Typically, process tanks require thorough cleaning with appropriate fluids to allow for mandatory inspections that ensure the tank’s welds are secure and the tank is suitable for use.

A Spec 1 clean, required by most authorities, involves physically examining the bottom of the tank and its welds to assess durability. Tanks have traditionally been cleaned manually, which is an extremely time-consuming and labor-intensive process that often involves degassing and debulking the tank and manually cleaning it with shovels and high-pressured water. This method also requires maintenance staff to be exposed to high-risk confined space entry, enclosed in the large vessel for prolonged periods of time, putting workers at risk.

This traditional method can cost a business significant time and money and often generates large amounts of wastewater that has to be disposed of using environmental waste companies. With process tanks requiring inspection of bare metal every eight years, the importance of thoroughly cleaning a tank safely and cost effectively while minimizing environmental impact is a critical challenge.

NON-CONVENTIONAL USE OF A CONVENTIONAL FLUID

Having been requested with finding a cleaning fluid solution to dissolve the deposits from a large skim oil tank, the PetroCanada Lubricants team identified CALFLO Cleaning Fluid.

The unique formulation of CALFLO Cleaning Fluid made it an ideal solution to dissolve hydrocarbons and clean the very large skim oil tank. Using state-of-the-art high-pressure pumps and robotic cannons, the fluid was circulated throughout the tank, causing the deposits to break up and gradually dissolve over a period of time. Once the deposits were gone, a first time Spec 1 cleaning of the tank was achieved so that a full inspection of the tank could be completed, meeting regulatory requirements.

Tasked with a challenge from a large oil sands customer, Petro-Canada Lubricants provided a safe and effective product solution for the cleaning of process tanks.

Upon immediate success cleaning various small to midsized process tanks, CALFLO™ Cleaning Fluid was put to its biggest test—a 30,000m³ skim oil tank.

In this project, the benefits of using CALFLO Cleaning Fluid were extraordinary: increased worker safety, reduced environmental impact, less downtime and a lower project cost.

Compared to the cleaning of the same tank two years prior, which was carried out using traditional methods, notable benefits were realized.

Worker safety significantly improved due to a 38% reduction in exposure hours for confined space entry and a 73% decrease in the amount of degassing chemicals used. Water usage also decreased by 62%, resulting in an equal decrease of disposal costs and a reduction in the use of fresh water.

In total, the skim oil tank was cleaned in 19.5 days— 4.5 days ahead of schedule and $578,000 CAD under the estimated budget—with first time Spec 1 cleaning of the tank achieved. The impressive results demonstrate that CALFLO Cleaning Fluid can effectively clean large process tanks, providing significant benefits to users.

- 38% reduction in worker-confined space entry exposure

- 73% decrease in degassing chemicals used

- 62% decrease in water usage and disposal cost

- 4.5 days ahead of schedule

- 35% reduction in cleaning duration

- $578K CAD under budget