Improving safety through better access and control
Many workplace hazards arise not because equipment is poorly designed, but because critical components are difficult to access, operate or maintain safely.
A simple example is a fuel shut-off valve. In theory, operating a valve is straightforward. In practice, that valve may be located beneath a vehicle, rail carriage or storage tank, requiring personnel to work in awkward positions or potentially hazardous environments to access it. These challenges create unnecessary safety risks and operational inefficiencies.
The challenge
Flexible Drive was engaged to help solve a safety and maintenance challenge affecting a fleet of passenger trains.
Each train carriage contained an auxiliary generator set responsible for powering essential services including lighting, air conditioning and door operation. Engineering investigations identified that the routing of fuel lines between the fuel tank and generator set could allow air to accumulate within the system, eventually causing fuel starvation and loss of auxiliary power.
The solution was to reroute the fuel lines. However, this created a new problem.
To safely carry out maintenance activities, technicians needed to manually isolate the fuel supply. Following the fuel line modifications, the shut-off valve was located in between the train carriage, making it difficult to see, reach and operate safely.
The solution
Flexible Drive designed and manufactured a mechanical remote valve operating system that allowed the fuel shut-off valve to remain in its optimal location while relocating the control point to an easily accessible position on the exterior of the carriage.
The new system provided:
- Safe and convenient operator access
- Intuitive operation
- Lockable controls for maintenance safety
- Reliable mechanical actuation
- No electrical power requirements
- Reduced ignition and fire risk in hazardous environments
The result was a practical engineering solution that improved safety, simplified maintenance procedures and eliminated the need for personnel to access difficult-to-reach areas beneath the train.
The outcome
The success of this project led to the development of the Aktivo Remote Valve Operating System, a versatile solution now used across a range of transport and industrial applications.
The system is particularly suited to:
- Tanker vehicles
- Rail applications
- Industrial processing equipment
- Fuel systems
- Hazardous operating environments
- High-mounted or difficult-to-access valves
By relocating valve controls to safer and more accessible locations, operators can perform critical isolation procedures quickly, safely and confidently.
Aktivo system features
- Available with 3", 4" and 6" (150 mm) stroke options
- Locking capability
- ¼" or M6 connection options
- Clamp or bulkhead mounting configurations
- Custom lever lengths
- Custom gate plate designs
- Engineered load and torque calculations
- Flexible installation options
- Minimum bend radius specifications
- High push and pull load capacity
Engineering solutions for unique challenges
Every application is different. That's why Flexible Drive works closely with customers to design and configure remote valve operating systems that meet their specific operational, safety and engineering requirements.
Whether you need to improve operator safety, simplify maintenance access or solve a complex control challenge, our engineering team can help develop a reliable and practical solution tailored to your application.