Pumps and valves reconditioning company Enserve, a subsidiary of engineering firm VBV Holdings, imported a full-lift automated safety valve test rig from Netherlands-based valve test rig manufacturer Ventil to expand its service offering.

Enserve MD Steve Bannister says that the safety valve test rig, delivered in August, is the first and only of its kind in South Africa.

He states that the full-lift automated safety valve test rig unit is quick, efficient and tamperproof. Valves are tested for compliance with API 576 and are tested for leaks according to API 527. Testing for compliance to other standards is possible on request.

“The equipment’s introduction is part of VBV Holdings’ ongoing commitment to being internationally competitive and to being compliant with international safety standards and environmental legislation,” says Bannister.

“The South African economy faces a myriad of challenges and, as the powerhouse of Africa, neighbouring countries look to South Africa to take the lead as the continent moves into a period of growth and prosperity.”

Bannister points out that the safety valve test rig’s fully integrated computer system assures a simple operating procedure and the test and operation system controls the test procedure. “A combination of accurate pressure sensors and flow meters detect and measure any leakage,” he says.

He adds that the intelligent software compares the test results with the programmed test standard. “Within seconds, the system gives a pass or fail signal.”

Bannister adds that the testing apparatus electronically stores all documentation.

“A Windows XP-based computer registration system (CRS) stores and retrieves all valve testing and repair data electroni- cally.

“All test records are accessible through a unique customer portal. Third-party inspection and testing can be monitored remotely online and pre-testing and final testing is standard,” he says.

Bannister further notes that the CRS system includes a fully automated testing program, which requires no operator intervention.

“The entire process is tamperproof. Full-lift testing of pressure-relief valves with water is achieved, owing to the 20 ℓ high-pressure liquid accumulator. Full-lift testing of safety valves with compressed air is achieved through the addition of a 200 ℓ air reservoir,” he adds.

He adds that a 25 t hydraulic clamping system enables the testing of valve sizes up to 250 mm nominal bore and pressures of up to 200 bar and an acoustic measurement system is used to verify the simmer pressure on gas valves and the set pressure of safety valves in liquid service.

Environmental Division
Enserve’s environmental division has developed a volatile organic compound (VOC) leak-detection program, which it believes can play a role in the reduction of hydrocarbon leaks at refineries and petrochemical plants.

“VOC emissions emanate from a variety of sources, including valves and pumps at refineries, chemical plants and pipeline transfer stations.

“We have two leak detection programs – the conventional leak detection and repair (LDAR) program and the Smart LDAR program,” says Bannister.

He explains that Enserve’s conventional LDAR program uses equipment capable of detecting and measuring a large number of VOCs, as well as non-VOC gases, such as hydrogen, ammonia and carbon monoxide.

“The Smart LDAR program uses a specially adapted infrared GasFindIR camera to identify the leaks using thermographic imaging, in conjunction with conventional leak concentration measurement tech- niques.

“We have Smart LDAR equipment that enables us to see leaks from distances of up to 30 m. The R1-million infrared camera detects hydrocarbon leaks that manifest as smoke in the viewfinder.

“The Enserve Smart LDAR solution reduces survey time by up to 75%, compared with conventional emissions monitoring techniques,” notes Bannister.

He adds that the company’s program includes valve identification and tagging, the physical measurement of emissions, the recording of emissions data and the on-site installation of low-emission packing and gasketing.

Leaking equipment is tagged, leak con- centrations are quantified with conventional gas monitors and all data is recorded.

Bannister notes that, if necessary, the company quantifies the leak using tradi- tional gas sniffing equipment.

“The customer receives a spreadsheet with a list of all the leaks and a video clip of the leaks that need urgent attention, owing to their severity. Depending on customer requirements, we can provide either an overview of the hydrocarbon leaks above 10 000 parts per million (ppm) or a detailed scan where we identify leaks at levels down to 300 ppm.
“The service is also used to detect leaks after plant out- ages, significantly reducing the risk of fire,” he states.

Enserve is providing leak-detection services to a number of South African petrochemicals firms.

Bannister explains that there is a global drive to reduce VOC emissions, as they are harmful to the environment, pose a significant fire risk and are a health risk. “Excessive leaks also contravene environmental legislation.”

He notes that the physical measurement of emissions concentration is taken and the recording and reporting of emissions data are done in a format tailored to customers’ requirements.

“Sealant injection leak repair equipment can be used on site, in line and on line.

“We regularly monitor and audit sites to ensure legal compliance at the request of our customers,” Bannister concludes.