Hey there, everyone! I’m Jake, the guy who runs the vapor recovery equipment side of our chemical plant supply company. For the last 10 years, I’ve talked to so many plant ops managers, maintenance leads, and EHS folks who are so focused on picking the right vapor recovery system (VRS) that they totally overlook one tiny—but massively critical—detail: how to actually store that gear when it’s not in use. I’ve seen brand-new VRS units crack because they were left outside in a Texas summer, or valves seize up in a Louisiana winter freeze, all because someone grabbed the wrong storage spot during a plant turnaround. Today, I’m breaking down exactly what we (and our clients) have learned the hard way about storing chemical plant vapor recovery equipment—no boring textbook jargon, just real, actionable stuff you can use. Chemical Plant Vapor Recovery Equipment
First off, let’s cut to the chase: vapor recovery gear isn’t just a hunk of metal with pipes. It’s precision-built to capture volatile organic compounds (VOCs), hazardous fumes, and even flammable vapors—so cutting corners on storage is a recipe for either broken equipment, safety risks, or both. I’ve had a client come to us last year whose stored VRS blower was so rusted out from being left in a damp warehouse nook that it couldn’t pass a pressure test when they needed it. They had to rent a temporary unit for three weeks, which cost them way more than if they’d just stored it right. That’s the kind of headache we want to help you avoid.
Let’s start with the big, non-negotiable basics: environment controls. Most folks think “storage” is just a corner in a warehouse, but for vapor recovery gear, it’s way more specific. Temperature is first on my list. We’re talking about a range of 40°F to 85°F (that’s 4°C to 29°C for our metric friends, though I still think in Fahrenheit for shop stuff) with NO big swings. Why? Seals, gaskets, and hoses—all the soft parts that keep vapor from leaking—are made of materials like EPDM, Viton, or Buna-N, and extreme temps make them go bad fast. Too hot, and they dry out, crack, and turn brittle. Too cold, and they get stiff, crack when you try to bend them to connect. I remember last winter, a client stored their spare VRS condensor unit outside near a loading dock—overnight temps dropped to 18°F, and when they uncrated it, the plastic inlet valve had split down the middle. They had to order a replacement, and that delay cost them a full production shift. No bueno.
Then there’s humidity. Chemical plant gear doesn’t handle high moisture worth a damn. I always tell clients to keep storage areas under 60% relative humidity. Even if your unit is made of stainless steel (most good VRS parts are these days), those fasteners, pipe threads, and electrical connectors? They rust or corrode fast. I once visited a plant that stored their spare vapor recovery blower in a open shed (they said it was “temporary” for 8 months) and the motor terminals were so caked in rust that when they flipped the switch, it sparked like a Christmas light gone wrong. That’s not just equipment damage—that’s a safety hazard waiting to blow. So if you don’t have a climate-controlled warehouse, at least get a dehumidifier for the storage space, and cover any exposed parts with a breathable tarp (not plastic, that traps moisture).
Next, location and positioning. A lot of people stack VRS units like firewood in a corner, but that’s a terrible idea. First, never store them directly on concrete. Concrete leaches moisture, and over time, it’ll wick up into the base of the unit and cause rust on the bottom pipes or the frame. I always recommend putting pallets (the wooden ones, not plastic that’s slippery) under the gear to keep it elevated at least 6 inches off the ground. Also, leave 2-3 feet of space around the unit—you need access to check seals, valves, and gauges every few months, right? If you stack stuff on top of a VRS unit, you’ll crush the delicate parts: the pressure relief valve, the vapor sensor, even the blower housing. I’ve seen clients stack empty drums on top of a spare vapor recovery skid, and when they finally moved it, the sensor was bent so bad it had to be replaced. Not cheap.
Wait, and don’t forget about the actual vapor recovery components that hold residual fumes. Oh right—even if you “empty” a unit, there’s still leftover VOCs in the pipes, the condensor, the absorbent beds (if it’s an adsorption-based VRS). So storage can’t just be physical—you’ve got to prep the unit first to avoid safety issues. That’s a step most people skip, and it’s the reason for a lot of small (and scary) incidents. Here’s the drill: before you store a VRS unit, do a full “flush and purge.” Use dry, inert nitrogen (we supply this to clients if they don’t have it on-site) to blow out all residual vapors from the pipes, the chambers, and the filter beds. Then, cap all the inlet and outlet ports with tight, thread-sealed caps or plugs—don’t leave them open, because dust, moisture, and even critters (yes, spiders and mice love to nest in small pipes) will get in. Also, if the unit has activated carbon filters or other absorbent media, take those out before storage. Those things hold onto VOCs like a sponge, and if you leave them in, they’ll off-gas over time, creating a flammable or toxic atmosphere inside the closed unit. I learned this from a client who stored an adsorption VRS for a year, put the filters back in without replacing them, and when they opened the inlet port, the VOC off-gassed so fast that the air monitor went off the charts. They had to ventilate for 2 hours before they could even touch the unit. Dumb move, easy to avoid.
Also, regular maintenance checks while in storage. It’s not set it and forget it, I tell everyone. Even if you prep the unit perfectly, parts still degrade. Every 3 months, go check on it. Here’s what to do: inspect all caps and plugs to make sure they’re still tight, check for any signs of rust on the frame or fasteners, wiggle the valves a little to make sure they’re not seized (sometimes humidity makes lubricant go bad), and if you had to remove the media, store that separately in airtight plastic bins with labels so you know when you need to replace it. I once had a client who stored their VRS for 18 months and never checked it—when they went to use it, the seal on the pressure relief valve was so dry that it wouldn’t seat properly. They had to replace the whole valve, which cost them $1,200, and that’s money they could’ve saved with a 5-minute check every 3 months.
Wait, what about if you’re storing smaller parts that go with the VRS? Like spare vapor sensors, gaskets, or connectors? A lot of people mix these up with other plant parts, and then when you need them, you can’t find them. I recommend keeping all VRS spare parts in a labeled, climate-controlled bin—same temp and humidity as the unit—so you don’t lose them, and they don’t go bad. I’ve even seen clients store gaskets in a hot tool room, and when they pulled them out, they were all squishy and unusable. That’s another wasted cost.
Now, let’s talk about special cases, because not all chemical plants are the same. If you’re in a colder climate (think Minnesota, Canada, northern Europe), you’ve got to make sure the storage area is above freezing, or drain all water lines completely. Even a little water in a pipe will freeze, expand, and crack the pipe when temps drop. I had a client in Michigan last year who stored their VRS in a unheated garage, and the water in the drain line froze, cracked the line, and when they tried to use it, vapor started leaking out of the crack. That’s a safety violation, and a huge hassle. If you’re in a super hot, dry climate (Arizona, Saudi Arabia), you’ve got to make sure the unit isn’t in direct sunlight. Sunlight will degrade the plastic parts and the paint on the metal, and it can also make seals go bad faster. So keep it in a shaded area, or cover it with a UV-resistant tarp if you have to put it outside temporarily.
And let’s not skip on safety stuff when storing. Even though the unit is not in use, it’s still handling hazardous materials residue, so the storage area needs to be in a designated, non-public area of your plant, away from any ignition sources (like welding areas, electrical panels, or other flammable storage). Make sure the area is marked with proper warning signs—like “Hazardous Equipment” or “Flammable Vapors Present”—so no one accidentally messes with it. I always tell clients to keep a copy of the unit’s original documentation, including pressure test certificates and parts lists, with the stored unit. That way, when you go to reinstall it, you don’t have to hunt for that paperwork, which saves time and headaches.
Look, I get it—chemical plant guys are busy, turnarounds are chaotic, and storing equipment feels like a low-priority task next to fixing a broken reactor or ordering chemicals. But from 10 years in this business, I can tell you that bad storage of vapor recovery equipment costs more in the long run than doing it right. I’ve seen companies waste thousands on replacement parts, rental gear, and safety fines because they skipped these simple steps.
If you’re not sure if you’re storing your VRS the right way, or if you need help picking out the right storage gear (like pallets, dehumidifiers, or caps), we’re here. We don’t just sell equipment—we work with you to make sure it lasts, whether it’s in use or sitting in storage. If you have questions about your current storage setup, or you’re looking for new vapor recovery equipment and want to make sure you know how to store it properly, just reach out to us. We’re here to help you avoid the mistakes we’ve already made.
Don’t cut corners on storage—it’s the quiet way to save money and keep your plant safe. Catch you next time.
Skid-mounted Vapor Recovery Equipment References
- Occupational Safety and Health Administration (OSHA). (2020). Storage Requirements for Hazardous Process Equipment. U.S. Department of Labor.
- Environmental Protection Agency (EPA). (2019). Vapor Recovery System (VRS) Maintenance and Storage Guidelines for Chemical Plants. U.S. Environmental Protection Agency.
- National Fire Protection Association (NFPA). (2021). NFPA 30: Flammable and Combustible Liquids Code. National Fire Protection Association.
- American Society of Mechanical Engineers (ASME). (2018). ASME PCC-2: Repair of Pressure Equipment and Piping. American Society of Mechanical Engineers.
- Chemical Manufacturers Association (CMA). (2022). Best Practices for Storing Industrial Air Pollution Control Equipment. American Chemistry Council.
Shandong Kosman Environmental Technology Co., Ltd.
Shandong Kosman Environmental Technology Co., Ltd. is one of the leading manufacturers and suppliers of chemical plant vapor recovery equipment in China, featured by quality products and low price. Please rest assured to buy advanced equipment made in China here and get pricelist from our factory. Customized orders are welcome.
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