assist the movement of vapors and a vapor processor to treat excess vapors that
may be produced in the storage tank when ambient temperature rises. Piping in this .figure is shown schematically
and does not include required valves and fittings. Refer to PEIIRP200 for a thorough description of the valves and
fittings required on aboveground storage tank fuel piping.
penser, to draw vapors from the vehicle fuel tank and
then push the vapors through the vapor piping to the stor-
age tank. The vane pump may be electrically operated or
may be powered by the flow of fuel through the product
piping. In the electrically operated pump the speed of
the pump is electronically controlled. In the fuel-flow
powered pump, the speed of the pump is proportional
to the product flow. In both types of pump, the speed of
the pump is precisely controlled so that the volume of
vapor/air moved is proportional to the volume of fuel
dispensed.
A second type of vacuum-assist system diverts a portion
of the fuel flow from the submersible pump through
a venturi mechanism located in the vapor piping.
High-volume facilities may have a submersible pump
dedicated solely to producing a vacuum in the vapor
piping. The venturi mechanism is usually located on
top of the tank near the submersible pump. After flow-
ing through the venturi, product is returned to the tank.
The venturi mechanism produces a steady vacuum in
the vapor-recovery piping during fueling operations. A
valve in the nozzle controls the flow rate of the vapor/
air mixture drawn into the vapor-recovery system so
PressureNacuum
Vent
Fill Inside Spill
Containment
,
,, i - - - - - - - - - - - - - - --1
,,
,,
,,
,,,,
,,,,
,,
,,,,
~·
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
that it is proportional to the flow rate of the fuel lbeing
dispensed. This type of nozzle may also be used wi.th an
electrically operated constant-speed vapor pump located
in the dispenser.
4.4 Aboveground Tanks. Stage II balance systems
may be less efficient when used with non-insulated
aboveground tanks because the ambient temperature
will influence the pressure inside the tank much more
dramatically than in an underground application. Higher
pressure is also generally required to force vapors
upward against gravity into the aboveground tan k. In
addition, because of the upward slope to the tank, liquid
accumulation in the vapor pathway can also be a prob-
lem. In some cases, a liquid-collection point can be used
to overcome this liquid-accumulation problem.
For these reasons, vacuum-assist Stage 11 systems (see
Figure 4-4) are recommended for aboveground storage
systems unJess the distance between the vehicle tank and
the storage tank is very short and the height difference
is small.
Balance Stage II systems may sometimes be used with
insulated aboveground tanks because the effects of
ambient temperature on pressure in the tank ullag;e are
reduced. Coaxial balance vapor-recovery dispensing
hoses that incorporate a system to remove Liquid product
from the vapor path can also overcome problems with
liquid accumulation in the vapor pathway.
Consult local regulatory authorities for guidance when
selecting a Stage 11 vapor-recovery system for albove-
ground storage tanks.
E Stage Il vapor-recovery systems installed in
aboveground tanks located in underground vaults
are very similar to Stage IT systems installed in
underground tanks. The discussion above is limited
to aboveground tanks located above grade.
5. STAGE II VAPOR·
RECOVERY SYSTEM
COMPONENTS
5.1 General. This chapter describes materials and
components common to most Stage II systems.
H E Regulations typically certify complete Stage
U systems, not individual components. A system
may be certified only for components produced by
a specific manufacturer or for specific models of
components produced by different manufacturers.
Check regulations and/or regulatory equipment
approval lists to determine compatibility of specific
brands and models of components with the specific
Stage II system installed.
E All Stage II hanging-hardware fittings screw
together using straight rather than tapered (NPT)
threads and rely on one or more 0-rings to provide
a liquid- and vapor-tight seal. Lubricate the threads
and 0 -rings with a light film of lithium grease or
anti-seize compound ptior to assembly, but do not
use thread sealant (pipe dope) or Teflon® tape on
these types of fittings.
5.2 Nozzles. Installation of the correct nozzle is criti-
cal to the proper operation of Stage II vapor-recovery
systems. Ensure that nozzles are certified for use with
the specific Stage ll system that is installed.
5.3 Hoses. Most Stage II vapor-recovery dispenser
hoses in operation today are coaxial. In a typical bal-
ance vapor-recovery hose, the fuel travels through the
inner hose and the gasoline vapors flow withi n a lighter-
weight outer hose. Vacuum -assist vapor-recovery sys-
tems typically use an inverted coaxial hose, where the
vapors travel within the inner hose and the product flows
through the outer hose. (See Figures 4-2 and 4-3.)
Stage II hoses used with vapor-recovery systems may
include a liquid-removal device in the vapor pathway if
the hose length and drape create a trap that could contain
sufficient liquid to restrict the free flow of vapors. If the
drape of the hose extends more than 10 inches down-
ward from the fuel inlet of the nozzle when it is hung on
the dispenser, a liqujd-removal device may be req uired.
Consult equipment approvals and local regulations to
determine whether a liquid-removal device is required
for the specific Stage II system that is to be installed.
PEI Recommended Practices 300-09

To accomplish the liquid removal, the opening of a
small-diameter liquid-pickup tube located inside the
vapor hose is positioned at the low point of the hose.
Liquid is typically drawn into the pickup tube by a
vacuum created using a venturi mechanism located in
the product flow path at either end of the hose or within
the nozzle. Proper positioning of the liquid pickup tube
is critical to the proper operation of this type of hose. To
help ensure proper installation, the hose fitting that must
be connected to the nozzle inlet is clearly identified by
the hose manufacturer.
5.4 Swivels. Swivels may be separate fittings or a
swivel feature may be incorporated into the fittings
at one or both ends of a dispensing hose. Swivels are
usually installed at the nozzle end of Stage II hoses to
facilitate the nozzle's movement and orientation as it
is inserted into a vehicle fill pipe. Swivels may also be
used at the breakaway/dispensing hose-connection point
to reduce stress on the breakaway and whip hose dur-
ing fuel dispensing. [nverted coaxial hose is typically
equipped by the manufacturer with swivel fittings at
both ends of the hose. Local regulations may prohibit
swivel fittings that are not incorporated within the hose
e nd fittings.
5.5 Breakaways. Breakaways must be matched to
the type of hose (inve1ted or standard) instaJled. Break-
aways may be designed for single use, in which case
they must be replaced after they separate, or reconnect-
able, in which case they can be put back together and
returned to service after they separate. Breakaways may
also be combined with swivels into a single fitting that
is designed to be instaJled at the nozzle inlet.
• Refer to PEI/RP 500, Recommended Prac-
tices fo r Inspection and Maintenance of Motor
Fuel Dispensing Equipment for procedures to fol-
low when replacing or reconnecting a breakaway
after a drive-off has occurred.
5.6 Hose Retractors. Hose retractors are frequently
used with balance Stage lJ vapor-recovery systems on
low-hose dispensers. They may also be used on high-
hose dispensers. Hose retractors aJlow longer hose
lengths to be used while still minimizing the drape of the
hose below the nozzle when the nozzle is hung up.
5. 7 Vapor Valves. Vapor valves are required to pre-
vent the release of vapors from the vapor pathway of
the nozzle between fueling events. Vapor valves may be
located in a nozzle, in the dispenser cabinet, or in the
vapor/liquid splitter fitting.
5.8 Dispensers. Most dispensers sold today are avail-
able in Stage II and non-Stage II versions. Dispenser

Hose Retractor

Nozzle

Coaxial Hose

FuelNapor Splitter

FIGURE 5-1. To operate properly, breakaway fittings must be correctly positioned in the dispensing hose. On
!ow-hose dispensers equipped with a hose retractor, install a breakaway fitting on the nozzle side where the
retractor cable is attached to the dispensing hose. For high-hose dispensers, install a whip hose between the Jue/-
outlet .fitting of the dispenser and the breakaway fitting.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

manufacturers
.
may require modifications to exi1stino b
dispensers if they are to be retrofitted for Stage II vapor- Emergency Vapor Shear
recovery service. For example, coax.ial-bose adapters Shut-off Valve Valve
or fuel/vapor splitters may need to be installed inside
or outside the dispenser housing. Some manufacturers
supply retrofit kits that provide all the necessary parts Dispenser t
Anchor
to convert a non-Stage TT dispenser to Stage Il seirvice. Bar
Requirements vary among manufacturers and dispenser
models. Pollow manufacturer's instructions applicable to 0
the specific dispenser to be retrofitted.

5.9 Vacuum-Assist Devices. Stage II vacuum-assist

devices are typically installed at the dispenser. (See •,,"" ......
Figure 4-3.) Vacuum-assist devices may occasionally ~ ,. I)

<I 9
be located at rhe submersible pump or at other points in
the vapor-return path. Manufacturers of vacuum-assist
1,,

"'q
..
q9

~p

systems typically provide most of the vacuum-producing p

4

"
..
p
q
I>

and vacuum-controJJing components of the system. as q

well as detailed installation and operating instructions. Island

Some components, such as dispenser banging hardware. t Anchor
Bar
may need to be obtained separately. Ve1ify with the
equipment supplier which components are included and
which must be purchased separately to construct a com- Fuel ....
plete working system. Vapor

5.10 Ball Valves. A balJ valve may be installed in

the vapor piping above the vapor shear valve in each
dispenser so that the vapor-handling components iof the
dispenser and hanging hardware can be isolated from
the underground vapor piping. When searching for the
source of vapor leaks during pressure decay testing of
the vapor-recovery system, these ball valves can be
used to determine whether the leak is in the below-
grade piping or in a dispenser, and to determine which
dispenser(s) may have vapor leaks. Local regul ations
may prohibit the installation of ball valves.
5.11 Vapor Shear Valves. Emergency shut-off valves
(also known as impact, shear, or crash valves) instalJed
in product piping adjacent to vapor-recovery piping may
not function as intended unless the vapor-recovery pip-
ing is designed to shear under the same conditions as the
product piping. Install a vapor shear valve (see Figure
5-2) in Stage Il vapor piping whenever an emergency
shut-off valve is installed in the product piping. In some
jurisdictions, the vapor shear valve must be approved for
use with the vapor-recovery system.
The vapor shear valve may include poppet.s that close
when the shear section separates, closing off the vapor
piping to the tank and within the dispenser. Some jurisdic-
tions may require the use of poppeted vapor shear valves.
FIGURE 5-2. A vapor shear valve must be installed in
the vapor piping whenever an emergency shut-off valve
is present in the product piping. Both the vapur shear
valve and the emergency shut-off valve must be rigidly
anchored with their shear sections even with the top
surface of the pump island.
plug that can be used to introduce nitrogen into the vapor
piping during testing of the Stage Il vapor-recovery sys-
tem. Check local regulations to detennine whether this
type of vapor shear valve is permitted.
Install the vapor shear valve according to the manufactur-
er's instructions. The vapor shear valve must be securely
anchored to both the dispenser island and the structural
framework of the dispenser cabinet to ensure that it will
operate as intended. The shear joint of the vapor shear
valve must be installed level with the shear joint of the
emergency shut-off valve in the product piping and level
with the top of the dispenser island. (See Figure 5-2.)
Local jurisdictions may have specific requirements for
mounting vapor shear valves.
5.12 Pressure/ Vacuum Vent Valves. Most pressure/
vacuum vent valves are preset with specific pressure/
vacuum settings by the manufacturer. Vent valves may
be designed for use with either Staoe 1 only or Staae
b b

The vapor shear valve may also incorporate a threaded TT installations. Consult the specifications of the vapor-
PEI Recommended Practices 300-09
Branch Lines
~ispenser (typ.) (2' Diameter)
Trunk Line
(3' Diameter)- - Lowest
/ Octane Tank
• among all the tanks. The vapor-return pipe is connected
Vapor Manifold
(3' Diameter)--=::
-------
• Vapor risers beneath dispensers are typically construct-
Vent Pipe
(3" Diameter) ~
- - ' - - - -- '
FIGURE 5-3. Schematic diagram of a typical 11w.ni-
folded vapor piping layout. A single vapor line is used to
cany gasoline vapors from the fuel islands to the lowest
octane tank. The gasoline tank ullage spaces are mani-
folded to equalir,e the pressure in all the tanks. A single
vent line services all the gasoline tanks. Product piping
is not shown.
recovery system installed and/or local regulations to
determine the pressure/vacuum settings required for the
pressure/vacuum vent valve(s) installed at a specific
installation.
5.13 Vapor-Return Piping. Vapor-return p1pmg must
provide a clear, unobstructed path from beneath each
dispenser to a storage tank. Liquid motor fuel may enter
the vapor-return path as a result of overfilling or topping-
off the vehic le fuel tank or condensation of fuel vapors in
the cooler underground environment. Uniform sloping of
the piping permits gasoline to drain back into the storage
tank. The accumulation of gasoline in any low spots in
the piping decreases the effective diameter of the vapor-
return piping, thus restricting the free flow of vapors.
Vapor-return piping must have a uniform slope of at
least I /8 inch per foot back to the tank to prevent traps.
A slope of 1/4 inch per foot or greater is preferred. Take
special care to avoid low spots or traps when using
flexible-piping materials for vapor-return piping. Some
jurisdictions may have restiictions on the use of flexible
piping for Stage ll vapor recovery. Refer to Chapters 6
and 7 of this document for additional guidance concern-
ing the installation of vapor piping.
Vapor-return piping is typically manifolded together in
the vicinity of the dispensers so that a single vapor pipe
retm-ns vapors to all the storage tanks. (See Figure 5-3.)
This arrangement also requi res that the vent lines of all
the gasoline tanks be manifolded together, either under-
ground or abovegrnund. Most equipment certifications
require that a common length of piping may not serve as
both the vent line and the vapor-return path from the dis-
pensers so that returned vapors can be evenly ilistributed
to the lowest-grade gasoline tank so that any liquid gaso-
line that may flow down the vapor-return pipe drains into
the lowest-octane tank and does not affect the quality of
the higher-octane gasoline products.
ed of I-inch-diameter pipe. Vapor-recovery piping is
typically 2 or 3 inches in diameter between dispensers.
Three-inch-diameter pipe is typically used for the com-
mon vapor-return line between the dispenser islands and
the tanks. Vapor manifolds between tanks are usually
constructed with 3-inch-diarneter pipe. Check the certi-
fication documents for the specific Stage 11 system being
installed, as well as local regulatory requirements, before
establishi ng piping size or piping material.
Tank vapor-recovery and vent connections are typically
made through extractor fittings to permit isolation of the
vapor piping for tank~ or piping-testing purposes. (See
Figure 5-4.)
5.14 Liquid-Collection Point. Some underground stor-
age facilities may not have a sufficient difference in
height between the tank and the dispensers to provide
a minimum of 1/8-inch-per-foot uniform slope in the
piping from the dispensers back to the storage tanks. At
these facilities, install a liquid-collection point to accom-
modate the required piping slope. (See Figure 5-5.)
T he liquid-collection point is typically installed at a
point in the piping system that allows for a minimum
1/8-inch-per-foot uniform slope in the piping from the
dispensers to the liquid-collection point, and from the
liquid-collection point to the storage tank.
The liquid-collection point must be constructed of non-
corrosive material or protected against corrosion and
must be liquid- and vapor tight. Provide a riser and man-
hole to permit grade level access and manual removal of
 Recommended Practices for lnstallar[on and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

Normal Operation Tightness Testing

Vent Line Va or Manifold Vent Line Va or Manifold

Extractable Ball Float

Valve (Optional)

FIGURE 5-4. An underground tank vapor riser can serve

a number offunctions. A vapor adapter may be installed Access tor Inspection
at the top of the riser to sen1e as the Stage I vapor-recov- and Pump Out '\,.
ery connection point. The base of the vapor riser may
serve as a connection point for both a vent line and a ------_ Vapor-Tight
vapor manifold 10 an adjacent tank. If an extractable fit- To Tank Removable Cap
ting is installed at the base of the vapor rise,; a ball .float
valve may be installed. During a tightness test of the tank
or vapor piping, the vapor piping and the tank can b,e iso-
lated ji-orn one another by installing a removable tes.t plug From Dispensers
in the extractor fitting.
-~:
any gasoline that may accumulate in the liquid-collec-
tion point.
Loofrom +-
Submersible Pump
.,,.
,•
.,.,
,.
:I
Include a mechanism, such as a connection to a submers-
ible-pump suction poit, to automatically remove liquid t qq!,

gasoline from the jjquid-colJection point. The connection :,

to the submersible-pump suction port can be made using
small-diameter copper tubing that extends to the bottom
of the liquid-collection point. Consult the submersible
pump manufacturer's installation instructions for further
details.
A high-level alarm mechanism that will notify the opera-
tor when the Liquid-collection point needs to be pumped
out is recommended.
Fuel -+
Vapor
FIGURE 5-5. A liquid-collection point must be installed
in the vapor return piping when there is not enough dif-
ference in elevation between the dispenser( s) and the
tank field to provide un(form slope of the vapor piping.
Liquid collects in the bottom of the liquid-collection point
where it will not interfere with the flow of vapors toward
the tank. Small diameter copper tubing connected to the
siphon port of the submersible pump is used to remove
the liquid that collects in the bottom of the liquid-collec-
tion point.
PEI Recommended Practices 300-09
6. ABOVEGROUND VAPOR·
RECOVERY PIPING
CONNECTED TO
ABOVEGROUND TANKS
Refer to CARB documents, manufacturer's recommen-
dations, and local regulations for further guidance in the
design and installation of aboveground Stage II vapor-
recovery piping.
7. UNDERGROUND PIPING
AND FITIINGS
7 .1 General Requirements for Underground Vapor-
Recovery Piping. Exercise great care in selecting and
installing underground piping materials. An efficient pip-
ing design minimizes the length of the piping, enhances
operations. and facilitates testing and maintenance.
Vapor-recovery piping, valves, fittings, and related
components must have adequate capacity, strength, and
durabiHty to withstand the operating pressures, structural
stress, and conditions encountered during construction
and subsequent operations of a facility. Exercise the
same degree of care in the selection of vapor-recovery
pipe and fittings as in the selection of tanks, pumps,
hoses, and other components.
Construction documents should specify the materials and
components to be provided, the piping layout, and test-
ing requirements. Follow local codes, designer's plans
and specifications, and piping and component instaJJa-
tion instructions provided by the manufacturer. Strict
adherence to manufacturer's instaJlation instructions is
generally required to preserve product warranties.
Where conflicts between requirements of different sourc-
es are found, use the requirement that is the most conser-
vative and that provides the greatest margin of safety.
Carefully inspect materials and components for defects
and for consistency with specifications in the construc-
tion agreement. Correct any deviations fro m specifica-
tions before construction begins.
1n some jurisdictions, secondary containment of under-
ground vapor piping may be required. Consult wi th local
authorities before finalizing piping-system design.
7 .2 Underground Piping Materials. Underground
vapor piping may be made of fiberglass or flexible mate-
rials intended for this purpose. Use extreme care when
installing flexible pipe to avoid creating low points in the
piping that can become liquid traps. Some jurisdictions
may not allow flexible piping to be used for vapor-recov-
ery purposes or may require that the piping be installed
within a rigid conduit.
Low melting-point materials may be used underground if
they will not be subjected to fire exposure. Piping should
be listed for the intended use.
All piping components, including fitti ngs, flange gaskets,
pipe dope, and the piping itself, must be fully compatible
w ith the products stored.
7 .3 Underground-Piping Practices. Inspect aJI piping
materials prior to installation to detect damage caused by
shipping and handling and to confirm compliance w ith
specifications. Handle piping carefull y to avoid damage
to piping materials during installation and testing. Keep
pipe and fitting interiors and threads free from dirt, mois-
ture, and debris.
Exercise care to measure and cut pipe accurate ly to avoid
failure that can occur when pipe fittings are installed
under stress.
7 .4 Underground Piping Layout and Trenches. Where
practical, run underground piping in a single trench
between the tank area and the dispensing island. Piping
should follow the shortest practical route. Avoid cross-
ing piping runs whenever possible. If crossing of lines
is unavoidable, provide adequate clearance to prevent
contact. Consult the manufacturer's instructions for the
minimum c learance required for the type of piping being
installed.
Make piping trenches wide enough and deep enough to
accom modate both the p iping and the backfi 11 material
requi red to provide protection from damage that might
be caused by settlement, abrasion, vibration, expansion,
contraction, and contact with foreig n mate1ials. (See
Figure 7- 1.) Separate piping runs by a distance of at least
twice the nominal pipe diameter. Allow at least 6-inches
distance between the piping and the trench excavation
walls and ensure that the trench is sufficiently deep to
permit 6 inches of bedding. If conditions permit, 18
inches of compacted backfilJ material and pavement
over the piping is recommended; otherwise, follow the
piping manufacturer's recommendations.
 Recommended Practices for Installation. and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
V,o4.~</<Jp,t>q'"''lq.a41:,. <14q4.q
I>~
4(\ ,J A,Q <J ,,.t4 ~~"11~ '°,QAl;I,
,l!J .,4<1"J,e,.~ 4</,04_,q t,. 'QA
Locatin Ta e or Wire
All Dimensions in Inches.
Vapor
FIGURE 7-1. Piping trench dimensions must allow for
placement of 6 inches of backfill between the piping and
the trench and twice the piping diameter between the
piping runs.
Proper sloping of underground vapor piping is critical
to the effectiveness of the system. Carefully grade and
compact bedding to ensure a minimum slope of 1/8 inch
per foot toward the underground tank. A slope of 1/4
inch per foot, or more, if feasible, is preferred.
Connect the vapor-return pipe from the dispensers to the
lowest-grade gasoline tank so that any liquid gasoline
that may flow down the vapor-return pipe drains into
the lowest octane tank and does not affect the 1quality
of the higher-octane gasoline products. Slope vapor-
manifold piping between tanks according to thesie same
guideHnes.
Traps created by unevenly sloped lines will adversely
affect the efficiency or operation of vapor-recovery
piping. Take extra care in preparing bedding for vapor-
recovery piping to ensure trouble-free operation of the
system.
7.5 Underground Piping Backfill and Com-
paction. Use pea gravel (3/4-inch maximum size) for
piping backfill material. If permitted by the piping man-
ufacturer, crushed rock ( 1/2-inch maximum size) may be
used for piping backfill.
Before backfilLing, remove any rocks, debris, o,r other
foreign material from the piping trench. Also remove
any chocks or bracing used to support or align piping
during construction. Clearly mark trenches and protect
them during construction to prevent damage to piping
from traffic, excavation, grade stakes, or other construc-
tion work.
Document the actual location of piping in as-built draw-
ings. Additional methods of documenting the piping
location include:
• taking photographs of the piping layout prior to
burial
• placing marking tape or metalHc locating tape in
the backfiJJ over the piping to help locate the pip-
ing in case it must be uncovered
• placing a bare copper wire over the piping with its
ends exposed at the dispenser and tank. This wire
can be used in conjunction with buried-ulility-
locating equipment to locate the piping at a later
date.
7.6 Flexible Connectors. When installing rigid non-
metalHc piping, install flexible connectors in vapor-
recovery piping at the base of the dispensers.
Do not twist or kink flexible connectors. Buried flexible
connectors should be listed for underground use. Flex-
ible connectors installed in dispenser or transition sumps
should be listed for aboveground use. Local regulations
may require that flexible connectors be installed only
within containment sumps.
7. 7 Underground Fiberglass Piping. Install fiber-
glass piping systems according to the manufacturer's
instructions. Some jurisdictions require that instaJlers be
certified by the piping manufacturer in order to install
fiberglass piping. Recommended practices include:
• Exercise care in joining fiberglass pipe and fittings
to avoid leaks. Prepare joints, apply adhesives,
and cure according to manufacturer's instruc-
tions. These installation instructions also elaborate
on temperature and moisture considerations and
should be carefully followed.
• When making a transition from steel to nonme-
tallic piping, join female steel threads lo male
nonmetallic threads. If a female fiberglass fitting
is used to connect fiberglass to metallic pipe, take
care not to over tighten and split the fiberglass fit-
ting.
7.8 Underground Flexible Piping. lnstaJl all flexible-
piping systems in strict accordance with the manufactur-
er's installation instructions. Some jurisdictions require
PEI Recommended Practices 300-09
that installers be certified by the piping manufacturer in
order to instaJI flexible piping.
Pay particular attention to provide an even slope for flex-
ible piping. Some flexible-pipi ng manufacturers provide
piping specifically designed for vapor-recovery applica-
tions. Consult local regulations to ensure that flexible
piping is acceptable. Recommended practices include:
• Do not interchange piping and couplings from dif-
ferent manufacturers.
• Heed the manufacturer 's warnings concerning
installation of flexible-piping materiaJs at low
temperatures.
• Ensure that both primary and secondary p1p111g
consist of continuous lengths between containment
sumps. Carefully measure piping lengths to avoid
su·etching or kinking. Make all piping connections
within the confines of containment sumps.
• Be aware that flexible-piping systems may require
different trenching configurations than rigid pip-
ing. Do not exceed the recommended bending
radius specified by the manufacturer for the spe-
cific pipe diameter being installed.
7.9 Containment Sumps. Containment sumps may be
used with fiberglass or flexible piping. Install all sumps
in strict accordance with the manufacturer's installation
instructions. Recommended practices include:
• Position dispenser sumps beneath each dispenser,
and provide a transition sump where aboveground
piping goes underground.
• To avoid leaks into the environment and possible
groundwater or rainwater infiltration into sumps,
make all sump penetrations liquid-tight. Use the
size of hole saw recommended by the manufac-
turer to cut appropriate holes for pipe penetration
fitti ngs. Pipe penetration fittings should minimize
stress on sump penetration seals.
7.10 Riser Piping. Three- or 4-i nch diameter Sched-
ule 40 steel pipe is commonly used for Stage I vapor-
recovery risers. One-inch Schedule 40 pipe or flexible
connectors are commonly used as dispenser vapor risers.
Check the certification documents for the specific Stage
U system being installed, as well as local regulatory
requirements, before establishing piping size or piping
material for vapor risers.
Do not use nonmetallic p1pmg for tank risers. The
repeated connecting and disconnecting of deLivery hoses
at fill and vapor risers causes unacceptable stress in
nonmetalLic piping. Steel fill-pipe risers also provide
a grounding path for static electrical charges produced
when fuel is delivered into the tank.
7 .11 Testing of Underground Primary Vapor
Piping. The following sections describe test procedures
that should be performed on new vapor piping and
vapor-recovery systems during construction and before
placing a system into operation.
7.11.1 Initial Piping Test. Afr test new vapor
piping at 50 psig or the manufacturer's recom-
mended test pressure for a period of one hour.
Local jurisdictions may require testing at greater
pressures or for longer periods. Apply a soap solu-
tion to all joints and inspect for bubbles. Leaks are
indicated by the formation of bubbles created by
air escaping from damaged or defective piping or
joints that are improperly tightened or assembled.
A constant pressure-gauge reading aJone will not
determine whether the piping is tight, but any loss
in gauge pressure should be carefuJiy investigated.
Follow specific instructions provided by individu-
al manufacturers of fiberglass and flexible piping.
\\ \ • <,: Isolate piping from tanks and
dispensers before air testing. Installation of
block valves or extractor fittings to provide a
convenient means of isolation is recommend-
ed. Do not air test lines that have contained
hazardous, flammable, or combustible liquids
or vapors unless they are purged and made
safe beforehand. If purging is not feasible, an
inert gas such as nitrogen or helium may be
used to pressurize the piping.
7.11.2 Initial System Test. This test is intended
to locate leaks in tank-top fittings and any other
storage-system components not tested by the
initiaJ piping test described in 7. l l.l that could
be a source of vapor leaks. Test the vapor tight-
ness of the storage system by pressurizing the
tank(s) and all associated piping to 1 psig. Use
an inert gas to pressu1ize the system if it contains
or has contained product. Leaks are indicated by
the formation of bubbles created by air escaping
from damaged or defective piping or joints that
are improperly tightened or assembled. A constant
pressure-gauge reading alone will not detennine
whether the piping is tight, but any loss of gauge
pressure should be carefully investigated.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
• Do not air test tanks or lines that h.ave
contained hazardous, flammable, or com-
bustible liquids or vapors unless they are
purged and made safe beforehand. H pu1r g-
ing is not feasible, an inert gas such as
nitrogen or helium may be used to press:ur-
ize the tank(s) and piping.
• Use a pressure-relief device to prevent
overpressurizing the tank(s).
• Use two gauges to monitor the test pressure
to reduce the chance of overpressuriz:ing
the tank due to gauge failure.
• Test gauges and pressure-rel.ief deviices
before each use.
• Refer to PEI/RPlOO, Recommended Pmc-
tices for Installation of Underground Liquid
Storage Systems, for further information
concerning pressure testing storage tanks.
7 .11.3 Dynamic Backpressure Test. After back-
filling the piping and making the final tank- and
dispenser-piping connections, but before paving.
perfonn a dynamic backpressure test to confirm
the efficiency of the completed system. This test
will disclose liquid traps. which should be cor-
rected before covering and paving over th1e pip-
ing. The details of the dynamic backpressu re test
procedure are described in Chapter 9 of this docu-
me nt. lf the tank has been ballasted with water,
water may be used instead of product to conduct
the dynamic backpressure test.
7 .11.4 Monitoring During Construction. After
the initial piping and systems tests and dynamic
backpressure test are completed, l O psig air pres-
sure may be maintained in the piping provided the
piping has not contained any product or product
vapors. If piping has contained product or vapors,
an inert gas such as nitrogen or helium may be
used to pressurize the piping. Monitoring the pres-
sure during subseque nt construction can provide
an early warning of piping damage. If damage is
suspected, retest the lines.
7 .11.5 Post Construction Testing. Immediately
before or shortly after underground piping is
placed into service, conduct a pressure decay test
(see Chapter 8), a dynamic backpressure test (see
Chapter 9), and, if vacuum-assist Stage IT vapor
recovery has been installed, an air/liquid ratio
test. (See Chapter 10.) To minimize waiting time
between tests, these tests should be performed in
the order listed here.
7 .12 Testing of Underground Secondary Vapor
Piping. The following sections describe test procedures
that should be perfmmed on new secondary-containment
vapor piping during construction and before placing a
system into operation.
7 .12.1 Initial Test for Underground Secondary
Piping. Air test new secondary piping for a period
of one hour, using the test pressure prescr ibed by
the piping manufacturer. Apply a soap solutio n to
all j oints and inspect for bubbles that indicate a
leak is present. A constant pressurn-gauge read-
ing alone will not determine whether any piping
is tight, but any loss in gauge pressure should be
carefully investigated. ln general, adhere to the
fo llowing pressure-test limits and procedures:
• For fiberglass secondary-containment piping
that operates at atmosphe1ic pressure and uses
clamshell termination fittings, test at IO psig. If
flexible termination fittings are used, test at 5
psig.
• For flexible secondary piping, test at 5 psig.
Expect that a slight expansion of piping may
occur while the piping is under pressure.
7 .12.2 Monitoring During Construction. After
the initial test, 5 psig air pressure may be main-
tained in the secondary piping. Monito1ing the air
pressure during subsequent construction can pro-
vide early warning of piping damage. If damage is
suspected, retest the piping.
7.12.3 Final Integrity Test for Secondary
Piping. Immediately before placing piping in ser-
vice, repeat the test procedure desc1ibed in Section
7.12.1 , soaping any exposed j oints. Monitor the
pressure for one hour and investigate any pressure
loss. After testing is completed , loosen and back
off test fittings to allow any product released from
the primary piping during future operation of the
facility to flow into the containment sumps where
sensors may detect it.
7.12.4 Cleaning Up. When testing is completed,
remove all trash, dirt, wate r, or product that may
be present in dispenser or tank-top containment
sumps and dispose of properly.
PEI Recommended Practices 300-09
8. PRESSURE DECAY TEST
8.1 General. The integrity of the vapor-recovery sys-
tem must be proven to ensure its proper operation. A
system that will not hold pressure will permit the release
of liquids or vapors to the environment. Leaks may result
in excessive YOC emissions and decrease the effective-
ness of the vapor-recovery system.
The pressure decay test described here is a low-pressure
testing method that evaluates all vapor-recovery system
components fro m the nozzle through the hanging hard-
ware, the dispenser, the piping, the tank and tank risers,
and the vent pipe and vent valve. A pressure decay test
is usually conducted just prior to or shortly after placing
a new vapor-recovery system into operation and periodi-
cally thereafter. The testing frequency of operating sys-
tems is determined by local regulations but is typically
annual.
Unlike prei nstallation air tests of underground storage
tanks (see PEI/RP l 00), where little or no loss of pres-
sure is expected during the test, pressure decay tests of
vapor-recovery systems almost always result in some
loss of pressure during the test period. This is due to the
large number of val ves, fittings, and joints susceptible to
leakage that are pressurized dming the test and the very
low test pressures that are used. The allowable loss of
pressure during the test period varies with the volume of
the tank ullage during the test and the number of nozzles
included in a particular test.
The pressure decay test described in this
chapter is based on Stage Il vapor recovery CARB
test procedure TP-201.3, Detennination of 2 Inch
Water Column Static Pressure Performance of Vapor
Recovery Systems ofDispensing Facilities, March 17,
1999 edition. Local authorities may require differ-
ent test pressures, test lengths, or test procedures.
Refer to Appendix D of this document for a complete
reference citatio n for this document.
In instances where the Committee believes
that the CARB procedures are impractical to
execute or apply to equipment that is rarely seen
in today's storage systems, e lements of the CARB
procedures have been omitted or modified to
improve the relevancy and utility of this document.
Before using the pressure decay test procedure
described in this document, verify that it is accept-
able to local authorities.
8.2 Test Equipment. The following sections describe
the testing equipment required to conduct a Stage II
vapor-recovery pressure decay test.
8.2.1 Nitrogen Cylinder and Regulator. Use
commercial-grade nitrogen in a high-pressure
cylinder capable of maintaining at least 2,000
psig of pressure. The nitrogen cylinder should be
equipped with a two-stage pressure regulator or
separate high- and low-pressure regulators to pro-
vide re liable nitrogen flow at the specified pres-
sures and flow rates.
' J ' Use only gaseous nitrogen for
testing; do not use compressed air, helium,
argon, or liquid nitrogen. Do not introduce
nitrogen into the system at flow rates greater
than 5 cubic feet per minute (CFM).
8.2.2 Provision for Bonding and Grounding.
Provide wires that can be used to bond and ground
metallic test-equipment components through
which nitrogen will flow. Wires may be perma-
nently attached to metalJic equipment components
or equipped with appropriate clips for a temporary
connection.
8.2.3 Pressure-Relief Valve. A l psig pressure-
relief valve is required to prevent overpressurizing
the low-pressure components of the vapor-recov-
ery system.
8.2.4 Pressure-Measuring Equipment. Sever-
al different types of pressure-measuring devices
can be used to monitor the pressure change during
the pressure decay test. Whatever type of device is
used, changes of pressure of at least 0.05 inches of
water column (WC) must be able to be easily and
accurately measured.
All pressure-measuring devices must be calibrated
at least every 90 days to ensure accuracy. Calibra-
tion must be conducted using a reference gauge
of known accuracy or an incline manometer. Cali-
brate gauges at 20, 50, and 80 percent of fulJ scale.
Refer to Tables 8-1 and 8-2 for more information.
Following are specifications for specific types of
gauges:
8.2.4.1 Digital Manometer. If a digital
manometer is used. it should be accurate to
within 2.5 percent of full scale. Check the
gauge manufacturer's specifications to deter-
mine the meter accuracy.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

Digital Mechanical
20% full 50% full 80% full 20% full 50% full 80% full
Manometer Gauge
scale scale sct e scale scale scale
Range Range
0 to 20 4.0 +/-0.5 10.0 +/· 0.5 16.0 +/ · 0.5 0 to 20 4.0 +/- 0.8 10.0 +/· 0.8 16.0 +/- 0.8

Oto 10 2.0 +/· 0.25 5.0 +/-0.25 8.0 +/· 0.25 0 to 10 2.0 +/- 0.4 5.0 +/- 0.4 8.0 +/- 0.4

0 to 5 1.0 +/- 0.125 2.5 +/· 0.125 4.0 +/- 0.125 Oto 5 1.0 +/- 0.2 2.5 +/· 0.2 4.0 +/- 0.2

Oto 2 0.4 +/· 0.05 1.0 +/· 0.05 1.6 +/· 0.05 Oto 2 0.4 +/· 0.08 1.0 +/· 0.08 1.6 +/-0.08

0 to 1 0.2 +/· 0.025 0.5 +/· 0.025 0.8 +/· 0.025 O to 1 0.2 +/- 0.04 0.5 +/· 0.04 0.8 +/-0.04

Oto 0.5 0.1 +/- 0.0125 0.25 +/· 0.0125 0.4 +/· 0 .0125 Oto 0.5 0.1 +/· 0.02 0.25 +/· 0.02 0.4 +/- 0.02

NOTE: AU numbers are inches water column (WC)
TABLE 8-1. This table illustrates calibration values and
allowable errorfor digital manometers with various.full-
scale ranges. For example, (f you are calibrating a meter
with a f ull-scale range of JO inches WC at 50 percent of
full scale, whe11 the reference gauge reads 5.0 inches WC,
the gauge you are calibrating must read between 5.25 and
4.75 (5.0 +/- 0.25) inches WC.
NOTE: AU numbers are inches water column (WC)
TABLE 8-2. This table illustrates calibration values and
allowable error for mechanical pressure gauges with vari-
ous ji,ll-scale ranges. For example, if you are calibrating a
meter with afull-scale range of JO inches WC at 50 percent
offull scale, when rhe reference gauge reads 5.0 inches
WC, the gauge you are calibrating must read between 5.4
and 4.6 (5.0 +I- 0.4) inches WC.

8 .2.4 .2 Mechanical Pressure Gaui~e. lf
mechanical spring-diaphragm pressure gaug-
es are used, a minimum of three gauges, one
with a full -scale reading of O to 2.0, one with
a fu ll-scale reading of O to 1.0, and one with
a full-scale reading of O to 0.5 inches WC is
required. Each gauge must have a minimum
4-inch diameter dial face with marked gradu-
ations of no more than 0.05 inches WC and
must be accurate to within 4.0 percent of full
scale. Check the gauge manufacturer's :speci-
fications to de termine the meter accuracy. The
gauges must be connected together in parallel
du1ing the test. Install a ball valve at the inlet
of each gauge so that individual gauge:s can
be isolated from pressures that exceed the
full-scale reading of the gauge.
8.2.4.3 Manometer. If a liquid manometer
is used, a sensitive manomete r with a range of
at least O to 2.0 inches WC is required.
8.2.5 Vent Plug. If there is no pressure/vacuum
vent valve on the ve nt pipe, instal l one with
appropriate pressure/vacuum ratings for the type
of vapor-recovery system installed. If the pressure/
vacuum vent valve opens at a pressure of less than
2.5 inc hes WC, the vent pipe opening should be
sealed during the pressure decay test. Remove the
vent valve and temporarily seal the vent pipe with
an appropriately sized threaded cap or a rubber
plug or cap. Local regulations may not allow test
fixtures to replace operational components during
a pressure decay test. Check local rules before
removing any operational components.
8.2.6 Flow Meter. The flow rate of nitrogen
into the storage system must be between l .O and
5.0 cubic feet per minute (CFM). An appropriate
flow meter is required to measure the nitrogen out-
put of the delivery pressure gauge on the nitrogen
suppl y pressure regulator.
8.2. 7 Stopwatch. A stopwatch accurate to
within 0.2 seconds is required to accurately mea-
sure the test period.
8.2.8 Shut-Off Valve. An appropriately sized
ball valve or similar valve that can reliably isolate
the nitrogen supply hose from the storage system
being tested is required.
8.2.9 Isolation Valve. For vacuum-assist Stage
IT systems which utilize a vacuum pump located
between the Stage 11 vapor riser at the dispenser
and the storage tank, an airtight isolation valve
must be present in the piping between the vacuum
pump and the storage tank.
8.2.10 Test Assembly. A test assembly for intro-
ducing nitrogen into the storage system with
provisions for mounting the pressure gauge(s),
a pressure-relief valve, a flow meter, and a shut-
off valve is required. This test assembly may be
PEI Recommended Practices 300-09
designed to connect to various components of the
storage system. Typical attachment points include
a Stage T vapor-recovery adapter, a test port in a
vapor shear valve, a " tank" port on a submersible-
pump manifold, or a testing port drilled and tapped
into the side of a vent pipe.
8.2.11 P/ V Vent Valve Test Assembly. Equip-
ment to bench test the operation of the P/V vent
valve is required. The test fixture should consist of
a short length of appropriately sized pipe capped
at one end and able to accept the vent valve at the
other. The test fixture should have a volume of less
than 0. 1 cubic foot and should include fittings and
equipment to pressurize, pull a vacuum, and moni-
tor the pressure inside the test fixture.
8.2.12 Leak-Locating Methods and Devices. It
will frequently be necessary to identify leaking
components of the storage system in order to pass
the pressure decay test. There are several means
of detecting vapor leaks. The following are com-
monly used:
• A solution of water and dishwashing detergent
or other bubble-forming agent may be applied
to storage-system components using a spray
bottle. The fo1mation of bubbles will indicate
the leak location.
• Nozzles may be submerged in a shallow pan
of clean water. The formation of bubbles wil l
indicate the leak location. Dispose of water
properly after completing the test.
• A combustible-gas detector equipped with a
flexible probe may be used to detect vapor leaks
in the vicinity of storage-system components.
• Helium may be injected into the storage system
and a sensitive helium detector used to locate
the leak. Helium dissipates quickly, so it should
be injected into the storage system slowly and
continuously while searching for the leak with
the heli um detector. Helium may also be used to
locate leaks in bu1ied piping and fittings.
8.3 Preparing for the Test. For new instaJ!ations, the
pressure decay test is conducted after backfilling, paving,
and installation of all Stage I and Stage IT components
have been completed. T he following pre-test procedures
must be followed:
8.3.1 Safety. Survey the site layout and evalu-
ate the level of activity of non-test personnel (e.g.,
customers, clerks, mechanics. other construction
workers) at the facility. Be sure that all required
safety equipment, including but not limited to
applicable personal protective equipment, bar-
ricades, safety cones, barrier tape, warning signs,
fire extinguishers, and e lectrical lockout/tagout
devices, is on hand and sufficient to ensure a safe
environment for all personnel that may be present
at the site.
8.3.2 Delay After Deliveries. Conduct the pres-
sure decay test at least three hours after a product
delivery. Local jurisdictions may require differ-
ent waiting periods after a delivery. Verify local
requirements before proceeding. Do not allow any
product def iveries during the test.
8.3.3 Delay After A/ L Testing. Conduct no air-
to-liquid (NL ) volume-ratio testing on the storage
system in the 24-hour pe1iod immediately before
the test.
8.3.4 Delay After Dispensing. Allow no prod-
uct dispensing for 30 minutes prior to the test or at
any time during the test procedure.
8.3.5 Place Dispensing Equipment in Normal
Operating Position. AU fuel-di pensing equip-
ment should be in normal operating mode. AJI
nozzles must be properly hung up and dispenser
cabinet covers in place.
8.3.6 Remove Fill Adapter Caps and Vapor
Adapter Dust Caps. For two-point and mani-
folded Stage I vapor-recovery systems, the dust
cap on the vapor adapter and the fill adapter cap
must be removed during the test. For coaxial Stage
I vapor-recovery systems, the fill adapter cap must
be removed during the test. A poppeted coaxial
drop tube must be installed for the pressure decay
test to be conducted on coaxial Stage I systems
with the fill adapter cap removed.
8.3. 7 Check Product Level. The liquid level in
the tank must be at least 4 inches higher than the
highest point of tbe bottom end of the drop tube.
8.3.8 Check Drains in Spill-Containment
Manholes. If the spill-containment manhole is
equipped with a drain valve, the test must be
conducted with the drain valve installed. Clean,
inspect, and repair drain valves before beginning
the test procedure. If the spill-containment man-
hole cover contains gaskets or 0 -rings designed
to provide a liquid-tight seal, the test must be con-
ducted with the manhole cover removed.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
8.3.9 Check Ullage Volume. Calculate the
ullage space in each tank by subtracting the vol-
ume of product present from the maximum capac-
ity of each tank, as indicated on the appropriate
tank chart. The ullage can also be determined
by reviewing the ullage volume calculated lby an
automatic tank gauge for each tank. To conduct a
test, the ullage volume for each tank with a capac-
ity of 4,000 gallons or more must be at least 1,000
gallons. For tanks with a capacity of less than
4,000 gallons, the ullage volume must be at least
25 percent of the tank capacity. The total ullage
of all tanks that are manifolded together mu:st not
exceed 25,000 gallons.
8.3.1.0 Drain Liquid-Collection Points. If there
are liquid-collection points installed at the facility.
remove the access cover(s) and check for the pres-
ence of liquid product. If product is present, drai n
the liquid-collection point(s) before conducting
the pressure decay test.
8.3.1.1. Connect Test Assembly. Attach the test
assembly to a convenient connection point, such
as a Stage I vapor-recovery adapter, a "tank" port
on a submersible-pump manifold, a testing port
drilled and tapped into the side of a vent pipe, or a
test port in a vapor shear valve. lf utilizing the test
port in a vapor shear valve for attaching the test
assembly, use care not to damage the valve when
attaching and removing fittings.
8 .3.1.2 Bond and Ground the Test Equip-
ment. Bond the nitrogen supply bottle to each
metallic testing component such as regulators,
gauges, and fittings that are not electrically contin-
uous with one another. Ground the test equipment
to a suitable location such as a metallic compo nent
of the dispenser frame.
8.3.13 Calculate Pressurization Time. Calcu-
lating the time that should be required to pre:ssur-
ize a non-leaking system and then monito1ing the
time required to actually pressurize a system can
provide an early indication of a substantial leak. If
the time required to achieve a pressure of 2 ir1ches
WC is more than twice the calculated time, a sub-
stantial leak is present which must be iden1tified
and corrected before the test can proceed. The for-
mula for calculating the minimum time required to
pressurize a storage system from O to 2 inches WC
is as follows:
T = V/(1,980)F
Where:
T = the minimum time required to pressur-
ize the storage-system ullage from O to
2 inches WC, in minutes.
V = the ullage volume being pressurized, in
gallons.
F = the flow rate of nitrogen into the stor-
age-system ullage, in cubic feet per
minute.
1.980 a constant that incorporates the volume
of nitrogen required to increase the
ullage pressure and a conversion factor
from cubic feet to gallons.
Example: If the u!Jage volume is 5.000
gallons and the flow rate is 4 CFM, the
minimum time required to pressurize
this system to 2.0 inches WC is:
T = 5,000/(1,980)4
T = 5,00017,920
T = 0.63 minutes
8 .3.14 Turn Off Vapor Processors. For vacuum-
assist Stage Il systems that utilize an incinerator
or other vapor-processing unit, turn off power to
the vapor processor during pressure decay testing,
observing proper lockout/tagout procedures.
8.4 Test Procedure.
8.4.1 Initiate Safety Procedures. Take al I pre-
cautions necessary to protect testing personnel,
facility employees, and the general public from
safety hazards that may be produced by testing
activities.
8.4.2 Warm Up the Digital Manometer. If a
digital manometer is used to monitor the ullage
pressure, turn the instrument on and allow it to
warm up for at least 15 minutes. After the instru-
ment has warmed up, monitor the ambient pres-
sure for five minutes. lf tbe meter reading drifts
more than 0.01 inches WC during the five-minute
period, it cannot be used to conduct a pressure
decay test.
8 .4.3 Pre-Test the Stage I Vapor-Recovery
Adapter. If nitrogen is to be introduced into the
storage system via a Stage I vapor adapter fitting
(two-point and manifolded Stage 1 syste ms), the
integrity of this vapor adapter must be established.
If more than one vapor adapter is present at the
PEI Recommended Practices 300-09
facility, a simple way to establish the integrity of
the vapor adapter is to perfonn the pressure decay
test twice, usi ng a different vapor adapter as the
nitrogen introduction point for each test. If both
tests pass, then both vapor adapters are sufficiently
vapor tight.
If there is only one vapor adapter present, test the
integrity of the vapor adapter before conducting
the pressure decay test usi ng the following pro-
cedure.
• Remove the adapter and install a temporary cap
on the vapor riser to prevent the emission of
vapors during the testing of the vapor adapter.
• Install the vapor adapter on a test fixture con-
sisting of a short length of appropriately sized
pipe capped at one end and threaded to accept
the vapor adapter at the other. The test fixture
should have a volume of less than 0.1 cubic feet
and should include fittings that can be used to
pressurize the test fixture and monitor the pres-
sure inside the test fixture.
• Carefully pressurize the test fitting to 2.0 inches
WC and monjtor the pressure for one minute. If
the pressure in the test fitting is less than 0.25
inches WC after one mfoute, the storage-system
pressure decay test cannot be conducted using
this vapor adapter as the point of introduction
of nitrogen into the system.
This test of the vapor adapter is more sensitive
than the storage-system pressure decay test, so
that, depending on how many other leaks are
present in the storage-system ullage, the vapor-
recovery adapter may be sufficiently vapor tight to
pass the overall system test. Fmling this test only
means that this Stage I adapter cannot be used to
introduce nitrogen into the ullage space during the
pressure decay test. [f the vapor adapter fai ls to
hold adequate pressure, test a new vapor adapter
according to the procedure in this section and, if
it passes the test, install it on the vapor riser and
proceed with the pressure decay test.
. The procedure described here for bench
testing the vapor adapter differs from the procedure
described in the CARB pressure decay test proce-
dure. The CARB procedure tests the vapor adapter
wru le it is installed on the vapor riser by attaching
a test fixture and applying pressure to the top of
the valve. The RP300 Committee believes that the
procedure described here is a more appropriate test
26
of the vapor adapter because the pressure is applied
from the bottom of the valve, which is bow the
valve functions under operating conditions.
8 .4.4 Close the Valve Between the Vacuum
Pump and the Storage Tank. If the storage
system is the type that includes a vacuum pump
between the dispenser vapor-recovery riser and
the storage tank, close the isolation valve located
between the vacuum pump and the storage tank.
8.4.5 Stop Dispensing and Monitor Pressure.
No product should be dispensed for 30 minutes
prior to the test or at any time during the test
procedure. During the 30-minute "no dispensing"
period, monitor the pressure in the storage system
usi ng the pressure gauge(s) in the test assembly.
Be sure the shut-off valve in the test assembly is
closed so that the storage system is isolated from
the nitrogen supply. If the pressure at the begin-
ning of the 30-rninute period exceeds 0.5 inches
WC, the pressw·e must be relieved to less than 0.5
inches WC. At the end of the 30-minute period,
before pressurizing the storage system with nitro-
gen, the pressure should again be lowered to less
than 0.5 inches WC, if necessary.
8.4 .6 Pressurize the Ullage Space of the Stor-
age System. Open the shut-off valve and adjust
the pressure regulator(s) so that the flow rate of
nitrogen into the storage system is between J .0
and 5.0 CFM. Record the flow rate used during the
test.
8.4. 7 Monitor the Time Required to Pressur-
ize the Storage System. If the time required to
reach the initial test pressure of 2.0 inches WC
is more than twice the time calculated in Section
8.3.1 3, stop the test. The excessive time required
to pressurize the storage system indicates the pres-
ence of a large leak that must be corrected in order
for the test to proceed. Maintain a small flow of
nitrogen into the storage system to maintmn posi-
tive pressure witrun the ullage space and facilitate
leak detection. Use the methods listed in Section
8.2. 12 to locate leaks. Verify that aU test equip-
ment and fittings are tight.
8.4.8 Pressurize the Ullage to 2.2 Inches
WC. When all large leaks, if any, have been
sealed, continue to introduce nitrogen into the
storage system at a flow rate between 1.0 and 5 .0
CFM. lncrea<;e the pressure witruo the storage sys-
tem to a minimum of 2.2 inches WC.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
FIGURE 8-1. Pressure Decay Test Equipment. Test ,equip-
ment ser up for a pressure decay test. For safety and con-
venience, the nitrogen supply bottle remains secured in the
testers vehicle. At this facility, a permanently installed ''T"
filling provides the connection poinr to the vapor recove,y
piping.
8.4.9 Conduct the Test. Close the shut-off
valve to isolate the storage system from the nitro-
gen supply. Close the nitrogen supply valve at the
nitrogen bottle and disconnect the nitrogen slllpply
hose from the test assembly. Monitor the pressure
in the storage system and start the stopwatch when
the pressure drops to 2.0 inches WC. Record the
pressure at one-minute intervals during the, test.
After five minutes, record the final storage-syste m
pressure. Refer to the applicable table in App.end.ix
A to determine whether the final storage-system
pressure is acceptable. For ullage volumes that fall
between the ullage volumes listed in Appendix A,
use interpolation to determine the final pre:ssure
value for a given ullage volume. Ao example of an
interpolation calculation is given in Appendix A.
8.4.10 If the Storage System Falls the Test. If
the final storage-system pressure at the end of
the five-minute test period is Jess than the value
specified in Appendix A, repressurize the ulllage
space and locate the leak(s) us ing the techniques
described in Section 8.2.12. After correcting the
leak(s), repeat the test procedure in Sections 8.4.8
and 8.4.9.
8.4.11 If the Vapor-Return Lines Are Not
Manifolded. If there are multiple storage tanks at
the facility but the ullage spaces of the tanks are
not manifolded and there are separate vapor-return
lines for each product, repeat the pressure decay
test for each grade of gasoline.
8.4.12 If the Vapor Piping Was Isolated from the
Tank(s). For vacuum-assist Stage II systems that
utilize a vacuum pump located between the Stage II
vapor riser at the dispenser and the storage tank, use
the column from the tables in Appendix A for '' l -6
affected nozzles" to determine the approp1iate pres-
sure when comparing the uUage pressure at the end
of the test to the allowable minimum pressure. Test
the vapor pathway between the isolation valve and
the nozzle using a separate test procedure. Consult
manufacturers' recommendations and local authori-
ties for the appropriate test procedure to use.
8.4.13 Test the P/ V Vent Valve. Test the P/V
vent valve to verify that it is operating within spec-
ifications. Install the vent valve on the test fixture
described in Section 8.2. 11. The P/V vent valve
should release at 3.0 ( +/- 0.5) inches WC pressure,
and 8 inches ( +/- 2.0) inches WC vacuum. Local
authorities may require different test procedures.
After the functional test of the P/V vent valve is
successfully completed, replace the P/V vent valve
on the vent pipe.
8.4.14 Reporting Results. At a mjnimum, the
following information should be recorded on the
test data reporting form:
• name and address of the faciUty
• name of the facility owner
• facility identification number assigned by the
state
• testing company and testing personnel
• date and time
• Stage I system type (two-point or coaxial)
• Stage II system type and manufacturer
• presence or absence of a P/V vent valve
• whether the system is manifolded
• a listing of the following information for each
tank:
- full tank capacity
- gallons of product present
- ullage
- nitrogen flow rate used to pressurize the sys-
tem
- initial pressure in inches WC
pressure at the end of each one-minute
period,
- final pressure after five minutes
PEI Recommended Practices 300-09
• conclusions and comments, including:
- the minimum acceptable pressure remaining
at the conclusion of the test for the specific
test conditions (ullage volume, number of
nozzles, and type of Stage II system) present
at the facility
- a statement with a conclusion as to whether
the storage system passed or failed the pres-
sure decay test
- a statement of whether the PN vent valve
passed or failed the test.
Refer to Appendix B- l for an example of a pres-
sure decay test data reporting form.
8.4.15 Cleaning Up. Release any remaining pres-
sure in the storage system by opening the shut-off
valve in the test assembly. Ensure that there are no
sources of ignition in the area where vapors will be
released. Disconnect all test equipment and return
the facility to operating condition, unless further
testing is to be conducted immediately following
the pressure decay test.
8.5 Testing Aboveground Tanks. The pressure decay
test procedure for aboveground storage tanks is very
similar to the procedure described above for under-
ground tanks. The most significant difference is that the
minimum ullage required for aboveground tanks is 300
gallons or 25 percent of the tank capacity, whichever is
greater. [f applicable, vent pipes may be manifolded dur-
ing the test to achieve the required ullage. The minimum
required pressure at the end of the five-minute test period
is also specific to aboveground storage systems. Refer
to Table A-3 in Appendix A for a listing of acceptable
minimum pressures.
Local authorities may require different test pressures,
test lengths, or test procedures for aboveground tanks.
9. DYNAMIC
BACKPRESSURETEST
9.1 General. The vapor-return pathway from the noz-
zle to the tank must be free of obstructions and have
sufficient capacity to acconunodate the flow of vapors
generated by the fueling operation. Low spots (com-
monly called traps) in hoses or piping may accumulate
liquid, reducing the area of the vapor path and restrict-
ing the flow of vapors to the tank. Undersized piping or
obstructions in the vapor-return piping, such as crimped
flexible connectors or collapsed or plugged piping, may
al so restrict the flow of vapors to the tank.
The dynamic backpressure test simulates system opera-
tion by flowing nitrogen gas through the vapor pathway
and measuring the resistance to flow (backpressure)
that is produced. Depending on the type of equipment
installed at a faci lity, nitrogen gas is introduced into
each nozzle or into each dispenser vapor riser. Back-
pressure measurements are made at three equipment-
specific nitrogen flow rates and the results are compared
to acceptable limits that are also specific to the type of
Stage II vapor-recovery system being tested. Consult the
equipment manufacturer or local regulatory autho1ities
to determine required flow rates and acceptable back-
pressures.
A dynamic backpressure test is recommended after Stage
11 piping is bwied, but before paving, so that traps result-
ing from insufficient or inaccurate sloping of the piping
can be easily remedied. Repeat the dynamic backpres-
s ure test after the instalJation of the storage and dispens-
ing system is complete, either before it is placed into
operation or soon afterward. Repeat the test periodically
thereafter. The testing frequency of operating systems is
determined by local regulations.
The dynamic backpressure test procedures
described here are based on CARR test procedure
TP-201.4, Dynamic Back Pressure, July 3, 2002
edition. Local authorities may require different
test procedures. Refer to Appendix D for a complete
reference citation for this document.
9.2 Dynamic Backpressure Test Methods. The
CARB test procedures describe five variations on the
dynamic backpressure test that can be performed on
Stage Il vapor piping, as well as a sixth dynantic back-
pressure test that is applied to the vent piping. Table 9- l
describes the applicability of the six methods and how
they will be addressed in this document. OnJy Methods
I and 4 wiU be fully described in this document.
Test Method J evaluates the complete vapor pathway
from the nozzle back to the storage tank. The nitrogen
is introduced into the Stage II piping by inserting the
nozzle into a simulated automobile fill pipe connected to
the nitrogen source.
Test Method 4 evaluates the vapor pathway from the
dispenser riser back to the storage tank. The nitrogen is
 Recornmended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

Method Applicability Notes 9.3 Dynamic Backpressure Test Equipment. The

Balance vapor- This method is
fo llowing sections describe the equipment required to
recovery systems described in this cond uct dynamic backpressure testing;
1 without a remote document.
9.3.1 Nitrogen Cylinder and Regulator. Use
vapor check valve.
commerc ial-grade nitrogen in a high-pressure
Vapor-recovery The installed base of
cylinder capable of maintaining at least 2,000
systems where a this type of system
remote vapor check is not sufficient to psig of pressure. The nitrogen cylinder should be
valve is present and justify inclusion of equipped with a two-stage pressure regulator or
2 the vapor path on this method in this separate high- and low-pressure regulators to pro-
each side of the valve document. Refer vide reliable nitrogen flow at the specified pres-
is tested separately. to CARB TP-201.4 sures and flow rates.
for applicable test
procedures.
l \ fl ,Use only gaseous nitrogen for
•,
Vapor-recovery The installed base of
systems where a this type of system
testing; do not use compressed air, helium,
remote vapor check is not sufficient to argon, or liquid nitrogen.
valve is present and justify inclusion of
3 the valve can be this method in this
9.3.2 Provision for. Bonding and Grounding.
disabled by removing document. Refer
the poppet. to CARB TP-201.4 Provide wires that can be used to bond and ground
for applicable test metallic test-equi pment components through
procedures. which nitrogen will flow. Wires may be perma-
Vacuum-assist This method is nently attached to metallic equi pment components
systems where t he described in this or equipped with appropriate clips for a temporary
4 vacuum-producing document. connection.
device is located in
the dispenser. 9.3.3 Pressure-Relief Valve. A 1 psig pressure-
A test of vapor- This method is relief valve is requi red to prevent overpressurizing
recovery systems described in this the low-pressure components o f the vapor-recov-
5 where the test is document. ery system.
conducted during an
actual fueling event. 9.3.4 Pressure-Measuring Equipment. Two
A backpressure test The RP300 Committee different types of pressure-measuring devices
for the vent piping, has insufficient can be used to moni tor the backpressure during
not the Stage II vapor- experience with this dynamic backpressure testing. Following are the
recovery piping. test met hod to include specifications for specific types of gauges:
6 it in this document.
Refer to CARB TP- 9.3.4.1 Digital Manometer. Jf a digital
201.4 for applicable
manometer is used, it should be accurate to
test procedures.
within 2.5 percent of full scale. Check the
TABLE 9-1. CA RB test procedure TP-201.4 contains six gauge manufacturer's specifications to deter-
different methods for conducting dynamic backpressu re mine the meter accuracy.
testing. This table notes the applicability of each test
method and whether each method is described in this 9.3.4.2 Mechanical Pressure Gauge. If a
document. mechanical spring-diaphragm pressure gauge
is used, the gauge must have a minimum 4-
introduced into the Stage II piping by disconnecting the inch diameter dial face and must be accurate
vapor piping at the base of the dispenser. The vapor path- to 4.0 percent of full scale. Check the gauge
ways in the dispenser cabinet and the hanging hardware manufacturer's specifications to determi ne
are not tested. the meter accuracy.

Consult equipment approvals and local regulatory
requirements to detem1ine the dynamic backpressure
testing requirements for vapor-recovery systems with a
vacu um pump located between the dispenser riser and
the tank.
The number and pressure range of mechanical
gauges required for Test Methods 1 and 4 are
as follows:

29
PEI Recommended Practices 300-09
• Method l requires two gauges: one gauge
that reads from Oto 0.5 inches WC and one
gauge that reads from O to 1.0 inch WC.
• Method 4 requires one gauge that reads
from O to 0.25 inches WC.
Install a ball valve at the inlet of mechanical
gauges so that indi vidual gauges can be iso-
lated from pressures thal exceed the full-scale
reading of the gauge.
9.3.5 Flow Meter. Use a calibrated flow meter
that can acc urately measure the nitrogen flow rates
specified by the equipment-approval documents
for the Stage II equip ment installed at the site.
While the flow rates to be used during tests are
equipment specific, typical flow rates are in the
range of 20 to 100 cubic feet per hour (CFH).
9.3.6 Shut-Off Valve. Use an appropriately
sized ball valve or similar valve that can reliably
isolate the niu·ogen supply hose from the tesl
equipment.
9.3.7 Simulated Fill Pipe. Method 1 requires a
simulated automobile fill pipe that is compatible
with bellows-equipped vapor-recovery nozzles.
The simulated fi ll pipe should include a connec-
tion point for a pressme gauge to monitor back-
pressure, a fl ow meter, an inlet for the nitrogen,
and a drain valve to remove any product intro-
duced into the test fitting from the nozzle.
9.3.8 Gasket. A flat, flexible, gasoline-com-
patible ting-shaped gasket with an outside diam-
eter of approximately 3.5 inches and an inside
diameter of approximately 1.5 inches is required if
Method I is used. This gasket is placed at the top
of lhe simulated automobile fill pipe to help ensure
a proper seal between the nozzle face seal and the
simulated fi ll pipe.
9.3.9 "T" Assembly. Method 4 requires a "T"
assembly to introduce the nitrogen into the dis-
penser vapor riser and measure the backpressure.
One branch of the "T" fitting connects to the
dispenser vapor riser, the other branch to a quick-
connect fitting that connects to the nitrogen sup-
ply hose, and the third branch of the "T" fitting is
connected to a pressure gauge. Make provisions to
insert a flow meter into the nitrogen supply line so
that the nitrogen flow rate into the Stage II vapor
piping can be measured.
9.3.10 Pump. Use a gasoline-compatible hand
pump, or other pumping device that can be used
to remove gasoline present in any liquid-collec-
tion points in the Stage II piping. If the pump is
elecuically operated, verify that it is rated for use
in C lass 1. Division I areas and that it is properly
grounded and bonded.
9.3.11 Portable Gasoline Tank. Use a small
metal container for fuel pumped from any liquid-
collection points. Use a container approved for
gasoline, and be sure the container is placed on the
ground when gasoline is being pumped into it.
9.3.12 Stopwatch. Use a stopwatch accurate
to within 0.2 seconds to accurately measure time
intervals during the test.
9.3.13 Vapor-Adapter Opener. Because ni tro-
gen will be added to the tank ullage space during
dynamic backpressure testing, a means of venting
the tank that presents little resistance to flow must
be provided. This is typically done by opening a
Stage T vapor-recovery adapter. A standard vapor-
recovery delivery elbow (the device that connects
to the Stage I adapter during a delivery of fuel) can
be used to hold open the vapor-recovery-adapter
poppet.
A more compact device can be fabricated from
a vapor-recovery dust cap by drilling a 3/8-inch
hole in the center of the cap and installing a 2-
inch-long carriage or machine bolt so that it will
depress the vapor-recovery-adapter poppet when
the cap is fastened to the vapor adapter. Several
1-inch diameter holes must also be drilled into the
top of the dust cap to allow the tank to vent freely
through the dust cap when it is installed on a Stage
I vapor-recovery adapter.
9 .4 Preparing for the Test. UnJess otherwise noted,
the following steps should be performed prior to starting
the dynamic backpressure test when either Melhod 1 or
4 is used:
9.4.1 Initiate Safety Procedures. Take all pre-
cautions necessary to protect testi ng personnel.
fac ility employees, and the general public from
safety hazards that may be produced by testing
acti vities.
9.4.2 Verify the Integrity of the Storage
System. Conduct a pressure decay test to verify
the integrity of the vapor-handling portions of
the storage system before conducting a dynamic
backpressure test. Repair or replace any damaged
or leaking components.
 Recommended Practices for lnscallation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
9.4.3 Flow Liquid Through the Vapor Piping.
Beginning at the clispenser farthest from the tanks,
introduce a minimum of two gallons of gasoline
into each Stage Il vapor-recovery dispenser 1iser.
Local regulations may require that larger volumes
of gasoline be introduced. When vapor piping is
manifolded, this is the only way to ensure that each
length of branch piping feeding into the vapor-
recovery trunk line is properly sloped. Dispensing
fuel from a nozzle is a convenient way of introduc-
ing fuel into the vapor-recovery piping. Wait for
the gasoline in the Stage IT piping to drain into the
storage tank before continuing with the test.
• Some regulatory agencies may waive the
requjrement to flow gasoline through the vapor
piping for eidsting facilities that have been in
operation prior to the day of the test.
If this test is being conducted during ins1tal-
lation when the tank is ballasted with water, water
may be poured into the vapor piping rather than
gasoline.
9.4.4 Drain Liquid-Collection Point. Determine
whether a liquid-collection point is present in the
vapor-recovery piping at the facility. If the Stage
n piping includes a liquid-collection point, inspect
it to determine whether it contains any gas.oline.
Pump any gasoline present out of the liquid-col-
lection point into a portable tank before conduct-
ing the dynamic backpressure test.
9.4.5 Bond and Ground the Test Equipiment.
Bond the nitrogen supply bottle to each m etallic
testing component such as regulators, gauges. and
fittings that are not electrically continuous with
one another. Ground the test equipment to a suit-
able location such as a metallic component of the
dispenser frame.
9.4.6 Check Test Equipment for Leaks. For
Method I only, check the test equipment for leaks.
The simulated fill pipe and associated tubing,
valves, gauges, and fittings must be leak-free to
ensure an accurate test. Seal the opening of the
simulated fill pipe using an automotive gas-tank
cap or other convenient sealing device . Close any
valves that open to the atmosphere.
Pressurize the test equipment to 50 percent of the
full-scale reacting of the pressure gauge. ff two
gauges are used. pressurize the test equipment to
50 percent of full scale of the higher-range pres-
sure gauge. Close the nitrogen cylinder valve and
monitor the pressure for five minutes. A decrease
in pressure of less than 0.2 inch WC is required to
pass the test.
If the simulated fill-pipe test equipment fails the
test, locate the leak by repressurizing the testing
unit and applying a soap solution to all joints and
fittings. A leak is inclicated by the formation of
soap bubbles. Tighten, repair, or replace any leak-
ing component and repeat tbe test. When the test
bas been successfully passed, remove the cap used
to seal the opening of the simulated fill pipe.
9.4.7 Check Method 1 Test Equipment for
Backpressure. With the simulated fill pipe open
to atmosphere (no cap, no nozzle inserted), flow
nitrogen through the test equipment at each of the
specified flow rates. Allow the nitrogen to flow for
at least 30 seconds, then read the pressure gauge.
The reading should be zero. U the reading is not
zero, adjust or replace the gauge.
9.4.8 Check Method 4 Test Equipment for
Backpressure. With the "T" assembly open to
atmosphere (not connected to the Stage IT piping),
flow nitrogen through the "T" assembly at each of
the specified flow rates. Allow nitrogen to flow for
at least 30 seconds, then read the pressure gauge.
The reading should be zero. If the reading is not
zero, adjust or replace the gauge.
9.4 .9 Connect "T" Assembly. For Method 4
only, disconnect the vapor piping at the base of the
dispenser and cap off the vapor piping leading to
the storage tank using the "T" assembly described
above (Section 9.3.9). The "T" assembly may also
be installed in the test-plug opening of the vapor
shear valve. There must be no vacuum-producing
equipment be tween the "T" assembly and the stor-
age tank.
9.5 Test Procedure. Unless otherwise noted, the fol-
lowing steps describe the test procedure to be followed
for dynamic backpressure testing when either Method I
or 4 is used.
9.5.1 Initiate Safety Procedures. Take all pre-
cautions necessary to protect testing personnel,
facil ity employees, and the general public from
safety hazards that may be produced by testing
activities.
9.5.2 Vent the Storage System. Open one
Stage I vapor poppet by attaching a vapor-recovery
PEI Recommended Practices 300-09
delivery elbow or the vapor-adapter opener
described above (Section 9.3.13). If a coaxial drop
tube is present, remove the drop tube.
9.5.3 Insert Nozzle in Simulated Fill Pipe. For
Method I only, be sure that any gasoline contained
in the nozzle spout, bellows, or hose is completely
drained. Insert the nozzle to be tested into the sim-
ulated fill pipe. The flexible gasket (Section 9.3.8)
may be used to help ensure a tight seal between the
nozzle face seal and the rim of the simulated fill
pipe.
9.5.4 Close t he Nitrogen Flow-Control
Valve. Verify that the nitrogen flow-control valve
is closed to ensure that nitrogen is not prematurely
introduced into the system.
9.5.5 Close the Inlet Valve of the Low-Pres-
sure Mechanical Gauge. For Method 1 only, if
mechanical pressure gauges are being used, close
the valve at the inlet of the O to 0.5 inch WC gauge
to protect it from possible exposure to excessive
p ressure. Verify that the inlet valve of the O to 1.0
inch WC gauge is open.
9.5.6 Setthe Nit rogen Delivery Pressure. Con-
nect the nitrogen supply to the simulated fill pipe
(Method 1) or the "T" fitting (Method 4), open the
nitrogen pressure regulator and set the delivery
pressure to 5 psig.
9.5. 7 Adjust the Nitrogen Flow Rate. Open
the nitrogen flow-control valve slowly and adjust
the flow rate to the lowest flow rate specified for
the Stage II system being tested. Take care not to
exceed the lowest flow rate at which a backpressure
measurement is to be made. If the lowest flow rate
is exceeded, then the procedure for pouring liquid
gasoline through the Stage II piping (Section 9.4.3),
waiting for the liquid to drain, and pumping out any
liquid-collection points, must be repeated.
9.5.8 Record Backpressure. Allow the nitro-
gen to flow at the specified flow rate for a mini-
mum of 30 seconds before taking a backpressure
reading on the pressure gauge. Record the back-
pressure reading on the test data sheet.
For Me thod 1, if mechanical gauges are used and
the reading on the O to 1.0 inch WC gauge is 0.5
inch WC or less, open the valve at the inlet of the 0
to 0.5 WC gauge and use the reading on this gauge
as the backpressure reading.
9.5.9 Compare Measured Backpressure to
Acceptable Backpressure Level. Refer to the
32
equipment-approval documents and local regula-
tions to determine the acceptable backpressure
levels for the Stage U system being tested. Deter-
mine whether the measw-ed backpressure reading
exceeds the allowable backpressure for the nitro-
gen flow rate used in this test.
9.5.10 If the Backpressure Exceeds the Accept-
able Level. If the pressure reading exceeds the
acceptable level a blockage may be present. Con-
firm that the test equipment is operating properly.
If the problem is not in the test equipment, check
the following:
• For Method I. check to be sure the blockage is
not in the nozzle by closing the nitrogen flow
valve, disengaging the nozzle from the simu-
lated fill pipe, and draining the nozzle and hose
assembly again. Reconnect the nozzle to the
test assembly and repeat the test. If blockage
is still present, repeat the test using the base of
the dispenser as the test point (see Method 2) to
determine whether the blockage is in the vapor-
return piping or the dispenser. Locate and repair
the portion of the piping responsible for the
blockage.
For Methods I and 4, retest the system when the
cause of the blockage has been removed.
9.5.11 Record Results. For Method 1, record
the following information on the test data report-
ing form:
• dispenser number (or djspensing position) and
product grade
• nozzle manufacturer and model
• nitrogen flow rate in CFH
• measured dynamic backpressure, in inc hes of
WC
• whether the nozzle passed or failed the test.
For Method 4, record the following infonnation on
the test data reporting form:
• dispenser number (or dispensing positions) and
product grade (if there is more than one vapor
riser per dispe nser)
• nitrogen flow rate in CFH
• measured dynamic backpressure, in inches of
WC
• whether the piping passed or failed the test.
 Recommended Practices for installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
Refer to Appendix B-2 for an example of a
dynamic backpressure test data reporting form. An
electronic version of this data-reporting form is
available at www.pei.org/RP300.
9.5.12 Increase Nitrogen Flow Rates. Repeat
the test procedure in Sections 9.5.3 to 9.5.9 on the
same nozzle (Method 1) or the same vapor riser
(Method 4) for the next highest nitrogen flow rate,
and then again for the highest nitrogen flow rate.
9.5.1 3 Repeat Test for All Other Nm2les/
Dispensers. For Method 1, repeat the test proce-
dure for each nozzle at each dispenser at the facil-
ity.
For Method 4. repeat the test procedure foir each
dispenser vapor riser at the facility.
9.5.14 Clean Up. When the testing is complete,
remove the vapor-recovery elbow or vapor-adapter
opener from the Stage I vapor adapter and replace
the dust cap. Reinstall the coaxial drop tube if one
was removed.
For Method 4, remove the "T" assembly and
reconnect the Stage II piping or replace the test
plug in the vapor shear valve.
Remove all test equipment and return the facility
to operating condition, unless further testing is to
be conducted immediately following the dynamic
backpressure test.
9.6 Aboveground Tanks. The procedures described
here are generally applicable to aboveground tanks.
Consult equipment approvals and local authorities for
specific requirements.
10. AIR-TO-LIQUID (A/L)
VOLUME RATIO TEST
10.1 General. The air-to-liquid (AIL) volume ratio test
is applicable to vacuum-assist Stage II vapor-recovery
systems only. The AIL test is conducted by simultane-
ously measuring the volume of air collected by the vacu-
um-assist nozzle, the volum e of gasoline dispensed, and
then calculating the ratio of these two volumes. Thie A/L
test is typically conducted on new vacuum-assist Stage
II vapor-recovery systems just prior to or shottly after
placing them in service and periodically thereafter. T he
testing frequency of operating systems is determined by
local regulations.
To conduct the test, a tight-fitting adapter is placed on
the spout of a vacuum-assist nozzle and adjusted so that
the vapor inlet ports are completely inside the adapter.
The adapter isolates the vapor inlet ports on the nozzle
spout so that vapor flow or airflow through the nozzle is
channeled through the adapter. The adapter is connected
to a meter that records the volume of air passing through
it while a measured amount of fuel is dispensed into a
portable test tank. The volume of air collected by the
nozzle is compared with the volume of liquid dispensed
to calculate the A/L volume ratio. The measured ratio
must be compared to the acceptable ratio of air to liquid
for the specific equipment being tested.
The air to liquid volume ratio test described
here is based on CARB test procedure TP-201.5,
Air to liquid Volume Ratio, February 1, 2001 edi-
tion. Before implementing this test procedure,
verify that this test is acceptable to locaJ authori-
ties. Refer to Appendix D for a complete reference
citation for this document.
10.2 Test Equipment. There are two types of equip-
ment that can be used to implement the A/L test pro-
cedure. The testing company can assemble the various
components needed to conduct the test, or a factory-built
unit that incorporates all of the required measurement
hardware along with electronic processing of the data
can be purchased. Verify current state and local approv-
als for the factory-bu ilt device before using this equip-
ment to conduct AIL testing.
This chapter describes equipment and procedures nec-
essary to conduct AIL testing using user-assembled
components. Follow the manufacturers' insb·uctions if a
factory-built device is used to conduct AIL testing.
10.2.1 Air-Volume Meter. The air-volume meter
used in the testing must be very sensitive to small
air-flow volumes and be very acc urate. The air-
volume meter must be able to measure volumes
as small as 0.01 cubic feet with a precision of ar
least+/- 5.0 percent of the reading. The air-volume
meter must be able to measure air-flow rates as
small as 25 cubic feet per hour, with a maxi mum
measurable flow rate between 250 and 3,000
CFH.
Resistance to airflow created by the meter, mea-
sured as a pressure drop between the inlet and
outlet of the meter, must also be accurately known.
Acceptable meters should meet the following pres-
sure-drop specifications.
PEI Recommended Practices 300-09

For a mete r with a maximum rated capacity of a nominal inside diameter between 0.75 and 1.00
1,000 to 3,000 CFH, the maximum allowable pres- inches. The tubing length should be between 3 .0
sure drop is: and 6.0 feet. Use clear tubing so that the presence of
liquid or other foreign material that might obstruct
• 1.10-inches water column at a flow rate of
the flow of air in the tubing can easily be detected.
3,000 CFH
Regulations may specify the use of certain nozzle
• 0.05-inch water column al a flow rate of 30
vapor adapters with certain nozzle spouts. lf so,
CFH
use only the specified nozzle vapor adapter to con-
For a meter with a maximum-rated capacity of 800 duct compliance testing of these Stage II vapor-
to 1,000 CFH, the maximum allowable pressure recovery nozzles.
drop is:
10.2.3 Portable Gasoline Tank. A portable gas-
• 0.70-inch water column at a flow rate of 800 oline tank, meeting all the applicable fire-safety
CFH requirements associated with gasoline storage is
necessary to receive the fuel dispensed during the
• 0.04-inch water column at a flow rate of 16
testing. The tank must have sufficie nt capacity
CFH
to receive 4.5 to 5.0 gallons of gasoline without
Consult the meter manufacturer's specifications to activating the nozzle shutoff mechanism. A sub-
verify that all of these requirements are met. stantially larger tank capacity of 30 to 50 gallons
The air-volume meter must have been calibrated is recommended to increase efficiency by reducing
within 180 days of conducting any Stage II vapor- the number of times the tank musl be drained dur-
recovery compliance testing. Calibration of the ing the testing of faci lities with multiple nozzles.
air-volume meter shall also be conducted after any Mount the tank on wheels or a heavy-duty hand
repairs or alterations to the meter. Perform calibra- truck to facilitate moving the tank during the test-
tions at 30, 60, and 90 CFH in accordance with ing. (See Figure l 0-1.)
accepted calibration procedures and criteria (e.g., The tank filling port should be l .5 to 2.0 inches in
the California Department of Food and Agricul- diameter and fitted with a non-sparking, electri-
ture, Field Reference Manual. Refer to Appendix cally conductive fitting made of aluminum, brass,
D for a full citation to this document). A copy of or similar mate rial. This wiJl help to electrically
the most recent calibration certificate must be kept bond the fueling nozzle to the tank and minimize
with the meter. The correction factor calculated the possibility of creating sparks.
during the calibration procedure for converting
measured air volumes to actual air volumes must
be used in the equation to calc ulate the AIL ratio.
(See Section 10.4.11.)
1 0.2.2 Nozzle Vapor Adapter. The nozzle vapor
adapter must be compatible with the nozzles pres-
e nt at the facility to be tested. Different nozzle
manufacturers use different patterns of distribu-
tion of vapor inlet ports on nozzle spouts. The
nozzle vapor adapter must seal all of the vapor
ports against infiltration of ambient air to obtain
an accurate measurement of the volume of vapors
taken in during fuel d ispe nsing. The nozzle-vapor-
adapter seals must be in good condition, with no
nicks, tears, or other defects that would interfere
FIGURE 10-1. AIL Test Equipment. This tester is con-
with a tight seal of the adapter against the nozzle
ducting an AIL test. The drum serves as a large capacity
spout. Lithium grease or s imilar lubricant may
portable fuel tank that greatly reduces the number of
be used to e nsure a vapor-tight seal between the
times the testing must be interrupted to empty the tank.
adapter and the nozzle spout. To protect against the discharge of static electricity, the
Connect the nozzle vapor adapter to the air-volume drum is grounded to the f uel dispenser and the nozzle is
meter using flexible, gasoline-resistant tubing with bonded to the drum.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
When using user-assembled test equipment, the
tank vent must include a connection to the air intake
of the air-volume meter. (See Section 10.2.4.)
Install a 2-inch diameter ball valve at the base of
the portable tank with a suitable hose to facilitate
draining the portable tank into an underground
tank.
The portable tank must be properly grounded. If
the tank is isolated from ground when it is being
filled or drained, make provisions for grounding to
reduce the possibility of static discharge.
1.0.2.4 Air-Volume Meter Air Intake. The air-
intake piping for the air-volwne meter is designed
to do two things:
• When testing multiple nozzles at a facility, the
air-intake piping directs vapors discharged from
the portable gasoline tank through the air-vol-
ume meter and then into the facility's Stage TI
vapor-recovery system.
• It allows the air-volume meter unrestricted
access to ambient air so that the accuracy of
the air-volume measurement is not affected by
Stage II systems with air/liquid ratios that are
not equal to 1.0.
The air intake should be constructed of suitable
piping that has a minimum internal diameter of 2.0
inches. The overall length of the air/vapor-intake
Ball Valve (2") \
FIGURE 10-2. User-assembled AIL test equipment. A 30 to 50 gallon capacity mobile tank to contain the fuel
dispensed during AIL testing greatly reduces the effort required to return the fuel to the underground tank. The
ground wire from the mobile tank is typically connected to the dispenser frame. The vapor hose between the
mobile tank and the air-volume meter imake channels vapors generated during the testing back into the facility's
Stage II vapor-recovery system.
piping must be between 6.0 and 18.0 inches. The
intake piping should include a "T" fitting that con-
nects via tubing to the portable gasoline tank vent,
and an elbow and short length of pipe to direct
the air intake downward. The tubing between the
portable gasoline tank vent and the "T" in the air-
volume meter intake must have a nominal internal
diameter between 0.75 and 1.0 inch, and a length
between 10.0 and 14.0 feet. Use clear tubing so
that the presence of liquid or other foreign mate-
rial that might obstruct the flow of air in the tubing
can easily be detected. Refer to Figure 10-2 for a
diagram of this an-angement.
1.0.2.5 Liquid-Volume Meter. The normal sales
display of the gasoline dispenser can be used to
measure the volume of gasoline dispensed during
a test. Inaccurate meter calibration will affect the
test results.
1.0.2.6 Stopwatch. A stopwatch accurate to
within 0.2 second is required to accurately mea-
sure the duration of the test.
1.0.2. 7 Lubricant. Lithium grease or other appro-
priate lubricants may be used to ensure a leak-tight
seal between the nozzle adapter and the nozzle
spout.
1.0.3 Preparing for the Test. For new and exist.mg
installations, this test is conducted after backfilling.
paving, and installation of all Stage I and Stage IJ com-
~ A/L Adapter Supply Line
0.75 - 1.00 inch inside diameter
3.0 foot minimum length
6.0 foot maximum length
[iJ Vapor Line to Gas Volume Meter
0.75 - 1.00 inch inside diameter
10.0 foot minimum length
14.0 foot maximum length
Tank
~ Vapor/Air Inlet
2.0 inch minimum inside diameter
6.0 inch minimum length
18.0 inch maximum length
PEI Recommended Practices 300-09
ponents have been completed. The following pre-test
procedures must be followed:
10.3.1 Initiate Safety Procedures. Take all pre-
cautions necessary to protect testing personnel,
facility employees, and the general public from
safety hazards that may be produced by testing
activities.
10.3.2 Determine Whether the Test Is to be
Conducted with the Pressure/ Vacuum Vent
Valve Installed. Jn most cases, the AIL testing
will be conducted with the pressure/vacuum vent
valve in place. However, some Stage TI systems
designed to operate at or near atmospheric pres-
sw-e may be adversely affected by the increase in
pressure produced by the addition of fuel from the
portable storage tank if the pressure/vacuum vent
valve is in place. Consult the Stage 11 equipment
certification and local authorities to determine
whether the pressure/vacuum vent valve should be
removed during d1e AIL testing.
10.3.3 Determine If the Test Is to be Conduct-
ed with the Vapor Processor On or Off. If the
Stage II equipment includes a vapor-processing
unit, check the equipment certification to deter-
mine whether the vapor processor should be left
on or turned off dming the AIL test.
10.3.4 Determine the Volume to be Dispensed
During the A/ L Test. Check the equipment cer-
tification for the equipment to be tested to verify
the quantity of fuel to be dispensed during the AIL
test.
10.3.5 Determine the Fuel-Dispensing Rate
Required by the Equipment Certification. Stage
IT vapor-recovery equipment certifications specify
minimum flow rates required for the equipment to
operate as desig ned. Check the approp1i ate certifi-
cation to determine the minimum flow rate fo r the
equipment to be tested.
10.3.6 Check to See If the Air-Meter Calibration
Is Current. For the user-assembled method, verify
that the air-volume meter has been calibrated within
the previous I 80 days. (See Section I0.2.1.)
10.3. 7 Verify that the Spouts of the Nozzles to
be Tested Are in Good Condition. Nozzle spouts
that are damaged such that the nozzle adapter will
not seal properl y cannot be tested. They must be
replaced prior to conducting the AIL test.
10.3.8 Check that the Nozzle Vapor Adapter Is
Compatible with the Nozzle Spout. Verify that
the nozzle vapor adapter to be used is compatible
with the type of nozzle present at the facility. The
nozzle vapor adapter must completely cover the
air-inlet holes in the nozzle spout.
10.3.9 Check the Condition of the Nozzle-
Vapor-Adapter Seals. Verify that the nozzle-
vapor-adaptcr seals are in good condition, with no
nicks, tears, or other defects that would prevent a
tight seal agai nst the nozzle spout.
10.4 Test Procedures. Use the following steps to con-
duct A/L testing of vacuum-assist Stage Il vapor-recov-
ery nozzles:
10.4.1 Initiate Safety Procedures. Take all pre-
cautions necessary to protect testing personnel,
facility employees, and the general public from
safety hazards that may be produced by testing
activities.
10.4.2 Ground the Portable Test Tank. Position
the portable Lest tank at a convenient location
adjacent to the nozzle(s) to be tested. Connect the
ground strap of the portable test tank to a suitable
ground.
10.4.3 Verify that There Is No Gasoline in the
Test-Equipment Tubing. Check the tubing between
the nozzle vapor adapter and the air-volwne meter
and the tubing between the pm1able tank vent and
the air intake of the air-vol ume meter to be sure that
there is no liquid or other foreign material present.
This check can be easily accomplished if the tubing
is made of clear plastic.
10.4.4 Install the Nozzle Vapor Adapter. Insert
the spout of the nozzle to be tested into the central
opening of the nozzle vapor adapter. Ensure that
there is a tight connection between the nozzle
spout and the nozzle vapor adapter.
• · Do not drain any liquid from the dispenser
hoses or from the dispenser vapor piping prior to
the AIL test. If any liquid enters the test equipment
during the testing of a nozzle. that nozzle fails the
AIL test.
C: Do not cover nozzles with a plastic bag or
otherwise seal off any other nozzles during AIL
compliance testing. Placing bags over nozzles can
be a useful troubleshooting technique, but nozzles
crurnot be bagged during compliance testing.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
10.4.5 Record the Initial Air-Volume Meter
Reading. Record the reading from the totalizer
of the air-volume meter on the test data sheet. The
air-volume meter toralizer must be read imme-
diately before each AIL test. Do not assume that
Lhe ending reading from the last test is the start
reading for the next test. Small air currents pass-
ing through the air-volume meter are sufficient to
change the air-volume-meter totalizer reading.
10.4.6 Reset the Dispenser Meter Display.. Ver-
ify that the dispenser is authoiized to dispense fuel
and that the dispenser-sales meter has reset to zero.
10.4 . 7 Reset the Stopwatch. Reset the stop-
watch to zero.
10.4.8 Insert Nozzle in Test Tank and Sta1rt the
Test. Inse11 the nozzle spout into the fill port of
the portable gasoline tank. Verify that the nozzle
spout is in contact with the fi ll port to provide
electrical continuity between the nozzle arid the
portable tank. Remember that the nozzle vapor
adapter is not elect1ically continuous with the
nozzle spout.
Squeeze the nozzle trigger fully and start the
stopwatch immediately when the dispenser sales
display indicates that flow has started.
10.4.9 Dispense Fuel and Time the Test .. Dis-
pense the appropriate quantity of fuel (see Section
10.3.4) into the portable tank. When the appropri-
ate amount of fuel has been dispensed, simultane-
ously stop the stopwatch and the fuel flow.
10.4.10 Calculate the Fuel-Dispensing Rate
and Verify that It Is Acceptable. Divide the
volume of fuel dispensed during the test period
by the time required to complete the dispensing.
Verify that the resulting dispensing rate meets the
minimum requirements set by the equipment cer-
tification (see Section 10.3.5) and the maximum
rate (10 gallons per minute) set by regulations.
Calculate the gasoline-dispensing rate as fol lows:
Qg = {G/t} x 60
Where:
Qg = The gasoline-dispensing rate, in gal-
lons per minute.
G = The volume of gasoline dispensed, in
gallons.
= Time recorded on the stopwatch during
the test, in seconds.
60 = Conversion factor from seconds to
minutes.
Example: lf the volume of gasoline
dispensed is 4.95 gallons and the
time recorded on the stopwatch is 36
seconds, the gasoline-dispensing rate
is:
Qg = {4.95/36} X 60
Qg = { . 14} X 60
Qg = 8.4 gallons per minute
: If the flow rate is outside the acceptable
range (7-10 gpm), the flow rate must be corrected
before valid AIL testing can be conducted.
10.4.11 Calculate A/ L Ratio. The AIL ratio is
calculated according to the following formula:
AIL = {y(Vf - Vi)/G} x 7.481
Where:
AIL = The air-to-liquid volume ratio.
y = The correction factor for the air-vol-
ume meter. (See Section I 0.2. I.)
Vf = The final air-volume-meter totalizer
reading at the end of the test, in cubic
feet.
Vi = The initial air-volume-meter totalizer
reading at the beginning of the test. in
cubic feet.
G = The gallons dispensed, in gallons.
7.481 = Conversion factor from gal Ions to cubic
feet.
Example: If the air-volume-meter cor-
rection factor is 1.02, the air-volume-
meter totalizer reading at the end of
the test is 983.78, the air-volume-meter
reading at the beginning of the test is
983. l 0, the gallons dispensed is 4 .97,
then the AIL ratio is:
AIL= { 1.02 (983.78-983.10)/4.97} x 7.481
AIL = { 1.02 (.68)/4.97} x 7.481
AIL = {.69/4.97} x 7.48 ]
AIL = { . 14} x 7.48 I
AIL= 1.05
PEI Recommended Practices 300-09
If the measured NL ratio is within the limits
specified by the equipment certification, then the
nozzle and associated Stage n equipment passes
the NL test.
1 0.4.12 If a Nozzle Fails by a Narrow Margin. If
the measured NL value is outside the allowable
range by an amount less than or equal to 0.10,
repeat the test two additional times. Calculate the
A/L ratio for each test run and then average the
results of the three tests. If the average of the three
tests is within the allowable range for the equip-
ment, the nozzle and associated equipment passes
the test. If the average value is still outside the
acceptable limits, the nozzle fails the test.
When using this averaging procedure, do not make
any adjustments to the gasoline-dispensing equip-
ment or vapor-recovery piping between tests.
10.4.13 Record Data. Record the following
data for each nozzle tested on the test-data report-
ing form:
• dispenser number or fueling position
• grade of gasoline
• manufacturer, model, and serial number of the
nozzle
• manufacturer, model, and serial number of the
dispenser
• air-volume-meter totalizer reading at the start of
the test, in cubic feet
• air-volume-meter totalizer reading at the end of
the test, in cubic feet
• volume of air measured du1ing the test
• volume of fuel dispensed according to the dis-
penser sales display, in gallons
• rate of fuel flow during the test
• time required to dispense the fuel as measured
by the stopwatch, in seconds
• calculated NL ratio
• pass or fail test result.
Refer to Appendix B-3 for an example of an
A/L test-data reporting form for use with user-
assembled test equipment. An electronic version
of this data reporting fo rm is available at www.
pei.org/RP300.
10.4.14 Testing Unihose Dispensers. When
testing unihose dispensers, each fueling point must
have an NL test for each product grade supplied to
the dispenser. For example:
• When testing a unihose dispenser (one hose,
three product inlets), test the nozzle for the
high-, middle-, and low-grade products.
• When testing a blending unihose dispenser (one
hose, two product inlets), test the nozzle for the
high- and low-grade products. The mid-grade
product does not requir e a separate NL test,
but the tester should confirm that the vacuum-
producing device(s) are activated and that the
flow rate does not exceed 10 gpm when the
mid-grade product is dispensed.
ln a blended system, it is not unusual for the
mid-grade product to have a higher flow rate than
the regular or the premium because there are two
pumps working together to de liver the fuel. This
can push the flow rate of the mid-grade product
above IO gpm, even when the regular and premium
are below IO gpm.
Local requirements for testing unihose dispensers
may differ.
10.5 Troubleshooting. If a nozzle fails a test, check all
of the test equipment connections, especially the fit of
the nozzle vapor adapter on the nozzle spout.
A lso, c heck for liquid or foreign materials in the tubing
between the nozzle vapor adapter and the air-volume
meter, and between the portable tank vent and the air
inlet of the air-volume meter.
If a problem with the test equipment is identified and
corrected, disregard the results of the first test and repeat
the test procedure.
10.5.1 Test the Nozzle Vapor Adapter Seal. The
seal between the nozzle vapor adapter and the
nozzle spout can be tested using the following
equipment and procedure:
10.5.1.1 Nozzle-Vapor-Adapter Test Equip-
ment. The nozzle-vapor-adapter test utilizes
a substitute nozzle spout consisting of a suit-
able length of pipe with a 13/ 16 inch outside
d iameter. Holes are drilled in the pipe of
simi lar size and in a similar pattern as a typi-
cal vacuum-assist nozzle spout. The pipe is
capped at one end and provided with a ''T"
fitting at the other end. One branch of the "T''
connects via tubing to a vacuum source, such
 Recomm.ended Practices for lnstallatiion and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
as a small squeeze bulb. The other branch
of the "T" connects to a vacuum gaug,e that
reads from 0.0 to 5.0 inches WC.
10.5.1 .2 Nozzle-Vapor-Adapter Test Pro-
cedure. To test the nozzle vapor adapter,
lubricate the adapter seals and inse1t the
vapor-adapter test unit described in the previ-
ous section into the nozzle vapor adapter. The
tubing between the nozzle vapor adapter and
the air-volume meter must remain connected.
Cap the air inlet of the air-volume meter.
To conduct the test, produce a vacuum of
5 inches WC in the substitute nozzle spout
using the squeeze bulb or other vacuum
source. Start the stopwatch and monitor the
vacuum for three minutes. The vacuum level
must be at least 4.95 inches WC at the e:nd of
the test period. If the test equipment fai ls this
leak test it must be repaired before it can be
used to conduct AIL testing.
10.6 Post-Test Procedures. Complete the fol lowing
steps after all AIL testing at a facility has been com-
pleted:
FIGURE 10-3. Use care when draining a portable gaso-
line tank into an undergmund tank. Use appropriate bar-
riers to keep unauthorized personnel away from the fuel
transfer area. Bond the portable tank to the underground
wnkfi/1 pipe and use a metal funnel or a hose inserted
into the fill pipe to prevent spills.
10.6.1 Replace P/ V Vent Valve. If the P/V vent
valve was removed while the NL testing was con-
ducted, replace the vent valve before draining fuel
from the portable tank into a storage tank after all
of the NL testi ng has been completed.
10.6.2 Empty Portable Tank. Empty the porta-
ble tank into the storage tank containing the lowest
gasol ine product grade at the facility. Ground the
portable tank to the tank fill pipe opening before
beginning to empty the product into the tank. (See
Figure 10-3.)
10.6.3 Carefully Seal the Inlet and the Outlet
of the Air-Volume Meter. Seal the inlet and outlet
openings of the air-volume meter to prevent any
foreign material from entering the meter and inter-
fering with its operation.
10. 7 Aboveground Storage Tanks. The procedures
described here are generally applicable to aboveground
tanks. Consult equipment approvals and local authorities
for specific requirements.
11. ELECTRICAL
INSTALLATION
11.1 General Requirements. All electrical work should
be performed by qualified electricians in conformity
with state and local codes and the National Electrical
Code. NFPA 70, published by the National Fire Protec-
tion Association. Improper electrical work can result in
equipment malfu nctions, safety, or fire hazards.
11.2 Classifications. Article 500 of the National Elec-
trical Code classifies substances and areas for purposes
of hazard identification. Areas in vehicle-fueling facili -
ties, where gasoline is normally stored and handled, are
classified as either Class l , Division 1 locations or Class
l , Di vision 2 locations. In Di vision l locations, flam-
mable vapors are usually present in ignitable concentra-
tions. In Division 2 locations, flammable vapors can
be expected to be present infrequently and only under
abnormal conditions. The hazardous-area classifications
presume that aJI components of a storage system are
consistent with applicable codes. If this is not the case.
hazardous areas may extend beyond the areas described
in the electrical code.
Refer to Table 1I - I and Figures 11-1 through 11-4 for
descriptions and illustrations of Division 1 and Division 2
39
PEI Recommended Practices 300-09

TABLE 11-1. Examples of Division 1 and Division 2 areas

Component Division 1 Division 2
commonly found at vehiclejueling facilities. Refer to the
Dispenser The fuel handling The area extending within National Electrical Code (NFPA 70) or NFPA 30Afor a
area inside 18 inches horizontally
complete listing of classified areas.
dispensers. in all directions from
the dispenser enclosure
or t hat portion of the
dispenser enclosure
containing fuel-handling
components.

The area up to 18 inches

above grade extending
20 feet horizontally in
all directions from the
dispenser enclosure.
Fill opening Any pit, box, or The area up to 18
space below grade inches above grade
level, any part of within a horizontal rad ius
which is within a of 5 feet from a tight
Division 1 or 2 fill connection and 10
classified area. feet from a loose fill 20 20

l l
connection.
Submersible Any pit or box The area up to 18 inches
pump below grade if any above grade extending
part is within a horizontally up to 10 feet
Not to Scale
horizontal distance from the any edge of the Class I, Division 2
All dimensions in feet.
of 10 feet from any pump.
edge of the pump.
FIGURE 11-2. The colored area shows the extent of the
Vent The area within The area between 3 and Division 2 classified area 1.5 feet above grade adjacent
discharging 3 feet of the open 5 feet of the open end of
to a typical dispenser. Refer to Figure 11-1 for additional
upward end of the vent the vent extending in all
extending in all directions.
details concerning classified areas inside of and adjacent
directions. to dispensers.

Dispensing Area

----_ Class I, Division 2

(Inside Dispenser Only)

r oo~
1.5 1.5 1.5 1.5

f
4

_ L_ _...,.___,..._ _---.,....-...---,_ _ 11.5

000 000 Class I, Division 1
Not to Scale -...___ Below Grade Sumps
All dimensions in feet. Class I, Division 2

FIGURE 11-1. Typical classified areas around a high hose dispenser. Note that above 4 feet, the inside of the
dispenser becomes Division 2 and there is no classified area outside the dispenser itself Dispenser manufactur-
ers may indicate different hazardous areas for their products.
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

areas commonly found at vehi-

cle-fueling facilities. Equipment
and wiring installed in Division
1 and, freq uently, Division 2
: • Concrete _ :
locations must be explosion-
proof or intrinsically safe.

11.3 Electrical Equipment.

Equipment for use in a clas-
sified area should be labeled
by the manufacturer with the
class, group, and normal oper-
ating temperature. An identifi-
cation number may be used to
indicate a range of operating
temperatures. Electrically oper-
ated vapor-handling equipment
should be labeled to indicate the 1fl dimensions-i ~ feet. Class I, Division 2
electrical power requirements
and temperature range. Ensure
FIGURE 11-3. Classified areas in the area of the tank pad above a typical under-
that all equipment installed in a
ground tank. Note that if loose ft/ l deliveries are made, the Division 2 classified
classified area is appropriate for area extends 10 feet horizontally in all directions from the fill rise,: The Division 2
the intended use. area in the vicinity of the submersible pump extends IO feet horizontally from the
edge of the pump.

Fill Vapor
0
ATG

00
Fill Vapor
0
ATG 8
Not to Scale
All dimensions in feet. Class I, Division -;-i
Class I, Division :J
FIGURE 11-4. Classified areas in the area of the tank
pad above a typical underground tank. Note that if loose
fill deliveries are made, the Division 2 classified area
extends JO feet horizontally in all directions from the fill FIGURE 11-5. There are classified areas around the
riser. The Division 2 area in the vicinity of the submers- vent pipe openings as well. Workers should always be
ible pump extends JO feet horizontally from the edge of careful when working in classified areas.
the pump.
PE! Recommended Practices 300-09

TESTING BEFORE OR SHORTLY AFTER PLACING

12. TESTING AND THE SYSTEM IN SERVICE
INSPECTION Component Test Procedure
Aboveground and Pressure decay test. (Chapter 8.)
12.1 General. Inspection and testing are integral parts
underground primary
of vapor-recovery installation requirements. Leaks or vapor piping
flaws that are detected early in the installation process
Double-walled 5 or 10 psig air/soap test (Section
are more easily repaired than when a storage system is underground vapor 7.12.1) and manufacturer's
complete. The installer is responsible for demonstrating piping recommendations.
the integrity of vapor piping and secondary containment. Tank risers Pressure decay test. (Chapter 8.)
as well as the satisfactory operation of vapor-recovery
Vent piping Pressure decay test. (Chapter 8.)
systems. either before or shortl y after a vapor-recovery
system is placed in service. The installer must also verify Dynamic backpressure test.
Vapor pathway
(Chapter 9.)
the safety of the system.
Vacuum-assist system A/L ratio test. (Chapter 10.)
Recommended procedures for testing during construc- Ensure that the valves are securely
tion are summarized in Table 12-1 . Recommended pro- anchored. Check the level of the
cedures for post-constructio n testing are summarized in Vapor shear valves shear point relative to the pump
Table 12-2. These tables list typical test procedures for island surface and the adjacent
impact valve. (Section 5.11.)
vapor-recovery piping and components. Omission from
these tables does not imply that a vapor-recovery-system TABLE 12-2. Recommended test procedures to be per-
component does not require testing. Follow manufactur- formed before or shortly after placing a vapor-recnve,)'
er 's instructions and/or regulatory requirements in all system in service.
cases.
12.3 Other Testing. Nothing in this recommended
12.2 Test Results. The results of all testing should
practice is intended to limit non-prescribed testing
be documented and signed by the tester. Provide the
performed by the installation contractor throughout the
orig inal signed documentation to the owner/operator and
vapor-recovery installation process or after construction
retain a copy as a permanent part of the project file. The
is complete.
owner/operator should also keep a copy of all final test
results. Provide copies of test results to local authorities
when required.

TESTING DURING CONSTRUCTION

Test Procedure
13. DOCUMENTATION AND
Component
New aboveground and 50 psig one hour air/soap test
TRAINING
underground vapor for vapor piping. Test underground
13.1 As-Built Drawings. As-built drawings or photo-
piping (isolated from vapor piping prior to backfilling.
the tank) (See Section 7.11.1.) graphs of underground piping and other system compo-
nents should be provided by the installer to d1e owner.
5 or 10 psig air/soap test (Section
Underground T he owner should maintain these documents on file for
7 .12.1) and manufacturer's
secondary piping as long as the storage system is in service, because no one
recommendations.
Dispenser and else has an ongoing interest in the facility. The documents
Manufacturer's recommendations. may take the form of a marked-up set of installation draw-
transition sumps
Underground tank 1 psig nitrogen or air/soap test
ings and/or photographs showing the location of piping,
risers and tank top before backfilling. (Section 7 .11.2.) conduit, and other significant system components.
Underground tank 1 psig nitrogen or air/soap test
13.2 Component Documentation. The installer or
vent piping before backfilling. (Section 7 .11.2.)
equipment vendor should provide the owner with:
Underground vapor Dynamic backpressure test.
piping (Section 7.11.3.) • installation and operating instructions for all vapor-
recovery components of the storage system
TABLE 12-1. Recommended test procedures to be per-
formed during construction of a vapor-recovery system. • vapor-recovery equipment manufacturers ' war-
ranty certificates
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites
• any regulatory pennits obtained by the installer
• documentation for all testing conducted during
construction and before or shortly after system
start up
• recommended test procedures
• equipment-maintenance schedules.
The owner should require that these documents be sub-
mitted at the time the vapor-recovery system is placed
in operation.
Responsibility for maintenance of these documents must
remain with the owner/operator, because no one else has
an ongoing interest in the facility. The owner/ope:rator
should have the documents available for inspection, as
required. Maintenance schedules should be kept a t the
storage system location.
13.3 Scheduled Maintenance. The owner/operator
should establish a program of scheduled maintenance
and periodic testing of the vapor-recovery system and its
components that is consistent with the equipment rnanu-
factmers' recommendations and regulatory requirements.
13.4 Training. The owner/operator should train fa::ility
personnel in the operation and maintenance of relevant
equipment before the system is placed in operation. Per-
sonnel must be trained to recognize improper operating
conditions and be prepared to take appropriate action
when these conditions are detected.
Vapor-recovery system designers, component man ufac-
turers, suppliers, installers, and owner/operators should
detennine who is to do the training. The owner should
coordinate when, where, and how the training will occur.
A record of the persons attending the training and the
topics discussed should be retained by the storage-sys-
tem owner.
14. DECOMMISSIONING
STAGE II VAPOR·
RECOVERY PIPING
14.1 Introduction. As of 2009. the methodology for
captuting gasoline vapors generated dw"ing vehicle fuel-
ing is in a transition phase. Stage ll vapor-recovery
technology is being replaced by onboard refueling vapor
recovery (ORVR) in the United States. Rather than cap-
twing gasoline vapors at the fuel inlet of d1e vehicle: and
bringing them to the underground storage tank, ORVR
uses a carbon canister to capture the vapors as they leave
the vehicle gas tank and retains them in the vehicle. Vehi-
cles equipped with onboard canisters were fast produced
in the l 998 model year in the United States. Since 2006,
all cars as well as light- and medium-duty trucks sold in
the United States have been equipped for ORVR. Federal
regulations state that once ORVR is in "widespread use:·
Stage II vapor recovery may no longer be required.
T he federal Environmental Protection Agency (EPA) has
been tasked with defining when ORVR will be in "wide-
spread use.'' Once this determination has been made, state
and local air quality control agencies may begin a process
to permit gasoline-dispensing facilities to discontinue the
use of Stage 11 vapor-recovery systems. Chapter 14 has
been added to this edition of this recommended practice to
provide a procedure for decommissioning Stage II vapor-
recovery equipment and piping.
This Chapter describes procedures to permanently dis-
connect Stage 11 vapor-recovery systems that have been
in active service. These procedures may also be applied
to storage systems in which Stage II vapor-recovery pip-
ing was installed and connected to the tank but Stage
ll vapor recovery was never actively implemented. If a
facility has vapor-recovery piping instal1ed, but the pip-
ing is capped on both ends and has never been in service,
then the procedures described here are not necessary.
: Verify that Stage II is no longer required at a
specific faci lity before initiating deconunissioning
procedures.
14.2 Nature of the Procedure. The procedure described
here involves capping off and disconnecting various
Stage H components. but it leaves the below-grade
Stage IT vapor-recovery piping in place. It was common
practice in the past to install vapor-recovery piping at
new facilities that did not yet require the use of Stage II
so that vapor recovery could easily be implemented at
a later date. Many of these facilities wid1 installed but
inoperative vapor piping have been in service for many
years without problems. Leaving inactive vapor piping
in the ground will not impair the operation of the storage
system as long as the piping is vapor tight.
Below-grade Stage TI vapor piping will in
many cases remain connected to the tank and will
contain vapors after it has been decommis ioned.
The integrity of this piping wi ll be verified in an y
subsequent pressure decay testing that may be
conducted.
PEI Recommended Practices 300-09
Likewise, decommissioning the Stage 11 piping does not
require the removal of the vapor piping located inside
the dispenser cabinet provided the procedures described
here are followed.
14.3 Qualifications. Competent personnel are required
not only to install vapor-recovery systems but also
to decommission them. Only technicians who have
received appropriate training, have all of the required
tools, and possess the required regulatory and equip-
ment-manufacturer certifications should perform the
Stage II decommissioning procedure.
14.4 Paperwork. In many jurisdictions, a permit must
be obtained or a notification procedure must be fol-
lowed before the decommissioning work is initiated.
Also, facility operating permits or registration certifi-
cates may need to be updated to reflect that the Stage 11
vapor-recovery system .is no longer in service. Verify the
regulatory paperwork requirements for a specific facility
before beginning the work of decommissioning Stage II
vapor recovery.
14.5 Applicability. The procedures described here are
intended to be applied to the most common types of
Stage II vapor-recovery systems. There may be some
Stage Il systems that have characteristics or compo-
nents that differ from those described here and may
require different decommissioning procedures. It is the
responsibility of the qualified technician responsible
for decommissioning a Stage Il system to determine the
applicability of the following decommissioning steps:
• initiate safety procedures
• relieve pressure in the tank ullage
• remove liquid from any below-grade liquid-collec-
tion points
• electrically and mechanically disconnect all vapor
pumping or processing units
• disconnect all electrical components of the Stage
Il system so that no electrical hazards are created
• reprogram the dispenser electronics to reflect that
Stage IT vapor recovery is no longer in service
• seal off the below-grade vapor piping at a height
below the level of the base of the dispenser
• seal off the below-grade vapor piping at the tank
end if this can be done without excavation
• seal off the vapor piping inside the dispenser
cabinet
• replace the Stage TI hanging hardware with con-
ventional hanging hardware
• install appropriate pressure/vacuum vent valve(s)
• remove any Stage lI instrnctions from the djs-
penser cabinet
• conduct a pressure decay test and a tie-tank test
• conduct a final visual check
• complete the decommissioning checklist.
14.6 Decommissioning Procedure. The decommis-
sioning procedure should be carried out in the order
described in the paragraphs that follow.
14.6.1 Initiate Safety Procedures. Take all pre-
cautions necessary to protect decommissioning
personnel, facility e mployees, and the generaJ
public from safety hazards that may be produced
by decommissioning activities.
14.6.2 Relieve Pressure in the Tank Ullage. To
reduce the volume of vapors that may be released
when the vapor piping is disconnected at the dis-
penser, temporarily remove the pressure/vacuum
vent valve. Leave the vent valve off until the
procedure is completed. If there is a concern about
precipitation entering the open vent riser during
the decommissioning procedure, a standard (non-
pressure/vacuum) vent cap may be temporarily
installed.
14.6.3 Drain Liquid-Collection Points. Lf there
are any liquid-collection points (see Section 5. 14
of this Recommended Prac tice) present, open
them and check for the presence of liquid. Pump
out any fluid present using a gasoline-compatible
hand pump or a properly grounded and bonded
elec tric pump rated for use in Class I, Division l
areas. Pump the tluid into an appropriately sized
contai ner approved for use with gasoline. Set the
container on the ground when gasoline is being
pumped into it. Verify that the fluid is gasoline
and carefully pour it into the lowest-grade gasoline
tank. Use a metal funnel if the gasoline container
is not equipped with a spout. Bond the gasoljne
container to the metal fun nel or fill pipe before
pouring the gasoline. If the liquid is contaminated
or does not appear to be gasoline, dispose of it
properly.
Most liquid-collection points have a small-diam-
e ter copper tube that leads back to the vacu um port
of a submersible pump. Disconnect this tube at the
submersible and seal it off using a compression or
 Recommended Practices for Installation and Testing of Vapor-Recove,y Systems at Vehicle-Fueling Sites
flare fitting so that it is vapor tight. Install a plug
in the submersible pump to seal the vacuum port.
When feasible, seal off the end of the copper tube
inside the liquid-collection sump using a compres-
sion or flare fitting.
Alternatively, remove the copper tube completely
if this can be accomplished without excava-
tion. If the copper tube is removed, the opening
tlu-ough which the tube entered the liquid-collec-
tion sump must be sealed so that it is vapor tight.
If the submersible pump is located in a liquid--tight
containment sump, the hole through which the
tube entered the containment sump must also be
seaJed.
Replace the cap on the liquid-collection sump.
Take whatever steps are necessary (e.g. , apply
thread sealant to threaded plugs or replace gas-
kets on snap caps) to produce a vapor-tight seal
between the cap and the liquid-collection sump.
14.6.4 Vacuum-Assist Systems with Vapor
Pumps for Each Fueling Position. If the Stage
TI vapor-recovery system includes an electrically
operated vapor pump, open the electrical junction
box and disconnect the wiring at the pump motor.
Disconnect and cap off aU wires using appropri-
ately sized wire nuts to isolate the wires. Carefully
replace the wires in the electrical junction box
for the motor. Replace the electricaJ junction box
cover. making sure that all gaskets and seals are in
good condition and properly positioned.
Reprogram the dispenser electronics as req1Uired
to disable vapor-pump motor-control circuits and
to indicate that Stage II vapor recovery is no lon-
ger active. This step is necessary to prevent error
codes and avoid dispenser malfunction. Consult
the dispenser manufacturer's literature to dieter-
mine how to reprogram the dispenser electronics.
Only properly trained technicians should repro-
gram the dispenser electronics.
Drain liquid that may be present in the vacuum
pump by temporarily disconnecting the vacuum
tubing at the bottom of the pump. Remove any
gasoline remaining in the pump, or else remove
the pump. There is no need to remove the vacuum
pump if there is no gasoline left in it.
14.6.5 Vacuum Assist Systems with a Cen-
t rally Located Vapor Pump. If the Stage U
vapor-recovery system includes a centrally located
vacuum pump, completely remove the vacuum-
pumping mechanism. After removing the vacuum-
generating mechanism, seal the vapor piping that
was attached to the vapor pump using a threaded
plug, threaded cap, or glued fitting if the piping is
fiberglass. Do not use any type of rubber cap held
in place by a hose clamp to seal the vapor piping.
The vapor piping must be sealed so that it is vapor
tight.
14.6.6 Isolate the Below-Grade Vapor Piping
at the Base of the Dispenser. Disconnect the
below-grade vapor piping from the dispenser at
a point that is at or below the level of the base of
the dispenser. This may require the removal of the
vapor shear valve. Seal the below-grade portion of
the vapor piping using a tlu-eaded plug, threaded
cap. or glued fitting if the piping is fiberglass. Do
not use any type of rubber cap held in place by a
hose clamp to seal the vapor piping. The vapor
piping must be seaJed so that it is vapor tight.
14.6.7 Disconnect the Vapor Piping at the
Tank Top. Disconnect the Stage II piping from
the tank only if this procedure can be done without
excavation. Examples of situations where excava-
tion is Lypically not necessary include;
• vapor-piping connection to the tank is located in
a tank-top sump
• vapor-piping can be isolated by screwing a plug
into an extractor fitting that is accessible from
grade.
If the piping is fiberglass, it may need to be cul
in order to be disconnected. Be careful when dis-
connecting or cutting vapor piping inside a sump
because gasoline vapors will be released into the
sump. Seal both the tank end and the dispenser
end of the vapor piping with vapor-tight threaded
plugs, caps, or glued fittings.
\\ h. I '1(,: Follow all applicable safety pro-
cedures. Plan ahead and have all the com-
ponents required to seal off both ends of
the vapor piping ready to install so that the
amount of time the vapor piping is open is
kept to a minimum.
I ~ 1 • Many tanks will have both the
tank vent piping and the vapor-recovery pip-
ing connected to the low-grade product at the
same tank opening. Be sure that the piping
disconnected and capped off is the Stage II
vapor piping and not the tank vent piping.
PEI Recommended Practices 300-09

1.4.6.8 Seal the Dispenser Cabinet Vapor duct a tie-tank test to verify that the tank vents are
Piping. Seal off the lower end of the vapor piping still functional.
that is inside the dispenser cabinet using a threaded
plug or cap. Do not use any type of rubber cap held See CARE test procedure TP20 l .3C. "Tie-
in place by a hose clamp to seal the vapor piping. Tank Test," for a description of this test.
The dispenser vapor piping must be sealed so that
it is vapor tight. 14.6.13 Conduct a Final Visual Check. Visu-
14.6.9 Replace Hanging Hardware. Replace all ally verify that the storage system is in a condition
the Stage U hanging hardware with conventional that will reliably prevent the release of any vapors
(non-Stage 11) hanging hardware. This applies to or liquids from any component of the storage
both balance and vacuum-assist hanging hard- system, and that all critical safety devices are still
ware. Before disconnecting the Stage II hanging functioning. Restore the facility to operating sta-
hardware from the dispenser, drain product in the tus.
hanging hardware into an appropriate container 14.6.14 Complete the Checklist in Appendix
placed on the ground. C of this Document. Many authorities having
If the dispenser fuel-outlet fitting is coaxial, install jurisdiction require that all work conducted on
an adaptor fitting supplied by the dispenser manu- a vapor-recovery system be documented. Some
facturer or an approved equi valent to convert the jurisdictions also require notice to the regulatory
coaxial fuel outlet to a non-vapor-recovery fitting. agency. The checklist presented in Appendix C
The adaptor must effectively isolate the vapor pip- provides a convenient means of documenting
ing in the dispenser from the fuel-handling compo- which decommissioning steps for the Stage II
nents of the non-Stage 11 hanging hardware. vapor-recovery system were conducted at a spe-
cific facility. Complete the checklist and provide
If there are separate dispenser outlets for fuel and
a copy to the owner or the owner's representative.
vapor. install an adaptor fitting supplied by the
Retain a copy for your records.
dispenser manufacturer or an approved equivalent
that will convert the straight thread of the fuel
outlet to the National Pipe Thread (NPT) standard
that is required for conventional hanging hard-
ware. Install a threaded plug or cap in the vapor-
inlet opening to create a vapor-tight seal.
14.6.10 Replace the Pressure/ Vacuum Vent
Valve(s). Install the required number of pressure/
vacuum vent valves on the vent riser(s). Consult
local requirements to determine the appropriate
pressure and vacuum-relief pressures for the vent
valve(s).
14.6.11 Remove Stage II Operating Instruc-
tions from Dispensers. Many jurisdictions
require Stage Il operating instructions to be posted
on dispensers to infonn customers about the oper-
ation of the system. lf present, carefully remove
these instructions, taking care not to damage the
dispenser finish.
14.6.12 Conduct Pressure Decay Test and Tie-
Tank Test. Conduct a pressure decay test accord-
ing to the procedw·es described in Chapter 8 of this
Recommended Practice to verify that the Stage I
vapor-recovery system and all vapor piping and
fittings still connected to the storage system are
tight. After passing the pressure decay test, con-
 Recommended Practices for Installation and Testing of Vapor-Recovery Systems at Vehicle-Fueling Sites

AP PENDIX A
1

PRESSURE DECAY TEST TABLES

Table A-1 Table A-2

Stage II Vacuum-Assist Systems Stage II Balance Systems

Underground Storage Tanks Underground Storage Tanks

Two Inches of Water Column Initi al Test Pressure Two Inches of Water Column Initial Test Pressure
Minimum Accept able Pressure Remaining after Fiive Minimum Accept able Pressure Remaining after Five
Minutes (Inches of Water Column) Minutes (Inches of Water Column)
Ullage Number of Affected Nozzles Ullage Number of Affected Nozzles
(Gallons) 1-6 7-12 13-18 19-24 >24 (Gallons) 1-6 7-12 13-18 19-24 >24
500 0.73 0.69 0 .65 0.61 0 .57 500 0.44 0.41 0.38 0 .36 0.34
550 0.80 0.76 0.72 0.68 0.64 550 0 .50 0.47 0.45 0.42 0.40
600 0 .87 0.82 0.78 0.74 0.71 600 0 .56 0.53 0.51 0.48 0.46
650 0.93 0 .88 0 .84 0.80 0 .77 650 0.62 0.59 0.56 0.54 0.51
700 0.98 0.94 0.90 0.86 0.82 700 0.67 0.64 0.62 0 .59 0 .56
750 1 .03 0.98 0.94 0.91 0.87 750 0.73 0.70 0.67 0.64 0.61
800 1 .07 1.03 0 .99 0.95 0 .92 800 0.77 0.74 0.71 0.69 0.66
850 1.11 1.07 1.03 1.00 0.96 850 0.82 0.79 0.76 0.73 0.70
900 1.15 1.11 1.07 1.03 1 .00 900 0.86 0.83 0.80 0.77 0.75
950 1.18 1.14 1.11 1.07 1.04 950 0.90 0.87 0.84 0.81 0.79
1,000 1 .21 1.18 1 .14 1.10 1.07 1 ,000 0.93 0.91 0 .88 0 .85 0.82
1,200 1.32 1.28 1.25 1.22 1.19 1 ,200 1.06 1 .03 1.01 0.98 0.95
1,400 1.40 1.37 1.34 1.31 1.28 1,400 1.16 1.14 1 .11 1.09 1.06
1,600 1 .46 1.43 1.41 1.38 1.35 1 ,600 1.24 1.22 1 .19 1.17 1.15
1,800 1.51 1.49 1 .46 1.44 1.41 1,800 1.31 1 .29 1 .27 1.24 1.22
2,000 1.56 1.53 1 .51 1.49 1.46 2 ,000 1 .37 1 .35 1 .32 1.30 1.28
2 ,200 1.59 1.57 1.55 1.53 1.51 2,200 1.4 2 1.40 1 .38 1.36 1 .34
2 ,400 1.62 1 .60 1.58 1.56 1.54 2,400 1.46 1.44 1.42 1 .40 1 .38
2 ,600 1.65 1.63 1.61 1.59 1.57 2,600 1 .49 1 .47 1.46 1.44 1.42
2,800 1 .67 1.65 1.64 1.62 1.60 2,800 1.52 1 .51 1 .49 1.47 1.46
3,000 1.69 1 .68 1.66 1.64 1.62 3,000 1.55 1.54 1 .52 1.50 1.49
3,500 1 .73 1.72 1.70 1 .69 1 .67 3,500 1.61 1.59 1.58 1.57 1.55
4,000 1.76 1 .75 1.74 1.72 1.71 4 ,000 1.65 1.64 1.63 1.61 1.60
4,500 1 .79 1.78 1.77 1 .75 1 .74 4,500 1.69 1.68 1 .67 1.65 1 .64
5,000 1 .81 1.80 1.79 1.78 1.77 5,000 1.72 1.71 1.70 1.69 1.67
6,000 1 .84 1.83 1.82 1.81 1.80 6 ,000 1.76 1.75 1.74 1.73 1.72
7,000 1 .86 1.85 1 .85 1.84 1 .83 7,000 1 .79 1.79 1.78 1.77 1.76
8,000 1.88 1 .87 1.86 1.86 1.85 8,000 1.82 1.81 1.80 1.80 1 .79
9,000 1.89 1.89 1.88 1.87 1 .87 9,000 1.84 1.83 1.83 1.82 1.81
10,000 1.90 1.90 1.89 1.88 1.88 10,000 1.85 1.85 1.84 1.84 1.83
15,000 1.93 1.93 1.93 1.92 1.92 15,000 1.90 1 .90 1.89 1 .89 1.89
20,000 1.95 1 .95 1.94 1.94 1.94 20,000 1.93 1.92 1.92 1.92 1.91
25,000 1.96 1.96 1.96 1.95 1.95 25,000 1.94 1.94 1.94 1.93 1.93
PEI Recommended Practices 300-09

Table A-3

Stage II Vapor-Recovery Systems

Aboveground Storage Tanks

Two Inches of Water Column Initial Test Pressure

Ullage Minimum Acceptable Pressure Remaining To determine inches of water column for intermedi-
(Gallons) after Five Minutes (Inches of Water Column) ate values of ullage, interpolate between values in the
300 0.16 tables. For example, in Table A-1 to calculate the value
for I , 150-gallons ullage with 1-6 affected nozzles, use
350 0.23
the values for 1,000-gallons and 1,200-gallons ullage,
400 0.30 as follows:
450 0.37
500 0.44 (1200 - 1150) = 50 = 0.25
1200-1000 200
550 0.50
600 0 .56 then: 0.25 ( 1.32- 1.21) + 1.2 1 = 0.0275 + 1.21 = 1.2375
650 0.62 or 1.24 (rounded)
700 0.67
750 0.73
Therefore, the minimum acceptable test pressure remain-
ing after fi ve minutes for a system with I , 150-gallons
800 0.77
ullage is 1.24 inches of water column.
850 0.82
900 0.86
950 0.90
1,000 0.93
1,200 1.06
1,400 1.16
1,600 1.24
1,800 1.31
2,000 1.37
2,200 1.42
2,400 1.46
2 ,600 1.49
2,800 1.52
3,000 1.55
3,500 1.61
4,000 1.65
4 ,500 1.69
5,000 1.72
6,000 1.76
7,000 1.79
8,000 1 .82
9,000 1.84
10,000 1.85
15,000 1.90
20,000 1.93
 APPENDIX B-1: SAMPLE FORM FOR RECORDING PRESSURE DECAY TEST DATA

:::0
PRESSURE DECAY TEST DATA n:,

Facilitv Owner Facility Name and/or ID# Facility Address Facility City & State
8;:i
;:i
n:,
Date/Time l Permit/Application # Testinq Company Tester Name Tester Phone ~
I ~
'"t,
2l
Q
Type of Sta!=)e I Vapor-Recovery System : D Two-Point D Coaxial ;::;·
n:,
Type of Sta!=)e 11 Vapor- Recovery System: D Balance D Vacuum-Assist Manufacturer: ""
~
Pressure/Vacuum Vent Cap? D Yes D No If Yes: Pressure Set Point: Vacuum Set Point: :?
""
1:i
D Yes
Tanks Manifolded? D No Nitro!=]en Flow Rate Used to Pressurize System:
~
.....
c:,
Tank ID Tank Volume of Ullage Inches WC Pressure At: Acceptable Pass or Fail ~
i:::i
Capacity Product (gals) Start 1 min 2 min 3 min 4 min 5 min Final Pressure Pressure P/V Vent :::s
~
(gallons) (gallons) (Inches WC) Decav Cap ~
"".....
s·
Oo

~
~
"!;::;
c:,
....,·
:::0
{'I)
(")
c:,
,::
{'I)

~
Total Total Total Inches WC Pressure At: Acceptable Pass or Fail ~
For
System Volume of Ullage Start 1 min 2 min 3 min 4 min 5min Final Pressure Pressure P/V Vent ""~
Capacity Product (Inches WC) Decay Cap ~
Manifolded
~
Tanks ~
;:s-
r;·
~

~
n:,
NOTES:
~
Oo
V)

&'
 APPENDIX B-2: SAMPLE FORM FOR RECORDING DYNAMIC BACKPRESSURE TEST DATA

DYNAMIC BACKPRESSURE TEST DATA

wner Facility Name and/ or ID Number Facility Address Facility City & State

e I Permit/Application# TestinQ Company Tester Name Tester Phone

I
Vapor-Recovery System: D Balance D Vacuum-Assist
eling Grade(s) of Nozzle Make Backpressure Backpressure Backpressure Pass or
tion(s) Gas & Model At Nitrogen Flow At Nitrogen Flow At Nitrogen Flow
(balance only) of CFH of CFH of CFH
{Inches WC) {Inches WC) {Inches WC)
 APPENDIX B-3: SAMPLE FORM FOR RECORDING A/L TEST DATA WHEN USING AN AIR VOLUME METER

AIR TO LIQUID VOLUME RATIO (A/L) TEST DATA ::0

(1:,
Facility Owner Facility Name and/or ID Number # Facility Address Facility Citv & State (")
C)
~
~
Date/Time I Permit/Application# Testinq Company Tester Name Tester Phone (1:,

I t
"ti
Fueling Grade(s) Nozzle Nozzle Dispenser Dispenser Beginning Air Ending Air Volume Volume Time Rate of A/L Pass i::l
(")

Position of Gas Make& Serial Make& Serial Vol Meter Vol Meter of Air of Fuel Needed to Fuel Flow Ratio or ~-
Model Number Model Number Reading Reading Measured Pumped Pump Fuel Fail "'
(cf) (cf) CcO (gals) (sec) lnnm) 'c>
...
;i'
"'~
.....
....~
s·
;::s

l
~
"'....
l
~
~
,:,
C)
i'
::0
(1:,
(")
C)
,::
(1:,

~
~
"'~
~
£?.
~
;:r-

I
r)'
~

NOTES: ~
(1:,

I!
I= V)
~-
"'
PEI Recommended Practices 300-09

APPENDIX C
STAGE II DECOMMISSIONING CHECKLIST
PEI RP300 STAGE II DECOMMISSIONING CHECKLIST

Facility ID# Facility Name/ Address Qualified Technician

Doing the Work Date

RP300
Decommissioning Activity Completed N/ A
Reference
14.6.1 Initiate safety procedures.
14.6.2 Relieve pressure in the tank ullage.
14.6.3 Drain liquid-collection points.
14.6.4,
Disconnect all vapor pumping or processing units.
14.6.5
Disconnect all electrical components of the Stage II system so that
14.6.4
no electrical hazards are created.
Reprogram the dispenser electronics to reflect that Stage II vapor
14.6.4
recovery is no longer in service.
Securely seal off the below-grade vapor piping at a height below the
14.6.6
level of the base of the dispenser.

14.6.7 Securely seal off the below-grade vapor piping at the tank end if it is
easily accessible.
14.6.8 Securely seal the vapor piping inside the dispenser cabinet.
Replace the Stage II hanging hardware with conventional hanging
14.6.9
hardware.
14.6.10 Install appropriate pressure/vacuum vent valve(s).
14.6.11 Remove any Stage II instructions from the dispenser cabinet.
14.6.12 Conduct a pressure decay test and tie-tank test.
Verify that the visible components of the storage system are left in
14.6.13 a condition that will reliably prevent the release of any vapors or
liquids from any component of the storage system.
14.6.13 Restore the facility to operating status.

NOTES

Signature of technician doing the work:------- - - - -- - -- - - Date: _ _ _ _ __ _

Signature of owner or owner's representative: - - - - - -- - -- - - - - - Date: _ _ __ __ _

 Recommended Practices for Installation and Testing of Vapor-Recove,y Systems at Vehicle-Fueling Sites

AP'P ENDIX D
PUBLICAl"ION REFERENCE
Many of the recommendations contai ned in this publication have been derived from the standards and recommended
practices of other industry organizations. Listed below are the names, addresses, telephone nu mbers, and websites of
selected industry organizations, followed by the titles of their publications, which have some relation to the instal1a-
tion and/or decommissioning of vapor recovery equipment.

NOTE: Links to download or purchase many of these references can be found at www.pei.org/RP300

•API California Air Resources Board. Stationary Source

1220 L Street NW, Washington, D.C. 20005-4070.
(202) 682-8375. www.api.org
American Petroleum Institute, RP 1615, Installation
of Underground Petroleum Storage Systems, Fifth
Edition, 1996.
American Petroleum Institute. RP 1632. Cathodic
Protection of Underground Petroleum Storage Tanks
and Piping Systems. Third Edition, l Q96.
American Petroleum Institute, RP 1639, Owner/
Operators Guide to Operation and Maintenance
of Vapor Recovery Systems at Gasoline Dispensing
Facilities, First Edition. July 2003.
• CALIFORNIA AIR RESOURCES BOARD
P.O. Box 28 15, Sacramento, California 958 14-2815.
(9 16) 327- 1525. www.arb.ca.gov
Vapor Recovery Test Procedure TP-201.3,
Determination of 2 Inch WC Static Pressure
Performanc:e of Vapor Recovery Systems of Dispensing
Facilities, Adopted April 12. 1996; Amended March
17, 1999.
Vapor Recovery Test Procedure TP-20 l .3A.
Determination of 5 Inch WC Static Pressure
Petformance of Vapor Recovery Systems of Dispensing
Facilities, Adopted April 12, 1996.
Vapor Recovery Test Procedure TP-20 1.38,
Determination of Static Pressure Petformance of Vapor
Recovery Systems of Dispensing Facilities with Above-
Ground Storage Tanks, Adopted Ap1il 12, 1996.
Vapor Recovery Test Procedure TP-201.4,
Determination of Dynamic Pressure Petformance
of Vapor Recovery Systems of Dispensing Facilities.
Adopted Ap1il 12, 1996; Amended April 28, 2000 &
July 3, 2002.
Vapor Recovery Test Procedure TP-201.5,
Determination (by Volume Meter) of Air to Liquid
Volume Ratio of Vapor Recovery Systems of Dispensing
Facilities, Adopted April 12, 1996; Amended February
I , 2001.
Control Divi ion, Air Monitoring Quality Assurance,
Volume VI, Standard Operating Procedures for
Stationary Source Emission Monitoring and Testing,
January 1979.
• CALIFORNIA DEPARTMENT OF FOOD AND
AGRICULTURE
1220 N Street, Sacramento, California 95814.
(916) 654-0466. www.cdfa.ca.gov
Field Reference Manual, California Code of
Regulations, Title 4, Division 9, Section 3.33,
Hydrocarbon Gas Vapor-Measuring Devices, Amended
January I , 2009.
• INTERNATIONAL CODE COUNCIL
Publications, 405 1 West Flossmoor Road, Country
Club Hills. Illinois 60478-5795. (888) 422-7233.
www.iccsafe.org
International Code Council, International Fire
Code, 2009.
• NACE INTERNATIONAL
1400 South Creek Drive, Houston, Texas 77084-0496.
(800) 797-6223. www.11ace.org
NACE International, Standard RP-0285-2002,
Corrosion Control of Underground Storage Tank
Systems by Cathodic Protection, Revised 2002.
• NATIONAL FIRE PROTECTION ASSOCIATION
1 Batterymarch Park, P.O. Box 9 101, Quincy,
Massachusetts 02 169-7471. (800) 344-3555.
www.nftJa.org
National Fire Protection Association. NFPA 30,
Flammable and Combustible Liquids Code, 2008.
National Fire Protection Association, NFPA 30A.
Code for Motor Fuel Dispensing Facilities and Repair
Garages, 2008.
National Fire Protection Association, NFPA 70,
National Electrical Code, 2008.
PEI Recommended Practices 300-09
• PETROLEUM EQUIPMENT INSTITUTE
P.O. Box 2380, Tulsa, Oklahoma 74101-2380.
(918) 494-9696. www.pei.org
Petroleum Equipment Institute, RP100-
05, Recomrnended Practices for Installation of
Underground Liquid Storage Systems. 2005.
Petroleum Equipment Institute, RP200-
08, Recommended Practices for Installation of
Aboveground Storage Systems for Motor Vehicle
Fueling, 2008.
Petroleum Equipment Institute, RP400-02.
Recommended Procedure for Testing Electrical
Continuity of Fuel-Dispensing Hanging Hardware.
2002. Reaffirmed 2007.
Petroleum Equipment Institute, RP500-
05, Recommended Practices for Im.pection and
Maintenance of Motor Fuel Dispensing Equipment,
2005.
Petroleum Equipment Institute, RP900-08,
Recommended Practices for the Inspection and
Maintenance of UST Systems, 2008.
• STEEL TANK INSTITUTE
570 Oakwood Road, Lake Zurich, Illinois 60047.
(847) 438-8265. www.steeltank.com
Steel Tank Instin1te, ROO I, Flameshield®
Installation Instructions. June 2009.
Steel Tank Instinite, R82 l , Sti-PJ® Installation
Instructions, July 2007.
Steel Tank Institute, R9 l 2, Installation Instructions
for Shop Fabricated Aboveground Storage Tanks for
Flammable, Combustible Liquids, June 2009.
Steel Tank Institute, R9 13, ACT-JOO® Installation
Instructions. July 2007.
Steel Tank Institute, R923, Permatank® Installation
Instructions, July 2007.
Steel Tank Institute, R931 , F921® Installation
Instructions, June 2009.
Steel Tank Institute, R942, Fireguard® Installation
Instructions, June 2009.
Steel Tank Institute, R97 I, ACT-/OOU® Installation
Instructions, July 2007.
• TEXAS COMMISSION ON ENVIRONMENTAL QUALITY
12 lOO Park 35 Circle, Austin, Texas 78753.
(512) 239-1000. www.tceq.state.tx.us
Texas Commission on Environmental Quality,
RG-399, Vapor Recovery Test Procedures Handbook,
December 2002.
• UNDERWRITERS LABORATORIES INC.
333 Pfingsten Road, Northbrook. Illinois 60062-2096.
(847) 272-8800. www.ul. com
Underwriters Laboratories, Standard 87, Standard
for Power-Operated Dispensing Devices for Petroleum
Products, October 2001.
Underwriters Laboratories, Standard 567, Standard
for Emergency Breakaway Fittings, Swivel Connectors
and Pipe-Connection Fittings for Petroleum Products
and LP-Gas, Revised October 2004.
• U.S. DEPARTMENT OF LABOR, OCCUPATIONAL
SAFETY AND HEALTH ADMIN ISTRATION
Frances Perkins Building, 200 Constitution Avenue
NW, Room S23 17, Washington, D.C. 20210.
(202) 693-2000. www.osha.gov
Occupational Safety and Health Administration,
Title 29, Code of Federal Regulations (CFR), Part
'1910, Occupational Safety and Health Standards.
• U.S. ENVIRONMENTAL PROTECTION AGENCY
Ariel Rios Building, 1200 Pennsylvania Avenue NW,
Washington, D.C. 20460. (202) 272-01 67.
www.epa.gov
U.S. Environmental Protection Agency, Title 40,
Code of Federal Regulations (CFR), Part 63, National
Emission Standards for Hazardous Air Pollutants
for Source Categories: Gasoline Distribution Bulk
Terminals, Bulk Plants, and Pipeline Facilities; and
Gasoline Dispensing Facilities; Final Rule January 10,
2008. Direct Final Rule June 25, 2008.
U.S. Environmental Protection Agency, Title 40,
Code of Federal Regulations (CPR), Part 112, Oil
Pollution Prevention, November 11 , 1976 and Revised
April 2, 1987.
U.S. Environmental Protection Agency, Quality
Assurance Handbook.for Air Pollution Measurement
Systems, Volume Ill. Stationary Source Specific
Methods. EPA/600/4-77/027B, 1977.
U.S. Environmental Protection Agency, Technical
Guidance - Stage fl Vapor Recovery Systems for
Control of Vehicle Refueling Emissions at Gasoline
Dispensing Facilities, EPA/450/3-91/022B, November
1991.
U.S. Environmental Protection Agency, Section 182
of the Clean Air Act of 1990.