Bladder Retrofit / Conversion

Upgrading Proven Systems with Modern Technology

Based on evaluation of multiple surge protection methods, bladder vessel technology is identified as the most effective solution under current operating conditions.

However, instead of replacing existing infrastructure, this approach focuses on upgrading conventional surge tanks—which have already demonstrated reliable performance for over 25 years.

Concept & Working Principle

In conventional surge tank systems:

• Surge protection is achieved by maintaining an air-water balance inside the tank
• For example, 85 m³ water requires ~85 m³ compressed air at the same pressure
• This air cushion is maintained using compressors and instrumentation systems

In the upgraded system:

• The air column is contained within a reinforced rubber/polymer bladder (balloon)

This bladder is designed with very low permeability, ensuring:

• No air leakage
• No air dissolution into water
• This creates a complete and permanent separation between air and water

Key Technical Advantage

• Eliminates air solubility issues (air loss into water = zero)
• Removes need for continuous air replenishment
• Maintains stable air cushion without external systems

System Transformation

By adopting bladder technology:

• Existing surge tanks can be retained and reused
• Compressors, air receivers, and instrumentation systems are completely eliminated
• The system becomes self-sustaining and independent

Performance Benefits

• Consistent and reliable surge protection
• No dependency on power or instrumentation
• Reduced operational complexity
• Improved long-term system stability

Why This Upgrade Makes Sense

• Utilizes existing, proven surge tank infrastructure
• Eliminates high-maintenance compressor systems
• Ensures long-term reliability with minimal intervention
• Combines legacy performance + modern efficiency

METHODOLOGY

The job is to Install the Rubber Bladder inside existing surge vessel and convert it into bladder vessel. We have to do this activity on site itself.

ISOLATION OF VESSELS

CLEANING OF VESSELS

MINOR FABRICATION IN VESSEL

SANDBLASTING IF POSSIBLE

PAINTING OF VESSEL

BLADDER INSERTION IN VESSEL

PRECHARGE and COMMISSIONING SYSTEM