After the long experience and know-how gained during more than a decade providing petroleum services, and after studies conducted by the company research and development team on the problems faced by oil producers; including leakage and corrosion of tank walls and pipelines. Problems related to health, safety, and environment, as well as the problem of storage tanks, shut down for a long time due to the lack of using modern technology for desludging and cleaning crude oil storage tanks.
In 2008, Maayear Global Engineering Petroleum Services developed a unique solution for desludging and cleaning crude oil storage tanks, by manufacturing the first Maayear mobile refinery with an automated, No-Man-Entry system, specially designed to recover sludge and clean large fixed-floating tanks without the presence of personnel inside the tank.
The Maayear high-efficiency robotic system is manufactured according to the latest technologies and to the international HSEQ standards, safe for use in hazardous/explosive atmospheres ATEX CERTIFIED providing a safer work environment for employees and reduces the tank downtime, without the need for staff entrance into a permit-required confined space and with the ability to recover 95-98% of the hydrocarbons present in the composition of the sludge.
It is an automated sys designed for desludging and cleaning crude oil storage tanks; the sys combines cleaning, hydrocarbon recovery, and application of robotic sludge removal technology, which
reduces human risks in hazardous environments, reduces implementation time and process costs, as well reduces the equipment downtime thus enables the customer to reuse the tank is in a record time, and what distinguishes the Maayear (MSRRS) system for automatic sludge recovery is that it is a Closed Loop cleaning
system which greatly reduces the impact of tank cleaning on the environment.
Once the process of Nitrogen purging to convert the tank to gas-free is done; Oxygen is less than 8%, and the Steam Air Pipes, Screw pumps, and Hydraulic fans are installed through the tank roof nozzles. And the personnel install successfully all equipment according to the plan organized by the owner, the operation is
carried out by the control panel located in the office of the trailers in a safe area and at a distance from the tank. A key prerequisite for the installation and operation of the equipment is the use of qualified personnel trained by the company to certify the reliability, efficiency, and safety of the process.
The first stage of the cleaning operation is breaking up and fluidizing the waxy oil through the mechanical action of steam air, screw pumps, and hydraulic fans and by recycling the material within the tank. Next is suctioning the fluidized waxy crude oil from the tank being cleaned using a vacuum pump “with a capacity of 450 tons per hour” to the vacuum tanks, passing it through a filter for filtration and on to heat exchanger in the first trailer and pump it via a filter to the heat exchanger on the second trailer; route it to oil/water separators and the four centrifuges for the further separation process, clean oil is transferred to a storage tank and dirty water is routed to the Sludge tank.
sludge treatment, before the opening of the man-hole; nitrogen purging If the sludge is more than 20cm then the recirculation process continues by the mechanical action of steam air, screw pumps, and hydraulic fans and through sucking the fluidized sludge by a vacuum pump and pass it through the filter to the heat exchanger and pump it back to the tank for recycling and sludge fluidization.
Then the vacuum pump sucks the fluidized sludge to the vacuum tanks, pass it through a filter and on to heat exchanger in the first trailer and pump it through a filter to the heat exchanger on the second trailer and rout it to oil/water separators and the four centrifuges for the further separation process, clean oil is transferred
to a storage tank and dirty water is routed to the Sludge tank.
When the sludge is less than 20cm the Robotic cleaning process starts, a remote control vehicle equipped with a powerful high-pressure water jet (5 sprinklers each 60-70 bar), steam air (10 bar), spiral shovel,
camera surveillance, and lighting systems. (all equipment is ATEX certified) enters into the tank for sediments shoveling and suctioning the sludge for separation processes where clean oil is transferred to a storage tank and dirty water routed to the sludge tank.
In the final stage, nitrogen purging, workers can safely enter the tank for Installing
trusses beneath the tank roof and for the floor, walls, and roof final washing, tank
draining, and delivering the tank clean to the customer for inspection and maintenance.
Dry sludge and final residues are put in drums and handed over to the customer.
Compared with other cleaning techniques, Maayear (M.S.R.R.S) cleaning system is more
capable of cleaning heavy hydrocarbon deposits in large floating and fixed-roof tanks, it is a safe and efficient system and is designed to save 80-85% of the time, recover 95-98% of crude oil and meet the
local and global health, safety and environment standards.
What makes the Maayear system (M.S.R.R.S) unique and distinct from other systems is that the system is carried on three unique trailers which facilitate its transportation. Maayear sludge recovery robot system (M.S.R.R.S) consists of:
Each trailer has an office equipped with control panels through which the system operating units can be operated and modified. It allows human crews to manage the process remotely, which reduces human risks. The system provides the customer with the ability to follow up on the cleaning operations from the trailer’s equipped office or via IPad.
Safety is a top priority feature of the Maayear system (no-man-entry sys), no staff is required inside the tank during the cleaning process.
the Maayear (M.S.R.R.S) sys is carried on three trailers which facilitate its transportation and make it easier to change the equipment to another site as dismantling and installation in a new place takes several days. As well as reduces costs for mobilization and demobilization.
Up to 80% reduction of tank cleaning time.
Safe and Fast.
No venting to the atmosphere