Totus was appointed for the safe removal of 1,000m³ of crude oil tank bottoms from an Oil Terminal as part of a large-scale decommissioning and site repurposing project.
Overview
The tank was selected for demolition, requiring Totus (with the help and support of the onsite safety team) to execute its work in parallel with demolition activities—a task that demanded meticulous planning and coordination in conjunction with the overall site demolition contractor. Key challenges included preventing any release of hydrogen sulphide (H?S) and completing the project without confined space entry; adding significant complexity to the scope.
These strict constraints necessitated innovative solutions, comprehensive risk management, and precise execution to uphold safety, environmental, and operational standards.
Beyond achieving its immediate objectives, the project also served as a testament to Totus’s expertise in handling high-risk industrial projects under stringent conditions, reinforcing its reputation for delivering excellence in safety and efficiency. Some of the project highlights were:
Volume Managed:
1,000m³ of crude oil tank bottoms processed and 1,000 IBC’s delivered to the disposal facility with no environmental incidents.
Innovative Methods:
First-ever use of a carbon filter on a DISAB and a gas detection system for the Byworth Steam Boiler.
Site Client Recognition:
Praised for professionalism, adaptability, and successful project delivery under challenging conditions.
Safety Excellence:
Over 10,000 hours worked without a single lost time incident, demonstrating Totus’s commitment to a strong safety culture.
Environmental Success:
Zero Hydrogen Sulfide releases was of paramount importance. This was achieved through rigorous sampling and strategic system design.
Regulatory Navigation:
Successfully operated under top-tier COMAH site restrictions with direct HSE involvement, highlighting Totus’s expertise in managing high-stakes industrial projects.
Project Design & Implementation
The initial plan involved using an ADR DISAB vacuum system to remove the oil and decant it into IBCs for off-site recovery. However, early investigations revealed that the oil’s viscosity made this approach impractical. Therefore, Totus adapted the methodology to include a temporary 70m³ coiled tank to heat the material for easier processing and ensuring operational efficiency without compromising safety.
Equipment Used:
- DR DISAB with an industry-first carbon filter for ventilation, a groundbreaking innovation to handle high airflow volumes safely.
- H?S suppression system with two strategically placed dosing rigs to maintain a closed-loop system.
- Byworth Steam Boiler, equipped with a gas detection system for safe operation in a zoned area, providing an automatic shutdown feature in case of gas detection.
- 70m³ coiled tank with integrated mixers to facilitate material heating and maintain uniform consistency.
- Hydraulic-driven Molex pump powered by a dedicated power pack for robust material transfer.
- Duplex filter system to manage unexpected solids in the material.
- IBC filling frame for precise and safe packaging of crude oil tank bottoms.
Totus provided detailed technical drawings, risk assessments, and a comprehensive project methodology. This methodology was subjected to rigorous reviews, including HAZID, HAZOP, and environmental risk assessments, and was presented to the Health and Safety Executive (HSE) for approval. A trial was conducted to validate the approach’s safety and effectiveness, ensuring all potential risks were addressed prior to full-scale execution.
Challenges & Adaptation
A significant issue arose due to the unexpected presence of solids in the crude oil tank bottoms, which had not been detected in the initial sampling. This challenge was further complicated by ongoing demolition activities that introduced additional complexity to the material handling process.
Totus quickly adapted by installing a duplex filter system to capture and manage these solids effectively, preventing blockages that could have severely delayed the project.
Additionally, a cleaning schedule for the 70m³ tank was implemented to maintain operational efficiency. Delays were minimised by swiftly adjusting workflows and deploying additional resources as needed; to ensure that the project timeline remained largely unaffected.
Safety & Compliance
With over 10,000 hours worked and zero lost-time incidents, Totus’s strong safety culture proved highly effective. Daily site safety meetings aligned team members on objectives and potential hazards, while a near-miss reporting system encouraged proactive identification and resolution of risks.
Weekly internal audits, alongside periodic client audits, reinforced strict compliance with safety and regulatory standards. Operating on a top-tier Control of Major Accident Hazards (COMAH) site, Totus successfully navigated complex regulations with precision. As a result, the project proceeded without complaints or environmental breaches.
Environmental & Waste Management
The crude oil tank bottoms were processed and packaged into IBC’s, with strict controls limiting on-site storage to a maximum of 100 IBCs at any time. This disciplined approach ensured streamlined logistics management and full compliance with all hazardous material transport regulations.?
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A unique feature of the project was the innovative inline H?S suppression system. Equipped with two dosing rigs and supported by regular H?S sampling conducted by Totus personnel, the closed-loop system maintained continuous effectiveness, preventing any H?S releases. This was a critical environmental achievement.
Positive Outcomes
The project was completed within the site client’s deadline, successfully packaging 1,000 IBCs of crude oil tank bottoms for off-site recovery. The team’s professionalism, adaptability, and technical ingenuity earned high praise from the Project Team.
It also showcased Totus’s ability to overcome complex challenges while delivering exceptional results.
