Axi MTC HC-50 Installation guide

MTC HC-50 INSTALLATION,
OPERATING, AND
MAINTENANCE MANUAL
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 REV0303HC50011217

MTC HC-50
High Capacity Mobile Fuel Polishing System
The MTC HC-50 Mobile Fuel Polishing System is a high capacity system designed to efficiently and safely clean and restore
fuel to pristine condition. The MTC HC-50 incorporates a multi-stage filtration process that reconditions, stabilizes and
decontaminates diesel, biofuels, light oils and hydraulic fluids. All MTC HC systems are specifically designed for tanks with
contaminated fuel that require the removal of water, sediment, and sludge accumulation.
MTC HC-50 SPECIFICATIONS
MTC HC-50 SERIES FEATURES:
High Capacity Multi-stage Water Removal,
Particulate Filtration, and Fuel Conditioning
Multiple Discharge and Sampling Ports
Large Contaminant Holding Capacity
Robust Compact Industrial Design
Liquid-Filled Vacuum and Pressure Gauges
AXI Watect Water Sensor
PLC Smart Filtration Systems Controller
1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
1.877.425.4239 Toll Free
www.AXI-International.com
Flow Rate Adjustable 25 GPM to 75 GPM
(94.6 LPM to 284 LPM)
Primary Filter Carbon Steel Pre-Filter Housing
Filter Bags Replaceable Filter Bags 1 – 800μ
Secondary Filter Carbon Steel Filter Housing
Filter Cartridges Particulate Filter 2-30μ Water Block Filters 5,
10, 30μ, Absolute Microglass Filters 3-10μ
Water Separator AXI FP-90 With Drain Valve and Air Vent
Fuel Conditioner LG-X 4000 Inline Conditioner
System Controller Programmable, Fully Automated UL 508A
SMART Filtration Controller with BMS/BAS
Interface and Digital Text Readout (Optional)
Dimensions 59” x 36” x 45” (H x W x D)
Ports 2” Cam & Groove In
2” Cam & Groove Out
Connectors Cam & Groove Fittings with Covers
Pump Power
50 GPM (189 LPM) - 25 SCFM @ 90psi (620.5 kPa)
70 GPM (265 LPM) - 50 SCFM @ 90psi (620.5 kPa)
1/2” Air Hose Connection
(150 x 91 x 114 cm)
Weight ≈ 630 lbs (286 kg)
Not for use with fluids that have a flash point below 100°F (37.8°C).
Air Requirements
Adjustable Flow Rate
Air Driven, Double Diaphram Pump
Hoses 2” - 25 ft (7.6 m) Clear Suction Hose
2” - 25 ft (7.6 m) Discharge Hose
REV0203HC50011217

Filtration options for bag filters range from 1-800μ.
Contact a sales representative for all available options.
Digital Flow Meter
AFC 705/710 Fuel Catalyst
8” Pneumatic Wheels
- Skid Mounted
PLC Controller
MTC HC-50 OPTIONS
REPLACEMENT FILTER OPTIONS
MTC HC SYSTEM INTEGRATION
MTC HC-50
High Capacity Mobile Fuel Polishing System
1.239.690.9589
AXI.International AXInternational AXIFuel AXIFuel
1.877.425.4239 Toll Free
www.AXI-International.com
Water Separator
SMART Controller
Alarm Light
Air Connection
Pre Filter
Cart/Drip Tray
Quick Connect/Disconnect Inlet
(Ball Valve)
Pneumatic Pump
Quick Connect/Disconnect
Discharge Port 1 (Ball Valve)
Quick Connect/Disconnect
Discharge Port 2 (Ball Valve)
Fine Filter
AXI Inline LG-X 4000 Conditioner
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
12
11
10
987
6
1
5
23
4
REV0203HC50011217

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 ......................................................................................................................................................................
5
6
6
6
6
6
6
7
7
7
8
8
8
8
9
11
12
12
13
13
14
15
15
16
17
18
19
20
21
22
REV0303HC50011217

5
OVERVIEWSYSTEM COMPONENTSPRIMARY INSPECTION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC50011217
General Overview
MTC HC-50 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 ................................................................
System Weight .......................................................................
Operating Temperature ..........................................................
Pump .......................................................................................
Fuel Conditioner .....................................................................
Inlet ..........................................................................................
Outlet(s) ..................................................................................
Adjustable 25 GPM to 75 GPM
(94.6 LPM to 284 LPM)
59” x 36” x 45” (150 x 91 x 114 cm) (H x W x D)
≈ 630 lbs (286 kg)
41 - 104°F (5 - 40°C)
Adjustable Flow Rate Air Driven, Double Diaphram Pump
LG-X 4000
2” Cam & Groove
2” Cam & Groove
OVERVIEW

6
SYSTEM COMPONENTSPRIMARY INSPECTION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC50011217
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 (Auto/Off/Manual), weatherproof, key operated
• Alarm Reset --‐ weatherproof push button
• Power available indicator
• Inlet and outlet shut off ball valves
• Internal pressure relieve valve
• Primary lter high vacuum alarm indicator and system shutdown (vacuum sensors)
• Mechanical water separator high water alarm indicator and system shutdown (water sensors)
• Secondary lter high pressure alarm indicator and system shutdown (pressure sensors)
Pump
• Adjustable Flow Rate, Air Driven, Double Diaphragm Pump
Pre-Filter/Water Separator
• Drain valve on the bottom
Final Filter
• Down to 1µ nominal, 3µ absolute, and 5µ water blocking lter
• Pressure gauge
• Isolation ball valves for lter changes
Fuel Conditioner
• Inline Magnetic Fuel Conditioner eliminates and prevents the formation of sediments that naturally occur in diesel fuel
and bio-blends
Black Steel Plumbing
SYSTEM COMPONENTS

7
SYSTEM COMPONENTSPRIMARY INSPECTION OPERATIONPRIMING CONTROLLERMAINTENANCE
REV0303HC50011217
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
The MTC has two different operating modes, providing the operator exibility and time efciency.
In Bypass Mode, bulk water and sludge are removed from the tank into a separate container for disposal. The fuel bypasses
the ne lters, removing free water, sludge, and particulate, as small as 1 micron, from the tank. During this step, the system
is not in a re-circulating mode. The fuel enters through Inlet Port and exits through the Discharge Port 1 (before ne lters)
into a separate waste container. Water and sludge are directly removed from the tank and collected in an appropriate
container for disposal. Next step, while still in bypass mode, put the hose that was in a separate container back into the main
tank to create a kidney loop. This process will further save and extend the life of the spin-on lters, and remove the worst of
contaminants, before polishing with ne lters to meet the required cleanliness.
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 free water and 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
REV0303HC50011217
OVERVIEW
OPERATION
System Operation
Operating Procedure
Hoses: The intake/suction hose is a clear, see-through 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 clear suction hose to the quick disconnect Inlet Port of the MTC.
2. We highly recommend attaching a straight wand 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 Discharge Port 1 of 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 both 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.
Phase 1:
AXI recommends 3 phases to successfully polish a fuel tank. 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 see-through suction hose. Watch for a steady ow of fuel into the container.
1. Connect a “snorkel” to the tank end of the suction hose. The snorkel is obtained locally and fashioned according to the
requirements of the particular job. In general, the snorkel 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 “snorkel”, or if the length of the suction hose is increased, reduce the ow rate so that the vacuum gauge remains in the
green color band.
2. Connect the Suction hose to the Inlet Port.
Note: If your system is equipped with the optional ow meter please make sure to use at least a 400 micron ltration
upstream of the Digital Flow Meter in order to protect the Digital Flow Meter.
3. Connect the Discharge Hose to the Discharge Port 1.
4. Check all connections for integrity.

9
SYSTEM COMPONENTSPRIMARY INSPECTION OPERATIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC50011217
OPERATION OVERVIEW
5. Install a bag lter in the Bag Filter Vessel and close vessel securely
6. Install a lter element in the Final Filter Vessel and close vessel securely
7. Open the Inlet Ball Valve.
8. Open the Discharge Port 1 Ball Valve.
9. Insert suction “snorkel” into the tank and secure.
10. Insert discharge hose into separate container for disposal.
11. Verify that the manual/off/switch is in the “OFF” position.
12. Connect the system to an appropriate power source.
13. Switch the Smart Filtration Controller circuit breakers to on - the “System Power” light illuminates.
14. Switch the Smart Filtration Controller to “MANUAL” and turn on air supply (not included) to begin pumping.
17. Observe System Priming (Suction line is transparent).
18. Check for leaks or other abnormalities.
Phase 2:
After removing the bulk of the sludge and water from the tank into a separate container for disposal and draining the
separator, the return hose is now inserted into the tank. 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. It should be noted that meeting required cleanliness codes is typically not possible with
per-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 many 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 watch the clear suction hose for 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 separator. It may be necessary to depress the air purge valve on top of the
separator after opening the drain valve.
Repeating this process and observing the fuel ow will indicate how long the pump should run before it is necessary to drain
the separator.
3. The MTC should be kept running in the Phase Two recirculating mode until clean fuel samples can be drained from the
separator. Then, switch off the pump for nal polishing.
4. Now is the time to add AXI International AFC-705 Fuel Catalyst in a dose of 1 : 2500 or 1 gal of AFC-7010 for 2500
gallons of fuel. Higher doses of AFC-705 may be necessary depending on condition of fuel.

10
SYSTEM COMPONENTSPRIMARY INSPECTIONPRIMING CONTROLLERCOMMISSIONINGMAINTENANCE
REV0303HC50011217
OVERVIEWOPERATION
Phase 3:
Phase Three is the most important phase in meeting specic cleanliness codes. Unlike the pre-lter, the ne lter 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 2.
2. Switch the Smart Filtration Controller to “MANUAL” and turn on air supply (not included) to begin pumping.
3. If “High Suction” conditions/alarms halt the operation, it is most likely possible to continue operations at a reduced ow
rate.
4. Monitor process and change bag lters and lter elements as necessary.
5. The Bag Filter Vessel has two vacuum gauges. The upper gauge indicates the vacuum loss in the suction line, and the
bottom gauge indicates the total vacuum at the pump inlet. The difference between the two gauges is the vacuum loss
across the lter bag. Replace the lter bag when the difference between the two gauges exceeds 15” Hg. The Smart
Filtration Controller monitors the vacuum level during operation, and will halt the system and illuminate the Alarm light
when the lter bag needs to be replaced.
6. The Final Filter Vessel has two pressure gauges. The difference between the two gauges is the pressure drop across
the nal lter element. Replace the nal lter element when the pressure drop reached 20 PSI. The Smart Filtration
Controller monitors return line pressure during operation, and will halt the system and illuminate the alarm light when
the nal lter needs to be replaced.
7. Water Alarm: If signicant water accumulates in the AXI FP-90 Water Separator, operation will be halted by the Smart
Filtration Controller and the alarm light will illuminate on the Smart Filtration Controller. Using the Water Separator Drain
Valve, drain the water from the Water Separator into an appropriate container, and resume operation.