MANWAY CANNON REMOTE CONTROLLED CLEANING SYSTEM

Transcription

1 MANWAY CANNON REMOTE CONTROLLED CLEANING SYSTEM Avoidance of man entry for tank cleaning operations is rapidly becoming standard practice in all European Countries. The Manway Cannon is a remote control tank cleaning system to internally clean tanks remotely, reducing exposure of personnel to a hazardous environment and avoiding entry to confined spaces. The technology is the ultimate for cleaning tanks at refineries, bulk terminals and other chemical and industrial plants. At the heart of the sealed cleaning system, the remote controlled cannon equipped with an ATEX certified low light video camera, lighting system, gas detection and jetting supply pumps. The system is attached to an air tight manway door and is controlled by a technician from the control room. The cannon sprays a diluent to dissolve product deposits and clean the tank, washings are collected and pumped out through a sump while the tank is sealed. The main advantages of the Manway Cannon are gained from the closed cleaning system technology. Safety is enhanced by reduced man entry and exposure to hazardous environments, and legal compliance particularly to The Confined Space Regulations 1997 with an obligation to avoid entry to confined spaces. The closed system ensures operatives and co workers are not exposed to emissions during the tank cleaning operation. Emissions to atmosphere are minimised preventing VOC or product vapour release during the tank cleaning operation. A reduced cleaning duration is also achieved. The Complete cannon system is installed in a specially modified standard ISO 20Ft shipping container. The container is fully certified by Lloyds for shipping by sea. The container is separated into 3 compartments. The control room is fully lined and insulated and comes with heating and air conditioning for operator comfort. The centre compartment houses the hydraulic power pack, umbilical and reel and also the manway cannons. The third compartment is a fully acoustic lined generator room. As well as the generator there is also space for the centrifugal pump to be stored for shipping and transportation.

2 The Manway Cannon is certified for use in zone 1 equivalent area s, all installation work required for cannon operation is done from the outside of the tank to be cleaned. The Manway Cannon is equipped with a low light capability camera with integrated high intensity lighting. The result as shown has meant the incorporation of a fully certified Zone 1 (ATEX Grp2 Cat II) spot light. The Manway Cannon may be inserted though a >14 (305mm) manway opening and has a hydraulic powered sweep of 200 o horizontal and 190 o vertical. Position sensors on the Manway Cannon display accurate graphical representation of position on the control panel mimic. The range of movement on the Manway Cannon allows the cleaning operation to be precise with the cleaning jet directed to the tank wall or the roof. Many refineries and tank farms are also employing the services of this system for internal visual inspections of tanks for damage and content clarification.

3 THE CONTROL ROOM The remote controlled system can be operated safely from the control room by a skilled technician. The operator console is designed for maximum ease of use. The cannon is remotely controlled by a joystick for movement or automatically via the integrated touch screen, graphical display indicates the position of the cannon. All operations can be recorded direct to HDD DVD and the tank is constantly monitored via a gas detection system which will shut the system down should preset levels for LEL be reached. Real time graphical simulation of the cannon allows the operator not only to have the ability to clean with a fully automated system. Insertion and extraction of the cannon from the tank must be done with the cannon pointing straight ahead. The computer generated image allows the operator to remove the cannon from the tank safe in the knowledge that the unit is ready for de mobilisation.

4 THE ENGINE ROOM Hydraulic power unit, umbilical, reels and manway cannons are stored safely within the unit. The Manway cannon is stored on hinged frames either side of the centre compartment access door. This allows the cannons to be swung on their frames through the door ready for removal either by crane or fork truck. Umbilical storage is made easy using the twin stacking hydraulically driven reels. By means of a simple switch operation the reel will either rotate clockwise or counter clockwise. Operators are protected from the chain drives by a stainless steel guard complete with E stop. The centre compartment also contains the mains incoming electrical control panel which can be switched by the operator from local power (on board generator) to shore power (Site power). The unit has a 3 phase incoming power receptacle attached to the panel and a loose mating plug for connection, if required, to a site mains cable. The centre compartment also contains a small access panel, which if removed gives maintenance access to the rear of the generator in the third compartment.

5 The third compartment is fully acoustically lined and insulated with louvers for constant air flow. This room is where the generator is permanently installed. The generator, complete with silencer and fully certified spark arrestor is capable of supplying the power requirements for the complete system. The spark arrestor is fully insulated for safety. A Chalwyn valve is fitted to the generator with the safety handle mounted within a recess on the outside of the container. The centrifugal pump is stored and shipped in front of the generator

6 Summary Benefits Enhanced safety Reduced man entry and exposure of cleaning personnel to hazardous conditions. Cost Reduced timescale i.e. no venting Lowers overall costs Environmental Control of emissions to atmosphere during cleaning and no pre venting of tank required. Process Control by operator or automatic from control room. Ability to use a range of fluids and diluents Mounting on the shell or roof Gas detection Visibility of the tank internals as the work progresses Ability to assess the tank condition at an early stage Specification Generator:100 KVA 415 V 50 HZ Diesel Driven Manway Cannon: All stainless steel with Chemical protection Centrifugal Pump:950 litres/minute (251 USG 18 Bar (261 psi) Diesel or water 80 Deg C Maximum Hydraulic Power:0.75 kw fixed displacement flow controlled. Control: Manual joystick or automatic software control. Gas Detection: Oxygen and LEL detection with alarm and auto shutdown. Container: Acoustic engine compartment, Insulated air conditioned control room Umbilical: Standard 100 Mtr optional 150 Mtr extensions. Cannon operation: Horizontal tank shell or roof operation. CCTV:Real time recording and playback via DVD recorder. Software: Interactive software control and monitoring with graphical representation