Fueltec Model CF75.0 Mobile Fuel Polishing & Tank Cleaning Systems Fueltec Systems LLC 828-212-1141 www.fueltecsystems.com
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 process is used extensively on the purification of military and domestic jet fuel. Off-road diesel before polishing Off-road diesel after polishing 2
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 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 3
Quick Change swing bolt top covers Quick acting swing bolts Stainless Steel Filter Housing Stainless Steel Water Separator Housing Vacuum Gauge Primary Filters inlet Sight Tube for separated water Filtered fuel return to tank valve Locking Casters 8 Pneumatic diaphragm pump Static Ground 4
Swing Bolt Eye Nut (hand tighten) Vacuum Gauge Sludge Filters inlet port Stainless steel Primary filter housings WARNING: Set air pressure regulator not to exceed sixty (60) psi at any time 5
PRIMARY FILTER REPLACEMENT The Model CF75.0 Mobile has two independent primary bag filters within stainless steel housings. Each filter can be changed without stopping the system by closing the respective supply and return valves. Note: Change primary filter bags when vacuum gauge reads 15 1. Close inlet & outlet valves on left or right 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) 13. Close air bleed valve and open inlet & outlet valves 14. Resume operation. 6
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. 7
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 CF75.0.0 1 Chassis Aluminum Standard 2 Air Diaphragm Fuel Pump flow rate* 0 4,500 GPH 3 Compressed Air Required at 60 PSI 60-80 CFM 4 Maximum Lift wet 22 feet 5 Stainless Steel Bag Filter Housings 24 inch bag 6 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 16 Water Separator Elements two (2) ea. Standard 17 Width X Length X Height.. Lbs. 47x47x60..550lbs. * 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. 8
Supply & Return Hoses The Systems come with two (2) 2 X 12 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. 9
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. 10
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 11
SUCTION HOSE RETURN TO TANK HOSE CLEAN DRY FUEL RETURNING TO TANK THROUGH SHORT PIPE SUCTION INTAKE ON TANK BOTTOM FUEL TANK BOTTOM 12
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. 13
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. 14
SAVE THESE INSTRUCTIONS WORK AREA Mark work area with orange colored safety cones placed in a radius of at least twenty five (25 ) feet from fuel tank cleaning equipment, fuel containers, and fuel tank openings. Place Flammable Liquid Warning Signs within 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 twenty five (25 ) 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. Keep Air Compressor at least twenty five feet (25 ) feet from fuel tank cleaning equipment, fuel containers, and fuel tank openings. PERSONAL SAFETY Stay alert, watch what you are doing and use common sense when operating or maintaining the system. Do not install or maintain the system while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while installing 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 with side shields which comply with current national standards, or when needed, a face shield. This applies to all persons in the work area. Also use non-skid safety shoes, hardhat, gloves, and hearing protection when appropriate. 15