Fueltec Model CF75.0 Mobile Fuel Polishing & Tank Cleaning System

Transcription

1 Fueltec Model CF75.0 Mobile Fuel Polishing & Tank Cleaning System Featuring High Capacity Filtration Water Separation at 4,500 Gallons per hour Fueltec Systems LLC LENZ

2 Cf75.0 first stage primary bag filters remove particulates down to one micron; DUAL STAINLESS STEEL HOUSINGS WITH 24 INCH BAG FILTERS REMOVE SLUDGE, RUST SHARDS, AND BACTERIA CLUSTERS DOWN TO ONE MICRON BEFORE THEY REACH THE FUEL PUMP These primary filters can be used at 4,500 gallons per hour to clean fuel and remove particulate matter 2

3 Featuring High Capacity Filtration Water Separation at 4,500 Gallons per hour Separating water from fuel down to 50 PPM at 75 GPM requires a state-of-the-art separator system. The CF75 utilizes 5 ea. coalescer/filters and 2 ea. Water separators The first stage filter/coalescer removes more particulates with an inside to outside flow then coalesces tiny water droplets into larger drops which stream to the systems water trap. The third stage water separator prevents the water from flowing with the fuel with a Teflon barrier. This is the same process and technology that is used extensively on the purification of military and domestic jet fuel. 3

4 SEPARATED WATER DRAIN The Model CF75.0 is equipped with a clear sight tube to observe water levels in real time as moisture is separated from the fuel Separated water level Connect fuel suction hose from tank bottom here Clean dry fuel return to tank after water separation Water can be drained while the system is in operation by opening the drain valve The Fueltec Model CF75.0 Fuel Polishing System Exceeds engine manufacture s cleanliness levels for tier four engines. Water separation adjustable flow rate 0-75 GPM, 4,500 gallons per hour Downstream free water level typically below fifty (50) PPM Filtration adjustable flow rate 0-75 GPM, 4,500 gallons per hour Down to one (1) micron to meet ISO 4406 particle counts Intrinsically safe for diesel, gasoline, ethanol, kerosene, and jet fuel 4

5 CF75.0 Settings for Underground Storage Tanks When separating water from fuel in underground fuel storage tanks always position the return to tank valve so the pump pressure gauge reads a min. of 10 PSI. This pressurizes the water separator housing so you can drain the separated water without stopping the operation. After starting the pump, rotate return to tank valve handle upward until the pump pressure gauge reads 10 PSI. 5 Clean dry fuel return to tank valve

6 Separator air bleed valve Quick Change swing bolt top covers Water Separator Housing Sight Tube for separated water Primary Filters inlet port Water separated fuel return to tank valve port DIAPHRAGM PUMP Filter only port return to tank Static Ground Reel 6

7 FILTER ONLY PORT THREE-WAY VALVE OPERATION SELECTOR VALVE FOR FILTER ONLY OR FILTER AND WATER SEPARATION. When all water has been separated and removed from the storage tank, operate three-way valve to select filter only. Vacuum gauges will indicate condition of filter bags. Filtered fluid will flow from FILTER ONLY PORT 7

8 Swing Bolt Eye Nut (hand tighten) Primary Filter Air Bleed Valves Vacuum Gauge Stainless steel Primary filter housings Air Diaphragm Pump WARNING: Set air pressure regulator not to exceed sixty (60) psi at any time 8

9 CF75.0 Compressed air supply & control Air pressure relief valve Air regulator adjusting knob Air supply connection 1/2 Pump air supply valve shown in off position Air regulator adjusting knob Set air pressure gauge Air supply connection 1/2 Water drain 9

10 WATER SEPARATOR AIR BLEED The Model CF75.0 is equipped with an automatic and manual air bleed valves. CAUTION: It is required that all air is removed from the water separator housing for safe efficient operation. Whenever the water separator function is used: 1. First open the manual air bleed valve which is located on the top cover of the water separator housing. 2. Place 3-way fluid flow selector valve handle in a vertical position as shown on page 9 of this manual. This will direct fluid from the pump to the water separator housing. 3. Clear the work area for a 50 radius around the CF75.0 before starting the pump. 4. When the pump is started you will hear air escaping from the manual air bleed valve. USE EXTREAM CAUTION as this air may contain explosive fumes from contact with fuel. 5. When air stops escaping from the manual air bleed valve, close the valve. Manual Air Bleed Valve Automatic Air Bleed Valve 10

11 PRIMARY FILTER REPLACEMENT The Model CF75.0 Mobile has two primary bag filters within stainless steel housings. Note: Change primary filter bags when vacuum gauges read Close inlet valve on filter housing. 2. Open top air bleed valve. 3. Loosen swing bolt eye nuts and remove housing cover. 4. Remove bag filter hold down. 5. Remove and dispose soiled filter bag after each use. 6. Insert new filter bag into housing and seat bag flange on housing baffle plate. 7. Insert filter hold down. 8. Install filter housing cover and swing bolts into slots in cover. 9. Tighten swing bolt eye nuts hand tight then 1/4 turn more. (do not over tighten) 10. Close air bleed valve and open inlet valve 11. Resume operation. 11

12 WATER SEPARATOR/ COALESCER CARTRIDGE REPLACEMENT The Model CF75.0 Mobile has five coalescer and two water separator cartridges within a stainless steel housing. Note: Change coalescer cartridges when pressure gauge on the fuel pump reads 20 PSI 1. Close air supply valve on fuel pump stopping the system. 2. Close outlet valve at bottom of water separator housing. 3. Close inlet valves on primary bag filter housings. 4. Loosen swing bolt eye nuts and remove housing cover. 5. Remove fastener wing nuts and remove and replace coalescer cartridges. 6. Replace fastener wing nuts hand tight. 7. Inspect O-ring cover seal 8. Install filter housing cover and swing bolts into slots in cover. 9. Tighten swing bolt eye nuts hand tight then 1/4 turn more. (do not over tighten) 13. Open inlet & outlet valves 14. Resume operation. 12

13 Fueltec s Fuel Polishing = water and particulate removal Fuel is relatively clean when it leaves the refinery, as it s transported downstream it can easily become contaminated with water, rust, silica, and bacteria. As a result the fuel falls below the engine manufacturers recommended cleanliness levels. Fuel in storage becomes even more contaminated with bacterial and fungi growth. Fueltec s fuel polishing systems first stage primary bag filters remove particulates down to one micron; the second stage filter/coalescer removes more particulates with an inside to outside flow then coalesces tiny water droplets into larger drops which stream to the systems water trap. The third stage water separator prevents the water from flowing with the fuel with a Teflon barrier. This is the same process and technology that is used extensively on the purification of military and domestic jet fuel. Off-road diesel before polishing Off-road diesel after polishing 13

14 Fueltec Systems Model CF75.0 Mobile Fuel Polishing and Tank Cleaning System Fuel polishing is the technical cleaning process; essentially the removal of water, sediment and microbial contamination from such fuels as diesel, gasoline, jet fuel, and ethanol blends. Page 2. Page 3. Index Page 4.Operating procedure Page 5. Compressed air supply Page 6. CAUTION water separator housing air bleed Page 7. Underground tank operation Page 8. Separated water sight glass and drain Page 9. Hose connection ports & Air bleed valve Page 10. Three-way valve and Vacuum gauges Page 11. Primary filter valves Page 12. Primary filter change Page 13. Water separator and coalescer change Page 14. Specifications Page 15. Fuel hose Page 16. Static ground Page 17. Fluid Pickup tube Page 18. Supply and return to tank Page 19. Contaminated diesel Page 20. Microbes in fuel Page 21. ISO 18/16/13 cleanliness target. Page 22. Phase Separation in ethanol blended gasoline Page 23. Fuel Sampler Page 24. Safety 14

15 Model CF75.0 OPERATING PROCEDURE The Model CF75.0 is designed for use on fuel storage tanks with a capacity greater than 2,000 gallons. On tanks smaller than 2,000 gal. slow the fluid flow rate 35 GPM by reducing the discharge valve opening and air supply. 1. Take a fluid sample from the fuel tank s bottom, (see page 24) to check for water, sludge, rust, bacteria, fungi, or other particulates. Most contamination is heavier than fuel and is normally found at the lowest 5%-10% of the storage tank. 2. First attach a 3/4 or min. 1/2 compressed air line to the system s air regulator. The CF75.0 requires 60 CFM at PSI. (See Page 5.) 3. Attach the 2 x 25 fluid supply hose to the primary filter manifold with cam and groove fittings. Attach a fluid pickup tube to the opposite end of the hose, (page 11) 4. For bulk water removal attach the 2 x 25 return to tank hose to the discharge port nearest the diaphragm pump, (page 10). 5. To separate water from fuel to less than 100 parts per million attach the 2 x 25 return to tank hose to the water separator housing lower discharge port, (page 7.). Attach the fluid discharge stinger to the tank end of the hose. 6. Check to see that the bag filters are secured in the primary filter housings, (page 12.) 7. Check to see that the five coalescers and two water separators are secured in the water separator housing, (page 13.) 8. Set air supply regulator to 60 PSI (page 5.) 9. Open all four primary filter inlet and discharge valves by turning handles to a vertical position, (page 11) 10. For filtration only or bulk water removal without the water separator, set 3-way valve at diaphragm pump to discharge by rotating the handle to a horizontal position 11. For both primary filtration and water separation, set the 3-way valve at the diaphragm pump to a vertical position. (page 10) 12. If the tank bottom water level is greater than three inches, pump the bulk water level down to three inches with the CF75.0 set on filtration only, then set the system for water separation, to remove water to less than 100 Parts Per Million. 13. Open air bleed on the top of the water separator housing, (page 6) when air stops escaping, close the valve. 14. Before starting the system position the fluid pickup (suction) tube above any accumulated water in the storage tank. 15. Start system by opening air supply valve, (page5.) 16. Run the system until fuel fills the sight tube and all air has escaped from the separator housing, then lower the fluid pickup tube to the storage tank bottom. 17. As the water is being separated from the fuel, the water level can be seen in real time in the clear sight tube. (page 8.). 18. Drain the water from the pressurized water trap by opening the drain valve, (page 8.) The separated water can be drained with out stopping the operation; and with no loss of fuel in the process. 19. Primary filter bags can be changed without stopping the operation by closing the two valves on one primary filter housing. 20. To drain fluid from the system after use, stop system, close primary filter supply valves, (page_) close all return to tank valves, open primary filter air bleed valves, open water drain valve after placing discharge hose in a waste container. Start system. Stop system when fluid discharge stops from water drain hose. 15

16 WARNING You are working in a potentially dangerous environment of flammable fuels, vapors, and fluid pressures. Only trained and authorized individuals knowledgeable in the related procedures should operate, inspect, maintain or service this equipment. FREE Training Free training is available at Fueltec s factory located in Granite Falls, NC USA. Call 1- (828) Warnings and Instructions This section introduces the hazards and safety precautions associated with operating, maintaining or servicing this product. Before performing any task on this product, read this safety information and the applicable sections in this manual, where additional hazards and safety precautions for your task will be found. Fire, explosion, or pressure release could occur and cause damage to property, environment, resulting in serious injury or death, if these safe service procedures are not followed. This fuel polishing system should NEVER BE OPERATED inside a truck cargo body, enclosed trailer, confined space, or within fifty (50) feet of an operating or hot engine, electric motor or fuel dispenser. Follow the Regulations Applicable information is available in National Fire Protection Association (NFPA) 30A; Code for Motor Field Dispensing Facilities and Repair Garages, NFPA 70; National Electrical Code (NEC), Occupational Safety and Hazard Association (OSHA) regulations and federal, state, and local codes. All these regulations must be followed. Failure to operate, inspect, maintain or service this equipment in accordance with these codes, regulations and standards may lead to legal citations with penalties or affect the safe use and operation of the equipment. OSHA fall protection rules apply when working on above ground fuel storage tanks. 16

17 PRELIMINARY PRECAUTIONS Read the Manual Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not understand a procedure, call to locate a qualified technician. It is imperative to your safety and the safety of others to understand the procedures before beginning work. Make sure your employees and any service contractors read and follow the instructions. Prevent Explosions and Fires Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels and used filters cause vapors. All used filters should be promptly placed in an approved safety container until disposed of. Even filling air compressor fuel tanks will cause potentially dangerous vapors in the vicinity of the work area. NO SMOKING. Extinguish all open flames and pilot lights, such as on RV appliances. TURN OFF cell phones and other electronic devices including flash lights, power tools, engines and electric motors during the operation or maintenance of fuel polishing equipment to prevent sparks which could cause an explosion or fire. Working Alone It is highly recommended that someone who is capable of rendering first aid be present during operation. Familiarize yourself with Cardiopulmonary Resuscitation (CPR) methods, while working around fuel vapors. This information is available from the American Red Cross. Always advise other personnel about where you will be working, and caution them not to activate power tools or engines while you are working with fuel filtration equipment. Use the OSHA Lockout/Tagout procedures. If you are not familiar with this requirement, refer to OSHA documentation. Hazardous Materials Some materials may present a health hazard if not handled correctly. Ensure that you clean hands after handling equipment. Do not place any equipment in the mouth. 17

18 CHEMICAL EXPOSURE HAZARD! Wear appropriate safety equipment during operation or maintenance of equipment. Avoid exposure to fuel and vapors. Prolonged exposure to fuel may cause severe skin irritations and possible burns. PERSONAL SAFETY Stay alert, watch what you are doing and use common sense when operating or maintaining the system. Do not operate or maintain the system while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating or maintaining the system may result in serious personal injury or death. Dress properly while operating this system. Do not expose bare skin or eyes to fuels. Prolonged contact with fuel can damage the skin. Use safety apparel and equipment. Use safety goggles or safety glasses. Also use non-skid safety shoes, hardhat, gloves, and fall protection when appropriate. BEFORE YOU START FUEL POLISHING! Establish and secure a safe work area: Mark work area with orange colored safety cones placed in a radius of at least forty (40 ) feet from fuel polishing equipment, fuel containers, and fuel tank openings. Place Flammable Liquid Warning Signs within work area Conspicuous and Legible Warning Signs prohibiting smoking shall be posted. Class I liquids shall not be pumped into storage tanks unless the nozzle and tank are electrically interconnected. This will prevent static electricity from providing a source of ignition. 18

19 Secure Work Area 25 ft. Keep Air Compressor at least forty feet (25 ) horizontally and four feet (4 ) vertical from fuel tank cleaning equipment, fuel containers, and fuel tank openings. At least one portable fire extinguisher having a rating of not less than 20 B units shall be located not less than 25 feet, nor more than 75 feet, from the FUEL POLISHING SYSTEM. Portable fire extinguishers must be located a minimum distance away from the FUEL POL- ISHING SYSTEM because fires involving Class I and Class II flammable liquids are likely to escalate rapidly. If the fire is too close to the work area, it may be impossible to get to the extinguishers once the fire has started. 19

20 SAVE THESE INSTRUCTIONS WORK AREA Keep work area clean, free of clutter and well lit. Cluttered and dark work areas can cause accidents. Keep children and bystanders away while operating this system. Distractions can cause you to lose control, so visitors should remain at a safe distance of at least forty (40 ) feet from the work area. Be aware of all power lines, electrical circuits, water pipes and other mechanical hazards in your work area, particularly those hazards below the work surface hidden from the operator s view that may be unintentionally contacted and may cause personal harm or property damage. Be alert of your surroundings. Using your system in confined work areas may put you dangerously close to unsafe conditions. Place soiled filters in an approved container for disposal. Store and label separated water in steel drums for disposal by a licensed hauler 20

21 FUEL SPILLS Before starting fuel polishing but after your fuel polishing system is primed with fuel: Look for fluid leaking from but limited to pumps, hoses, hose couplings, filters, filter housings, valves, and sight tubes. If any small leaks are found, stop the pump, close all valves, eliminate any ignition and heat sources, clear area of bystanders, and clean up any fluid with an approved absorbent that does not react with spilled product. Do NOT use combustible materials such as sawdust. Place used absorbent in an approved container. Flush spill area. Large spills or leaks: contact emergency services, stop pump if safe to do so, clear the area of bystanders, follow instructions of emergency responders. 21

22 WARNING: Read carefully and understand all INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury, or death. It is important that you read the entire manual to become familiar with this product before you begin using it. This machine is designed for certain applications only. FuelTec Systems cannot be responsible for issues arising from modification. We strongly recommend this machine is not modified and/or used for any application other than that for which it was designed. If you have any questions relative to a particular application, DO NOT use the machine until you have first contacted FuelTec Systems to determine if it can or should be performed on the product. Item SPECIFICATIONS Model CF SKU Part Number 1 Chassis Aluminum Standard 2 Air Diaphragm Fuel Pump flow rate* 0 4,500 GPH 3 Compressed Air Required at 60 PSI CFM 4 Maximum Lift wet 22 feet 5 Bag Filters in Stainless Steel Housings two (2) ea. 24 inch bag Fuel Pressure Working Max. 60 PSI 7 Supply & Return Fuel Hose with cam-lock connectors 2 in. x 25 ft. each 8 Filter Condition Vacuum Gauges One each housing 9 Air Regulator and Pressure Relief Valve Standard 10 Static Ground Safety Reel Standard 11 Flat Free 8 in. Casters Standard 12 Stainless Steel Water Separator Housing Standard 13 Supply & Return Ball Valves Standard 14 Quick Change Swing Bolt Housing Covers Standard 15 Coalescer Elements five (5) ea. Standard Water Separator Elements two (2) ea. Standard Width X Length X Height.. Lbs. 47x47x lbs. * Flow rates may vary with compressed air supply, filter type and condition, length and size of hoses, and size and shape of fluid pickup and return tubes. General Safety Regulations WARNING: Maximum air pressure setting not to exceed sixty (60) psi. WARNING: The warnings, cautions, and instructions discussed in this instruction manual cannot cover all possible conditions or situations that could occur. It must be understood by the operator that common sense and caution are factors which cannot be built into this product, but must be supplied by the operator. 22

23 Supply & Return Hoses The Systems come with two (2) 2 X 25 hoses equipped with cam lock fittings and adaptors. Fabricate suction tubes of the proper length to reach the tank bottom you are servicing. Suction and return tubes can be fabricated from PVC, Aluminum, Stainless Steel, or iron pipe. Flexible suction tubes can be made from polyurethane tube, nylon 11 tube, and PTFE (Teflon) tube. 23

24 FUEL TANK SAFETY Purge fuel tank (fill airspace inside the tank between any fuel and the top of the tank) with argon or CO2 prior to drilling or sawing holes that penetrate the tank to minimize the risk of explosion. Maintain a purged condition while installing fittings on a fuel tank. STATIC GROUND Always attach a static discharge cable from the Fueltec System to the fuel tank being serviced. The flowing movement of flammable liquids like gasoline inside a pipe can build up static electricity. Non-polar liquids such as gasoline, diesel, kerosene and light crude oils exhibit significant ability for charge accumulation and charge retention during high velocity flow. Static electricity can discharge into a fuel vapor. When the electrostatic discharge energy is high enough, it can ignite a fuel vapor and air mixture. Different fuels have different flammable limits and require different levels of electrostatic discharge energy to ignite. Electrostatic discharge while fueling with gasoline is a present danger at gas stations. Fires have also been started at airports while refueling aircraft with kerosene. The use of a static discharge cable can help to prevent or safely dissipate the build up of static electricity. 24

25 FLUID PICKUP TUBE BUILDING FOR FUELTEC S MOBILE SYSTEMS FUELTEC S FUEL SUCTION HOSE TYPE D CAM-LOCK INCLUDED WITH SYSTEM ATTACH PICKUP TUBE TO CAM-LOCK D WITH A STREET ELBOW FITTING FLUID PICKUP TUBE MADE IN FIELD TO REACH FUEL STORAGE TANK BOTTOM. TUBE CAN BE MADE FROM STEEL PIPE, ALUMINUM, STAINLESS STEEL, PVC, NYLON-6, POLYURETHANE, OR ANY MATERIAL IMPERVIOUS TO THE FUEL THAT YOU ARE IN CONTACT WITH. CUT TUBE BOTTOM AT 45 DEGREES FUEL TANK BOTTOM 25

26 SLUDGE BUSTER OPERATION WITH JET NOZZLE RETURN TO TANK HOSE SUCTION HOSE CLEAN DRY FUEL RETURNING TO TANK THROUGH JET NOZZLE AT 60 PSI WILL LOOSEN SLUDGE FUEL TANK BOTTOM SLUDGE SUCTION INTAKE ON TANK BOTTOM 26

27 SUCTION HOSE RE- CLEAN DRY FUEL RETURNING TO TANK THROUGH SHORT PIPE SUCTION INTAKE ON TANK BOTTOM FUEL TANK BOTTOM 27

28 CONTAMINATED DIESEL FUEL Off road Diesel dyed red Bacteria & Fungus Water Dead bacteria & fungus The fuel found above the tank bottom water is usually clean and water free. Water being heavier than fuel will be found at fuel tank bottoms. In fuel tanks, bacteria and fungus are commonly found at the fuel/ water interface. These microbes need water to live, without water they will die. They feed on components of the fuel while they float on the water. The dead microbes are heavier than fuel or water and sink to the tank bottom When the fuel is added to a tank where microbes are living, the microbes get mixed with both the fuel and water and can easily clog filters. 28

29 Microbes found in diesel fuel Virtually all diesel fuel contains some moisture. Additional water accumulates in tanks as atmospheric moisture condenses. Moisture accumulates in diesel tanks as condensate droplets on exposed tank surfaces, as dissolved water in the fuel and as water bottoms beneath the fuel microbes depend on this water for growth. Additionally, microbes depend on the organic and inorganic molecules in diesel fuel for nutrition. Consequently, some species attack the fuel directly, growing at the expense of hydrocarbons and non-hydrocarbon fuel components. The biodegradation of fuel, in support of microbial growth, is a direct impact of contamination. Color, heat of combustion, pour point, cloud point, detergent and anti-corrosive properties change as microbes selectively attack fuel components. Sulfur-containing molecules are metabolized by a series of species, leading ultimately to the production of high concentrations of hydrogen sulfide. In addition to creating new cells, many microbes produce metabolites which promote further attack. Surfactants facilitate the emulsification of fuel, leading to the formation of a cloudy, invert-emulsion layer above the fuel/water interface. Polysaccharide slimes create microenvironments wherein mixed populations (consortia) of bacteria and fungi carry out biodegradation reactions that would be impossible for a single species outside the microenvironment. The slime also serves as a barrier, protecting the microbes from preservatives. A variety of organic acids (primarily 2-4 carbon atoms) are also produced as by-products of bacterial and fungal growth. 29

30 Fueltec Model CF75.0 Is designed to be used for remediation of phase separated fuels 30

31 Fueltec Systems exceed the engine manufacturers recommended ISO 18/16/13 cleanliness target. ISO Fuel Requirements The standard established by ISO (International Organization for Standardization) provides a common measurement system that engine and fuel system manufacturers use to designate acceptable particle levels in the fuel system. Determining fuel cleanliness requirements includes the measurement of both particle size and count. ISO 4406 utilizes a series of three numbers (18/16/13) to identify the particle count per milliliter at 4, 6 and 14 micron sizes. Engine manufacturers recommend ISO 18/16/13 or better as the cleanliness target in fuel tanks. A micron is a metric measure equal to one millionth of a meter, or 1/25,000th of an inch. The smallest particle visible to the naked eye is 40 microns across. A human hair is 80 microns in diameter, and a single grain of talcum powder is 15 microns. 31

32 FUELTEC FUEL SAMPLER 4 oz. For use with Gasoline, Ethanol Blends, Diesel, Bio-Diesel to take before and after cleaning samples for analysis. One (1 ) inch diameter for access to generator and marine tanks The trip valve allows you to take samples from all fuel levels Easily disassembles for cleaning. Fuel samples taken before and after tank cleaning 100% Made in USA Size: 1 Diameter x Length % Made in 32 Copyright NUTEC2 2014