Challenge: Inefficient Tank Mixing Led to Costly Cleanouts and Lost Revenue
A midstream Oil & Gas producer in North America was facing operational challenges due to the accumulation of Crude Oil Bottom Sediment & Water (BS&W) in its storage tanks. This issue led to reduced working volume, increased downtime, and costly tank cleanouts required by the industry tank inspection API 653. Historically, the client relied on Jet Mixing with Eductors, but the system was inefficient, consuming excessive energy and failing to properly resuspend the bottom sludge. The industry allows a certain percentage of deposition and sediment to be sold as product; the customer was paying to have the tanks cleaned out and sent to a land fill when they could have recouped the majority of these as revenue.
In some cases, tank cleanouts cost over $1 million per tank. Corrosive water buildup was also a concern as it could lead to corrosion on the tank floors, which may lead to expensive tank floor replacements or in a worst-case scenario a crude tank rupture which happened in 2005 in Kallo Belgium. Seeking a long-term solution, the client required an efficient side entry mixer program that could enhance crude oil processing while minimizing downtime and maintenance costs.
Westpower’s Solution: Implementing SPX Flow Swivel Mounted BSER Mixers
To address these challenges, Westpower collaborated with the client to design a customized side entry mixer solution. The project, which started with two tanks in Eastern Canada, has now expanded to eight sites across Canada, with plans to install 10 to 15 mixers annually.
Westpower, in partnership with SPXFLOW and Philadelphia Mixers, provided Swivel Mounted BSER Mixers featuring:
- Advanced Forward Rake Propeller Design for enhanced bottom-to-top rotational flow, ensuring effective crude oil blending.
- Rigid motor mounting
- Mixer Housing c/w Vibration Pads for Accelerometer fittings at bearing locations and mixer housing mounting flange.
- All Transmission and Port Guards have ATEX compliant fasteners [full retention with the Guard or Port Covers].
- Polycarbonate Window in the Transmission Guard Cover to view the belt and provide access to belt for tension checking.
- Shaft c/w tank shut-off is Stainless Steel for increased corrosion resistance.
- Sleeve mounted Bearings for quicker Tank Shut-Off locking action.
- Bearings “grease sealed” ISO / B10 Rated at 60,000 hours.
- Tank Shut-Off Mechanism with Four Bolt Lockable Seal Flange provides a positive lock of the shaft under maintenance procedures.
- Tapered Tank Shut-Off Seats are Stainless Steel for increased corrosion resistance.
- Cartridge Mechanical Seal or Owner/Operator specified mechanical seal.
- Safety Valve at Tank Shut-Off for “proofing” tank shut-off.
Each mixer was carefully selected based on tank service requirements, ensuring that every storage facility received the optimal blending solution to maximize crude oil enhancement, optimizing, and upgrading. Additionally, quick deliveries were required for one location, and SPXFLOW met these tight deadlines.
Outcome: Improved Crude Oil Optimization and Reduced Maintenance Costs
Although the project is ongoing, early indicators suggest that the implementation of Swivel Mounted BSER Mixers will enhance crude oil blending and upgrading while significantly reducing costly cleanouts. The anticipated benefits include:
- Maximized Tank Working Volume: By reducing sediment buildup, the client can fully utilize its storage capacity, increasing efficiency and revenue potential.
- Eliminated or Greatly Reduced Tank Cleanouts: With continuous mixing, the need for costly cleanouts is expected to be significantly minimized.
- Hydrocarbon Recovery: By resuspending bottom sludge, previously trapped hydrocarbons can now be reclaimed and sold as product, enhancing profitability.
Westpower’s expertise in crude oil blending and sediment management, combined with Philadelphia Mixers’ cutting-edge technology, has provided the client with a long-term and operationally efficient solution. This strategic investment will allow the client to meet industry standards while achieving higher crude oil processing efficiency and reduced maintenance downtime.
Westpower continues to work closely with the client, ensuring the ongoing success of the Company-Wide Side Entry Mixer Program.
