DC-AW 2014-1 Chemicals March 2014

Target audience: Logistics Service Providers in the European jurisdiction only (due to differing legal
requirements).

EO Leaks from Dry Break Couplings

What happened:
In the space of a few weeks, several incidents involving
small EO leaks from dry break couplings (also known as
“dry break connections”) on both road cargo trucks and rail
tank cars were reported. In the same period, some near-
misses were also reported involving the same equipment. Figure 1 – Example of Dry Break Coupling

 Incident: On a number of occasions, a few leaking drops of EO were reported after disconnecting the dry
break coupling. Subsequent investigations indicated there was nothing operationally wrong with the subject
couplings. Technical design/data analysis revealed that in between the internal closed valves of the dry
coupling itself there is a small dead space. Therefore, with the presence of the dead space, there will
always be potential for a few drops to appear just after disconnecting (even if the connection is purged with
nitrogen).

 Incident: A dry break coupling was mechanically damaged by excessive force stresses on the coupling.
This kind of damage can be caused by misalignment of fixed unloading-arms or by a heavy weight
attached on the flexible connection. (eg a large valve). Rough handling can also cause damage.

 Incident: A small leak was caused by the presence of sand in the coupling. The hose was not stored in a
clean place and the couplings were not checked before use.
 Figure 2 - Flange mechanically
damaged by force or
misalignment

 Near miss: Damaged valve rings were found after failing a pressure-test. The subsequent investigation
revealed that that some rings were not replaced in accordance with recommended practice.

Figure 3 - Damaged valve ring

 Near-miss: After disconnecting from the line, a few drops were reported. The drops did not evaporate
afterwards as anticipated - indicating that the drops consisted of condensed water caused by the very low
temperature of the couplings just after discharge (~ 2degrees C)
Lessons learned:

 Dry-break couplings may not necessarily guarantee the line is 100% dry! Even following purging and
decompression of the product-line, it is possible that a few excess drops will be observed after disconnecting the
coupling. This is not always an indication that the connectors are failing. However, any reoccurrence of non-stop
dripping may indicate a failure of the coupling.

 Couplings and valve rings that are not regularly maintained over time will have a higher risk of failure.

 Couplings can be damaged when the connection is not straight-aligned or if excessive weight is placed on the
hose unit.

 A Dry-break coupling is considered a piece of high-tech equipment that should be handled and maintained with
due care.

Recommendations:

 Always use proper PPE while connecting and disconnecting a dry-break coupling.

 Always purge EO hoses and decompress completely before disconnecting a dry-break coupling.

 All O-rings in the male/female couplings should be replaced at least per manufacturer’s specification or every
two years or after 50 times of use or as part of a fixed maintenance scheme, whichever is sooner.

 When mechanical damage is visible, always get the unit repaired immediately - even if the coupling still
appears to be working well.

 Use of a balancer to prevent excessive weight on the connector is recommended.

Further information:
Please contact Rob Beneker (rob.beneker@shell.com) for more information.