What is reason #2 to choose for a vacuum system?

This question 7 is in continuation of question 6 in which we started explaining why an active vacuum leak detection system is superior over an active pressurized system.  Active leak detection systems can be either a pressurized system, in which an inert carrier gas stream flows through the leak detection circuits most probably only via the machined leak detection grooves present in the carbon steel and a vacuum system, where one pulls vacuum pressure underneath the liner.

We recommend a vacuum based leak detection system for several reasons:

Reason #2: Direct detection of the complete carbon steel surface

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The State-Of-The-Art Ammonia Terminal

Since 100 years ago the industrial production of ammonia began for the widespread agricultural and industrial application. Safety hazards and risks have been identified and for a large extend resolved.

Nowadays ammonia is used more and more as a very efficient hydrogen energy storage, carrier and carbon free fuel. This means that more and more people will get involved with this potentially toxic substance. How will the public and the authorities react?

Are the previously known safety regulations sufficient for the storage / bunkering of ammonia?

We say no, it can be better, more safe and reliable.

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What is reason #1 to choose for a vacuum system?

We recommend a vacuum based leak detection system for several reasons:

Reason #1: No risk of liner bulging

A first reason is that when using a vacuum system there will be no risk for liner bulging and damage due a to too high pressure in the leak detection system behind the liner. Be aware that the relatively large liner compartments are welded to the carbon steel pressure bearing wall. These large areas allow only a very limited pressure difference between each side of the liner.

Some vendors try to avoid this risk of bulging by switching off the leak detection system when the pressure in the synthesis section is below a certain value. In our view this is not a good solution because...

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Which kind of active leak detection systems exist ?

High pressure urea equipment consist of a heavy carbon steel pressure bearing wall, which is protected against corrosion by a thin corrosion resistant layer; this layer is in the most cases made out of stainless steel or a duplex. This protective layer can be an overlay welding, an explosive cladded layer but is in most cases a loose liner.

Any leak in a loose liner will lead to a dangerous situation because a potentially corrosive fluid can be spread and trapped in the gap between the carbon steel pressure bearing wall and the loose liner. This area will then be exposed to the extremely corrosive ammonium-carbamate.

Real situations have proven that ammonium-carbamate can corrode carbon steels with very high corrosion rates up to 1,000 mm (40 inch) per year. But also stainless steels will show accelerated corrosion because of lack of oxygen. That means that it is an absolute must to have a detection system present that already warns for al leak in an early stage. Then one can only conclude that an active leak detection system is required...

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