#9040 FUEL TANK SWEEPER

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1 #9040 FUEL TANK SWEEPER INSTRUCTION MANUAL FILTERS AND REMOVES FINE BIO-CONTAMINANTS, ALGAE, ETC. SWEEPING PROCESS REMOVES LARGE CONTAMINANTS FROM OIL TANKS SUCH AS RUST, WATER, CRUDE AND DIRT CIRCULATES FUEL ADDITIVES COMPLETELY FOR OPTIMUM RESULTS IMPROVES OIL QUALITY AND RESTORES CLEANLINESS BOOSTS OCTANE AND BOILER PERFORMANCE OPTIMIZES INJECTOR NOZZLE SPRAY PATTERN INCREASING FUEL EFFICIENCY AND BTU OUTPUT REDUCES BOILER DOWN TIME AND SERVICE INTERRUPTIONS EXTENDS OIL TANK LIFE BY REMOVING WATER AND CONTAMINANTS ELIMINATES COSTLY TANK CORROSION WHICH CAN LEAD TO TANK LEAKAGE AND LIABILITY

2 IMPORTANT SAFETY INSTRUCTIONS IT IS IMPORTANT TO READ, UNDERSTAND AND FOLLOW ALL SAFETY MESSAGES & INSTRUCTIONS PRINTED IN THIS MANUAL AND ON THE EQUIPMENT BEFORE OPERATING. IF SAFETY INFORMATION IS NOT HEEDED, RESULTS IN DEATH OR SERIOUS INJURY TO THE OPERATOR OR BYSTANDERS MAY OCCUR. DANGER indicates a hazardous situation, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. WARNING indicates a hazardous situation, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. CAUTION indicates a hazardous situation, if not avoided, may result in minor or major injury. The possible hazards are shown in the adjoining symbols or explained in the text. POTENTIAL BURN HAZARD. Sparks from electrical shorts can ignite flammable liquids such as fuel or oil. Heat from electrical overloads can cause fire hazards. POTENTIAL EXPLOSIVE AIR HAZARD. Pneumatic pressures used with this equipment can cause explosive failures on damaged equipment. POTENTIAL EYE HAZARD. Wear OSHA approved safety glasses. Battery acid and high air pressures create hazardous situations for eyes. POTENTIAL CHEMICAL BURN HAZARD. Wear protective gloves. Battery acid is corrosive and can cause skin damage. POTENTIAL FIRE HAZARD. Use caution with flammable liquids such as fuel and oil. Electrical shorts can ignite flammable liquids and wiring. 1

3 PARTS DESCRIPTION: SET UP INSTRUCTIONS: STEP 1 It is recommended that you visit the site 48 hours before tank sweeping to prepare the tank and assess the site condition. Using the IPA9041 sampling tool, insert the sampler all the way down to the bottom of the tank to be cleaned. Draw the piston shaft up enough to get a good sample of the fuel (aprox.12 ). Remove the sampler and note the amount of water and crude at the bottom of the tank. It is recommend that you transfer the sample into a glass jar and allow the various contaminants to settle and separate for 24 hours. This will give you an idea of the fuel condition inside the tank and the amount and type of the contaminated fuel. 2

4 STEP 2 Add an algae bio-cleaner or equivalent to the tank in appropriate amounts. Using the sampler, stir the tank briskly to mix the algae cleaner into the oil. After 48 hours, the algae should be killed off and the tank is now ready for sweeping. If convenient and safe, you may use a small jack to elevate the tank a few degrees on one side to allow the majority of contaminates to collect on one end of the tank. This is the end you will choose to sweep. TANK SWEEPING SET-UP: 1. Set up your Tank Sweeper near the tank to be cleaned allowing enough room for the inlet hose to reach the tank. 2. Install the outlet hose to a 55 gallon drum or similar making sure that the vent cap is loose. (Note: Use a clean, leak free 55 Gallon drum). 3. Connect the Fiber Staff to the inlet hose via couplings being sure to use the locking pins so the locking levers do to vibrate loose. 4. Insert the Fiber Staff adapter all the way down to the bottom of the oil tank to be cleaned. 5. Be certain to turn the main ball valve to Sweeper direction. 6. Attach air supply line to the inlet air on the pump assembly. Do not turn on the air ball valve yet. 7. Set the air pressure to 50 PSI. Air Operating Range is from 50 PSI to 100 PSI. A setting of 50 PSI is recommended to give the operator more control of the sweeping operation. Do not turn on the air ball valve yet NOTE: When ready to sweep the tank, be sure to check all connections for leaks and be prepared to shut down the sweeper in the event of a leak. Have your Emergency Spill Kit available and in reach. It is best to have this operation performed by two people- -one operating the air supply and the other person doing the actual sweeping of the tank. TANK SWEEPING: 1. Once all safety precautions have been complied with and you are certain of good and proper connections with the outlet hose firmly in the holding drum turn the AIR INLET ball valve to the ON position. This begins to actuate the pump assembly and suction through the Fiber Staff adapter. IN THE EVENT OF AN EMERGENCY FIRST CLOSE AIR BALL VALVE TO STOP THE PUMP. 2. Keep the adapter at the bottom of the tank and slowly sweep back and forth collecting all contaminants from the bottom of the tank only. NOTE: The pump can move up to 37 gallons per minute (GPM) at 100 PSI and fill up a 55 gallon drum in a very little time. Watch carefully and be sure not to place more than 50 gallons into the drum. This allows room for fuel expansion. Depending upon the amount of contaminates in the oil tank, you may require two 55 gallon drums to complete the service. 3

5 3. The Tank Sweeper will remove the bottom contents of the tank where the majority of fuel contaminants exist, i.e., water, crude, algae and rust. If a badly contaminated tank is expected, it would be best to run the cleaning through the lower filter housing without the screen. The Sweeper function incorporates a 150 micron screen which can capture the majority of the rust and large contaminates. However, the screen openings can still be clogged up quickly causing an implosion of the screen and a reduction of the flow. The Tank Sweeper operator should move the Fiber Staff back and forth across the bottom of the tank moving the stick when the oil shows clear in the hose. You will see it turn black then when that spot is clean it will turn red, this is the indication to move the staff to another spot on the bottom of the tank. Repeat this sweeping function until only clean fuel is removed. It may be necessary to use two 55 gallon drums depending upon the amount of contaminates found. NOTE: Be mindful of the 55 gallon drum level and be sure not to over-fill. Have your Emergency Spill Kit ready and available in case of a spill. Leave sufficient air space for expansion. After the sweeping is complete, remember to lower the tank to a level position by removing the jack. Remove the outlet hose from the 55 gallon drum and install all vent or port caps and seal drum completely for transport. FILTERING AND BLENDING THE FUEL: A great feature for the Sweeper is the ability to return the contaminated fuel clean and filtered to the same or new oil tank. To do this, allow the 55 gallon drum with the fuel that came from the sweeping to sit and settle for 24 hours. 1. Turn the main Ball Valve to the Filter Selection and you can complete the fuel restoration. Observe all instruction on page 1, 2 and 3 (up to Tank Sweeping section.) 2. Install the outlet hose in the tank you want to transfer the cleaned fuel into. 3. Insert the Fiber Staff on the Filter intake side into the top of the 55 gallon drum allowing it to just contact the fuel at the top of the drum. NOTE: When ready to sweep the tank, be sure to check all connections for leaks and be prepared to shut down the sweeper in the event of a leak. Have your Emergency Spill Kit available and in reach. It is best to have this operation performed by two people- -one operating the air supply and the other person doing the actual sweeping of the tank. 4. When in the filtering mode and turning the air valve to the ON position, slowly lower the fiber staff into the 55 Gallon drum following the fuel level watching the clear hose for signs of black contamination. The contaminates will be settled in the last few inches of the drum so when you get close to the bottom and as soon as you see the color of the fuel change to dark, lift up the fiber staff and stop the transfer operation. Dispose of the bottom of the tank with the contaminated fuel properly. 4

6 IF YOU WISH TO BLEND FUEL ADDITIVES OR FILTER THE OIL IN THE TANK: 1. While observing all safety precautions, turn the Sweeper to the Filter selection via Main Ball Valve. 2. Insert Fiber staff into one hole at the top of the tank and insert the outlet hose into another hole at the top of the tank. NOTE: When ready to sweep the tank, be sure to check all connections for leaks and be prepared to shut down the sweeper in the event of a leak. Have your Emergency Spill Kit available and in reach. It is best to have this operation performed by two people- -one operating the air supply and the other person doing the actual sweeping of the tank. 3. Turn the air valve on and allow the fuel to circulate through the filters and back into the tank. At this point you can turn the pressure up to maximum or 100 PSI to achieve a 37GMP rate. With this rate, you can move 275 gallons of fuel oil through the sweeper in several minutes. If there is a noticeable decrease in the fuel flow rate, the problem may be clogged filters. If this is the case, replace filter cartridges as necessary. NOTE: There are hose caps to be used to cap off hose ends. One hose plug has a stone filter in it. This is to be used only on the pump outlets, not the hose itself. The purpose of the stone filter is in case of an inadvertent pressurizing of the closed or plugged side of the pump. Instead of allowing pressure to build up which can be dangerous when plug is removed, the stone filter opening discharges fuel oil alerting the user that they have the main ball valve turned to the wrong position. The stone filter allows fuel oil to exhaust through the filter. This can cause a mess but is preferable to inadvertently pressurizing the wrong side of the pump where someone could get hurt. OPTIONAL ACCESSORIES: 8 FT. EXTENSION HOSE #9040-8EXT 1. To connect the 8ft. Extension Hose between the Sweeper and the hose that you want to extend, take the male quick disconnect of the 8ft. extension hose and put it into the desired female port of the Sweeper. 2. Take the female end of the 8 ft. extension hose and attach it to the male end of the hose you are extending. 5 #9040-8EXT 8 Ft. Extension Hose 3. To couple the male and female quick disconnects together, put the male quick disconnect into the female quick disconnect. 4. Pull the levers on the side of the female end all the way down towards itself tight against the side. Be sure to insert the cotter pins through the hole to lock the levers in place. NOTE: During the pump operation, excessive vibration has a tendency to vibrate loose the coupling locking handles. Be certain to use the locking cotter pins.

7 5. To maintain the clear appearance of the hose after use, it is good practice to gravity drain all fluid from the hose. Then using warm soapy water, flush until clean and air drain and dry afterwards. NOTE: Depending upon what contaminates are present when using the hose and how well it is cleaned afterwards determines how long the hose remains clear. The hose is warranted to be free from manufacturer s defects for one year. SAMPLE STICK #9042 The Sample stick is designed to remove a small sample of fuel oil from the bottom of a fuel tank so the operator can see what contaminates exist. TO OPERATE: 1. Insert the Sample Stick through one of the cap openings at the top of the tank all the way until it contacts the bottom of the tank. 2. Slowly withdraw the piston via the handle until the desired amount of fuel is drawn into the Sample Stick. 3. Remove the sample stick from the tank keeping an oil absorbent towel ready. Allow the Sample Stick to drip drain into the towel. 4. Have a suitable container made of glass or material that will not be affected by the fuel oil ready for the sample fuel oil. 5. Slowly withdraw the piston until it is removed completely from the sample tube. Place the piston on a towel to drip drain. 6. Pour the remaining contents of the sample tube into the sample jar. 6 #9042 Fuel Sample Stick 7. Once the sample is in the jar, let it sit for 24 hours to separate the contents. The water will settle to the very bottom with rust, and then algae, then the crude. The clear oil will be on top. This should be a real time view of what is happening at the bottom of the oil tank. 8. Once the sample has been taken, you must replace the piston in the sample stick tube. Because of the one way valve at the bottom of the foot valve, there will be a pressure block as you attempt to replace the piston. You need to break the suction seal by unscrewing the foot valve two turns counter clockwise. This allows the air to escape and the piston to be replaced. Once the piston reaches the bottom of the tube, you must retighten the foot valve. Be certain not to over- tighten the O-ring. A snug torque of the foot valve halves is all that is needed. Cleaning of the Sample Stick after use is necessary to maintain its clear appearance. When ready, allow the Sample Stick to gravity drain the oil. Once the stick has been drained, a solution of warm soapy water should be used to flush the stick a few times until clean. NOTE: The tube of the sample stick is made of a clear acrylic material. The Sample stick should not be used for gasoline, ONLY OIL!

8 AIR-OPERATED DIAPHRAGM PUMP DESCRIPTION 1:1 ratio air-operated diaphragm pump with aluminum body and Buna N diaphragms. Recommended for transferring oil or evacuating waste oil. TECHNICAL INFORMATION MAX. FLUID WORKING PRESSURE MAX. AIR CONSUMPTION (AT 5 BAR AIR PRESSURE) MAX. FREE FLOW DELIVERY INLET AIR FLUID INLET AND OUTLET WEIGHT 5 bar (70 psi) 700 l/min (25 SCFM) 120 l/min (28 GPM) 3/8 NPT 1 NPT Side Ports 9 Kg. (20 lb) TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSES SOLUTION THE PUMP CONTINUES OPERATING ALTHOUGH THE OUTLET VALVE IS CLOSED. THE PUMP DOES NOT OPERATE, OR CYCLES ONCE AND STOPS. THE PUMP OPERATES ERRATICALLY. AIR BUBBLES IN FLUID. There is a leak at some point of the outlet circuit. Worn check valve balls and/or seats. Air valve is stuck or dirty. Check valve ball severely worn and wedged in seat. Clogged suction line. Sticky or leaking valve balls. Diaphragm ruptured. Suction line loose or damaged. Diaphragm ruptured. Verify and tighten or repair. Replace the worn items. Disassemble and clean the air valve. Replace ball and seat. Verify and clean the suction line. Clean or replace. Replace diaphragm. Verify and tighten or replace. Replace diaphragm. FLUID IN EXHAUST AIR. Diaphragm ruptured. Replace diaphragm. THE PUMP EXHAUSTS AIR AT STALL. Worn parts in air valve. Repair or replace. Innovative Products of America Incorporated 234 Tinker Street, Woodstock, NY / phone / fax 9040-Fuel Tank Sweeper-INSTRUCTIONS-v14 7

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