Fueltec Models 950AW Mobile Fuel Tank Cleaning System FITTED W/ ARO PUMP 2017 Fueltec 955SS Fueltec Systems LLC 828-212-1141 www.fueltecsystems.com
Today s diesel engines require aircraft quality fuel. Not to many years ago diesel engines were quite simple, not too efficient, smoked, and burned high sulfur fuel (as much as 5,000 parts per million). The older diesel injection systems only use about 1 2 the fuel pressure modern engines do, and older injectors send the fuel through much larger passages. If there was a little moisture in the storage tank, the high sulfur content killed most of the filter clogging bacteria and fungi. Today s diesel fuel is ultra-low sulfur (15 parts per million) which allows bacteria and fungi to grow rapidly if any moisture is in the fuel storage tank. Today s diesel engines use high pressure, 27,000 to 35,000 psi fuel injectors with tiny fuel passages which are easily clogged with dirty fuel and damaged by water. The days of using grandpa s old style boat or tractor filters on your diesel fuel tank are over. The old style filters and water separators that remove 75% to 99% of the contamination are not good enough for today s diesel engines. Magnets and filter-less devices won't clean fuel to ISO 18/16/13 or remove water to 0.05% Both Caterpillar and Cummins call for fuel to meet or exceed ISO cleanliness levels of 18/16/13 with a water content of less than 0.05% Fueltec s systems meet or exceed these ISO levels with a one micron primary filter, micro-glass filter/coalescer, and Teflon coated stainless steel hydrophobic water separator. Fueltec uses this type of system on aircraft Jet-A or JP-8 Jet fuel. 2
Removing Water Build up and Contamination from Diesel Fuel and Heating Oil Storage Tanks with Fueltec s Model 950AW Fuel Polishing System 950AW Mobile Fuel Tank De-Watering and Filtration System In operation the system pulls fluid from the fuel tank bottom by a vacuum created by the fuel pump. A bag type filter is first to remove sludge and solid contaminates from the tank bottom fluid which may also contain water. The fuel/water mix leaves the fuel pump under pressure ( do not exceed 60 PSI) and is forced through a filter/ coalescer where the tiny water droplets are made larger and separate from the fuel. The Teflon separator prevents the water droplets from traveling with the fuel. The water falls to the bottom of the water trap. A clear sight tube allows you to see the level of the water that has been separated. With the system running; you can open a valve and send the water to a waste container and the clean fuel back to the fuel storage tank. The water level in the sight tube stops rising when all of the water has been vacuumed and separated from the fuel storage tank. Tank Cleaning is Done With No Loss of Product A static ground is provided to dissipate static electric build up while pumping fuel. Five (5) micron bag filters should be used with diesel fuels 3
Removing Water Build up and contamination from gasoline and ethanol blended fuel storage tanks with Fueltec s Model 950AW Fuel Polishing System 950AW Mobile Fuel Tank De-Watering and Filtration System In operation the system pulls fluid from the fuel tank bottom by a vacuum created by the fuel pump. A bag type filter is first to remove sludge and solid contaminates from the tank bottom fluid which may also contain water. The fuel/water mix leaves the fuel pump under pressure ( do not exceed 60 PSI) and is forced through a filter/ coalescer where the tiny water droplets are made larger and separate from the fuel. The Teflon separator prevents the water droplets from traveling with the fuel. The water falls to the bottom of the water trap. A clear sight tube allows you to see the level of the water that has been separated. With the system running; you can open a valve and send the water to a waste container and the clean fuel back to the fuel storage tank. The water level in the sight tube stops rising when all of the water has been vacuumed and separated from the fuel storage tank. Tank Cleaning is Done With No Loss of Product A static ground is provided to dissipate static electric build up while pumping fuel. One (1) micron bag filters should be used with Gasoline & ethanol blended fuels 4
Removing Water Build up and Contamination from Jet A and JP-8 Fuel Storage Tanks with Fueltec s Model 955SS Fuel Polishing System This system is designed for cleaning fuel storage tanks and is not certified to be used for dispensing fuel into aircraft. 955SS Mobile Fuel Tank De-Watering and Filtration System In operation the system pulls fluid from the fuel tank bottom by a vacuum created by the fuel pump. A bag type filter is first to remove sludge and solid contaminates from the tank bottom fluid which may also contain water. The fuel/water mix leaves the fuel pump under pressure ( do not exceed 60 PSI) and is forced through a filter/ coalescer where the tiny water droplets are made larger and separate from the fuel. The Teflon separator prevents the water droplets from traveling with the fuel. The water falls to the bottom of the water trap. A clear sight tube allows you to see the level of the water that has been separated. With the system running; you can open a valve and send the water to a waste container and the clean fuel back to the fuel storage tank. The water level in the sight tube stops rising when all of the water has been vacuumed and separated from the fuel storage tank. Tank Cleaning is Done With No Loss of Product A static ground is provided to dissipate static electric build up while pumping fuel. One (1) micron bag filters should be used with Jet A & JP-8 Fuels CMH HELI-SKIING Canadian Mountain Holidays (CMH), a helicopter skiing company in western Canada owns and maintains thirty 50,000L fuel tanks which require annual cleaning. With Fuel Tec s 955SS mobile fuel polishing system, removing water build up at the bottom of the tank has never been easier. The 955SS removes the water and sediment with virtually no fuel waste. This saves CMH thousands of dollars each year in waste fuel removal costs. If you are in the business of fuel tank cleaning or fuel maintenance, I highly recommend this unit. Brett Lawrence Fuel Systems Supervisor Canadian Mountain Holidays 5
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. TECHNICAL SPECIFICATIONS Model FT 950 AW Chassis Construction Steel and Aluminum Brite Tread Filter Housings Stainless Steel Maximum lift 22 feet Working pressure fuel max. 60 PSI Pump rated flow rate range 0 816 Gallons per hour * Water Trap two (2) Gallons US Compressed Air Required: 60 psi at 8-12 CFM Width: 32 Depth: 47 Overall Height 60 Pump 1 Air Operated Diaphragm Inlets/Outlets 1 Cam-Loc w/ Ball Valves Hose Supply& Return 1 X 12 each Vacuum Gauge 2 liquid filled Sludge Filters 24 Fueltec Bag Water Coalescer/Separator Fueltec Water Separator Fueltec Air Regulator 3/8 * 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. 6
Pneumatic Tank Cleaning Systems Common Replacement Filters, Hose, and Seals 2017 Fueltec 955SS Model 955SS comes with 2 ea. fuel hoses 1 x 12 with cam and groove fittings. This system requires a 25 CFM air at 40 PSI compressor and operates Use one micron filter bags for jet fuel and gasoline, one or five micron filter bags for diesel PART # 181019 100518 241004 241040 241041 241042 241007 241043 241044 241045 DESCRIPTION HOUSING TOP SEAL BUNA (STANDARD) TOP SEALS PACK OF 6 EA. FILTER BAG 1MICRON X 24 FILTER BAG 1 MICRON X 24 PACK OF 6 EA. FILTER BAG 1 MICRON X 24 PACK OF 25 EA. FILTER BAG 1 MICRON X 24 PACK OF 100 EA. FILTER BAG 5 MICRON X 24 FILTER BAG 5 MICRON X 24 PACK OF 6 EA. FILTER BAG 5 MICRON X 24 PACK OF 25 EA. FILTER BAG 5 MICRON X 24 PACK OF 100 EA. 241023 241038 COALESCER/FILTER FOR 950AW 10 INCH COALESCER/FILTER FOR 950AW 10 INCH PACK OF 12 EA. 100010 MANIFOLD M-2 FOR ACCESS TO GENERATOR 2 IN. TANK OPENING 200001 PUMP DIAPHRAGM VITON FOR 950AW, VITON 100033 100034 FUEL HOSE 1 INCH X 12 FEET FUEL HOSE 1 INCH X 25 FEET WITH CAM-LOCK ENDS Fueltec Systems 828-212-1141 PO Box 487, Granite Falls, NC 28630 www.fueltecsystems.com 7 2016 LENZ
FEATURES Stainless steel filter housings to resist the acids found in today's diesel and ethanol blended gasoline. Filtration down to one micron, water removal to less than 100 parts per million. Exceeds ISO particle code of 18/16/13 to meet engine manufacturers clean fuel requirements. Air operated diaphragm fuel pump intrinsically safe for all fuels. INTENDED USE AND OPERATING PRINCIPAL This System is designed to be used with diesel fuel, gasoline, jet fuel, heating oil, kerosene, and ethanol blended fuels for removing water and other contaminants from fuel tanks. The System has three modes of operation: 1. Bulk Fluid Transfer without Water Separation or Filtration is used when several inches of water are measured on the tank bottom. This water can be pumped directly into a container without wasting filters or having to empty the Separator water trap. 2. Fuel/Water Separation and Filtration mode is used to separate the remaining water and filter the fuel after the bulk water has been removed. 3. Filtration without Water Separation can be done at a higher flow rate than with water separation. Generally used to remove particulate in suspension after water separation. 950 AW Mobile Fuel Tank De-Watering and Filtration System In operation the system pulls fluid from the fuel tank bottom by a vacuum created by the fuel pump. A bag type filter is first to remove sludge and solid contaminates from the tank bottom fluid which may also contain water. The fuel/water mix leaves the fuel pump under pressure ( do not exceed 40 PSI) and is forced through a filter/ coalescer where the tiny water droplets are made larger and separate from the fuel. The Teflon separator prevents the water droplets from traveling with the fuel. The water falls to the bottom of the water trap. A clear sight tube allows you to see the level of the water that has been separated. With the system running; you can open a valve and send the water to a waste container and the clean fuel back to the fuel storage tank. The water level in the sight tube stops rising when all of the water has been vacuumed and separated from the fuel storage tank. Tank Cleaning is Done With No Loss of Product 8
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. 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
Primary Filter Inlet valve 1. Stainless Steel Water Separator Housing Filtered fuel return to tank port 2. Stainless Steel Sludge Filter Housing Fuel Pump Air Valve 7. Separated water Sight Tube Drip Pan Locking Casters Contaminant Drain Valve 4. Air Bleed Valve 5. Pressure Gauge When gauge reads 20 PSI replace coalescer cartridge Fuel Transfer Outlet 3. Vacuum Gauge Sludge Filter Inlet Port 1. 11 Pressure Gauge
Photo above shows selector valve in the filter only position. The fluid will flow from the tank bottom, through the primary bag filter, then out the bottom port, by-passing the water separator housing. Use this position when removing particulates from the fuel after all water has been removed from the storage tank. Or for removing bulk water from the fuel storage tank bottom. Photo above shows the selector valve in the separate water from fuel position. The will flow from the tank bottom, through the primary bag filter, then through the coalescer cartridge where the tiny water droplets are separated from the fuel. The clean dry fuel exits the top port on the separator housing and the separated water is trapped in the housing bottom where it can be drained without stopping the system. Fluid in Fluid in Filtered dry fuel out top right discharge port Filtered fluid out bottom right discharge port 12
Typical Fuel Tank De-Watering and Filtration: Underground and Aboveground Fuel Storage Tanks: Remove cap or fitting to access tank bottom. Test for high (2 +) bulk water level with a Fueltec Sampler. Set the System selector valve to filter only position to remove all but the last inch of bulk water from the tank. Attach a fluid pickup tube to the systems supply hose and lower to the tank bottom through a tank opening. Connect supply hose to system s primary bag filter housing. Connect return hose to system s bottom right discharge port and a waste container. Pump out bulk water. Set the System selector valve to Separate Water position. Operate the system and observe the separated water level in the water trap. Empty the water trap as the system is running; stop operation when water is no longer accumulating in the trap. If suspended particulates are observed in the sight tube after water has been removed; Set the System Mode to Filter only. Use 1 or 5 micron filters for diesel and 1 micron filters for gasoline, jet fuel, & ethanol blends. Operate system until the fuel is clear. 13
Air Bleed Valve 6. Swing Bolt Eye Nut (hand tighten) Primary Filter inlet valve 1. Sludge Filter Cover Vacuum Gauge When gauge reads 15 Hg. Replace bag filter Sludge Filter inlet port 1. WARNING: Fuel Pump Air Valve Set air pressure regulator not to exceed forty (40) psi at any time 14
Supply & Return Hoses The Systems come with two (2) 1 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. Optional return manifolds are available from Fueltec. Return Manifold for 2 tank opening is shown with pickup tube inserted. Pickup tube draws fluid from the tank bottom. Clean dry fuel is returned to tank through manifold ports. 15
BAG FILTER REPLACEMENT 1. Open air bleed valve 6., close primary filter inlet valve 1. (page 6) 2. Run fuel pump for 30 seconds to drain housing. 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 6. and open primary filter inlet valve 1. (page 6) 14. Resume operation. FILTER BAG SELECTION Gasoline: 1 micron bag Kerosene: 1 micron to 5 micron bag Jet Fuel: 1 micron to 5 micron bag No. 2 Diesel: 5 micron to 5 micron bag Note: Fuel tanks with heavy sludge build up will require multiple bag changes. Do not operate this system without filter bags installed. 16
Coalescer and Separator Replacement Filter/ Coalescer Water Separator 1. Close fuel pump valve and shut off air supply to system. 2. Open air bleed valve 5., open contaminant drain valve for one minute then close both valves. 3. Loosen swing bolt eye nuts and remove housing cover. 4. Loosen 3/8 hex separator retaining nut. 5. Remove Separator cartridge. (coalescer may come with it) 6. Apply Vaseline to new coalescer o-rings and insert coalescer into separator. 7. Insert coalescer and separator into housing until 3/8 tie-rod protrudes through top of separator. 8. Install 3/8 o-ring, washer, and hex nut onto tie-rod and tighten to 5 ft/lbs. 9. Install housing cover, swing bolts into place and hand tighten eye nuts then 1/4 turn more. ( caution: Do not over tighten eye nuts) 10. Resume operation. 17
Maximum Water Separation & Filtering Connect Return to Tank Hose to Port 2. Connect Pickup Tube Hose to Filter Port 1. Open Valves 1. & 2. Note 3-Way Valve position Fast Filter Without Water Separation Connect Pickup Tube Hose to Filter Port 1. Connect Return Hose to Port 4. Open Valves 1. & 3. Close Valve 2. Fuel will flow through primary filter only. Note 3-Way Valve positions Caution: Do not use this option if water is found in the fuel tank as the fuel and water may become emulsified beyond separation. 18
First Start Up of the System to Service a Fuel Tank 1. Close air bleed valve 6. page 6, contaminant drain valve 8. pages 7, and fuel pump valve 7.. 2. Install Bag Filter as shown on page 9. 3. Prime pump by filling sludge filter housing with one gallon of product. 4. Attach 40 psi air supply from outside source to fuel pump valve 7. 5. Attach fluid supply hose to sludge filter port 1. 6. Attach fluid return hose to return flow control valve port 2. 7. Attach pickup supply & return tubes & manifold to hoses. 8. Adjust air supply regulator to a maximum 40 psi. 9. Attach the Static Ground to the tank being serviced with the spring clip. 10. Insert Manifold into fuel storage tank opening and connect hose. 11. Insert fluid supply pickup tube into the tank manifold to a point just under the fluid level until the fuel pump is primed. 12. Open air supply valve 7. & adjust flow rate 13. Open Supply Port Valve 1. full open. 14. Open Return Valve 2. Pump will start to cycle. 15. Fluid should appear in sight tube within three minutes. 16. Cycle pump until the system is full of clean fuel. 17. Close supply port valve 1. until vacuum gauge reads 12Hg. Then open supply port valve 1. full open. 18. Move the fluid pickup tube to the lowest portion of the fuel tank to remove the contaminates only after steps 1 thru 16 have been completed. 19. Watch sight tube for the presents of water. (water on bottom fuel on top) 20. When water level reaches six (12 ) inches; open contaminant drain valve 8. and place drain hose into waste container. 21. Control water level in sight tube with drain valve 8. & return to tank valve 2. (This allows you to send the separated water to a waste container and the cleaned fuel back to the tank without any loss of fuel) 21. The water level in the sight tube stops rising when all of the water has been vacuumed and separated from the fuel storage tank. 22. The air operated fuel pump allows you purge the fuel from the system after tank cleaning is completed. (this can t be done with an electric pump) 19
23. Observe Vacuum Gauge 3. two minutes after fluid appears in sight tube; The initial Vacuum reading will be determined by the elevation of the supply port 1. relative to the elevation of the fluid level in the tank being serviced. Make note of this first gauge reading. As the bag filter accumulates debris the vacuum reading will increase. When the gauge reading has increased 8 Hg. above the initial reading; the filter bag needs to be changed. 24. Observe the Pressure Gauge. When the gauge reads 22PSI, the coalescer filter needs changing. Use only Fueltec 24 Bag Filters in this System 1 micron. 1M24 #241004 5 micron. 5M24 #241007 Use only Fueltec Filter/ Coalescers in this System CF-10 for the 950AW #241023 CF-20 for the 955SS #241024 Water Separators S11 for the 950AW #241033 S22 for the 955SS #241035 20
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 21
SUCTION HOSE RETURN TO TANK HOSE CLEAN DRY FUEL RETURNING TO TANK THROUGH SHORT PIPE SUCTION INTAKE ON TANK BOTTOM FUEL TANK BOTTOM 22
TANK CLEANING USING THE FUELTEC M-2 SUPPLY & RETURN MANIFOLD ALLOWING SUPPLY AND RETURN THROUGH ONE 2 TANK FITTING TYPICAL ON GENERATOR BASE TANKS SUCTION HOSE RETURN TO TANK HOSE CLEAN DRY FUEL RETURNING TO TANK THROUGH MANIFOLD 1/2 INCH PIPE FUEL PICKUP SUCTION TUBE SUCTION INTAKE ON TANK BOTTOM FUEL TANK BOTTOM 23
CONTAMINATED DIESEL FUEL 2017 Fueltec 955SS 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. 24
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. 25