Tank Blanketing Basics Covered

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Tank Blanketing, or padding, refers to applying a cover of gas over the surface of a stores commodity; usually a
liquid. Its purpose is either to protect or contain the stored product or prevent it from harming personnel, equipment,
or the environment. In most cases the blanketing gas is nitrogen, although other gases may be used.
Blanketing may prevent liquid from vaporizing into the atmosphere. It can maintain the atmosphere above a
flammable or combustible liquid to reduce ignition potential. It can make up the volume caused by cooling of the
tank contents, preventing vacuum and the ingress of atmospheric air.
Blanketing can simply prevent oxidation or contamination of the product by reducing its exposure to atmospheric
air. It can also reduce the moisture content. Gas such as nitrogen is supplied in a very pure and dry state.
The list of products blanketed is extensive ---- everything from adhesives, catalyst, chemicals, fats and oils, foods,
fuels, inks, pharmaceuticals, photographic chemicals, soaps, and water.
Pressure Points
In order to effectively perform any of these functions the blanketing system must be capable of pressurizing the
vapor space and accurately maintaining that pressure.
Further, conserving the amount of gas used requires that the blanketing pressure be very low. Additionally, it must
be less than the tank's pressure capability. This pressure also must be below the normal tank venting pressures top
prevent unnecessary actuation of these devices and the subsequent discharge of blanketing gas, as well as product
loss.
These functions have been performed in various ways over the years. One method involves continuous purging,
whereby blanketing gas introduced into the tank as a continuous flow exits through a vent or other opening. This
method is wasteful of the blanketing gas and not always effective in maintaining an inert atmosphere.
Another approach employs a simple, direct-operated pressure-reducing valve (PRV) to blanket the tank. However,
these devices are the best suited to a continuous flow rate. When used to blanket a tank they must throttle over a
wide flow range. Ranging from a shut-off to a full flow condition varies the controlled pressure significantly due to
droop and lockup conditions.
Pressure variations can be as much as 30 percent below or 20 percent above setpoint. The results are the poor
control, wasting of blanketing gas, and possibly not maintaining the necessary atmosphere within the tank.
Another Approach
One of the more effective techniques relies on a blanketing system with the necessary controls and valving to sense
and maintain the set pressure within the tank to as close as 0.25 inch w.c. [water column] ( 0.009 psi). Set
pressures of 0.5 inch w.c. are possible and common.
Such a system will directly sense the tank pressure, control the inlet blanketing gas pressure if required and, through
a main control valve, throttle blanketing gas into the tank.
The system may also provide a purge in the sensing and main supply piping, plus reverse flow protection to keep
product out of the blanketing system. The installation may also require a pressure switch to monitor tank pressure
and perform alarm or control functions in response to over- or under-pressure conditions.
Operation, Activation
When blanketing gas enters the typical system (figure 1), the first-stage regulator (A) reduces inlet pressure from
high to low. (This is not always required.) From here, the gas flows to the main control valve (E), which is closed
when the tank is at or above its setpoint.
Supply is also piped to a filter regulator (B) supplying the pilot loading pressure - typically 10 psi - for actuation of
the main flow control valve. This reduced pressure then floes through an orifice (C) and to the lower case of the
main flow control valve as well as to the inlet of a sensing regulator (D).
The sensing regulator includes a diaphragm, which directly senses tank pressure. Its design, weighted and inverted,
allows sensitivity to as close as 0.1 inch w.c. as well as the ability to sense and control vacuums at any pressure up
to the inlet pressure. The outlet of the sensing regulator connects to the tank vapor space.
In operation, if tank pressure is below setpoint, the spring will move the sensing regulator diaphragm upward,
opening the seat and allowing flow from the filter regulator through the orifice and into the tank. The size of the
orifice limits the volume flowrate of gas to the tank. This minimal flow may be all that's necessary to satisfy a small
demand.
However, as demand increases due to pump-out or thermal cooling, the pressure drops in the pilot loading line that
connects (C) to main valve (E). This then reduces the pressure applied to the underside of the main valve diaphragm,
which allows the spring to move the diaphragm, throttling the main valve open and supplying blanketing gas to the
tank.
Setpoint Response
When the tank reaches setpoint, tank pressure operating against the sensing regulator diaphragm causes the seat to
close. This blocks pilot loading flow and pressure rises to the 10 psi setting. This pressure then operates against the
main valve diaphragm, causing the main flow control valve seat to close. Flow to the tank ceases.
At pressures below the setpoint the sensing regulator will throttle, varying pressure in the sensing system and then
throttling the main valve. The amount of throttling is proportional to the offset from setpoint. Therefore, as tank
pressure rises and approaches the setpoint, the main valve throttles and is closing as the tank reaches setpoint. This
maintains accurate setpoints and reduces overshooting.
In addition to a blanketing system, the tank will contain the emergency vent as well as normal pressure and vacuum
vents --- all of which must be properly sized for outgassing from pump-in, increases in temperature, drop in
barometric pressure, or fire. The vacuum relief provides redundant tank protection for unforeseen conditions, loss of
blanketing gas supply or system failure.
 The selection of a blanketing pressure is very important. It
must be less than the tank's pressure capability, and also
should allow some dead-band below the tank vent operating
pressure to avoid interaction.
Figure 2 illustrates a tank blanketed to 0.5 inch w.c. having
an allowable working pressure of 6 ounces per square inch. A
pressure of 0.25 inch w.c. added for shut-off results in a
maximum blanketing pressure of 0.75 inch w.c. The tank has
a normal pressure breathing vent that starts to open at 1.5
ounces per square inch (2.6 inches w.c.) and is full open at
1.8 ounces per square inch (3.1 inches w.c.).
Further, an emergency vent opens at 3 ounces per square inch
(5.2 inches w.c.) and is fully open at 3.5 ounces per square
inch (6.1 inches w.c.). There is a dead-band of 2.1 inches
w.c. between the two vents. The dead-band between the
blanketing system and the normal vent is 2.6 -0.75 = 1.85
inches w.c. The presence of an adequate dead-band will
ensure stable operation and avoid unnecessary loss of
blanketing gas or product going out an open tank vent.
Proper sizing is important for stable operation. Under-sizing
can result in tank pressures dropping well below the setpoint
as the main flow control valve struggles to keep up with
demand. Over-sizing is less critical. However, taken to an
extreme, it can result in unstable operation due to exceeding
setpoint.
Blanket Summary
A gas blanketing system will effectively contain gases within
the vapor space of a tank. Such a system can contain the gas,
or protect the tank contents form contact with atmospheric
air. It also can maintain the vapor space contents at an oxygen concentration level low enough to prevent ignition of
flammable vapors.
The system are simple to use and require little, if any, maintenance. They are capable of blanketing at pressures as
low as 0.5 inch w.c., minimizing consumption of blanketing gas.
Nitrogen is the most common blanketing gas, but others are used if compatible with the process. From a virtually
endless list of products that qualify for blanketing, those that are volatile as well as those sensitive to contact with
moisture or air are all candidates.
This article was written by Paul R. Ostand and editied by Joshua Sinsel of McNeil Consumer Healthcare
Author's Comments:
"Since the original publication date there have been advances in the technology used to provide gas blankets. While
this article does not illustrate these, the basics discussed in the article are still valid."