1. How Breakaway Valves Enhance Safety

Breakaway valves are critical safety devices designed to prevent accidents during fluid transfer operations (e.g., CNG, LNG, gasoline, diesel). Their protective mechanisms include:

• Emergency Separation:
  If a tanker truck accidentally drives away while connected to the dispenser, the valve detects excessive tensile force and instantly breaks apart at a predetermined point. This prevents the hose or loading arm from rupturing and causing a massive spill.

• Instant Sealing:
  After separation, the valve automatically seals both ends of the broken flow path (the station side and the truck side). This dual sealing action stops the release of flammable or hazardous fluids, mitigating fire, explosion, and environmental contamination risks.

• Equipment Protection:
  By triggering a controlled disconnection, the valve protects expensive infrastructure, including dispensers, hoses, pipelines, and the tanker truck’s filling system, from mechanical damage.

• Operational Safety Compliance:
  These valves help refueling stations meet industry safety standards (e.g., NFPA, OSHA) by providing a fail-safe mechanism for unexpected operational errors.

2. Maintenance and Restoration Procedures

Post-Activation Response:

• Immediate Shutdown:
  Secure the refueling operation, isolate the affected area, and ventilate if flammable gases are involved.

• Inspection:
  Check for damage to the valve, hose, dispenser, and tanker truck connection. Replace the valve if it is a single-use mechanical type.

• Resettable Valves:
  For hydraulic or reusable valves, follow the manufacturer’s guidelines to reset the mechanism and replace shear pins or hydraulic cartridges.

Routine Maintenance:

• Visual Checks:
  Regularly inspect for corrosion, wear, leaks, or physical damage.

• Functionality Tests:
  Simulate activation conditions (using calibrated tools) without triggering actual breakage to ensure reliability.

• Component Replacement:
  Replace seals, O-rings, and other wear-prone parts periodically to maintain integrity.

Restoration Steps:

1. Deactivate the System:
   Shut off fuel supply and depressurize the line before any repair.

2. Valve Replacement/Reset:

   • Mechanical Valves: Replace the entire valve assembly.

   • Hydraulic Valves: Reset the mechanism and replace fractured shear pins.

3. Pressure Testing:
   After restoration, conduct a pressure test to verify leak-free performance.

4. Documentation:
   Record the incident, maintenance actions, and test results for compliance and auditing.

3. Key Considerations

• Training: Ensure personnel are trained to handle activations and perform repairs.

• Spare Parts Inventory: Keep spare valves and components on-site to minimize downtime.

• Manufacturer Guidelines: Always adhere to vendor-specific procedures for maintenance and resetting.

By implementing these practices, refueling stations and tanker trucks can maintain high safety standards while ensuring rapid recovery after an emergency activation.