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LECTURE 06 Equipment Sizing and Capital Cost Estimation
LECTURE 06 Equipment Sizing and Capital Cost Estimation
4th edition
GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR
EMISSION CONTROLS AT DISTRIBUTION TERMINALS
4th edition
Oct 2014
Published by
ENERGY INSTITUTE, LONDON
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
CONTENTS
Page
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Acknowledgements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Guide to contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Floating roof tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.1 External floating roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.2 Internal floating roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.3 Seal systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Vertical fixed roof tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 Connection to a VRU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.4 Horizontal cylindrical tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
4.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5 Marine loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.5 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
Annexes:
Annex A Requirements of the European Directive 94/63/EC on the control of VOC
emissions during petrol storage and distribution . . . . . . . . . . . . . . . . . . . . . . 61
Annex B Sizing of vapour collection and recovery systems . . . . . . . . . . . . . . . . . . . . . . 63
Annex C Thermal oxidation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Annex D Vapour balancing during rail tank car off-loading . . . . . . . . . . . . . . . . . . . . . . 74
Annex E Model sequence for dealing with a temperature excursion in a carbon
adsorption type VRU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Annex F VRU emission measurement test method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Annex G A model baseline survey for the development of a mechanical integrity
inspection programme for carbon adsorption type vapour recovery units . . 93
Annex H Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Annex I References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
FOREWORD
This publication has been prepared by the Vapour Recovery Working Group of the EIs Distribution
and Marketing Committee.
EU Directive 94/63/EC placed controls on volatile organic compound (VOC) emissions resulting from
the storage of petrol and its distribution from terminals to filling stations. The first two editions
of this publication provided information to assist terminal operators and filling station operators
in their design and operation of vapour emission controls. The third edition, published in 2008,
focused solely on the design, operation and maintenance of petrol vapour emission control systems
at petrol distribution terminals, with comprehensive guidance on emission controls at filling stations
being provided in the joint EI/APEA publication Design, construction, modification, maintenance and
decommissioning of filling stations. This fourth edition provides an update on the 2008 publication
taking account of industry experience of the operation and maintenance of vapour emission control
systems over the last five years. As carbon adsorption type vapour recovery units are the norm in
the UK, more detailed guidance on the operation of these types of units is included, in particular
concerning the control of high temperature excursions.
The revision of the guidelines has been undertaken to incorporate good practice learnt during the
implementation of EU Directive 94/63/EC, both in the UK, and elsewhere in Europe.
Although this publication has been written in response to European legislation, it is the intent that
the recommendations are applicable wherever Stage 1 petrol vapour emission controls are to be
implemented.
The information contained in this code is provided as guidance only and while every reasonable care
has been taken to ensure the accuracy of its contents, the EI cannot accept any responsibility for any
action taken, or not taken, on the basis of this information. The Energy Institute shall not be liable to
any person for any loss or damage which may arise from the use of any of its publications.
Suggested revisions are invited and should be submitted to the Technical Department, Energy
Institute, 61 New Cavendish Street, London, W1G 7AR.
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
ACKNOWLEDGEMENTS
This fourth edition of the guidelines was prepared by the EIs Vapour Recovery Working Group,
comprising:
The EI wishes to record its appreciation of the work carried out by them, and thanks are also extended
to Neil Bretherick (Emco Wheaton), John Robson (SGS Roplex Ltd) and Dave de Halle (Phillips66) for
their assistance in the updating of these guidelines.
Technical editing and project coordination was carried out by Brian Smithers (Consultant to EI) and
Andrew Sykes and Toni Needham (EI).
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
GUIDE TO CONTENTS
SECTION 1 INTRODUCTION AND SCOPE
VAPOUR
EMISSION
CONTROLS
DURING:
SECTION 2 STORAGE
SECTION 5 MARINE
LOADING
VAPOUR COLLECTION
SECTION 6 SYSTEMS IN TERMINALS
VAPOUR BALANCING
ANNEX D DURING RAIL TANK CAR
OFF-LOADING
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
1.1 BACKGROUND
Concerns about the environmental and health effects of emissions of non-methane volatile
organic compounds (NMVOCs) have led to European legislation imposing emission controls on
the principal man-made sources of NMVOCs, e.g. solvents and petrol-powered automobiles.
In addition, Directive 94/63/EC mandates emission reductions during the distribution of
petrol.
The reduction in emissions during the storage, loading, and off-loading of petrol is
known as Stage 1 vapour control. Stage 1 is subdivided into:
Stage 1a: the control of emissions during the receipt, storage and loading of petrol
at terminals, and
Stage 1b: the control of emissions during off-loading of road tankers into service
station storage tanks.
European legislation has also been introduced to control emissions during the refuelling of
automobiles. Directive 2009/126/EC mandates so-called Stage 2 controls which require
modification of the petrol dispenser permitting the vapours displaced from the automobile
fuel tank to be fed back to the filling station storage tanks. The abatement of refuelling
emissions can also be undertaken, as is mandated in the USA, by using a larger version of the
carbon canister system which is currently installed on-board the automobile to control fuel
system evaporative losses.
Figure 1 shows the location of the stages diagrammatically. Both Stages 1 and 2 are
closed systems in which vapours are prevented from being vented to atmosphere by being
captured and collected for subsequent processing; for example, in a vapour recovery unit
(VRU).
Refinery
Stage 1 Stage 2
Stage 1a Stage 1b or onboard
carbon canister
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GUIDELINES FOR THE DESIGN AND OPERATION OF PETROL VAPOUR EMISSION CONTROLS AT DISTRIBUTION TERMINALS
1.2 SCOPE
These guidelines focus only on the design, operation and maintenance of vapour emission
control systems at petrol distribution terminals, i.e. Stage 1a. The principles outlined may also
be used at other sites, e.g. refinery off-sites, bulk liquid storage terminals, etc, although these
may have their own additional specific considerations to be taken into account that are not
addressed here.
These guidelines apply to vapour collection and control systems for petrol vapour.
They may not be appropriate for the control of emissions from the storage or handling of
other products.
Although the guidelines have been influenced by the need to comply with Directive
94/63/EC, it is the intent that they may be used wherever petrol vapour emission controls
are to be installed. The guidelines have been written without reference to other legislation
or local requirements which also have to be met in the installation and operation of control
equipment.
Only single stage vapour recovery technologies are addressed in the guidelines.
No guidance is given on the installation and operation of more complex multi-stage units
designed to meet emission limits which are much more stringent than those required by the
Directive.
For marine loading, the guidelines discuss primarily the on-shore vapour collection
and control systems. For sea-going vessels the on-ship equipment requirements have been
formulated by the International Maritime Organization (IMO) in MSC Circular 585 Standards
for vapour emission control systems.
1.3.2 Loading of mobile containers (road tankers, rail tank cars and marine vessels)
Directive 94/63/EC mandates that petrol vapours displaced from mobile containers whilst
being loaded should be returned through a vapour-tight collection system to a VRU. At
terminals where petrol is loaded onto inland waterway barges under certain circumstances
vapour thermal oxidation can be substituted for recovery (see Annex A).
The vapours displaced during the loading of a mobile container can be captured and
fed to a vapour control system by the following means:
Bottom loading: the vapours can be collected by connecting the vapour space(s) of a
mobile container to a common vapour line. This can then be connected to a terminal
vapour collection system. This is the loading mode mandated in the Directive for road
tankers.
Top loading: the vapours can be captured by modifying the loading arm so that the
vapours are displaced directly into the terminal vapour collection line. This loading
mode is the most commonly used in Europe for rail tank cars.