CWI Tank Cleaning
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CWI Tank Cleaning

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CWI Tank Cleaning CWI Tank Cleaning Presentation Transcript

  • CLEAN WORLD INNOVATIONS Tank Cleaning Services
  • WE OFFER: • Turnkey Operation • Global experience • On-site Support • Joint planning • Rapid Turnaround • Resource Recovery
  • COMPREHENSIVE TURNKEY PLAN Turn-key critique Scope Development Job Execution/ Quantitative Analysis Supervision Environmental and Pre- Safety Requirements Inspection Develop Material Assessment Procedures/ Design Program Costing Scheduling
  • WHY CLEAN TANKS? • Repair leaks • Recover storage capacity • Eliminate crude unit upsets • Floating roof seal replacement • Floor coating • Inspection
  • BENEFITS • Reduces turnaround time • Reduces labor costs • Reduces air emissions • Reduces danger of explosive and toxic vapors - lowers H2S & TEL levels • Restores equipment efficiency/capacity
  • BENEFITS • Minimizes waste • Provides virtually oil-free surfaces and gas-free environment ready for entry • Water has no impact on wastewater treatment plant • Water has low BOD, COD, and TOC levels (dependent on sludge characteristics)
  • MECHANICAL SUPPLIER • Experience working with independent mechanical and turnaround contractors in various regions. • Experience in coordinating and running projects with customer specific maintenance contractors
  • MECHANICAL CONTRACTOR REQUIREMENTS • Equipment specifically designed for chemical cleaning • Capability to perform several circulation loops within one unit • Self-contained equipment • Equipment meets all customer requirements • Closed-loop circulation • Ability to process sample during circulation
  • WASTE MINIMIZATION INCENTIVES • Landfarm restrictions mounting • RCRA legislation compliance issues • Reduce disposal costs • Valuable crude oil recovery
  • TRADITIONAL METHODS-SLUDGE REMOVAL • Shovel or vacuum truck • Front end loader • Remote mechanical devices • Power spray nozzle
  • TRADITIONAL METHODS- HYDROCARBON RECOVERY • Move to another crude tank • Mix with crude in vat • Belt press • Centrifuge • Separation tank
  • CWI CAPABILITIES • Storage Tank Cleaning • Patented Warm Water Method • Proven experience • Storage Tank Degassing • Patented degassing chemistry • Proven experience
  • TANK CLEANING-ONES APPROACH PATENTED WARM WATER METHOD EVALUATION • Obtain representative sample • Determine job requirements • Determine limitations • Tank cleaning beaker simulation • Customized cleaning program
  • CRITERIA FOR SUCCESS • Obtain a representative sample • Apply proper heat and chemistry • Develop processes to separate recovered hydrocarbon, water, and solids
  • LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS BEAKER WITH SLUDGE
  • LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS ADDITION OF SOLUTION
  • LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS ADDITION OF DILUENT, START TEST
  • LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS BEAKER SIMULATION IN PROGRESS
  • LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS END OF OF BEAKER SIMULATION
  • APPLICATION METHOD - CRUDE STORAGE TANK • Pump crude from tank • Floating Roof - Lower roof to lowest level • Add equal volumes of water-chemical solution, and diluent • Floating Roof - Allow roof to float (2 ft) • Heat and circulate the cleaning solution • When complete, initiate customized recovery program
  • MONITORING • In Process Monitoring • Emulsification Progress • Temperatures • Suspended Solids • Free Oil • Water-Wet Solids
  • CRUDE STORAGE TANK - FIXED OR FLOATING ROOF IDENTIFY EXISTING PUMPS & HEATING SLUDGE SOURCES PUMP TANK TO LOWEST LEVEL USING EXISTING DRAIN LINES
  • CRUDE STORAGE TANK - FIXED OR FLOATING ROOF CLEANING DILUENT SOLUTION SLUDGE ADD WATER, CHEMICAL, AND DILUENT
  • CRUDE STORAGE TANK - EXTERNAL CIRCULATION DILUENT CLEANING SOLUTION WATER CUTS CHANNEL SLUDGE
  • EXTERNAL CIRCULATION OF WATER USING CARGO HOSE
  • MANWAY WITH HARD PIPE
  • MANWAY CONNECTIONS FOR WATER CIRCULATION
  • MANIFOLD USED FOR CIRCULATION PATTERN
  • SMALL EXCHANGERS AND PUMPS 250,000 BBL TANK
  • CRUDE STORAGE TANK - CLEANING CONFIGURATION POSSIBLE TANK CIRCULATION AND HEATING ARRANGEMENTS
  • CRUDE STORAGE TANK - CLEANING IN PROGRESS CUTTER OIL SLUDGE LIFTING FROM TANK FLOOR PENETRATING CLEANING SOLUTION CHEMICAL PENETRATES THE SLUDGE AND LIFTS IT OFF THE FLOOR
  • CRUDE STORAGE TANK - MONITORING PROGRESS
  • CRUDE STORAGE TANK - MONITORING THROUGH SAMPLE WELL
  • CRUDE STORAGE TANK - MONITORING THROUGH THE ROOF
  • MONITORING PROGRESS
  • CRUDE STORAGE TANK - END OF PROCESS RECOVERED OIL READY FOR PROCESSING SOLIDS ARE RECOVERED HYDROCARBON INITIATE RECOVERY HYDROCARBON AND DILUENT PROCESS FREE SPENT CLEANING SOLUTION SOLIDS
  • CASE STUDY #1  Tank Capacity - 500,000 bbl  Tank Diameter - 273 ft  Sludge Volume - 5.5 ft (60,000 bbl)
  • CRUDE STORAGE TANK SLUDGE SAMPLE Component % by Volume Hydrocarbon 73.3 Water 24.6 Sediment 2.1 Recoverable Oil = 44,000 bbl
  • CRUDE STORAGE TANK CLEANING IN PROGRESS
  • CRUDE STORAGE TANK CLEANING RESULTS • Tank cleaned in 21 days • 43,500 bbl of oil recovered • 98.9% oil recovery • Net = $70,000 after expenses
  • CRUDE STORAGE TANK 500-3 INTERNALS
  • CASE STUDY #2  Tank Capacity - 400,000 bbl  Tank Diameter - 224 ft  Sludge Volume - 5 ft (35,900 bbl)
  • CASE STUDY #2 - CUSTOMER GOALS • Eliminate crude unit upsets • Restore storage tank capacity • Monitor crude deliveries • Three week window
  • CASE STUDY #2 - CUSTOM PROCEDURE • Sludge sample obtained • Sample tested using beaker simulation • Located existing pumps and exchangers • Light cycle oil used as diluent
  • CASE STUDY #2 -TANK BOTTOM SLUDGE COMPOSITION Component % by Volume Hydrocarbon 92 Water 6.7 Sediment 1.3 Recoverable Oil = 33,000 bbl
  • CASE STUDY #2 - RESULTS • Back in service in 17 days • Average 1” solids on bottom (75 bbl) • Tank entry not required • 33,000 bbl of oil recovered • 99.9% recovery
  • CASE STUDY #2 - ECONOMIC RESULTS Improved technique (Dollars) Item/Basis 495,000 Income 0 0 Recovered Hydrocarbon: 3,000 13,200 33,000 bbl at 15$/bbl 74,800 1,500 Expenses 17,800 Sludge Disposal - None 0 $103,100 $391,900 Tank Downtime - None Manpower - Estimate
  • STORAGE TANK DEGASSING
  • TRADITIONAL METHODS FOR DEGASSING OPEN MANWAYS • Produces vapors • Several weeks to degas • Environmentally unsound
  • APPLICATION METHOD - DEGASSING • Pump out the tank • Remove the access doors • Apply cleaning/degassing solution • Use degassing solution EC9008A • PORTA-FEED Jr. per 100,000 bbl tank capacity • Monitor the process
  • MONITORING • In Process Monitoring • Emulsification Progress • Temperatures • Suspended Solids • Free Oil • Water-Wet Solids
  • APPLICATION METHOD - DEGASSING FIXED ROOF DEGASSING PROCEDURE • Remove product • Vacuum last 6 - 8 inches FIXED ROOF • Educt water-chemical solution DRAIN
  • APPLICATION METHOD - DEGASSINGFIXED NOZZLE DEGASSING PROCEDURE • Remove product • Vacuum last 6 - 8 inches • Use Butterworth or Gammajet to spray cleaning solution FIXED ROOF DRAIN
  • APPLICATION METHOD - DEGASSINGFLOATING ROOF DEGASSING PROCEDURE • Remove product • Lower roof FLOATING ROOF • Educt water-chemical degassing solution DRAIN
  • EDUCTOR
  • DEGASSING CASE STUDY - PROBLEM • Large Gulf Coast Refiner needed to enter a 180,000 barrel crude storage tank. • Previously required taking the tank out of service to clean with conventional methods • Air ventilation was taking a significant amount of time
  • DEGASSING CASE STUDY - PROCESS • Site review from the local team resulted in applying the following process: • Tank drained of HC and filled with several feet of water to float excess HC for removal. • Flush water drained from tank • Opening of many ways showed 3-4% of HC present in the tank atmosphere.
  • DEGASSING CASE STUDY - PROCESS • ONES implemented the use of a special feed system to apply a solution of the ONES degassing chemical. • Spray nozzle was used for the chemical application. • Walls, roof, internal support and structures were thoroughly rinsed from each of the manways
  • DEGASSING CASE STUDY - RESULTS • After 6 hours the solution was drained to the API separator • No additional cleaning was necessary • Atmosphere within the tank was completely free of Hydrocarbon vapors in less than ONE day. Therefore providing a SAFE environment • Refiner able to begin immediate maintenance • Reduced total cleaning costs • No waste water problems were encountered