Safety Management of Air Storage Tanks

Air storage tanks play a crucial role in industrial production, especially in places where compressed gases or natural gases need to be stored, such as in the petroleum, chemical, natural gas, and fertilizer industries. To ensure the safe operation of these storage tanks and to effectively prevent accidents, it is essential to implement a comprehensive safety management approach. These measures not only include operational regulations and equipment inspections but also involve the coordination and complementarity of various safety systems. This article will delve into the safety management of air storage tanks from several key aspects, including the pressure regulation system, alarm system, shutoff device system, and safety relief valve system.

Pressure Regulation System

 

The pressure regulation system is one of the core systems for ensuring the safe operation of air storage tanks. Its main function is to regulate the internal gas pressure of the tank, ensuring that the tank operates within a safe pressure range throughout its operation. The pressure regulation system typically consists of regulators, pressure gauges, and pipelines. The regulator is responsible for stabilizing the pressure of the gas inside the tank according to the designed operating pressure of the storage tank.

1. Working Principle of the Pressure Regulation System

 

The regulator adjusts the gas flow and pressure passing through it to maintain a stable output pressure. If the pressure exceeds the set limit, the regulator will automatically reduce the flow rate to lower the pressure. Conversely, if the pressure drops below the acceptable range, the regulator will increase the gas flow to raise the pressure.

2. Routine Management Requirements

 

Regular Maintenance and Cleaning of Regulators: Regular maintenance is crucial for ensuring the smooth operation of the pressure regulation system. Over time, sedimentation from continuous use can reduce the performance of the regulator. Therefore, regular inspection and cleaning of regulators, particularly the filter mesh and adjustment valves, are critical.

Inspecting Pipeline Connections: Periodic checks of the pipeline connections in the pressure regulation system are necessary to prevent instability caused by loose connections or gas leaks, which could compromise the pressure stability.

Calibration of Pressure Gauges: Regular calibration of the pressure gauges is essential to ensure accurate readings. During calibration, attention should be given to checking the sensitivity and responsiveness of the gauges to ensure they can reflect changes in gas pressure promptly.

Alarm System

 

The alarm system serves as the second line of defense in the safety management of air storage tanks. If the pressure regulation system or other safety systems fail, the alarm system promptly issues alerts, notifying operators to take action and preventing safety accidents triggered by abnormal gas pressure or other faults.

1. Functions of the Alarm System

 

Pressure Alarm: If the pressure of the air storage tank exceeds the limit or fluctuates beyond an acceptable range, the alarm system will monitor this in real-time and automatically issue an alert, prompting the operator to take immediate action.

Leakage Alarm: If gas leakage occurs, the alarm system will detect changes in gas concentration through sensors and issue a leakage warning.

2. Routine Management Requirements of Alarm System

 

Regular Inspection of Alarm Equipment: Monthly checks should be performed on the sensors, signal transmission lines, and alarm devices to ensure their proper functioning. Special attention should be paid to the responsiveness of the pressure and leakage alarm devices to ensure accurate detection of pressure and gas concentration variations.

Testing the Alarm System: During routine inspections, a functionality test of the alarm system should be performed. This should include testing both the pressure and leakage alarm features to ensure that the alarm system will react promptly and accurately display warning information in case of an actual emergency.

Operator Training: Operators should undergo professional training to understand the workings of the alarm system and the corresponding emergency procedures. This ensures that operators can quickly assess and react when an alarm is triggered, minimizing the potential for accidents caused by improper operation.

Shutoff Device System

 

The shutoff device system plays a crucial role in ensuring the safety of air storage tanks when abnormalities occur. If the gas pressure exceeds a predefined safety threshold, the shutoff device will immediately close the gas intake, cutting off the gas source to prevent overpressure or potential explosions in the storage tank.

1. Working Principle of the Shutoff Device

 

The shutoff device operates based on pressure signals and automatic control systems. When the internal gas pressure exceeds the preset threshold, the shutoff valve automatically opens to close the pipeline that allows gas to flow into the tank. The shutoff device includes both manual and automatic control functions to address sudden pressure abnormality situations.

2. Routine Management Requirements of Shutoff Device System

 

Regular Inspection of Shutoff Valves: Since the shutoff valve is a critical component of the system, it should be checked at least twice a year for sealing integrity and sensitivity. This ensures it can quickly respond and shut off the gas flow in case of overpressure or other abnormal conditions.

Cleaning and Maintenance: The shutoff device, including the valve body and connected pipelines, should be cleaned and purged regularly to prevent impurities from blocking the pipes and ensure the valve operates smoothly.

Functional Testing: Regular testing of the shutoff device should be performed, including both manual and automatic tests. These tests ensure that the shutoff valve will function accurately and swiftly when required in an abnormal situation.

Safety Relief Valve System

 

The safety relief valve system is the last line of defense for air storage tanks. It is designed to automatically release pressure when the internal gas pressure of the tank becomes too high, thereby preventing tank rupture, explosions, or other safety accidents caused by excessive pressure.

1. Working Principle of the Safety Relief Valve

 

Safety relief valves are typically used in the system to release excess gas when the internal pressure exceeds the set threshold. The valve will open automatically to divert the gas to a safe area, avoiding the risk of tank damage or explosion due to excessive pressure.

2. Relief Valve Routine Management Requirements

 

Regular Calibration of Safety Relief Valves: Safety relief valves must be regularly calibrated to ensure that the set pressure aligns with the tank's design specifications. Calibration should be done by adjusting the opening pressure of the relief valve to match the system's working pressure to ensure that it activates quickly during abnormal pressure situations.

Regular Maintenance of the Safety Relief System: The safety relief system should be inspected regularly to ensure its sealing, sensitivity, and response speed are intact. This ensures that the system will activate rapidly to release excess pressure and prevent accidents in case of overpressure.

Replacing Damaged Components: During routine checks, any damaged components, such as safety relief valves or other system parts, should be replaced promptly to ensure the system functions correctly and efficiently.

Charging and Discharging Operation Requirements for Air Storage Tanks

 

The charging and discharging operations for air storage tanks must follow strict operational guidelines to ensure the safe operation of the tank. During the charging process, it is crucial to avoid overpressure, leaks, or other unsafe factors. Similarly, during the discharging process, care must be taken to avoid rapid pressure fluctuations that could damage the tank.

1. Air Storage Tank Charging Operation Requirements

 

Slow Valve Opening: During the charging process, the charging valve should be opened slowly to avoid excessive gas flow entering the storage tank too quickly, which can cause pressure shock.

Monitoring Pressure Changes: Constant monitoring of the pressure within the tank during charging is essential to ensure it remains within a safe range.

Closing the Valve: Once the tank reaches the set pressure limit, the charging valve should be immediately closed to prevent overpressurization.

2. Air Storage Tank Discharging Operation Requirements

 

Slow Discharge: Discharge operations should be done gradually to avoid significant pressure fluctuations that could lead to damage or leakage.

Orderly Pressure Reduction: The pressure should be reduced slowly and steadily to avoid putting unnecessary strain on the tank by rapidly decreasing the pressure.

Daily Inspections and Maintenance

 

Routine inspections and maintenance are vital to ensuring the long-term safety and operational reliability of air storage tanks. Inspection personnel should perform regular checks on the safety devices and systems to ensure their stability and reliability.

Routine Inspection Content

 

Leak Detection: A weekly leak inspection of the air storage tank should be conducted to ensure there are no gas leaks. This includes checking valves, joints, and all connection points.

Checking Pressure Gauges and Transmitters: Monthly checks should be performed on pressure gauges and transmitters to ensure they are functioning properly and providing accurate readings.

Cleaning and Maintenance: Quarterly cleaning and inspection of the air storage tank should be done to ensure there are no contaminants inside the tank and that no corrosion is present on the exterior.

Calibrating Safety Relief Valves: Annual calibration of the safety relief valves is essential to ensure they are functioning correctly.

Safety Hazards and Preventative Measures

 

There are potential safety hazards during the operation of air storage tanks. By identifying and eliminating these hazards in time, the likelihood of accidents can be significantly reduced.

Common Hazards and Preventative Measures

 

Poor Sealing: Poor seals at manholes, flanges, or other connection points can lead to gas leakage. Regular inspections and replacement of seals are essential to ensure all connection points are properly sealed.

Equipment Failure: Failure of equipment such as regulators and alarms can result in failure to respond to abnormal conditions. Regular checks and functional tests of equipment are necessary to ensure all devices are working properly.

Overpressure: Excessive pressure inside the air storage tank could cause an explosion or equipment failure. Regular calibration of safety relief valves and regulators is necessary to ensure the system operates within the designated pressure limits.

Conclusion

 

The safety operation of air storage tanks depends not only on the functionality of individual systems but also on the collaboration and mutual support of multiple systems. From the pressure regulation system to the safety relief system, as well as the shutoff device and alarm system, every aspect is vital. Through scientific daily management and standardized operations, it is possible to effectively prevent safety hazards and ensure the stable operation of air storage tanks. By strictly adhering to operational guidelines, conducting regular inspections and maintenance, and eliminating potential risks, the service life of air storage tanks can be extended, and reliable safety for production operations can be guaranteed.