Green Energy & Consulting
General description of the mobile system
The JetPetroClean™ Spectrum system is designed for scheduled maintenance of the tanks at the petrol filling stations, factory territory. The system allows internal cleaning and degassing of fuel storage tanks in order to prepare them for internal inspection (flaw detection) and for possible repair works inside the tank, including fireworks. The main advantage of the system is its complete autonomy and the ability to perform internal cleaning of the tanks in automatic mode. The system does not require connection to electricity, water supply and other resources on the site, which allows it to be used in almost any condition or condition of the filling station. The system has its own diesel generator and air compressor to ensure the operation of the entire equipment of the system. The system is assembled in a standard frame of a universal 20f container and can be transported to the work site by any truck which has a load capacity of up to 14 tons. The system can be operated directly stationed on the vehicle or can be removed from the vehicle and installed on the work platform separately. The system is designed to work with light oil products: gasoline, diesel fuel. It is also possible to use the system to clean petrochemical products with a density less than the density of water. The working pressure of the inner tank cleaning is 6 … 10 bar. In addition to servicing, the system can also be used for internal cleaning of distributor tanks (tank trucks, ISO tank containers, railway tank wagons), stationary horizontal tanks at tank farms and vertical tanks with a volume of no more than 2000 m3 and process pipelines.
- Process vessel for flush water
- Two multistage electric pumps
- Ejector pump
- Diaphragm Pneumatic Pump
- Degassing fan
- Two hose reels
- Pipe manifold with actuated valves
- Diesel-electric generator
- Air compressor
The capacity of the electric generator fuel tank is 85 liters. The fuel consumption at 100% load is 9.5 liters per hour, the time of continuous autonomous operation with full fuel filling and the maximum load on the generator is 9 hours. The total electric power of all consumers is 32 kW, the power required to perform the cleaning of the tank is 28 kW. The flush water volume inside process vessel is 3…5 m3. The equipment can be connected to an external power source with an available power of at least 28 kW, in case the generator does not switch on. The system has two operation modes: automatic and manual. In automatic mode, the operator needs to deploy the washing system (install a washing monitor in the tank, connect the monitor and the system by hoses) and start the automatic washing program using the automatic control panel. The system controlled by the program performs the internal washing of the tank. All process parameters are controlled by sensors and master control panel. After the program is complete, it is necessary to turn off the flushing system or move it to the next tank and install a degassing duct into the tank. In manual mode, the operator independently turns on and off the pumps, opens valves (all electrically actuated) and controls the process from the manual control panel. The sensors control the process and it’s the parameters and after the operation cycle stops the washing. The system allows performing work with a minimum number of employees. In the automatic mode, one person can perform the operation for the internal cleaning of the tank, the rest of the cleaning crew can perform other operations (dismounting/assembling tank hatches, working on pipe fittings, etc.). The average time of work at one filling station is 1 working day. Optionally, the system can be additionally equipped with a module for cleaning fuel residues from water and mechanical impurities. The system is designed in accordance with: 2006/42/EC, 2006/95/EC, 94/9/EC; EN 13480 Metallic industrial piping. EN/IEC 60079 Explosive atmospheres. Equipment. EN/IEC 60364 Low-voltage electrical installations. EN 61439-1 Low-voltage switchgear and controlgear assemblies. General rules. EN 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards – Emission standard for industrial environments. EN13094 Tanks for the transport of dangerous goods. Metallic tanks with a working pressure not exceeding 0,5 bar. Design and construction.
Technological operation diagram of the system JetPetroClean ™ Spectrum
Symbols on the diagram:
- Electric generator
- Main electrical board
- Manual control panel
- Automatic control panel
- Pump group
- Tube manifold
- Hose reels
- Vessel level sensor and pressure sensors
- The degassing fan
- Jet nozzle
- Jet nozzle fixing device
Operating principle of this system is “closed loop” mode.
System work sequence
Installation of the flushing system
- Set the complex in working position near the tanks to be washed, ground the equipment to the tanks grounding loop, start the power generator;
- Dismantle the hatch of the tank;
- Discharge commercial fuel from the tank;
- Install in the tank hatch the flushing monitor fixing device and the suction hose;
- Connect the unit pressure and suction hoses to the monitor fixing device;
The exact procedure for pumping out of the remains from the tank should be agreed with the Client.
Starting the flushing system
Switch on the washing system:
– start of the tank washing program automatic execution, or
– turn on the washing system in manual mode
The system has four tank washing programs. The first three have the same sequence of equipment operation and differ in the execution time of operations. The choice of the program is carried out depending on the tank and the product stored conditions.
Program 1 – for gasoline storage tanks
Program 2 – for diesel fuel storage tanks
Program 3 – for diesel fuel storage tanks with significant pollution
Program 4 – evacuation of flushing water and waste residues from the tank
To select the desired program, a selector is installed on the automatic control panel. The startup is done by pressing the START button on the LCD.
After starting the automatic program, its operation and parameters are displayed on the LCD. When the program is finished, the corresponding indication is displayed on the LCD. To start the system in manual mode, the corresponding buttons and switches for starting the pumps and opening/closing the valves on the manifold are installed on the manual control panel. In manual mode, the process parameters are controlled by the operator. The manual mode is used in case of failures of the automatic system, using a washing program different than automatic or for performing certain operations using a hydraulic system of the complex. The washing process is organized so that the water supply to the jet nozzle and it’s pumping out from the tank occurs simultaneously. In this case, all washed and pumped hydrocarbon wastes are separated. The working volume of the washing water is 3…5 m3, the volume for hydrocarbon waste is 1…2 m3.
Relocating the flushing system
After the washing of the tank is completed, the washing system is relocated to the next tank. To do this, it is necessary to disconnect the pressure and suction hoses from the jet nozzle fixing device, move it to the next tank prepared for the cleaning, re-connect the hoses to it. Each automatic washing program have a pressure hose emptying stage before the end of work, which avoids spills of washing water. After that, it is possible to start the washing system in automatic or manual mode. Degassing duct is installed to the washed tank and fan start in operation. All the tanks at the filling station are washed in such sequence.
After completion of degassing, it is necessary to perform gas-air space monitoring in the tank by gas analyzer. When a safe condition of the tank environment is reached, the operator entry into the tank to check the quality of the cleaning. If necessary water and contaminations residue must be remove. To remove water residue, use Program 4. For safe operation in the tank, the complex is equipped with a hose gas mask.
Transportation and storage modes
After the completion of cleaning works, a transport mode is settled for moving to another work site or storage area. In this mode, all valves are closed and the unit can be transported together with the filled flush water. The storage mode is set for storing the unit (also at the cold weather period). Before installing this mode, it is necessary to discharge and to drain all liquids from vessel and pipes. In the storage mode, all valves are opened. In this mode, the unit can be stored on an open area, under a shed or inside store house.
The minimum number of employees for the work is 3 people. We recommend the following distribution of duties: 1 person is a foreman and the work supervisor, he is also the base car driver and base car crane operator. 2 persons are operators. Operators perform work on opening/closing manholes, working with the washing system, working inside the tank. The structure of three workers is the minimum necessary to clean the filling station from four to five tanks (four to five hatches) in one day. In the case of an increase in the amount of work to 9 … 10 hatches per day, it is necessary to increase the number of the crew members.
Time for the deployment of the unit at the site without taking into account the standard safety procedure (instruction, documentation) is no more than 30 minutes. At the same time, hoses and a tool for dismantling/mounting hatches of tanks are deployed on the work site, the equipment is grounded to the grounding loop of the tanks.
The washing time of one tank is:
Program 1 – 30 min.
Program 2 – 40 min.
Program 3 – 50 min.
All programs can be adjusted by rewritten of parameters in LCD panel setting menu.
Clean technical water is used. Water is used according to its state and conditions. The total flow rate of the washing water depends on the condition of the tanks. On average, one water filling is enough to perform work at 3 … 5 stations of 4 … 5 tanks in each (depending on the condition of the tanks). In summer, it is sufficient to use water with the current temperature for washing the tanks without heating it. At an ambient temperature below + 5 ° C, it is possible to preheat the water with a built-in electric heater. In addition to technical water, it is allowed to use a washing solution of a technical detergent intended for such purposes. The use of technical detergents should be carried out in accordance with instructions. Rates of consumption are in accordance with the instructions of the manufacturer for their use at works in cleaning tanks after light oil products.
In addition to the equipment specified in paragraph 1, the unit equipped with the following elements:
- Degassing duct, 30 m.
- A set of hand tools for dismantling/mounting of the tank hatches
- A set of pneumatic tools for tank hatches mounting
- Set of hydraulic cutters for rusted nuts
- Air receiver for 100 liters
- Jet nozzle fixing devices for tanks hatches
- Jet nozzle
- Hose gas mask.
The jet nozzle fixing device has a special sealing mechanism to prevent the detergent spurt when the monitor is working in the tank. Additionally, a second device is provided to fix the jet nozzle to the hatch flange or its neck. This device has reflective screens to prevent the water stream outgoing from tank and can be used when it is not possible to install the sealing device. Pressure and suction hoses of 30 m long each are placed in hose reels. The pneumatic screwdriver is driven by air from the air compressor and receiver. The hydraulic nut cutter is designed for the safe splitting of corroded nuts during tank hatch dismantling.
The basic car
As a basic vehicle could be used a truck with a carrying capacity of 14 tons and a biaxial rear axle. The car body must be sized to accommodate and secure a standard 20-foot sea container. On the frame should be installed standard fittings for fastening the container. Preferably body modification is a platform without sides. To increase the efficiency of the car can have a truck-mounted crane (Palfinger or another) located behind the driver’s cab. The truck-mounted crane can be used to lift a dismounted assembly of the tank manhole with related pipes. This will significantly save labor costs by working with tank hatches. The load-carrying capacity of the manipulator crane is selected based on the specific operating conditions. In the event that a lifting capacity of 10 tons is available, the truck-mounted crane can be used to install or remove the unit from the vehicle if there is no flush water in it.
The equipment is manufactured within 4-6 months after prepayment.
Internal cleaning systems for above ground vertical tanks on terminals and tank farms
Tank cleaning unit JetPetroClean JPC20
Designed for internal cleaning of tanks with a diameter of up to 50 m with water or a detergent solution with a working pressure of 16…20 bar. It has a process vessel for flush water. The unit is complete with a rotary tank cleaning machine. The unit’s electrical power is 110 kW.
Tank cleaning unit JetPetroClean JPC10-LT
Designed for internal cleaning of tanks with a diameter of over 50 m with water or a detergent solution with a working pressure of 8…10 bar. A process vessel for flush water is not included. The unit is complete with an air driven single nozzle tank cleaning machine. The unit’s electrical power is 105 kW.
The system includes:
- JetPetroClean tank cleaning unit.
- Flush water separator Power unit.
- Set of external extraction pumps.
- Set of hoses and pipelines.
- Mobile steam generator working on liquid fuel.
Flush water separator
Serves as the basic element in the recirculating cleaning system. The separator is designed for purification of flush water and detergent solutions during the cleaning cycle. The separator can be manufactured for 16 m3 and 32 m3 working volume of flush water, depending on the size of the tank to be cleaned and the required volume of flush water. In order to increase efficiency of the purification of flush water, several separators can be used in a single system. The separator has control sensors for levels of flush water and separated product in order to monitor and automatically operate filler pumps.
Extraction pump set
To extract flush water and waste from tanks during cleaning, diaphragm pumps are used in JetPetroClean systems. The main advantage of these pumps is their ability to continue to work where fluid flow is disrupted or even with no flow at all. Since during the cleaning cycle, the flush water stream that is returned from the tank is not stable and its fluctuations (or even termination) are possible, diaphragm pumps are the most appropriate solution. Even with disruption of fluid flow or its absence the pumps continue working and create a vacuum at the intake that allows restoring the flow immediately after the obstacle (jamming) is removed.
JetPetroClean tank cleaning units in these systems can have a working pressure of 8…10 bar or 16…20 bar.
The systems use external extraction diaphragm pumps. This type of pump provides ample use opportunities during cleaning operations.
Equipment employed by the system allows it to perform cleaning of all existing types of tanks:
- with fixed (cone) roof;
- with fixed roof and internal pontoon (internal floating deck);
- with floating roof.
The system for tanks used for storage of dark products also has special equipment for removal of highly viscous residue from tanks. The system also has a special device for cleaning of the inner surface of the tank shell above the floating roof Units are assembled in standard 20F containers, which enables their mobility and ease of installation near a tank
Designed to accommodate power equipment: the main switchboard; air compressor; electrical steam generator. Power unit is the primary node for providing electrical power to the system’s equipment, as well as the production and supply of steam for heating of the flush water in the system, generation and supply of compressed air to the system consumers (diaphragm pumps, air driven single nozzle tank cleaning machines). One or two electric JetPetroClean-200 steam generators are installed in the power unit: each one has power of 200 kW and steam productivity up to 350 kg per hour. In the process of cleaning tanks that have significant residue of viscous products (fuel oil, crude oil) the system for warming up the residue is used in order to lower its viscosity level before pumping out from the tank. This system uses a separate steam generator working on liquid fuel with steam productivity of at least 1200 kg per hour.
System for internal cleaning and preparation for loading of oil products into railway tank cars
Besides the electrical steam generators installed in the power unit, an additional mobile steam boiler working on liquid fuel for warming up and extracting the residue shall be installed in the process of preparation of railway tank cars after transportation of fuel oil and crude oil. The standard set allows for preparation up to 10 railway tank cars after HFO products or up to 20 tank cars after light oil products per daily shift.
- JPC tank cleaning unit
- Flush water separator
- Power unit
- Set of external extraction pumps
- Pipelines for supply and removal of flush water
- Degassing fans
- Railway tank car top access platform
- Waste tank
The system based on mobile JPC10 or JPC20 units can be used for preparation of railway tank cars.
To perform the work on railway tank cars preparation (mostly after transportation of heavy products, such as crude oil and fuel oils) we recommend using the system based on JPC20 unit with the working cleaning pressure of 20 bar.
To perform the work on railway tank cars preparation after transportation of light products, such as motor fuel, jet fuel and motor oils, we recommend using the system based on JPC10 unit with the working cleaning pressure of 10 bar The system is installed in a mobile station for preparation of railway tank cars for loading of oil products or for maintenance using hot works.
The system can be placed on flat ground next to the railway if the site has sufficient electrical power.
No preliminary construction works are necessary for placing the equipment.