Quantify cost for various tank cleaning options and identify impacts on product quality . Outlining the processes of confined space entry and minimizing the manpower exposure to chemicals . Determining the appropriate manual cleaning methods to prevent accidents Investing in automatic tank cleaning services :Robotic technology is the way forward

1. 6 th Annual Tanks and Terminals: Capacity
management and expansion
Dubai ,UAE
7-9 th September 2015
marcusevans conferences
Enhancing existing tank cleaning practice
and weighting future options for
prolonged tank lifespan
ENG. Yacoub Bani Taha - Jordan refinery Terminal Loading and
Unloading Section Head

2. Enhancingexisting tank cleaning
practice and weighting future optionsfor
prolonged tanklifespan
• Quantify cost for various tank cleaning options
and identify impacts on product quality .
• Outlining the processes of confined space entry
and minimizing the manpower exposure to
chemicals .
• Determining the appropriate manual cleaning
methods to prevent accidents
• Investing in automatic tank cleaning services
:Robotic technology is the way forward .

3. Outlining the processesof confinedspace
entry and minimizingthe manpower
exposure to chemicals.
General Requirements Tank cleaning :-
1- Storage tanks content (chemical and physical test) /MSDS .
2- Safety Plan (identify and evaluate of cleaning hazards and risks –
Contractor Evaluation )
3- Training and Work Plan for qualified supervision cleaning staff .
4- suitable PPE and breathing air supply source
5- Tank Atmospheric gases indicators (Oxygen /explosives
/combustibles/hydrogen sulfide /carbon monoxide/benzene )
6-Ventilation system (Tank Exhaust Blower ).
7- Lighting .
8- Tank Cleaning Equipment .
8- Hazardous Waste Disposal Plan .

4. Enhancingexisting tank cleaning
practice (Scheduling and Cleaning)
Planning the
operation / cleaning
program
Preparation of
cleaning
Vapor -freeing of
the tank
Cleaning of the
tank
Clean-up, residue
disposal ,inspection
and acceptance

5. Outlining the processesof confinedspace
entry and minimizingthe manpower
exposure to chemicals.
Storage tank Confined Space Entry :-
• Complying with related Standards /Codes/ Best Practices
(References ):-
1- 29 CFR 1910 .146 : Permit-required confined spaces
2- ANSI/API STD 2015 :Requirements for safe entry and cleaning of
petroleum storage tanks .
3- ANSI/API STD 2016 :Guidelines and Procedures for Entering and
Cleaning of Petroleum Storage Tanks .
4- ANSI/API STD 2026 :Safe Access /Egress involving Floating Roofs
of Storage Tanks in Petroleum Services
5- NFPA-326 standard safeguarding of tanks for entry ,cleaning and
repair

6. StoragetankConfinedSpace Entry:-
• Confined space Entry Work Permit Requirements :-
1- High level position (maintenance position )of floating roof legs in
case of internal /external floating roof tanks
1-Empting the recoverable contents of the tanks to minimum
allowable levels via tank nozzles( keep manholes closed ).
2- Isolating the tank :Blinds isolating and blanking of all streams and
lines attached to the storage tanks after review floating roof drawing
and tank configuration /lock out –tag out and isolating energy source
/foam lines/ Cathodic protection .
3- Vapor , gas freeing ,degassing and mechanical ventilation of tank
and degassing vapor recovery or vapor treatment equipment .
4- Continuous Testing and monitoring the tank atmosphere
:atmosphere conditions shall be Oxygen (19.5-23.5%, Explosives gases
(Less than 10 % LEL ) ,permissible concentration of toxic gases or
vapors H2S , lead, Aromatics )

7. Storage tank Confined Space Entry :-
• Prevent the adverse weather condition (High Winds velocity
/Electrical Thunderstorm /Lighting )period permit issuing and
implement permit cancellation instruction .
• PPE (respiratory protection –OSHA 29 CFR 1910
- Fire retardant coveralls /Hard Hats /Safety boots /
goggles/Gloves /Approved continuous air supply system
• Continuous forced air ventilation
• Standby qualified persons outside the tanks
• Emergency Rescue Equipment Specific to the tank and the
Potential Hazards .

8. Determiningthe appropriate manual
cleaningmethods to prevent accidents
• Storage Tank major Hazards/ Prevention- Mitigation :-
Prevention /MitigationsMajor Hazards
(no proper ventilation O2 less
than 19.6%) or Enrichment (
e.g welding oxygen cylinders
leaks O2 more than 23.5 %)
1-Oxygen Deficiency
/Enrichment
Control of Ignition Source
Control of temporary
connections
2-Spillage of flammable
liquids, Fires And Explosions
(MSDS reviews /proper PPE
/toxic substance monitoring )
3-Toxic Substances Exposures
Proper PPE ,planning4-Physcial and other Hazards
(restricted entry and Egress,
tripping ,falling ,Tank
conditions /locations

9. Determining the appropriate manual
cleaning methods to prevent accidents
Removing sludge and residue from the tanks :-
-Sludge/Residue level measuring (ullage gauging of sludge ) and
quantity estimation (Entry permit to external floating roof
(Requirements API -2026)
-first of all Implement noninvasive procedure to remove as much
heavy product ,sludge as possible before the cleaning .
Cleaning methods :-
Removal using fixed connections (~Roof /shell nozzles /Hot tapping
injectors ) (Without opening the tank):-
Breaking/Dissolving the sludge by using petroleum solvent (kerosene
/FCC cycle oil ) ,chemicals (Dispersant /high surface active additives
/emulsion breaker ) ,hot washes with heating, circulation and
agitations (mixers shall be restricted when product level below
agitator level )

10. Hazards of confined
space storage

11. Sludge and residue Cleaning method
Removal using manholes /door ways or water cutting -door
sheet openings (After sludge and residue removed through
tank fixed connections )
Using suction pumps ,skimming ,solvent/water flooding
,vacuum and robotic mechanical cleaning without requiring
workers to enter inside the tank
Removal from inside the tank (After entry permit is issued )
Removing the remaining sludge and residue by workers and
manual tools :-
-Bonded Jet water streams/petroleum solvent hoses injection
for breaking of sludge
-Physical cleaning (vacuuming ,shoveling ,scrapping ,etc.)

12. Robotic tank cleaning system
• The Robotic tank cleaning system is relatively new technology
• Invention as gas tight tank cleaning method in 1998
• US5776257 A issuing number for gas tight tank cleaning method
• Abstract of the method :-
Methods for cleaning industrial tanks are disclosed in which a fast
temporary seal (rubber sheet side man way ) is applied to a man way
entry into a tank to be cleaned. A robotic tank cleaning system is
introduced through the temporary seal into the tank. The tank interior
is sprayed with diluent to remove liquid and solid volatile organic
compound (VOC) generating residue. VOC's are removed from the tank
by repetitive diesel and water/surfactant fogging (allowing the
diesel/water fog to settle, thereby absorbing airborne VOC's)until a
safe, legal level of VOC's remains in the tank atmosphere

13. Investingin automatictankcleaningservices
:Robotictechnologyis theway forward
Mechanical robotic cleaning device :-
• Used to carry cutter oil hoses and solvent /jet water nozzles to
specific location where the solvent is applied directly into heavy
non-recoverable product ,sludge or residue .(API-2016 definition )
Requirements of Mechanical robotic cleaning device :-
• At least one side man hole is opened (with sealing rubber man way)
• Low light video, lighting system and lens washers to assist the
remote operator in directing operations .
• Robotic device shall have explosion proof motors ,ground fault
interrupters and shall be bonded to the tank
• Robotic device may be equipped with oxygen ,hydrogen sulfide
,toxic gas and flammable gas and vapor detector .
• A technician, called a robot pilot, operates the tank-entry device by
video remote control

14. Robotic technology
CCTV /jet
connection/
Vacuum
System

16. Mechanicalroboticcleaningdevice :-
Main Benefit of automatic cleaning method ( mechanical
robotic cleaning devices ) :-
• Optimum Health, Safety and Environmental (HSE)
performance Which Limit or Eliminate high risky Confined
Space Operations for Personnel .
• Reducing Operating Costs of manual cleaning and method of
solvent or chemical /sludge –residue circulation .
• Reduce overall shut down period of storage tanks by
powerful concentrated cleaning of pressurized jet
water/solvent.

17. Mechanicalroboticcleaningdevicebenefit :-
• Robotic Tank cleaning method remove sludge online (The
tanks remain in service during cleaning) If waste processing is
needed, a phase-separation system with screeners and high-
speed centrifuges is integrated with sludge removal in a
continuous system (oil and gas journal)
• Ultrasonic inspection inside the tank ,special robot can
simultaneously chemical /jet water direction and vacuum
sludge removal and perform an ultrasonic inspection inside
tank floor (Thickness Measurement Map ~ corrosion of tank
bottom ) –API -653 requirements

18. Featuresof robotic cleaningsystem
• Robot control system : Robot can be controlled with pre-
programmed cleaning cycles or may be operated manually .
• High flow –low pressure heated water injection for efficient
blasting of sludge and scales ,then low flow –high pressure
water/chemical /solvent injection (powerful than manual
cleaning 5-6 times ).
• Low quantity of jetting water usage benefit (important for
poor water resource country ) and minimum water to
separate and treat .
• Robotic Lancing Machine with Water jet Nozzles
• High Pressure Heated Pump System
• High Flow Pump and Recirculation System
• Transfer Pump System (to storage, recycling, or disposal)

19. Quantifycost for varioustankcleaning
optionsand identifyimpactson product
quality.
• Considerations of total Cost comparison between highly costs of the
traditional cleaning method and robotic cleaning technology :-
1- Minimize shut down time or cleaning time of storage tank ( Faster
by 4-5 times ) - World Robotics 2005 (International Federation of
Robotics)
(Traditional method up to 1-3 months shut down time for cleaning
depended on the size of tank , contractor –maintenance department
capability and scope of repair which :-
 Reduce refinery production
 Marine demurrage, short load freight rates
 Product downgrading
 Need of alternative storage (switch of service of storage tank )
 Alternative product supply (importing of petroleum derivate )
2- Enhance the reduction of wastes disposal and vapor losses .
3- Reduce all operating cost of cleaning process .

20. Quantifycostforvarioustankcleaningoptions
andidentifyimpactson productquality.
Cost benefit summary :-
• Price of industrial robot having significant drop in prices
,accordingly strong demand and robust growth of robots
• The world investment in industrial robot increased
dramatically for service in professional use .
• Robotics tank cleaning method costs Saving ~ 40-50 % of
traditional cleaning method total costing (including the
direct and hidden costs )

21. United Nations
Economic Commission,
one of reason of
investment :to transfer
dangerous and
laborious work from
man to machine

22. Thanks for
your attention