Kleensafe

The Kleensafe Automated Tank Cleaning System is a state-of-the-art, technology-driven automated solutions for tank cleaning and oil recovery. Our systems are designed to prioritize Health, Safety, and Environmental (HSE) performance, operating as 100% closed-loop, non-man entry systems. We offer highly versatile, modular, and fully mobile solutions suitable for tanks of all sizes, whether floating or fixed roof. Whether your needs involve efficient tank cleaning or an integrated process encompassing tank cleaning, sludge separation, and oil recovery, we provide customized options tailored to your specific requirements.

Our advanced technology guarantees a minimum oil recovery rate of 97%, backed by a track record of surpassing 99% recovery rates. We believe in maintaining transparency with our clients, providing reliable flow meter-based recovery rates through daily project reports. We advocate for the use of the Best Available Technology (BAT), enabling simultaneous cleaning and recovery. Our system is designed to prioritize safety, timeliness, and cost-efficiency.

Stages in a Typical Automated Tank Cleaning Project

Planning

Thorough pre-planning and establishing a strong collaborative partnership with the refinery are essential for the successful execution of any major project. By working together, we develop comprehensive pre-job planning and ensure the approval of crucial documents such as Risk Assessments and Method Statements (RAMS) and Mobilisation plans. This cooperative approach is fundamental in achieving a successful project outcome.

Mobilisation

In an automated tank cleaning project, the successful execution requires careful equipment mobilization and planning. Here is an example of how this process is approached:

ATEX zone certification: All equipment utilized in the tank bund is certified for electrical use within ATEX Zone 1 and 2, surpassing the conventional methods of tank cleaning in the country.
Refinery-approved mobilisation plan: Equipment placement will be determined by a pre-approved mobilization plan in consultation with the refinery. Factors such as site logistics, tank design, suction point location, and locations of return oil, water, and solids will be considered.
Detailed mobilisation plan: A comprehensive mobilization plan will be developed in close collaboration with the refinery upon project award. This plan will address specific requirements and considerations for successful execution.

Fluidize closed loop - 100 m Diameter Tank

Nitrogen Inerting Procedure

During the nitrogen inerting process, specific measures are taken to maintain a controlled environment within the tank. Here is an outline of the steps involved:

Installation of plastic barrier: Once the tank roof is properly positioned on its roof legs, a plastic barrier is installed between the tank wall and the roof. This barrier serves two purposes: preventing nitrogen leakage and enhancing the effectiveness of the nitrogen purge.
Continuous nitrogen purge: A continuous nitrogen purge is initiated and maintained round the clock. This involves injecting nitrogen into the tank using a nitrogen generator. The goal is to ensure that the oxygen level remains consistently below 8% while the Automated Tank Cleaning System is operational. If the oxygen level reaches 8%, the Automated Tank Cleaning system will automatically shut down and trigger an alarm.
Safety precautions on the roof: All work carried out on the tank roof is conducted under Breathing Apparatus (BA) for enhanced safety and protection.

By following these procedures, the nitrogen inerting process creates an oxygen-deficient environment within the tank, allowing for safe and efficient operation of the Automated Tank Cleaning System.

Cold Tapping and Nozzle Insertion Procedure

In the cold tapping and nozzle insertion process, specific steps are followed to ensure safe and efficient operations. Here is an overview of the procedure:

Checking oxygen level: Before initiating the process, the oxygen level inside the tank is monitored. Cold tapping can only take place when the oxygen level is below 8% to ensure safety.
Cold tapping preparation: Cutting oil is added inside the trunk, and a hydraulic-driven cutting tool is mounted. The operator then proceeds to slowly cut out a circular plate in the roof using the cutting tool.
Nozzle installation: Two operators will carefully lift the nozzle in a vertical position and lower it into the trunk with the nozzle lifting tool. The nozzle is then securely installed using bolts and connected to the ball valve and Victaulic piping.
BA usage: All work performed on the roof, including the cutting and nozzle installation, is conducted under the protection of Breathing Apparatus (BA) for enhanced safety.

By following these steps, the cold tapping and nozzle insertion process can be carried out effectively, ensuring the safety of the operators and proper installation of the nozzle in the tank.

Fluidization and Separation Process

The fluidization and separation process involves specific steps to effectively treat the tank contents. Here is an outline of the procedure:

Addition of cutter stock: A 10 cm layer of cutter stock, such as LCO/Crude oil or a suitable alternative, is added above the sludge level in the tank. This cutter stock helps facilitate the fluidisation process.
Ensuring safe atmosphere: Once the tank atmosphere is determined to be safe, the circulation of the tank contents begins using pumps. Jetting nozzles are initially operated around the suction point to allow for the cutter stock to reach the suction point for the suction pumps.
Monitoring fluidization progress: Regular sampling and laboratory testing are conducted to monitor the progress of fluidization. The lab results indicate the saturation of cutter stock within the tank.
Commencement of stripping operation: Once the laboratory results confirm the saturation of cutter stock, the stripping operation is initiated. This process involves separating and recovering the product from the tank.
Disposal options: The stripped and recovered product can be directly sent to the refinery's designated point. However, if needed due to BS&W (Basic Sediment and Water) content or an oil and water emulsion, the product can be sent through a three-phase separation module for further separation to meet the required specs for the recovered oil and recovered water.

By following these steps, the fluidization and separation process effectively treats the tank contents, allowing for the recovery of valuable products while considering any necessary purification steps.

Solids and Water Removal - Tricanter Centrifuge

The solids and water removal process utilizes a Tricanter centrifuge as part of the Separation System. This centrifuge enables the separation of solids and water from the oil in a continuous and efficient manner. The centrifugal forces applied during this process can exceed 3000 times the force of gravity. These forces cause denser solid particles to be pushed outward against the rotating bowl wall, while the less dense liquid phase forms a concentric inner layer.

After the stripping operation, a fresh batch of 10cm cutter stock is introduced into the tank. The Jetting Nozzles are adjusted to operate at a higher angle, allowing for impactful cleaning of the tank, reaching all the way up to the floating roof. This process continues until all the sludge in the tank is saturated, absorbed, processed, and recovered in the designated tank.

Following the stripping process, Kleensafe proceeds with the Water Wash phase where the last oil residue on the walls is cleaned using cold or hot water wash.

Water Wash Process

The water wash process involves the introduction of 10 cm of fresh water into the tank for cleaning purposes. The following steps outline the procedure:

Introducing fresh water: A layer of 10 cm of fresh water is added inside the tank.
Circulation and separation: Using the temporarily installed suction point, the water/oil mixture is circulated through oil and water coalescing separators. These separators facilitate the separation of oil from the water.
Oil separation: The separated oil is collected and returned to the refinery for further processing.
Water circulation: The water, free from oil, is then circulated back into the tank through the Jetting Nozzle.
Monitoring oil presence: The water coming out of the tank is continuously monitored for any traces of oil. Once no more oil is observed in the water, the process is stopped, indicating successful completion of the water wash phase.

By following these steps, the water wash process effectively removes oil from the water, allowing for a clean and oil-free environment within the tank.

Ventilation Process

Once the water wash phase is completed, the tank undergoes a ventilation process to ensure a safe and controlled atmosphere within the tank. Here are the steps involved:

Stripping the tank: After the water wash, the tank is stripped, meaning the remaining water and any residual gases are removed from the tank.
Open for ventilation: The tank is then opened, allowing for natural ventilation to occur. This enables the exchange of air inside the tank with fresh air from the surroundings.
Ventilation parameters: The ventilation continues until the tank atmosphere reaches specific parameters. Usally within 3 dasy the target levels of 20.9% oxygen concentration and 0% Lower Explosive Limit (LEL) is reached. These parameters ensure a safe and non-flammable environment inside the tank.
Monitoring the atmosphere: Throughout the ventilation process, the atmosphere inside the tank is regularly monitored to ensure it meets the required oxygen and LEL levels.

By following these steps, the ventilation process effectively removes any remaining gases and establishes a safe working environment within the tank. It ensures that the oxygen concentration is at a normal level and eliminates any potential flammability hazards.

Equipment mobilization within the bund wall

Installation of Jetting Nozzles in the Floating Roof

To ensure thorough cleaning coverage inside the tank, jetting nozzles will be installed in the floating roof. This installation process involves penetrating the roof using a hydraulic-driven Cold Cutting-Tool. By implementing this method, the tank's interior can be effectively cleaned, providing ample coverage for the cleaning operation.

Roof mobilisation - Pipe and jetting nozzle installation.

Flow and Pressure Management

Effective management of flow and pressure is crucial for ensuring efficient operations. Here's an overview of the considerations related to flow and pressure:

Flow control: Implementing appropriate flow control measures is essential to regulate the movement of fluids within the system. This can involve the use of valves, flow meters, and other equipment to monitor and adjust the flow rate as required.
Pressure regulation: Maintaining optimal pressure levels throughout the system is important for the safe and effective operation of equipment and processes. Pressure regulators and control valves are utilized to manage and stabilize the pressure within acceptable limits.
System efficiency: Proper flow and pressure management contribute to system efficiency by minimizing energy consumption and optimizing performance. By ensuring the right balance between flow rates and pressure levels, overall system efficiency can be improved.
Safety considerations: Adequate flow and pressure management also play a critical role in maintaining system safety. Appropriate pressure relief mechanisms, such as safety valves, are installed to prevent over-pressurization and ensure the protection of equipment and personnel.

By carefully monitoring and controlling flow and pressure within the system, operators can achieve optimal performance, energy efficiency, and safety standards. Regular maintenance and calibration of flow and pressure instruments are necessary to ensure accurate measurements and reliable operation.

Piping System Configuration

The piping system installed for the project will consist of various sizes, including 2", 3", 4", and 6" piping. All piping components will be made of stainless steel, ensuring durability and corrosion resistance. The connections between pipes will be secured using Victaulic couplings, which utilize oil-resistant NBR gaskets.

To ensure the integrity of the piping system, quality control (QC) and hydrostatic testing will be conducted prior to start-up. The testing will involve subjecting the piping to a pressure of 1.5 times the working pressure to verify its strength and reliability. The refinery is invited to witness and approve this testing process to ensure transparency and compliance.

In addition, detailed pressure test certificates will be prepared for each spool piece, providing documented evidence of the successful testing. These certificates will undergo witness and countersigning by authorized personnel to validate the accuracy and authenticity of the test results.

Tank Suction Pumps and Coarse Filtration System

To facilitate the suction process and ensure effective filtration, the following equipment and measures are implemented:

Self-priming pump: A self-priming pump is positioned within a 6-meter distance from the suction point on the tank. This pump is capable of priming itself and is specifically designed to handle the required suction operation.
The pump is utilized to transport the cutter stock from the tank to a skid. The skid contains two coarse strainers that serve as filters, removing large impurities such as rust scales, rags, stones, and other debris. The strainers operate on a rotational basis, with one being used while the other undergoes cleaning. This ensures uninterrupted operation with no downtime.
Positive displacement Pump: In parallel with the centrifugal pump, a positive displacement pump is installed. This pump is capable of handling high-viscosity media, ensuring efficient pumping even with thicker fluids.

Pump Skids: Efficient Fluid Handling Solutions

Pump Skids: Efficient Fluid Handling Solutions: The Pump Skid 1 is equipped with a robust and powerful centrifugal feed pump responsible for receiving the cutter stock and transferring it to Pump Skid 2. Additionally, a buffer tank is installed on the skid. This buffer tank serves the purpose of separating the gas and liquid phases. By implementing this separation, only the liquid phase is directed through the circulation loop, while the gas phase is safely returned to the tank undergoing cleaning. This arrangement effectively eliminates air emissions and ensures environmental compliance.

Pump Skid 2: Media Heating, flow and pressure: The Pump Skid 2 focuses on crucial functions such as heating the circulating media and increasing the flow and pressure to desired configuration. After the media is heated, it is directed to the Jetting Nozzles, which are mounted on the tank roof for effective cleaning.

To ensure safe and optimal operation, a comprehensive control and monitoring system is integrated into Pump Skid 2. This system actively monitors the tank atmosphere and, if the oxygen level exceeds 8%, triggers an automatic shutdown of the unit. This safety measure prevents potential risks and maintains a controlled environment during the tank cleaning process.

Three-Phase Separation Module: Efficient Oil, Water, and Solids Separation

The three-phase separation module is an integral component of the tank cleaning process, operating in parallel with the cleaning and fluidization procedures. This module enables the simultaneous separation of oil, water, and solids within the tank.

The separation process is facilitated by employing a tricanter, a specialized centrifuge designed specifically for efficient separation of the three phases. The tricanter utilizes centrifugal forces to separate the oil, water, and solid components present in the tank.

During operation, the tricanter rotates at high speeds, subjecting the mixture to intense centrifugal forces. As a result, the denser solid particles are forced outwards against the bowl wall, while the less dense liquid phase forms an inner layer. The oil phase, being lighter than water, accumulates in the middle layer.

By utilizing this advanced separation technology, the three-phase separation module ensures effective and simultaneous separation of oil, water, and solids. This process significantly contributes to the overall efficiency and thoroughness of the tank cleaning operation.