IPA 9040 Owner's manual

Brand: IPA

Model: 9040

Type: Owner's manual

IPA 9040 is a powerful fuel tank cleaning system designed to remove fine bio-contaminants, algae, rust, water, and dirt from oil tanks, improving fuel quality and restoring cleanliness. It optimizes injector nozzle spray patterns, increasing fuel efficiency and BTU output. This system reduces boiler downtime and service interruptions, extending oil tank life by eliminating costly tank corrosion and leakage.

#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

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.

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.

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. 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.

#9040-8EXT 8

Ft. Extension

Hose

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.

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.

#9042 Fuel

Sample Stick

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.

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!

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 5 bar (70 psi)

MAX. AIR CONSUMPTION

(AT 5 BAR AIR PRESSURE) 700 l/min (25 SCFM)

MAX. FREE FLOW DELIVERY 120 l/min (28 GPM)

INLET AIR 3/8 ” NPT

FLUID INLET AND OUTLET 1 ” NPT Side Ports

WEIGHT 9 Kg. (20 lb)

TROUBLE SHOOTING

SYMPTOM

POSSIBLE CAUSES

SOLUTION

THE PUMP CONTINUES

OPERATING ALTHOUGH

THE OUTLET VALVE IS

CLOSED.

There is a leak at some

point of the outlet circuit.

Worn check valve balls

and/or seats.

Verify and tighten or

repair.

Replace the worn items.

THE PUMP DOES NOT

OPERATE, OR CYCLES

ONCE AND STOPS.

Air valve is stuck or dirty.

Check valve ball severely

worn and wedged in seat.

Disassemble and clean

the air valve.

Replace ball and seat.

THE PUMP OPERATES

ERRATICALLY.

Clogged suction line.

Sticky or leaking valve balls.

Diaphragm ruptured.

Verify and clean the

suction line.

Clean or replace.

Replace diaphragm.

AIR BUBBLES IN FLUID.

Suction line loose or

damaged.

Diaphragm ruptured.

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 12498

www.ipatools.com

888-786-7899 / 845-679-4500 phone / 845-647-8500 fax

9040-Fuel Tank Sweeper-INSTRUCTIONS-v14

IPA 9040 Owner's manual

Brand: IPA

Model: 9040

Type: Owner's manual

Download PDF

report

IPA 9040 Owner's manual

IPA 9040 Owner's manual

Other documents