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Gallagher
Vapour Recovery
www.gallagher.co
What you need to know about VR
The fuel vapour you smell as you fill your car is an expensive
chemical, dangerously carcinogenic to humans, and a major
pollutant to the environment.
Vapour Recovery (VR) regulations are in place in many countries
throughout the world. In Australia, New South Wales has
mandates for the recovery of vapour already in place, with other
states likely to adopt these soon.
VR compliance is a concern for forecourt owners and their staff.
Escaping vapour creates pollution and contributes to climate
change.
The worldwide fuel industry approaches VR at two levels.
VR Stage 1 relates to the petrol storage tanks, piping, vents,
and the tanker delivery process. VR Stage 2 applies to retail
deliveries of fuel to the end user.
Gallagher brings new technology to the market that offers
alternative methods of creating the vacuum required to prevent
vapour escaping.
As a site owner you can choose a central vacuum that offers a
quieter dispensing environment, or an integrated solution that
provides an easily installed per dispenser option. Both options
enable operators to fully comply with all existing VR legislations,
and in addition to other VR products have the added benefit of
providing a valid return on investment.
The current fuel system standards ensure liquid fuels are held in
sealed piping and tanks.
The difficulty faced by system designers is to manage and
provision the storage of product. Fuel has a natural tendency to
become vapour if allowed.
Fuel is an expensive asset, often sold at a minimal margin. It is
critical to seal fuel and its vapour into the storage tanks effectively.
This is where it stays in liquid form with very little vapour escaping,
meaning that every litre is retained as saleable fuel.
Under current and proposed legislation, businesses are required to
provide capital and cover on-going costs to ensure fuel vapour is
controlled. The current regulated VR systems are a forced expense
that do not improve the sales opportunity.
The Gallagher Vapour Recovery solutions provide the opportunity
for legislative compliance that can include a return on investment.
Many sites in Australia and New Zealand have petrol tanks that
have open vents in various layouts, which contribute to known loss
of fuel through vaporisation.
Gallagher
vapour recovery
solutions go
beyond just
compliance, they
bring compelling
commercial
reasons to buy.
A VR1 verified tanker delivering to a VR1 tank site will reduce
losses by ensuring this vapour is not lost to atmosphere during the
delivery process. The fuel that becomes vapour during this process
is no longer available as saleable product.
Gallagher now brings a new approach to vapour recovery. Our
solutions focus on ensuring any vapour created within the storage
system is not only retained, but is converted back to liquid fuel.
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Flexible solutions
ONE SOLUTION DOESN’T WORK
FOR EVERYONE. THAT’S WHY WE
OFFER A RANGE.
Our Vapour Recovery range
provides cost effective solutions for
service station operators.
Your system can be matched to
your priorities as the site owner
- compliance, environment, or
return on investment. Our solutions
create a new way of looking at the
problem of vapour recovery. Even
in non-compliant VR zones, any
service station can act now with the
certainty of a commercially sound
decision.
Gallagher and our Service Providers
will work with you to select
the perfect combination of VR
equipment to suit your needs.
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PRESSURE GUARD
CONTAINMENT MODULE
INHIBITION MODULE
RECLAIM MODULE
The Pressure Guard combined with
a monitoring system enables you to
fully comply with VR1 legislation. As
a compliance requirement for sites
within VR1 and combined VR1/VR2
New South Wales regulated zones,
it has the required German TUV
certification to record and alert on
pressure readings from the petrol
tank’s vent manifold.
Natural fluctuations of pressures
and temperature will cause some
vaporisation within the system. The
Containment Module ensures none of
this precious vapour is lost.
The biggest single cause of
vaporisation within the storage system
is agitation of fuel from incoming
tanker deliveries. Temperature
differences and momentum of delivery
potentially create a huge vapour
increase (1.5 times the volume of
delivered fuel). Without control, this
vapour is able to escape into the
atmosphere.
Any vapour generation within the storage system causes an increase in the tank vent
pressure. The Containment Module holds the fuel vapour under pressure, but it cannot
be sold until it is in a liquid form
Our system incorporates a very
accurate pressure gauge mounted
direct on the tank vent piping. The
recording system uses intrinsically
safe wiring to connect the Pressure
Gauge to the included Gallagher
Vapour Recovery Controller.
The Containment Module uses
weighted valves to stop vapour
escaping to the delivery tanker’s
VR1 line or to the atmosphere. This
retention enables the storage system
to hold the vapour until it naturally
re-condenses or can be directly
processed back into liquid form for
sale.
The VR Controller manages the
data and produces daily reports.
Pressure readings are taken every 30
seconds. If readings fall outside the
prescribed range, alerts are given. If
fault conditions persist beyond the
prescribed limit, the VR Controller will
shut down the site in accordance with
legislated requirements. The Containment Module is
incorporated into the manifold of vents
between the VR1 connection point and
the tanker fill points.
The Inhibition Module virtually
eliminates all vapour generation at this
point. It works to reduce agitation by
dispersing the flow and uses a venturi
system to circulate generated vapour
back into the fuel delivery stream,
within the tank.
The Reclaim Module actively processes vapour back into liquid petrol using a
compressor and carbon separator. The compressor is fed from the tank vent piping
and has a separate return tank line to the lowest octane tank.
Operating in ten-minute cycles, the Reclaim Module can process 100 litres of vapour
per minute. Liquid fuel is created by compressing the vapour and the remaining super
saturated vapour then returning it into the tank system. Through a combination of
compressing vapour and separating hydrocarbon from the air, liquid fuel is returned to
the tank and clean air is released to the atmosphere.
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Making the right choice
CENTRAL
VACCUM PUMPS
CONTAINMENT
MODULE
SH
OP
RECLAIM
MODULE
PRESSURE
GUARD
MONITORING
INHIBITION
MODULE
VR2 ENABLED
DISPENSER
THE BUILDING BLOCKS FOR AN OPTIMAL GALLAGHER VAPOUR
RECOVERY SOLUTION
Gallagher and our Service Provider network can work with
customers to review the combination of modules that target the
key drivers for Vapour Recovery on a site.
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CONTROLLER
Our VR solutions have been designed around modular
component-based architecture. We work with you, bringing your
knowledge and experience together with our expertise and the
support of our Service Providers.Together, we can build a system
that is designed around your priorities, ensuring that your
investment meets your demands.
For example, if your focus is on monitoring environmental
impact, your system will be centred on the containment module.
Containment ensures no vapour is allowed to escape, and by
extending these concerns to include compliance, the basic makeup
of your system becomes clear. However, if return on investment
is the main priority, containment will offer the best return when
combined with the Reclaim and Inhibition Modules.We can help
you prioritise from major factors such as site layout, compliance,
return on investment, and environmental impact. Whatever the
requirement from your VR site, Gallagher can provide a solution,
built from this architecture that is perfect for you.
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Controller
VR2
VR1
THE CONTROLLER IS THE ‘BRAINS’ OF GALLAGHER’S
VAPOUR RECOVERY SOLUTIONS.
At its most essential level, the cabinet contains the
components to monitor tank pressure, while in more
advanced systems it may control the entire VR1 and VR2
operation. The component design allows the Controller
to be easily upgraded and enhanced to suit the individual
system requirements.
Supplied as part of the Pressure Guard, upgrades are fitted
prior to leaving the factory when other modules are ordered
as part of a more comprehensive system. Depending on the
makeup of the system, the exact details may vary but the
Controller is effectively supplied in two configurations.
VR2
STATUS INDICATOR
CENTRAL VACUUM
INTEGRAL VACUUM
This module is available in either VR1 or VR2 form, and both
are inherently upgradeable to cope with changing conditions
and legislation.
One of the two options for the recovery module, the Central
Vacuum employs vacuum pumps housed in a cabinet away
from the dispensers. This provides the source to recover the
vapour from every filling point on site.
The Integral vacuum VR2 option has the vacuum source
designed into every dispenser. The vacuum pump used is a
dual sided solution, enabling independent suction on either
side of a dispenser.
Special VR2 nozzles are used at the dispenser to capture
the escaping vapour. The dispenser also includes VR2 pipework, which returns that vapour to the underground storage
tanks using the vacuum created. A liquid trap is positioned
between the inlet (suction) and outlet (blowing) on the VR
return line. This ensures liquid condensate does not enter
the vacuum pump of the module.
This option also uses special VR2 nozzles at the dispenser
to capture the escaping vapour. The dispenser includes VR2
pipe-work, which returns that vapour to the underground
storage tanks using the vacuum created.
For VR1 the Green LED indicates status ‘OK’ (within the
prescribed limits). The Amber LED indicates ‘Warning ‘levels
accompanied by an audible alarm, this can be silenced using
the button on the door. Each day where the fault is still
active a sound alert will be repeated. Under the regulation,
when ‘Warning”’ conditions arise, depending on test type, the
service person will have 7 or 30 days to correct and reset
the system or the site pumps will be shutdown automatically
after those days expire (accompanied by a Red LED signal).
In VR2 form the Status Indicator also displays VR2 status
LEDs. The Green LED indicates status ‘OK’ (within required
VR2 ratio band). Amber ndicates ‘Warning‘ levels and is
accompanied by an alarm, this can be silenced using the
button on the door. Every 8 hours where the fault is still
active a sound alert will be repeated. The service person will
have 7 days to correct and reset the system otherwise that
side of the dispenser automatically shuts down. The Red
LED indicates a shut down dispenser and requires service
intervention to correct. The VR2 version also allows for the
termination of RS485 wiring from each dispenser on site,
for the Vaporix unit in each dispenser head. The Vaporix is
a data centre and a TUV certified measuring device that
reports a range of data and status including the required VR
ratio, fuel flow rate and hydrocarbon content for every petrol
delivery.
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The Central Vacuum module requires mains wiring to be
positioned at the cabinet and has the required electrical
approval (IEC Ex) for hazardous zones . This unit is part
of the VR2 TUV certification of the system and provides
vacuum to the required recovery ratio of 100% +/-2%
in TUV testing, +/-5% in configuration and +/-15% in
operation on site.
The Durr vacuum pump has the required electrical approval
(IEC Ex) for hazardous zones and is integrated with a
dispenser control system to activate automatically after a
nozzle is lifted. The unit is part of the VR2 TUV certification
of the system and provides vacuum to the required recovery
ratio of 100% +/-2% in TUV testing, +/-5% in configuration
and +/-15% in operation on site.
The benefits of this module are based on site size and the
number of petrol dispensers in operation on the forecourt.
The benefits of this module depend on site layout and the
number of petrol dispensers in operation on the forecourt.
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Monitoring
Choosing your ideal system
GALLAGHER CAN WORK WITH YOU TO DESIGN A COMBINATION OF MODULES THAT TARGETS YOUR KEY DRIVERS FOR VAPOUR
RECOVERY. THE CHART BELOW SHOWS HOW THE SYSTEM ‘BUILDING BLOCKS’ CAN BE COMBINED TO CREATE A SOLUTION FROM A
BASIC VR1 CAPABLE SITE TO A MONITORED, FULLY COMPLIANT, LOW ENVIRONMENTAL IMPACT OPERATION.
✓
System
Code
VR MONITORING OVERVIEW
STATUS DISPLAY
REMOTE MONITORING
Under the New South Wales VR
regulations, the site owner or
occupier is responsible for all
compliance to the VR1 and VR2
guidelines. Our monitoring solutions
are about collection, control, and
accurate reporting of VR data into
a useful format that meets site
requirements. This will allow the
regulatory bodies to complete their
statutory processes. The huge
volume of required data under VR
regulation is a necessary function
but the storage and sorting of that
data into the essential views is the
smart partnering model.
With the Status Display, your system
is fully compliant. It can monitor
VR1, VR2 or both and is to cope with
future changes in the VR zoning and
legislation.
This module allows data to be collated
and reported in a remote location. The
current solution complies with the VR1
and VR2 New South Wales regulations
with secure access through a web site
portal.
Pick a monitoring solution that
fits the site, people, and process.
Leave the compliance needs to
us. Gallagher ensures that Vapour
Recovery is not your worry.
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The 8.9” touch screen shows real-time
status of the VR1 and VR2 health of
site. Data reports, including those
required for VR legislation compliance
are accessed within the Service
region.
While the primary purpose of this
data is to provide information to site
inspectors, it also offers a valuable
diagnostic tool for service engineers.
Drop-down lists are used to filter the
data selection as required.
At the touch of a button, the data
is retrieved and displayed in a selfcontained, scrollable window within
the page. This allows the user to
view the whole report at a readable
resolution without the need to navigate
through multiple pages of information.
This remote data is secure,
automatically backed up, and isolated
to individual customer login. The data
is viewed in its raw form as received
from the site but is easily viewed as
graphs. Colour and bands indicate
status and allow easy understanding
of the trends that are happening with
each dispenser fill point.
Any non-responding dispensers
are high-lighted in yellow to prompt
immediate service planning. Patterns
and trends (e.g. slow flow rates caused
by filter blockage) can easily be seen
and preventative measures taken.
Data can be downloaded off the
website or prompted from the
forecourt for the latest status of the
dispensers. All required data and
reporting for compliance purposes is
available on the website.
VR1-75
VR1-100
VR1-150
VR1-175
VR1-200
VR1-250
VR1-275
VR1-300
VR1-350
VR1-375
VR1-400
VR1-450
VR2-75
VR2-85
VR2-100
VR2-150
VR2-200
VR2-250
VR2-275
VR2-285
VR2-300
VR2-350
VR2-400
VR2-450
VR2-475
VR2-485
VR2-500
VR2-550
VR2-600
VR2-650
VR2-675
VR2-685
VR2-700
VR2-750
VR2-800
VR2-950
VRT-100
VRT-150
VRT-200
VRT-250
VRT-300
VRT-350
VRT-400
VRT-450
VRT-500
VRT-550
VRT-600
VRT-650
VRT-700
VRT-750
VRT-800
VRT-850
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Reclaim
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Monitoring
R.O.I.
Benefit
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Benefit
Compliance
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GALLAGHER FUEL SYSTEMS LTD
2 Station Road, Marton 4710, New Zealand.
TEL +64 6 327 0060
PO Box 308, Marton 4741, New Zealand.
FAX +64 6 327 6724
www.gallagher.co
EMAIL info@fuel-systems.gallagher.co
www.gallagher.co