Fueltec 955SS User manual
1
Model 955SS
Mobile Fuel Polishing &Tank
Cleaning System
Fueltec Systems LLC 800-511-4918
www.fueltecsystems.com
2
Model 955SS
Diesel Fuel Polishing & Tank Cleaning System
Quality First
SYSTEM INCLUDES:
(6) 1-Micron Parculate Filters (#241004)
(1) 5-Micron Water Separang Coalescer/Filter
(#241024)
(1) 4 OZ Fuel Sampler (#100013)
(1) 12′ x 1-1/2” Supply Hose (#100154)
(1) 12′ x 1” Return Hose (#100502)
(1)Stainless Steel/Teon Separator Cartridge (#241035)
(1) Quick-Disconnect Right Angle Fluid Pickup Tube 40” w/
Fueltec’s BIO-VAC Nozzle
Fueltec Systems LLC 800-511-4918
3
Model 955SS Mobile 2100 GPH Fuel Polishing &Tank Cleaning System
This pneumatic system is designed to safely purify fluids including gasoline, diesel. hydraulic, motor oils, and
jet fuel to meet or exceed the latest engine manufacturer’s cleanliness specifications. Free and emulsified
water can be removed to less than 50 PPM. Particulate matter is removed to one micron.
In use worldwide on:
• Marine– marina storage tanks, gasoline & diesel boats, including US Coast Guard at Guantanamo, Cuba
• Critical Power– Hospital and Data Center generator day tanks and large storage tanks
• Retail Fueling– C-Stores and Truck Stops underground diesel & gasoline storage tanks
• Fleet & Construction Equipment fuel tanks
• Remediation of phase separated ethanol blended fuels
• Aviation Fuel Storage Tanks– Avgas and Jet-A
• Industrial– Hydraulic and lube oils
TECHNICAL SPECIFICATIONS
Chassis Construcon Steel and Aluminum Brite Tread
Filter Housings Stainless Steel
Maximum li 22 feet
Working pressure fuel max. 60 PSI
Pump rated ow rate range 0 –1200 Gallons per hour *
Water Trap two (2) Gallons US
Compressed Air Required: 60 psi at 10-25 CFM
Width: 32” Depth: 47” Overall Height 60”
Pump 1” Air Operated Diaphragm
Inlets/Outlets 1-1/2” Cam-Loc w/ Ball Valves
Hose Supply 1-1/2” x 12’ Return 1” X 12’ each
Vacuum Gauge 2” liquid lled
Sludge Filters 24” Fueltec Bag
Water Coalescer/Separator Fueltec
Water Separator Fueltec
Air Regulator 3/8”
* Flow rates may vary with compressed air supply, lter type and condion, length and size of hoses, and size
and shape of uid pickup and return tubes.
Includes:
(6) 1-Micron Parculate Filters (#241004) • (1) 5-Micron Water Separang Coalescer/Filter(#241023) • (1) 4
OZ Fuel Sampler (#100013) • 12′ x 1” Supply Hose (#100502) • 12′ x 1” Return Hose (#100502) • (1) Stainless
Steel/Teon Separator Cartridge (#241033) • Quick-Disconnect Right Angle Fluid Pickup Tube 1” x 40” with a
BIO-VAC Nozzel(#100191) • Chassis Ground Cable Reel (#100192) •
4
Fueltec Model 955SS 35 GPM / 2100 GPH System for Gasoline & Diesel
• In operation the system pulls fluid from the fuel tank bottom by a vacuum created by the fuel pump.
• A bag type filter is first to remove rust, sludge, and solid contaminates from the tank bottom fluid which
may also contain water.
• The fuel/water mix leaves the fuel pump under pressure and is forced through a filter/ coalescer where
the tiny water droplets are made larger and separate from the fuel. This type of water separator is
commonly used on aircraft jet fuel.
• The Teflon separator prevents the water droplets from traveling with the fuel. The water falls to the
bottom of the water trap.
• A clear sight tube allows you to see the level of the water that has been separated.
• With the system running; you can open a valve and send the water to a waste container and the clean
fuel back to the fuel storage tank.
• The water level in the sight tube stops rising when all of the water has been vacuumed and separated
from the fuel storage tank.
• You can separate and remove one ounce or 1,000 gallons without stopping the system.
Fueltec’s Quality First:
• Stainless steel filter housings to resist the acids found in today's diesel and ethanol
blended gasoline.
• Filtration down to one micron, water removal to less than 100 parts per million.
• Meets engine manufacturers clean fuel requirements.
• Air operated diaphragm fuel pump intrinsically safe for all fuels.
• Static grounding reel for safety in class one areas
• Variable speed control to avoid phase separation or emulsification
The 955SS System has three modes of operation:
1. Bulk Fluid Transfer without Water Separation or Filtration is used when several inches of wa-
ter are measured on the tank bottom. This water can be pumped directly into a container without
wasting filters or having to empty the Separator water trap.
2. Fuel/Water Separation and Filtration mode is used to separate the remaining water and filter the
fuel after the bulk water has been removed.
3. Filtration without Water Separation can be done at a higher flow rate than with water separa-
tion. At 60 psi a sludge buster nozzle will loosen tank bottom sludge then the particulates in suspen-
sion are collected in the bag filter. (see page three)
5
SUCTION HOSE
RETURN TO TANK HOSE
FUEL TANK BOTTOM
SL
CLEAN DRY FUEL RETURNING TO TANK
THROUGH JET NOZZLE
SUCTION INTAKE ON
TANK BOTTOM
SLUDGE BUSTER
OPERATION WITH JET
NOZZLE AT 60 PSI
6
WARNING
This product operates in the highly combusble atmosphere of a diesel or gasoline storage tank.
FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECATIONS
COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT, RESULTING IN SERIOUS INJURY
OR DEATH
1.This fuel polishing system should NEVER BE OPERATED inside a truck cargo body, enclosed trailer, or within y (50) feet of
an operang or hot engine, motor or fuel dispenser.
2. All work must comply with the latest issue of the Naonal Electrical Code (NFPA 70), the Code for Motor Fuel
Dispensing Facilies and Repair Garages (NFPA 30A), and any European, naonal, state, and local code requirements that apply.
3. When servicing unit, use non-sparking tools and use cauon when removing or installing equipment to avoid gener-
ang a spark.
4. To protect yourself and others from serious injury, death, or substanal property damage, carefully read and follow all
warnings and instrucons in this manual.
Warnings and Instrucons
This secon introduces the hazards and safety precauons associated with operang, maintaining or servicing this product.
Before performing any task on this product, read this safety informaon and the applicable secons in this manual, where addi-
onal hazards and safety precauons for your task will be found. Fire, explosion, or pressure release could occur and cause
damage to property, environment, resulng in serious injury or death, if these safe service procedures are not followed.
Preliminary Precauons
You are working in a potenally dangerous environment of ammable fuels, vapors, and uid pressures. Only trained or au-
thorized individuals knowledgeable in the related procedures should operate, inspect, maintain or service this equipment.
Read the Manual
Read, understand and follow this manual and any other labels or related materials supplied with this equipment. If you do not
understand a procedure, call 1-828-212-1141 to locate a qualied technician. It is imperave to your safety and the safety of
others to understand the procedures before beginning work. Make sure your employees and any service contractors read and
follow the instrucons.
Follow the Regulaons
Applicable informaon is available in Naonal Fire Protecon Associaon (NFPA) 30A; Code for Motor Field Dispensing Facilies
and Repair Garages, NFPA 70; Naonal Electrical Code (NEC), Occupaonal Safety and Hazard Associaon (OSHA) regulaons
and federal, state, and local codes. All these regulaons must be followed. Failure to operate, inspect, maintain or service this
equipment in accordance with these codes, regulaons and standards may lead to legal citaons with penales or aect the
safe use and operaon of the equipment. OSHA fall protecon rules apply when working on above ground fuel storage tanks.
7
Prevent Explosions and Fires
Fuels and their vapors will explode or burn, if ignited. Spilled or leaking fuels and used filters cause vapors. All used
filters should be promptly placed in an approved safety container until disposed of.
Even filling air compressor fuel tanks will cause potentially dangerous vapors in the vicinity of the work area.
Working Alone
It is highly recommended that someone who is capable of rendering first aid be present during operation. Familiarize
yourself with Cardiopulmonary Resuscitation (CPR) methods, while working around fuel vapors. This information is
available from the American Red Cross. Always advise other personnel about where you will be working, and cau-
tion them not to activate power tools or engines while you are working with fuel filtration equipment. Use the OSHA
Lockout/Tagout procedures. If you are not familiar with this requirement, refer to OSHA documentation.
Hazardous Materials
Some materials may present a health hazard if not handled correctly. Ensure that you clean hands after handling
equipment. Do not place any equipment in the mouth.
FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECAUTIONS COULD RESULT IN
PROPERTY DAMAGE, INJURY OR DEATH.
FIRE HAZARD!
Do NOT use power tools (Class I Division I and Class I Division II) during the operation or maintenance of equip-
ment. Sparking could ignite fuel or vapors, resulting in fire.
CHEMICAL EXPOSURE HAZARD!
Wear appropriate safety equipment during operation or maintenance of equipment. Avoid exposure to fuel and va-
pors. Prolonged exposure to fuel may cause severe skin irritations and possible burns.
REQUIREMENTS FOR USE
Fueltec fuel polishing and tank cleaning systems are designed for use only by trained personal.
Free training is available at Fueltec’s factory located in Granite Falls, NC USA. Call 1- (800) 511-4918
The operation of Fueltec’s systems must be consistent with NFPA Code 30A, OSHA regulations, And federal, state
and local fire codes, and other applicable local regulations.
OPERATING PRECAUTIONS
NO SMOKING. Extinguish all open flames and pilot lights, such as on RV appliances.
TURN OFF cell phones and other electronic devices to prevent sparks which could cause an explosion or fire.
PERSONAL SAFETY
Stay alert, watch what you are doing and use common sense when operating or maintaining the system. Do not op-
erate or maintain the system while you are tired or under the influence of drugs, alcohol or medication. A moment of
inattention while operating or maintaining the system may result in serious personal injury or death. Dress properly
while operating this system. Do not expose bare skin or eyes to fuels. Prolonged contact with fuel can damage the
skin. Use safety apparel and equipment. Use safety goggles or safety glasses. Also use non-skid safety shoes,
hardhat, gloves, and fall protection when appropriate.
8
SAVE THESE INSTRUCTIONS
WORK AREA
•Mark work area with orange colored safety cones placed in a radius of at least forty(40’)
feet from fuel tank cleaning equipment, fuel containers, and fuel tank
openings.
•Place Flammable Liquid Warning Signs within work area
•Keep work area clean, free of clutter and well lit. Cluttered and dark work
areas can cause accidents.
•Keep children and bystanders away while operating this system. Distrac-
tions can cause you to lose control, so visitors should remain at a safe dis-
tance of at least forty (40’) feet from the work area.
• Be aware of all power lines, electrical circuits, water pipes and other me-
chanical hazards in your work area, particularly those hazards below the
work surface hidden from the operator’s view that may be unintentionally
contacted and may cause personal harm or property damage.
•Be alert of your surroundings. Using your system in confined work areas may put you danger-
ously close to unsafe conditions.
•Keep one or more Fire Extinguishers U.L. rated 10A-80B:C in the work area.
•Keep Air Compressor at least 40 feet (40’) feet from fuel tank cleaning equipment, fuel
containers, and fuel tank openings.
40 .
9
ueltec Systems LLC 828-212-1141
www.fueltecsystems.comWARNING
This product operates in the highly combustible atmosphere of a diesel or gasoline storage tank.
FAILURE TO COMPLY WITH THE FOLLOWING WARNINGS AND SAFETY PRECATIONS
COULD CAUSE DAMAGE TO PROPERTY, ENVIRONMENT, RESULTING IN SERIOUS INJURY
OR DEATH
1.This fuel polishing system should NEVER BE OPERATED inside a truck cargo body, enclosed
trailer, or within fifty (50) feet of an operating or hot engine, motor or fuel dis-
penser.
2. All work must comply with the latest issue of the National Electrical Code (NFPA 70), the Code for
Motor Fuel
Dispensing Facilities and Repair Garages (NFPA 30A), and any European, national, state, and local
code requirements that apply.
3. When servicing unit, use non-sparking tools and use caution when removing or installing equip-
ment to avoid generating a spark.
4. To protect yourself and others from serious injury, death, or substantial property damage, carefully
read and follow all warnings and instructions in this manual.
Warnings and Instructions
This section introduces the hazards and safety precautions associated with operating, maintaining
or servicing this product.
Before performing any task on this product, read this safety information and the applicable sections in
this manual, where additional hazards and safety precautions for your task will be found. Fire, explo-
sion, or pressure release could occur and cause damage to property, environment, resulting in seri-
ous injury or death, if these safe service procedures are not followed.
Preliminary Precautions
You are working in a potentially dangerous environment of flammable fuels, vapors, and fluid pres-
sures. Only trained or authorized individuals knowledgeable in the related procedures should op-
erate, inspect, maintain or service this equipment.
10
Read the Manual
Removing Water Build up and contamination from
gasoline and ethanol blended fuel storage tanks with
Fueltec’s Model 955SS Fuel Polishing System
•In operation the system pulls fluid from the fuel tank bottom by a vacuum created by the fuel
pump.
•A bag type filter is first to remove sludge and solid contaminates from the tank bottom fluid which
may also contain water.
•The fuel/water mix leaves the fuel pump under pressure ( do not exceed 60 PSI) and is forced
through a filter/ coalescer where the tiny water droplets are made larger and separate from the
fuel.
•The Teflon separator prevents the water droplets from traveling with the fuel. The water falls to
the bottom of the water trap.
•A clear sight tube allows you to see the level of the water that has been separated.
•With the system running; you can open a valve and send the water to a waste container
and the clean fuel back to the fuel storage tank.
•The water level in the sight tube stops rising when all of the water has been vacuumed and sepa-
rated from the fuel storage tank.
•Tank Cleaning is Done With No Loss of Product
•A static ground is provided to dissipate static electric build up while pumping fuel.
•One (1) micron bag filters should be used with Gasoline & ethanol blended fuels
11
PART #
• Model 955SS comes with 2 ea. fuel hoses: 1-1/2” X 12’ & 1” X 12’ with cam and
groove fittings.
• This system requires a 25 CFM air compressor and operates at 40 PSI
• Use one micron filter bags for jet fuel and gasoline, one or five micron filter bags for
diesel
DESCRIPTION
181019
100518
HOUSING TOP SEAL BUNA (STANDARD)
TOP SEALS PACK OF 6 EA.
241004
241040
241041
241042
241007
241043
241044
241045
FILTER BAG 1MICRON X 24”
FILTER BAG 1 MICRON X 24” PACK OF 6 EA.
FILTER BAG 1 MICRON X 24” PACK OF 25 EA.
FILTER BAG 1 MICRON X 24” PACK OF 100 EA.
FILTER BAG 5 MICRON X 24”
FILTER BAG 5 MICRON X 24” PACK OF 6 EA.
FILTER BAG 5 MICRON X 24” PACK OF 25 EA.
FILTER BAG 5 MICRON X 24” PACK OF 100 EA.
241024
241039
COALESCER/FILTER FOR 955SS 20 INCH
COALESCER/FILTER FOR 955SS 20 INCH PACK OF 12 EA.
100010 MANIFOLD M-2 FOR ACCESS TO GENERATOR 2 IN. TANK OPENING
211030
PUMP DIAPHRAGM VITON FOR 955SS
100033
100034
FUEL HOSE 1 INCH X 12 FEET
FUEL HOSE 1 INCH X 25 FEET
WITH CAM-LOCK ENDS
12
FUEL TANK SAFETY
•Purge fuel tank (ll airspace inside the tank between any fuel and the top of the tank) with argon or CO2
prior to drilling or sawing holes that penetrate the tank to minimize the risk of explosion.
•Maintain a purged condion while installing ngs on a fuel tank.
STATIC GROUND
Always aach a stac discharge cable from the Fueltec System to the fuel tank being serviced.
The owing movement of ammable liquids like gasoline inside a pipe can build up stac electricity. Non-polar
liquids such as gasoline, diesel, kerosene and light crude oils exhibit signicant ability for charge accumulaon and
charge retenon during high velocity ow. Stac electricity can discharge into a fuel vapor. When the electrostac
discharge energy is high enough, it can ignite a fuel vapor and air mixture. Dierent fuels have dierent ammable
limits and require dierent levels of electrostac discharge energy to ignite.
Electrostac discharge while fueling with gasoline is a present danger at gas staons. Fires have also been
started at airports while refueling aircra with kerosene. The use of a stac discharge cable can help to prevent or
safely dissipate the build up of stac electricity.
13
Drip Pan
Primary Filter Inlet valve 1.
Sludge Filter Housing
Fuel Pump Air Valve 7.
Air Bleed Valve 5.
Stainless Steel
Locking Casters
Fuel Transfer Outlet 3.
Vacuum Gauge
Sludge Filter Inlet Port 1. Pressure Gauge
Filtered fuel return to
tank port 2.
Separated water
Sight Tube
Water Separator
Housing
Pressure Gauge
When gauge reads
20 PSI replace
coalescer cartridge
Stainless Steel
Contaminant Drain Valve 4.
14
Photo above shows selector valve in the
filter only position. The fluid will flow from
the tank bottom, through the primary bag
filter, then out the bottom port, by-passing
the water separator housing.
Use this position when removing
particulates from the fuel after all water
has been removed from the storage tank.
Or for removing bulk water from the fuel
storage tank bottom.
Fluid in
Filtered fluid out bottom right discharge
Fluid in
Filtered dry fuel out top right discharge
Photo above shows the selector valve in the
separate water from fuel position. The will flow
from the tank bottom, through the primary bag
filter, then through the coalescer cartridge
where the tiny water droplets are separated
from the fuel. The clean dry fuel exits the top
port on the separator housing and the
separated water is trapped in the housing
bottom where it can be drained without
stopping the system.
15
Start Up of the System to Service a Fuel Tank
1. Close air bleed valve, contaminant drain valve, and fuel pump air supply valve 7.
2. Install Bag Filter in housing on the right side of the system
3. Prime pump by lling bag lter housing with two gallons of product.
4. Aach 40 psi air supply from outside source to fuel pump air supply valve
5. Aach uid supply hose to bag lter inlet port 1.
6. Aach uid return hose to return ow control valve port 2
7. Aach pickup supply & return tubes to hoses.
8. Adjust air supply regulator to a maximum 40 psi.
9. Aach the Stac Ground to the tank being serviced with the spring clip.
10. Insert fuel return tube into fuel storage tank opening and connect hose.
11. Insert uid supply pickup tube into the tank to a point just under the uid level unl the fuel pump is primed.
12. Open air supply valve 7. only half way unl system is primed and fuel is shown in clear sight tube. Then adjust ow
rate with air valve 7.
13. Open Supply Port Valve 1. full open.
14. Open Return Valve 2. Pump will start to cycle.
15. Fluid should appear in sight tube within three minutes.
16. Cycle pump unl the system is full of clean fuel.
17. Move the uid pickup tube to the lowest poron of the fuel
tank to remove the contaminates only aer steps 1 thru 16
have been completed.
18. Watch sight tube for the presents of water. (water on boom fuel on top)
19. When water level reaches about nine (9”) inches; open contaminant
drain valve 8. and place drain hose into waste container.
20. Control water level in sight tube with drain valve 8. &
return to tank valve 2. (This allows you to send the separated water to a waste container and the cleaned fuel back to
the tank without any loss of fuel)
21. The water level in the sight tube stops rising when all of the water has been vacuumed and separated from the fuel
storage tank.
22. The air operated fuel pump allows you purge the fuel from the system aer tank cleaning is completed. (this this should
be done with the air supply valve 7 open only 1/2 way.)
16
Typical Fuel Tank De-Watering and Filtration:
Underground and Aboveground Fuel Storage Tanks:
•Remove cap or fitting to access tank bottom.
•Test for high (2” +) bulk water level with a Fueltec Sampler.
•Set the System selector valve to filter only position to remove all but the last
inch of bulk water from the tank.
•Attach a fluid pickup tube to the systems supply hose and lower to the tank
bottom through a tank opening.
•Connect supply hose to system’s primary bag filter housing.
•Connect return hose to system’s bottom right discharge port and a waste
container.
•Pump out bulk water.
•Set the System selector valve to Separate Water position.
•Operate the system and observe the separated water level in the water trap.
•Empty the water trap as the system is running; stop operation when water is
no longer accumulating in the trap.
•If suspended particulates are observed in the sight tube after water has been
removed; Set the System Mode to Filter only.
•Use 1 or 5 micron filters for diesel and 1 micron filters for gasoline, jet fuel, &
ethanol blends.
•Operate system until the fuel is clear.
17
WARNING:
Set air pressure regulator not to
exceed forty (40) psi at any time
Air Bleed Valve 6. Swing Bolt Eye Nut (hand tighten)
Sludge Filter Cover
Vacuum Gauge
When gauge reads
15 Hg. Replace
bag filter
Sludge Filter inlet port 1.
Fuel Pump Air Valve
Primary Filter
18
Fabricate suction tubes of the proper length to reach the tank bottom you are servicing.
Suction and return tubes can be fabricated from PVC, Aluminum, Stainless Steel, or iron pipe. Flexi-
ble suction tubes can be made from polyurethane tube, nylon 11 tube, and PTFE (Teflon) tube.
Optional return manifolds are available from Fueltec.
Return Manifold for 2” tank opening is shown with pickup tube inserted.
Supply & Return Hoses… The Systems come with two (2) 1” X 12’ hoses
equipped with cam lock fittings and adaptors.
Pickup tube draws fluid from the tank bot-
tom. Clean dry fuel is returned to tank
through manifold ports.
19
BAG FILTER REPLACEMENy
FILTER BAG SELECTION
Gasoline: 1 micron bag
Kerosene: 1 micron to 5 micron bag
Jet Fuel: 1 micron to 5 micron bag
No. 2 Diesel: 1 micron to 5 micron bag
Note: Fuel tanks with heavy sludge build up will require multiple bag changes.
Do not operate this system without filter bags installed.
1. Open air bleed valve 6., close primary filter inlet valve 1. (page 6)
2. Run fuel pump for 30 seconds to drain housing.
3. Loosen swing bolt eye nuts and remove housing cover.
4. Remove bag filter hold down.
5. Remove and dispose soiled filter bag after each use.
6. Insert new filter bag into housing and seat bag flange on housing baffle plate.
7. Insert filter hold down.
8. Install filter housing cover and swing bolts into slots in cover.
9. Tighten swing bolt eye nuts hand tight then 1/4 turn more. (do not over tighten)
10. Close air bleed valve 6. and open primary filter inlet valve 1. (page 6)
11. Resume operation.
20
1. Stop Fuel Pump
2. Loosen swing bolts and remove
housing cover.
3. Remove 3/8” separator nut
4. Lift out Water Separator with
filter/coalescer inside.
5. Pull filter/coalescer from inside
of the separator cartridge and
discard.
6. Apply Vaseline to new coalescer
O-rings and insert coalescer In-
to separator.
7. Insert new coalescer element
(CF-20), push end over the boss
inside of the separator element.
8. When turned over the coalescer
element should stay inside sep-
arator to aid in alignment when
installing filter into housing.
9. Install the two elements into
housing until 3/8” bolt protrudes
from top of separator.
10.Install 3/8” O-Ring, washer and
nut tighten to 5ft/lbs
11.Before reinstalling cover verify
that O-ring seal (#568-361) is
seated properly and not dam-
aged.
12. Install cover, tighten eye nuts
evenly by hand.
13. Resume operation, check for
any leaks.
Coalescer and Separator Replacement
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