Axi MTC HC-300 Installation guide

MTC HC-3000 INSTALLATION,
OPERATING, AND
MAINTENANCEMANUAL
High Capacity Mobile Tank Cleaning,
Fuel Optimization, and Transfer System
AXI.International AXInternational AXIFuel AXIFuel
1.239.690.9589
1.877.425.4239 Toll Free
www.AXI-International.com REV0303HC300010318

1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
1.800.425.4239 Toll Free
www.AXI-International.com
MTC HC-300
High Capacity Mobile Fuel PolishingSystem
The MTC HC-300 Mobile Fuel PolishingSystem is a high capacity system designed to efficiently and safely clean and restore
fuel to pristine condition. Connected to a fuel storage tank as a “dialysis system,” it effectively removes sludge, particulate and
water while restoring, conditioning, and optimizing fuel. The system features isolation valves to allow for continuous operation
while changing filters, as well as an electronic variable frequency drive pump motor speed controller, allowing for a variable flow
rate ranging up to 300GPM.
MTC HC-300 SPECIFICATIONS
1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
1.877.425.4239 Toll Free
www.AXI-International.com
Flow Rate 300 GPM
Primary Filter Four Bag Filter Vessel, Carbon Steel, Davit
arm swing cover, Stainless Steel liner
basket for use with filter bags
Filter Bags Replaceable Filter Bags 5μ – 800 μ
Secondary Filter(s) 2 - CarbonSteel Filter Housing, Quick release
4-Bolt Swing Cover, Drain valve, & Air Vent
Filter Cartridges Particulate Filter 2-30 μ Water Block Filters 5,
10, 30 μ, Absolute Microglass Filters 3-10 μ
Fuel Conditioner Inline 4” Magnetic Fuel Conditioner
Smart Filtration Controller Fully Automated UL508a
SMART Filtration Controller (Optional Digital
Text Readout)
Instrumentation &
Automation
Vacuum Gauges on Primary Filter, Pressure
Gauge on Pump Discharge Pressure,
Gauges on Secondary Filter(Optional AXI
Watect 550, Water Sensor Alarm Module)
Dimensions 96” x 54” x 82”
Ports 4” Inlet, 4” Outlet
Connectors Cam & Groove Fittings with Covers
Hoses 4” - 25 ft Suction Hose
4” - 25 ft Discharge Hose
Skid Powder Coated Carbon Steel, Filter Service
Deck, and 200 Gallon Drip Tray with Drain
Power Required 480V 50/60Hz. 30 Amp Circuit. Three Phase
Pump Blackmer 4”, Sliding-vane, Positive
Displacement, Viton Seals, 15HP Motor,
18.3 FLA
(244 x 137 x 208 cm)
Weight ≈ 5500 lbs (2495 kg)
MTC HC-300 FEATURE:
High Capacity Multi-stage Water Removal,
Particulate Filtration, and Fuel Conditioning
Large Contaminant Holding Capacity
Robust Compact Industrial Design
Liquid-Filled Vacuum and Pressure Gauges
Smart FiltrationSystems Controller
High Flow Rate Vane Pump with High-Efficiency Motor
REV0203HC300010218

1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
1.800.425.4239 Toll Free
www.AXI-International.com
A unique and powerful broad spectrum concentrate for use
in diesel, gasoline, bio-fuel, kerosene, and HFO. Benefits
include:
Enclosure
AFC 705/710 Fuel Catalyst
AXI Watect Water Sensor
Filtration Options
ConnectionType
Dual Inlet Port
MTC HC-300 OPTIONS
REPLACEMENT FILTER OPTIONS
AFC 705/710 FUEL ADDITIVE
Tier 4 Compliant (710 only)
Stablized Fuel up to 12 mo.
Added Lubricity
Improved Combustion
Lower Emissions
Improved Fuel Economy
Extended Engine Life
Extended Filter Life
Removes / Prevents
Carbon Build Up
Prevents Corrosion
Cleans Injection System
MTC HC-300
High Capacity Mobile Fuel PolishingSystem
1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
1.877.425.4239 Toll Free
www.AXI-International.com
Primary Fine Filter Vessel
Secondary Fine Filter Vessel
Discharge Port
Pre-Filter Vessel
Inlet Port
Variable Frequency Controller
Pump& Motor
SMART Filtration Controller
Inline Magnetic Fuel Conditioner
1.
2.
3.
4.
5.
6.
7.
8.
9.
8 79
4321
5
6
Filtration options for bag filters range from 5-800μ.
Contact a sales representative for all available options.
REV0203HC300010218

Table of Contents
General Overview ...............................................................................................................................................................
System Components .........................................................................................................................................................
Pump/Motor .................................................................................................................................................................
Pre-Filter/Water Separator ..........................................................................................................................................
FinalFilter........................................................................................................................................................................
Fuel Conditioner ............................................................................................................................................................
Plumbing ........................................................................................................................................................................
Commissioning/Initial Startup ........................................................................................................................................
Preparations ...................................................................................................................................................................
General Tank Cleaning Procedure ...............................................................................................................................
System Operation ..............................................................................................................................................................
Operating Procedure .....................................................................................................................................................
Phase 1 ...........................................................................................................................................................................
Phase 2 ...........................................................................................................................................................................
Phase 3 ...........................................................................................................................................................................
AFC Fuel Additive ..........................................................................................................................................................
Primary Inspection .............................................................................................................................................................
Checklist .........................................................................................................................................................................
Priming the System ............................................................................................................................................................
Priming Procedure .........................................................................................................................................................
Controller..............................................................................................................................................................................
Maintenance ........................................................................................................................................................................
Preventative Maintenance ............................................................................................................................................
Servicing Pre-Filter/Water Separator ..........................................................................................................................
Servicing Final Filter(s) ..................................................................................................................................................
Saftey Notes ...................................................................................................................................................................
Troubleshooting .............................................................................................................................................................
Filter Chart ......................................................................................................................................................................
Warranty ...............................................................................................................................................................................
Parts/Service ......................................................................................................................................................................
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5
OVERVIEW
SYSTEM COMPONENTS
PRIMARY INSPECTION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC300010318
General Overview
MTC HC-300 Specications
Note: The system is designed to meet environmental standards for safe operation. (Not for use with uids that have a
ash point below 100°F (37.8°C), e.g. gasoline, alcohol, etc.)
Flow Rate ................................................................................
Outline Dimensions.................................................................
SystemWeight.........................................................................
Operating Temperature ..........................................................
Electrical .................................................................................
Pump .......................................................................................
Motor .......................................................................................
Suction Capability ...................................................................
Fuel Conditioner .....................................................................
Inlet ..........................................................................................
Outlet(s) ..................................................................................
Max. Fluid Viscosity ................................................................
Hose Weight.............................................................................
300 GPM (1135.6 LPM)
96”x 54” x 82” (244 x 137 x 208 cm) (H x W x D)
≈ 5500 lbs (2495 kg)
41 - 104°F (5 - 40°C)
480V/50/60Hz/30A/3Ph
4”, Sliding-vane, Positive Displacement, Internal Relief,
Viton Seals
15 HP Three Phase, continuous duty
15 ft vertical lift or 100 ft horizontal run (4” line, primed)
Inline 4” Magnetic Fuel Conditioner
4” Cam Lock Couplings
4” Cam Lock Couplings
5 cS
2.61 lb/ft
OVERVIEW

6
SYSTEM COMPONENTSPRIMARY INSPECTION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC300010318
OVERVIEW
System Components
Control and Safety Devices
• AXI International “Smart Filtration Controller” in electrical sub enclosure – UL 508A listed Industrial Control Panel
• Pump control switch (Off/Manual), weatherproof, key operated
• Alarm Reset --‐ weatherproof push button
• Power available indicator
• Pump running indicator
• Inlet and outlet shut off buttery valves
• Internal pressure relieve valve
• Primary lter high vacuum alarm indicator and system shutdown (vacuum sensors)
• Secondary lter(s) high differential pressure alarm indicator and system shutdown (pressure sensors)
• Pump motor starter with three--pole circuit breaker and contactor
• High system pressure
• High system vacuum
Pump/Motor
• Positive displacement sliding vane pump
• Internal relief valve
• TEFC (Totally Enclosed Fan Cooled)
Pre-Filter/Water Separator
• Single, multi-round bag lter vessels (#2 standard bag size)
• Drain valve on the bottom
• Differential vacuum gauge for vessel
Final Filter
• Dual nal ltration vessels (available with water block or particulate cartridge lters)
• Differential pressure gauge for each vessel
• Pressure switch for each vessel
Fuel Conditioner
• Inline Magnetic Fuel Conditioner eliminates and prevents the formation of sediments that naturally occur in diesel fuel
and bio-blends
Carbon Steel Plumbing
SYSTEM COMPONENTS

7
SYSTEM COMPONENTS
PRIMARY INSPECTION OPERATIONPRIMING CONTROLLERMAINTENANCE
REV0303HC300010318
COMMISSIONING OVERVIEW
Commissioning/Initial Start-Up
Preparations
Before operating the MTC, we recommend determining the amount of contaminants, free water, and sludge in the tank.
AXI International provides a variety of tank sampling equipment, including Sampling Pumps, tubing and bottles, as well as
Tank Samplers (“Bacon Bomb”) – please see our FS Fluid Sampling line of products. Please make sure the samples are
taken from the bottom of the tank (in the deepest spot). Use a stick with “Kolor Kut” paste on the end, reach through the top
of the tank, and place the end of the stick all the way at the bottom of the tank. Kolor Kut paste will show the water level in
the tank, and indicate how much water, and sludge, will have to be removed. Call AXI International for further information
on other fuel sampling equipment.
General Tank Cleaning Procedure
In Fine Filtration Mode, the MTC system is continuously restoring, reconditioning, and returning the fuel back to the tank.
Fine Filtration mode will continuously remove particles as small as 1 micron, utilizing high efciency spin-on lters.
We always recommend keeping a “before” and “after” bottom tank sample for “show & tell” purposes to demonstrate the
improvement of fuel color, clarity, and opacity.

8
SYSTEM COMPONENTSPRIMARY INSPECTION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC300010318
OVERVIEW
OPERATION
System Operation
Operating Procedure
Hoses: The intake/suction hose is a reinforced vacuum hose. The return hose is black or blue/black, non-marking, high
quality, discharge fuel hose. Both hoses are equipped with quick disconnects or Cam & Groove couplings.
1. Attach quick disconnect end of suction hose to the quick disconnect Pre-Filter Inlet Port of the MTC.
2. We highly recommend attaching a “stinger” or pipe (cut at an angle at the end that goes into the tank and is at minimum
the same inner diameter as the suction hose) to the suction hose to reach the lowest part of the tank bottom.
3. Attach quick disconnect end of blue/black discharge hose to quick disconnect Pump Skid Discharge Port (before ne
lters) of the MTC.
4. Place the end of the discharge hose in an appropriate-size container (Phase One only). Try to not agitate the fuel in the
tank and stir up and disperse water and sediment throughout the fuel –this will make it more difcult to remove later on.
5. For Phases Two and Three, place the end of the discharge hose back in the tank as far away as possible from the
suction hose. Ensure that the hose is secured and will not vibrate out of the container when the system is operating.
6. Verify that drain valves are closed and the system is set up in a stable and safe position.
Note: Never restrict the ow on the suction side of an MTC; e.g. by using a smaller ID hose or pipe or attaching the suction
hose to a tting on the tank that has a smaller ID than the hose. This will lead to excessive pump load, noise and ultimately
damage the pump.
AXI recommends 3 phases to successfully polish a fuel tank:
• 1. Bulk water and sludge removal
• 2. Pre-ltration
• 3. Final fuel polishing
This will ensure all water is removed from the fuel, particulate is removed, and the fuel is in an optimal condition. The goal
of Phase One is to remove any free water and sludge on the bottom of the tank without mixing the water into an emulsied
state within the fuel. Start the pump motor and be ready to immediately stop it. The vane pump will start pumping as long as
the system is primed and the suction lift is not excessive. The ow of fuel can be observed in the suction hose. Watch for a
steady ow of fuel into the container. Connect the Discharge Hose to the Pump Skid Discharge Port (before ne lters). It is
also recommended to install a small ball valve on the suction “stinger” to break the vacuum for draining.
Phase 1:
1. Connect a “stinger” to the tank end of the suction hose. The stinger is obtained locally and fashioned according to the
requirements of the particular job. In general, the “stinger” is a piece of PVC pipe cut at an angle to facilitate removal of
water and contaminants, when the “snorkel” is inserted into the fuel tank.
Note: Avoid restricting the ow on the suction side of the system. If it is necessary to use a smaller ID suction hose, a smaller
ID “stinger”, or if the length of the suction hose is increased, reduce pump speed with the Speed Control Dial so that the
vacuum gauge remains in the green color band. The system’s PLC controller will halt system operation automatically if the
suction vacuum exceeds safe limits.
Note: To adjust vacuum settings of MTC HC-300, please contact AXI International.

9
SYSTEM COMPONENTS
PRIMARY INSPECTION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC300010318
OPERATION OVERVIEW
2. Connect the Suction hose to the System Inlet Port.
3. Connect the Discharge Hose to the System Discharge Port
4. Check all connections for integrity.
5. Install a large micron (200µ or larger) bag lter in the Bag Filter Vessel and close vessel securely.
6. Ensure no ne lters are in either of the last two lter vessels.
7. Open the Inlet Ball Valve.
8. Open the Discharge Ball Valve.
9. Insert suction “stinger” into the tank and secure.
10. Insert discharge hose into separate container for disposal (removal of unwanted contaminants).
11. Verify that the “MANUAL/OFF” switch is in the “OFF” position.
12. Connect the system to an appropriate power source.
13. Verify that the Variable Frequency Controller dial is set at 20-30, so that the pump motor will start at lower intial speed.
14. Switch the Smart Filtration Controller circuit breakers to on - the “System Power” light illuminates.
15. Switch the Smart Filtration Controller to “MANUAL” to begin pumping.
16. If the pump does not start, toggle the Variable Frequency Controller Lever switch to “Start”. This will be necessary for
the rst cycle after the Smart Filtration Controller circuit breakers are switched on.
17. Observe System Priming.
18. Check for leaks or other abnormalities.
19. If anything deviates contact AXI International immediately
Phase 2:
After removing the bulk of the sludge and water from the tank into a separate container for disposal, the return hose is now
inserted into the tank, ending Phase One. The goal of Phase Two is to remove any additional free water within the tank and
also remove any large contaminants and sludge. This phase will clean the fuel and should be a precursor to using the more
expensive ne lters (which are higher efciency and cost). It should be noted that meeting required cleanliness codes is
typically not possible with pre-ltering alone. Phase Two is used to extend the life of the ne lters, and remove the worst of
the contaminants, before polishing with ne lters to meet the required cleanliness.
1. Insert blue/black discharge hose into tank as far away from the suction hose as possible. In some cases, it is
recommended to remove the sending unit cover to gain sufcient access to the tank. In some cases, both hoses will
have to be inserted through the same tank ll opening.
2. After verifying that both hoses are properly placed in the fuel tank and that the valves on the MTC system are in the
correct position, switch on the pump and ensure proper fuel ow.
Depending on the amount of contaminant in the tank, we recommend you stop the pump shortly after priming and check for
free water and sludge by draining the water from the bottom of the pre-lter.
Check the sump of the pre-lter periodically for build-up of free water.
3. The MTC should be kept running in the Phase Two recirculating mode until clean fuel samples can be drained from the
pre-lter. Then, switch off the pump for nal polishing.

10
SYSTEM COMPONENTSPRIMARY INSPECTIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC300010318
OVERVIEWOPERATION
Phase 3:
Phase Three is the most important phase in meeting specic cleanliness codes. Unlike the pre-lter, the ne lters typically
use absolute rated media. Absolute lters have a very high efciency and will ensure that fuel leaving the system is clean to
specication and has a low water content. Like previously mentioned, pre-ltering should be performed to remove any large
particulate, water, and sludge. Pre-ltering will extend the life of the ne lters.
1. Connect the Discharge Hose to the Discharge Port (after ne lters).
2. Ensure catridge lters are in the rst and/or second stage of nal lter vessels.
3. Increase pump motor speed as appropriate to continue fuel polishing and fuel restoration process.
4. Limit motor overspeed operations to light load conditions. Motor over speed is when the speed indicator window
indicates greater than the nominal 60 Hz. 60 Hz is the normal “rated RPM speed” of the motor. At 60 Hz, (displayed in
the Speed Indicator Window) Flow Rate will be approximately 300 GPM (attainable with new/lightly loaded lters).
5. Monitor process and change bag lters and lter elements as necessary.
6. Bag lter vessel is equipped with a vacuum gauges. Final lter vessels have pressure gauges to show the pressure
condition of the pump. Differential gauges are installed to show the pressure drop over each lter individually.
7. Now is the time to add AXI International AFC-710 Fuel Catalyst in a dose of 1 : 2500 or 1 gal of AFC-710 for 2500 gallons
of fuel. Higher doses of AFC-710 may be necessary depending on condition of fuel.
Note: System can run with ne lters in one, two, or none of the nal lter vessels. This allows for phasing of the fuel
cleaning process
Note: Pre-lter should always have some type of pre-lter bad in place during operation to extend life of the pump vanes.