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CWI Tank Cleaning

CWI Tank Cleaning

  1. 1. CLEAN WORLD INNOVATIONS Tank Cleaning Services
  2. 2. WE OFFER: • Turnkey Operation • Global experience • On-site Support • Joint planning • Rapid Turnaround • Resource Recovery
  3. 3. 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
  4. 4. WHY CLEAN TANKS? • Repair leaks • Recover storage capacity • Eliminate crude unit upsets • Floating roof seal replacement • Floor coating • Inspection
  5. 5. 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
  6. 6. 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)
  7. 7. MECHANICAL SUPPLIER • Experience working with independent mechanical and turnaround contractors in various regions. • Experience in coordinating and running projects with customer specific maintenance contractors
  8. 8. 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
  9. 9. WASTE MINIMIZATION INCENTIVES • Landfarm restrictions mounting • RCRA legislation compliance issues • Reduce disposal costs • Valuable crude oil recovery
  10. 10. TRADITIONAL METHODS-SLUDGE REMOVAL • Shovel or vacuum truck • Front end loader • Remote mechanical devices • Power spray nozzle
  11. 11. TRADITIONAL METHODS- HYDROCARBON RECOVERY • Move to another crude tank • Mix with crude in vat • Belt press • Centrifuge • Separation tank
  12. 12. CWI CAPABILITIES • Storage Tank Cleaning • Patented Warm Water Method • Proven experience • Storage Tank Degassing • Patented degassing chemistry • Proven experience
  13. 13. TANK CLEANING-ONES APPROACH PATENTED WARM WATER METHOD EVALUATION • Obtain representative sample • Determine job requirements • Determine limitations • Tank cleaning beaker simulation • Customized cleaning program
  14. 14. CRITERIA FOR SUCCESS • Obtain a representative sample • Apply proper heat and chemistry • Develop processes to separate recovered hydrocarbon, water, and solids
  15. 15. LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS BEAKER WITH SLUDGE
  16. 16. LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS ADDITION OF SOLUTION
  17. 17. LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS ADDITION OF DILUENT, START TEST
  18. 18. LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS BEAKER SIMULATION IN PROGRESS
  19. 19. LABORATORY TESTING FOR THE HYDROCARBON RECOVERY AND WASTE MINIMIZATION PROCESS END OF OF BEAKER SIMULATION
  20. 20. 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
  21. 21. MONITORING • In Process Monitoring • Emulsification Progress • Temperatures • Suspended Solids • Free Oil • Water-Wet Solids
  22. 22. CRUDE STORAGE TANK - FIXED OR FLOATING ROOF IDENTIFY EXISTING PUMPS & HEATING SLUDGE SOURCES PUMP TANK TO LOWEST LEVEL USING EXISTING DRAIN LINES
  23. 23. CRUDE STORAGE TANK - FIXED OR FLOATING ROOF CLEANING DILUENT SOLUTION SLUDGE ADD WATER, CHEMICAL, AND DILUENT
  24. 24. CRUDE STORAGE TANK - EXTERNAL CIRCULATION DILUENT CLEANING SOLUTION WATER CUTS CHANNEL SLUDGE
  25. 25. EXTERNAL CIRCULATION OF WATER USING CARGO HOSE
  26. 26. MANWAY WITH HARD PIPE
  27. 27. MANWAY CONNECTIONS FOR WATER CIRCULATION
  28. 28. MANIFOLD USED FOR CIRCULATION PATTERN
  29. 29. SMALL EXCHANGERS AND PUMPS 250,000 BBL TANK
  30. 30. CRUDE STORAGE TANK - CLEANING CONFIGURATION POSSIBLE TANK CIRCULATION AND HEATING ARRANGEMENTS
  31. 31. 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
  32. 32. CRUDE STORAGE TANK - MONITORING PROGRESS
  33. 33. CRUDE STORAGE TANK - MONITORING THROUGH SAMPLE WELL
  34. 34. CRUDE STORAGE TANK - MONITORING THROUGH THE ROOF
  35. 35. MONITORING PROGRESS
  36. 36. 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
  37. 37. CASE STUDY #1  Tank Capacity - 500,000 bbl  Tank Diameter - 273 ft  Sludge Volume - 5.5 ft (60,000 bbl)
  38. 38. CRUDE STORAGE TANK SLUDGE SAMPLE Component % by Volume Hydrocarbon 73.3 Water 24.6 Sediment 2.1 Recoverable Oil = 44,000 bbl
  39. 39. CRUDE STORAGE TANK CLEANING IN PROGRESS
  40. 40. CRUDE STORAGE TANK CLEANING RESULTS • Tank cleaned in 21 days • 43,500 bbl of oil recovered • 98.9% oil recovery • Net = $70,000 after expenses
  41. 41. CRUDE STORAGE TANK 500-3 INTERNALS
  42. 42. CASE STUDY #2  Tank Capacity - 400,000 bbl  Tank Diameter - 224 ft  Sludge Volume - 5 ft (35,900 bbl)
  43. 43. CASE STUDY #2 - CUSTOMER GOALS • Eliminate crude unit upsets • Restore storage tank capacity • Monitor crude deliveries • Three week window
  44. 44. CASE STUDY #2 - CUSTOM PROCEDURE • Sludge sample obtained • Sample tested using beaker simulation • Located existing pumps and exchangers • Light cycle oil used as diluent
  45. 45. CASE STUDY #2 -TANK BOTTOM SLUDGE COMPOSITION Component % by Volume Hydrocarbon 92 Water 6.7 Sediment 1.3 Recoverable Oil = 33,000 bbl
  46. 46. CASE STUDY #2 - RESULTS • Back in service in 17 days • Average 1” solids on bottom (75 bbl) • Tank entry not required • 33,000 bbl of oil recovered • 99.9% recovery
  47. 47. CASE STUDY #2 - ECONOMIC RESULTS Improved technique (Dollars) Item/Basis 495,000 Income 0 0 Recovered Hydrocarbon: 3,000 13,200 33,000 bbl at 15$/bbl 74,800 1,500 Expenses 17,800 Sludge Disposal - None 0 $103,100 $391,900 Tank Downtime - None Manpower - Estimate
  48. 48. STORAGE TANK DEGASSING
  49. 49. TRADITIONAL METHODS FOR DEGASSING OPEN MANWAYS • Produces vapors • Several weeks to degas • Environmentally unsound
  50. 50. 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
  51. 51. MONITORING • In Process Monitoring • Emulsification Progress • Temperatures • Suspended Solids • Free Oil • Water-Wet Solids
  52. 52. APPLICATION METHOD - DEGASSING FIXED ROOF DEGASSING PROCEDURE • Remove product • Vacuum last 6 - 8 inches FIXED ROOF • Educt water-chemical solution DRAIN
  53. 53. APPLICATION METHOD - DEGASSINGFIXED NOZZLE DEGASSING PROCEDURE • Remove product • Vacuum last 6 - 8 inches • Use Butterworth or Gammajet to spray cleaning solution FIXED ROOF DRAIN
  54. 54. APPLICATION METHOD - DEGASSINGFLOATING ROOF DEGASSING PROCEDURE • Remove product • Lower roof FLOATING ROOF • Educt water-chemical degassing solution DRAIN
  55. 55. EDUCTOR
  56. 56. 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
  57. 57. 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.
  58. 58. 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
  59. 59. 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

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