Dispenser Safety: Equipment Hose and Nozzle

Written by: Brian Pottebaum, Director of Training Services

Safety around the dispenser should never be ignored. Fueling facilities are very busy and accidents are bound to happen. To combat this problem, the petroleum industry requires certain safety components on petroleum dispensers as precautionary measures to help protect your customers, and more importantly, your investments.

A dispenser is the only retail device that allows a customer direct access to your UST system. Therefore, each dispenser unit must be equipped with the necessary safety components. The dispensing unit is regulated by the National Fire Protection Association (NFPA), specifically in NFPA 30A: Code for Motor Fuel Dispensing Facilities and Repair Garages.

Photo: Image 1. Gilbarco Veeder-Root, Encore 700 Series Fuel Dispenser with hanging hardware labeled.

Dispenser

The customer transfers fuel from the dispenser to their vehicle through dispenser equipment that is often referred to as “hanging hardware”. The Gilbarco Veeder-Root dispenser in Image 1 illustrates the different components that make up the hanging hardware. This general setup is common among all dispenser manufacturers. The whip hose is a shorter piece of hose that connects the remaining hanging hardware to the dispenser. The breakaway connects the two lengths of dispenser hose. The swivel then connects the nozzle to the hose and allows horizontal and vertical rotation of the nozzle for a proper fit in the customer’s vehicle filler tube. Please note that if you are planning to dispense renewable fuels (exceeding E15 or B20), be sure to install equipment that is compatible with these fuels. This includes all hanging hardware and the thread sealant that is used to connect the components.

Photo: Image 2. OPW 68EZR Dry Reconnectable Breakaway

Dispenser Hose

Although retail dispenser hoses seldom exceed 8 or 10 feet in length, the hose length on an automotive dispenser must not exceed 18 feet in total length. However, hose length can exceed 18 feet at Marinas if adequate steps are taken to support and protect the hose from damage.

All retail dispenser hoses must be equipped with an emergency breakaway (disconnect), excluding Marinas. It protects your dispenser from damage in the event of a customer driving off with the nozzle still attached to their vehicle. This safety device is generally located near the fuel outlet fitting on the dispenser, immediately after (downstream) the short 8–12-inch whip hose. Some breakaways are designed to be reconnected and put back into service. One example is illustrated in Image 2, the OPW Dry Reconnectable Breakaway. Make sure to inspect them thoroughly and follow manufacturer instructions before you put them back into service.

If your dispensers are equipped with a hose retrieval device, make sure that the breakaway device is installed between retrieval mechanism connection (to the hose) and nozzle. If it is located on the other side of the retrieval connection, the breakaway will be impaired by the retrieval device and a hazardous situation may be the result.

Photo: Image 3. Husky V34 Nozzle. Pressure activated, automatic shut-off vacuum assist nozzle for full-service, self-service and unattended stations.

Nozzle

Every retail dispenser hose, aside from at Marinas, must be equipped with a (UL) listed, auto-closing type nozzle, with or without a latch “hold-open” device. The auto-closing feature within the nozzle is specifically designed to close once the customer’s fuel tank is full. If the hold-open latch is in use, the auto-closing device will disengage so the fuel stops flowing. It is a good idea to inspect every nozzle periodically because daily use will cause these safety features to become unreliable or even stop working.

Photo: Image 4. OPW Nozzle, Breakaway and Swivel components with example “Remove By Dates”.

Maintain and Inspect

Although enforcement and regulatory requirements can vary in different areas, routine maintenance and inspections are always advised to ensure the hoses and nozzles are in good condition. According to Husky Corporation, the life expectancy of a dispensing hose depends on several factors, including frequency of use and exposure to the elements. Husky provides the following guidance for fueling hose:

  1. High volume locations: Hose replacement recommended every 2 years or less
  2. Average volume locations: Hose replacement recommended every 5 years
  3. Low volume locations: Hose replacement recommended every 5 to 8 years

Proper maintenance should include routine repairs, replacement, and cleaning around the work area, specifically any spilled fuel and absorbent materials used to soak up the fuel. You should also pay attention to the Useful Life “Remove-by Date” on the hanging hardware attached to the dispenser, which includes nozzles, swivels, and breakaways. Manufacturers recommend you replace the component when it has reached its full life-cycle (based on testing) to avoid potentially hazardous situations that could occur after the Remove-by Date. This predetermined date is 5 years plus 3 months from the manufacturing date. The extra 3 months is to allow for the time this product might typically sit on a shelf before it gets put into service.

To ensure continuous safe operation, the Petroleum Equipment Institute (PEI) issued PEI/RP500, Recommended Practices for Inspection and Maintenance of Motor Fuel Dispensing Equipment, which includes daily and monthly equipment checks for dispensers.

Summary of DAILY CHECKLIST:

  1. Nozzle in good condition, hose connection clean and dry (not leaking)
  2. Nozzle hold-open latch straight, moves freely, return spring operates properly
  3. Swivel fitting moves easily and is clean/dry
  4. Hose/Whip hose in good condition: No cuts, cracks, bulges, blisters, flat spots, kinks, or worn spots; and all fittings clean/dry
  5. Breakaway is clean/dry
  6. Dispenser unit and island/pavement show no signs of recent spill or leak
  7. If a defect is observed, repairs should be made immediately, or the dispenser should be placed Out of Service

Summary of MONTHLY CHECKLIST:

  1. Dispenser unit in good condition, no external damaged or signs of tampering
  2. All components inside cabinet clean and dry (not leaking)
  3. Under dispenser containment (if present) is free of liquid and debris
  4. Filters clean, dry and dated (recommend replacing annually at minimum)
  5. Emergency shutoff/shear valve clean and dry, trip arm not obstructed
  6. “Remove-by Date” has not passed on hanging hardware (breakaway, swivel & nozzle)
  7. Spill kit supplies are on hand

For a complete copy of PEI RP500 or to download the inspection checklists, visit https://pei.org/test/rp500.

Most of the leaks that are encountered during inspections are found at the dispenser units. The sooner leaks are found and fixed, the less severe any resulting contamination will be.

Remember to report all suspected and confirmed releases to the appropriate authority having jurisdiction (AHJ). Also keep in mind that any spill, overfill, or aboveground release to the environment that exceeds 25 gallons must be reported. Releases must be reported to the AHJ within 24 hours of knowledge of the release.

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