Case Studies
PROTEGO® safety devices have proven effective in diverse real-world applications.
Projects we are proud of
Case studies highlight challenges faced, strategies implemented, and results achieved, showcasing the ability to address fire and explosion protection Explosion protection An explosion protection is a flame arrester that prevents flame propagation into plant sections to be protected during explosions. , emission control, and storage tank safety. With a commitment to quality and proven methodologies, we support our customers with application-specific engineering and overall protection system design.
Enhancing Safety & Uptime
Flame Arrester Replacement on a Deep-Water FPSO
Background
A leading offshore energy producer operating a deep-water FPSO faced growing challenges with its existing flame arresters Flame Arresters A flame arrester, deflagration arrester, or flame trap is a device or form of construction that will allow free passage of a gas or gaseous mixture but will interrupt or prevent the passage of flame. . According to project documentation, the units were generating
- excessive pressure losses
- were difficult to clean
- required crane assistance during every maintenance Maintenance Combination of all technical and administrative actions, including supervision actions, intended to maintain or restore a unit in working order. cycle.
Cleaning inefficiencies forced monthly production stoppages, and the extended cleaning time often required work to be moved to an onshore workshop. The operator needed a solution that would
- reduce downtime
- improve safety conditions and
- minimise maintenance burden
without altering the existing piping layout.
Solution
PROTEGO® supplied a set of advanced Detonation Detonation Explosion propagating at supersonic velocity and characterized by a shock wave (EN 1127-1: 1997). Flame Arresters designed specifically to enable easy offshore maintenance. Based on the technical material in the report, the devices featured:
- Individual stabilized FLAMEFILTER® discs for easier handling and improved cleaning efficiency
- Tap-drain features to control condensation build-up and maintain stable performance
- Custom-matched dimensions to fit the existing equipment Equipment Machines, appliances, fixed or mobile devices, control parts and accessories, and warning and prevention systems, whether separate or combined, intended for the generation, transfer, storage, measurement, control, and conversion of energy, and for the processing of materials, which have their own potential source of ignition and may cause an explosion. footprint, eliminating the need for piping modifications
- On-site commissioning, ensuring seamless transition from the legacy system to the new units
These design improvements directly addressed the operator’s constraints around space, safety, and offshore accessibility.
Results
The FPSO achieved significant operational gains after the replacement. Internal performance summaries note improvements such as:
- Higher cleaning efficiency and improved handling
- Marked reduction in cleaning frequency
- Shorter maintenance duration, allowing work to remain offshore rather than shifting to onshore facilities
- Lower manpower requirements and reduced safety risks during servicing
Collectively, these enhancements contributed to better production continuity and improved safety conditions for offshore personnel.
The upgraded flame arresters have delivered a major improvement in both performance and maintenance safety. The solution has supported our goal of maintaining system integrity while reducing operational burden.
ZETOP Valves
Zero Emission at Tank Operating Pressure
Background
A leading petrochemical operator in China faced increasing regulatory pressure to reduce volatile organic compound (VOC) emissions from its storage tanks. The client’s site relied on standard pressure and vacuum Vacuum Vacuum is the pressure in an enclosed space that is lower than the ambient pressure. relief devices, many of which showed high leakage rates and lacked proper certification. This posed both compliance risks and environmental challenges.
Solution
To help the client meet tighter emission limits, PROTEGO® specified the use of certified low-leakage pressure and vacuum relief valves according to the applied Safety Standard for VOC collection and treatment across tank farms.
As part of the site upgrade, PROTEGO® supplied them with zero-emission valves engineered to achieve exceptional sealing performance at normal operating pressure Operating pressure Operating pressure is the pressure existing at normal operating conditions within the system being protected. . Side-by-side testing was conducted using a portable VOC detector to compare the leakage from PROTEGO® valves with that of the standard units previously installed on the tanks.
Near-zero leakage
The tests showed that PROTEGO® ZETOP valves achieved near-zero leakage, while the existing devices recorded emissions exceeding 5,000 ppm under identical conditions. With this performance verification in place, the operator approved a full replacement program.
Results
The facility installed 60 PROTEGO® ZETOP valves to replace all standard products across the tank farm. The upgrade delivered:
- Near-zero VOC emissions at operating pressure, supporting compliance with China’s evolving environmental regulations.
- Improved safety and environmental performance across all storage tanks.
- Standardisation of certified, high-integrity venting equipment in accordance with the client's VOC Safety Standard.
Following the installation, all tanks at the facility are now protected by PROTEGO® ZETOP valves, forming one of the region’s strongest examples of emissions-optimized tank venting.
The PROTEGO® valves demonstrated outstanding zero-emission performance and helped us achieve the environmental standards required for our site.
Fuel Handling
Floating Suction Units for clean fuel withdrawal
Background
A large international infrastructure development required advanced fuel-handling solutions for new storage tanks being constructed as part of a long-term airport expansion. The project team needed floating suction units (FSUs) that met strict technical specifications, ensured high operational safety, and complied with rigorous auditing standards to support clean fuel withdrawal and long-term performance.
Solution
PROTEGO® was engaged to provide 24" stainless-steel floating suction units tailored to the project’s tank configuration. The engagement began with a detailed technical presentation covering both tank devices and associated equipment. The subsequent audit of the manufacturing facility at PROTEGO® headquarters was meticulously coordinated and was immediately approved by the reviewing team.
Results
The deployment of PROTEGO® floating suction units contributed to reliable, safe, and efficient fuel-handling operations across the project.
Key outcomes included
- Consistent operational precision, supporting stable draw-off of high-quality product Product Includes equipment, protective systems, devices, components and combinations of these. .
- Smooth audit and approval processes, enabling rapid commencement of manufacturing.
- Timely installation, facilitating uninterrupted progress in early project phases.
- Scalable delivery, allowing additional units to be integrated as new tanks were constructed
- Overall, the PROTEGO® equipment supported long-term operational readiness for one of the region’s most significant infrastructure developments.
A senior executive involved in the project shared: “The audit and coordination were executed with remarkable precision. The units were delivered and installed exactly as required, and the delegation approved them immediately.
ZETOP Valves
Zero VOC Emissions at a Petrochemical Tank Farm
Background
A major petrochemical operator in Thailand was under increasing pressure to reduce fugitive emissions from benzene storage tanks. The facility relied on ageing breather valves Pressure and vacuum relief valve A pressure and vacuum relief valve is a pressure equalization valve for impermissible pressure and vacuum in a closed system. and emergency vent valves that exhibited heavy leakage, preventing compliance with zero-VOC performance requirements. Routine gas detector readings consistently indicated vapor escape at the tank roof, creating both environmental and safety concerns.
As part of a plant-wide initiative to tighten emissions control, the operator sought a certified, verifiable solution capable of delivering zero leakage at tank operating pressure.
Solution
The operator engaged PROTEGO® to evaluate the existing tank venting arrangement and recommend a suitable low-leakage replacement. Based on tank service conditions and the sensitivity of benzene vapor handling, PROTEGO® supplied ZETOP zero-emission valve technology engineered to achieve bubble-tight sealing at tank operating pressure.
The upgrade included the installation of PROTEGO® ER/V, V/SV, and PM-HF series valves sized to the tank’s low-pressure duty. After installation, the site’s engineering team conducted a field verification using calibrated gas detectors positioned on top of the tank roof.
The post-installation emissions assessment confirmed a zero ppm VOC reading, demonstrating complete elimination of vapor leakage at operating pressure. Key outcomes included:
- Zero VOC emissions detected during site measurements (verified via gas detector).
- Full containment of benzene vapor, supporting regulatory compliance and environmental performance targets.
- Replacement of all previously leaking devices with certified PROTEGO® ZETOP valve technology.
- Long-term reliability, validated through on-site tests conducted months after commissioning.
A senior engineering representative noted that the upgrade successfully met their zero-VOC requirement and resolved a longstanding emissions challenge.
Our measurements confirmed zero vapor leakage after installing PROTEGO® valves. The solution fully met our zero-emission goal.
Emergency Relief Venting
Solved Leak Problem
Background
A large chemical processing plant in the United States, operating with hazardous and highly toxic materials, struggled with persistent leaks from an Emergency Relief Vent installed on one of its storage tanks. The chemical handled was extremely volatile, making any fugitive emissions especially problematic. The facility’s LDAR readings were repeatedly spiking, leading to safety concerns, elevated maintenance workloads, and pressure to meet increasingly stringent emissions regulations.
The plant sought a solution that could deliver a verifiable, long-term improvement in sealing integrity.
Solution
The facility approached PROTEGO® for technical support. After analyzing the tank service conditions and the vapor characteristics of the chemical, PROTEGO® recommended installing two 12" PROTEGO® D/SVL pressure relief valves with metallic sealing in place of the existing 24" emergency relief vent.
The D/SVL series provides a particularly high flow capacity. Its extreme tightness is far above the normal standard and meets the stringent demands of emission control regulations.
The facility decided to adopt PROTEGO® D/SVL valves as its standard across operations.
Results
The PROTEGO® solution delivered:
- Near-zero leakage performance, supporting stable LDAR compliance
- Elimination of recurring vent failures, reducing operational risk
- Greater maintenance efficiency, cutting troubleshooting time and emergency interventions
- Improved environmental performance, with a measurable reduction in fugitive emissions
- Long-term reliability, validated by the plant’s repeat purchases
One thing I have learned is whenever faced with a difficult tank venting problem – call PROTEGO®. They know what they are doing. Their products work, and work often way better than they say. Our plant wouldn’t try to install another vent without going to these guys.
Safety Audit
Misapplied Flame Arresters
Background
A global specialty manufacturing company operating multiple chemical-processing facilities was facing growing concerns around equipment integrity and safety compliance. During internal reviews, the client discovered that several flame arresters installed across their plants were not properly matched to the operating conditions. The misapplications created:
- elevated operational risk
- unnecessary maintenance burdens
- potential non-compliance with current safety standards.
The client required an expert technical assessment to understand the true extent of the problem and identify a safe, economically sound path forward.
Solution
PROTEGO® conducted a comprehensive on-site safety audit, including a detailed survey of existing flame arresters and venting systems. The assessment identified multiple misapplied units and documented how these configurations could compromise system performance.
Using our engineering methodology, PROTEGO® provided a full safety and performance analysis report outlining
- correct arrester specifications
- risk mitigation recommendations
- the potential performance gains associated with replacement.
The findings supported both plant-level and corporate engineering teams in evaluating upgrade options. The audit results uncovered additional upgrade opportunities across the client’s wider operations, enabling standardized, compliant configurations across their global facilities.
Results
The safety audit delivered clear, actionable insights that helped the client significantly improve operational reliability. Key outcomes included:
- Identification and correction of misapplied arresters, reducing operational risk.
- Simplified engineering decision-making and faster internal approvals.
- A clearly defined replacement program that is expected to significantly improve system efficiency and long-term maintenance performance.
- Strengthened corporate-level confidence in PROTEGO® engineering support, leading to expanded opportunities in other regions.
Overall, the client achieved a more compliant, standardized, and safer venting and arrester configuration, resulting in improved reliability and reduced lifecycle costs.
The audit gave us clarity we didn’t have before. PROTEGO®’s engineering support helped us identify risks, justify upgrades, and move forward with a more reliable safety solution.
Talk to a PROTEGO® engineer to request guidance for your vessel or terminal loading application
