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

Enhancing existing tank cleaning practice and weighting future options for prolonged tank lifespan

• 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 .

Outlining the processes of confined space entry and minimizing the 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 .

Enhancing existing 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

Outlining the processes of confined space entry and minimizing the 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

Storage tank Confined Space 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 )

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 .

Determining the appropriate manual cleaning methods to prevent accidents

• Storage Tank major Hazards/ Prevention- Mitigation :-

Prevention /Mitigations Major 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 ,planning 4-Physcial and other Hazards (restricted entry and Egress, tripping ,falling ,Tank conditions /locations

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 )

Hazards of confined space storage

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.)

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

Investing in automatic tank cleaning services :Robotic technology is the way 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

Robotic technology CCTV /jet connection/VacuumSystem

Mechanical robotic cleaning device :-

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.

Mechanical robotic cleaning device benefit -:

• 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

Features of robotic cleaning system

• 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)

Quantify cost for various tank cleaning options and identify impacts on 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 .

Quantify cost for various tank cleaning options and identify impacts on product quality. 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 )

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

Thanks for your attention