Storage Tank-Emissions Control : Maintaining your Site Safety & Efficiency
As we all know a simple visual inspection is no longer accepted by the HSE (Health and Safety Executive) and Evidence of Site’s Preventative maintenance and management of ageing plant plans must be provided.
Every company needs to ensure its valves are functioning as well as they can be. They need to be calibrated, leakage tested and certified as fully functional. The consequences of poor maintenance practices can be very expensive and dangerous. A visual inspection is just not good enough.
Servicing breather vents is not the most enthralling part of your maintenance routine, but if you don’t look after them they could lead to your plant being closed, a fine by the Health and Safety Executive (HSE) or worse still, harm to your employees or loss of life. It is that serious.
Breather vents lose their ability to seal over time. We often inspect vents that have had weight added to the pallet assembly to compensate for poor sealing; this is a very dangerous correction because it would not be picked up unless we had conducted a weight test as part of our calibration check. It could result in a collapsed tank. The subsequent HSE investigation would centre on why the weight was added, by whom and for what reason.
The conservation of vapour and the minimisation of water ingress are key elements in sustaining the quality of stored liquids. Storage tanks are typically large volume, low-pressure vessels so the provision of tight sealing and adequate vapour/air exchange is essential.
An efficient breather vent safely conserves vapours up to the maximum allowable working pressure of the tank. Many tanks have nitrogen blanketing. Any loss of nitrogen is expensive and savings are immediate if the vent is serviced and tested correctly.
Assentech recently assisted a customer with annual nitrogen costs in excess of £250k. With calibrated breather vents and blanketing gas regulators we saved the customer £90k in the first year following completion of our work which cost less than £15k.
Valve Servicing, which includes CALIBRATION and LEAKAGE TESTS, is fast becoming a basic health and safety requirement. As experts in valve sales, installation and maintenance, we recommend an annual check for each valve on site. Any changes to calibration, in-depth remedial work and exterior coating needs more extensive work.
With our mobile test equipment, fully equipped service vehicles and comprehensively trained engineers, we can provide onsite servicing at your facility.
We can also offer offsite servicing. This will involve taking the valve back to our state-of-the-art workshop and taking it apart, piece by piece, checking every component. When fixing a valve, we always begin with a full survey. Only then will we be able to determine the necessary repairs.
We sometimes find that key components have been eroded. We use the authentic manufacturer’s replacements where possible, however if lead time is an issue or the parts are obsolete we have sophisticated machining and fabrication capabilities to create complex components ourselves.
Assentech operates under high quality standards; every valve is fully serviced, calibrated and tested by our experts before being used again in Site. Lead times are kept to a minimum and will save you weeks compared to a new replacement.
External coatings are another important aspect of the valve. These can deteriorate, for example on fibreglass valves due to UV degradation. But now that we are fully equipped with our new Paint Facility, we are quickly able to re-finish vents as new and return to site.
The key to reliable breather vent performance is structured regular checks. A full strip and removal from the tank every year is not necessary in most cases unless the application is extremely severe. In most cases a combination of full service and calibration can be followed by one or even two routine annual visual checks.
Some deterioration of the vent and its components can be visible if compared to their as new condition. Assentech can work with operators and train site maintenance staff to conduct structured annual inspections so that we are only called in to calibrate and certify in the second or even third year.
Ultimately we can make the valve virtually as good as new. We can bring what would otherwise be considered an obsolete product back up to factory-new condition. The potential cost savings are huge. You can see the difference in the photos.
Servicing and Maintaining Valves does need specialist knowledge and equipment and we proudly have the specialists and the equipment. Our customers are happy to let us focus on the performance of their vents while they concentrate on running their business.
The initial benefits of servicing, calibrating and certifying breather vents may not be so clear but once you consider the cost to a business following a contaminated load going into production, a collapsed tank or action by the Environment Agency, the payback for servicing, calibrating and certifying the performance of your breather vents makes sense.
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