In air‑control and security systems at petrochemical refineries, reliability and safety are closely parallel: dependable air supply ensures security functions operate safely and consistently in hazardous conditions.
One small failure or a little breach in the damper could trigger catastrophic consequences. EB Air Control was to provide a highly reliable damper system able to meet the client’s demand for 100% bubble-tight sealing in harsh and corrosive environments. With its specifications to be met by the letter and under validation Third party tested by TUV Germany, this project stood as a testament of innovation and quality finished product
The Challenge
The project had to face a few complex issues before EB Air took over. This was for a petrochemical refinery, throughout which the dampers would be exposed to adverse environmental conditions of corrosive gases and temperatures. Even the slightest leakage, in this case, could greatly endanger safety and operational efficiency.
The client ultimately required zero-leakage dampers in compliance with the following criteria:
- They must remain 100 percent bubble tight when subject to medium to high pressure.
- The dampers must resist interference from toxic gaseous substances without any degradation of the material.
- The gaskets should be EPDM that would resist corrosive exposure without disintegration.
- Must be able to work with fast-acting actuators that require a rapid response to control signals.
- Should maintain their sealing performance after thousands of operations.
In simple words, the damper was required to withstand tough conditions, resist corrosion, seal tightly while in operation, and continue to do so after repeated use without sign of stress or degradation.
Project Goals
The primary goal of the project was to deliver dampers that were leak-proof, highly responsive, and durable enough to maintain performance across hundreds of operating cycles.
Specific objectives included:
- Achieve and maintain Zero Leakage (Bubble Tightness)
- Ensure the EPDM gasket does not distort or degrade over time
- Create a fast-response mechanism with fail-safe actuators
- Ensure long-term reliability and minimal maintenance
- Implement a strong adhesion technique to secure the EPDM gasket to the galvanized metal
- Satisfy client with TUV Germany’s third part test validation before dispatch
The client placed strong emphasis on third-party testing as part of the final quality check to ensure zero room for error.
The Solution
To meet these demanding requirements, EB Air proposed the use of its Industrial Positive Seal Dampers, coupled with Belimo fast-acting fail-safe actuators. Engineers have already performed these dampers for over 100,000 operational cycles, proving their durability and consistency.
Key features of the solution included:
- 100% Positive Seal: EB Air has engineered these dampers to seal perfectly under atmospheric pressure as well as under slightly positive operating pressure.
- High-Quality EPDM Gasket: The selected gasket was noncorrosive and chemically stable, making it ideal for petrochemical environments.
- Innovative Adhesion Technique: In bonding this EPDM gasket to the galvanized damper body, EB Air investigated various bonding methods and tested adhesives with highest quality producer to develop a solution that would withstand chemical exposure and mechanical pressure.
- Fast-Acting Actuation: The rapid closing/opening of the damper upon reception of the control signal is ensured by the Belimo actuator, which is a requirement, in any case, for emergencies and quick shut off.
By combining precision engineering, premium materials, and expert consultation, EB Air ensured the product met every technical and safety specification set by the client.
Implementation Process
The design expert says that while the design proceeded smoothly, the assembly process had some problems, mainly in choosing the correct adhesive that would bond the EPDM gasket to a galvanized surface without failing.
Several adhesives were tested under numerous conditions to guarantee compatibility and durability. This step entailed a lot of trial and error, lengthening the overall schedule for assembly. But EB Air held out for quality and refused to rush through before the best bonding procedure was developed and confirmed.
Once assembled, the last step needed before validation testing had to be carried out. TUV Germany mostly supervised the testing done at EB Air’s premises.
These Tests Involved:
- Applying between 2500-3000 pascal pressure
- Checking for zero air/gas leakage (bubble tight condition)
- Testing the response time of actuators. Carrying out selective cycle tests.
- Verifying seal integrity post multiple cycles
The results? Every single unit passed with flying colors.
The Outcome
The successful execution of this project was a milestone achievement for EB Air. Despite initial delays during gasket bonding, the final output exceeded expectations. Here’s a breakdown of the results:
Zero Leakage: Each damper held up against high pressure without any leakage.
- TUV Germany third party witness tested.: The project got validated and tested by a third party.
- Durability Proven: The dampers worked fine over many cycles before being considered reliable for the long run.
- Innovation Achieved: This marked the first successful integration of EPDM gaskets with galvanized bodies by EB Air using modern adhesives, thus opening new avenues for future use.
- Rapid Operation: Use of the Belimo actuators meant that the operation was fast and fail-safe.
The project demonstrated EB Air’s capability in manufacturing and customizations, while at the same time cementing their position as a trusted partner with large design companies on critical industrial applications.
Conclusion
The case study shows that EB Air is committed to innovation, quality, and customer satisfaction, and how these factors contributed to the successful deployment of bubble-tight dampers in one of the most demanding environments: oil and gas refinery and ancillary operations..
Through the interplay of ingenuity, cooperative effort, and certified testing, EB Air not only gave a product that fulfilled the brief but also raised the standard, posing what is achievable in an industrial air control system.
Because of this success, EB Air is now ready to engage in much more challenging industries, wherever custom damper solutions are needed that must withstand the harsh environment.
Need a Zero Leakage Damper Solution? Partner with EB Air Control for industry-leading performance, reliability, and innovation.