Crude Oil Tank Cleaning System
Automated crude oil tank cleaning for large storage tanks. A Zone 0 tank cleaning robot enters through the manway, excavates tank-bottom sludge and pumps it to surface units for oily sludge recovery.
Cleaning a crude oil tank should not depend on people working in sludge.
Tank-bottom deposits reduce usable capacity and complicate inspection. Conventional manual cleaning adds confined-space exposure, variable results, prolonged shutdowns and a large waste stream to an already demanding maintenance project.
Explore the West Petroleum approachConfined-space exposure
Flammable vapors, oxygen deficiency, H₂S and engulfment hazards make man-entry a permit-controlled confined-space activity.
Lengthy cleaning cycles
Labor-intensive mobilization and inconsistent removal rates can extend the tank's return-to-service schedule.
Valuable oil leaves as waste
Untreated tank-bottom mixtures increase transport, disposal and downstream reprocessing requirements.
Unpredictable outcomes
Changing sludge properties and limited visibility make productivity and final cleanliness difficult to manage.
Remove bottom sludge. Recover hydrocarbons. Reduce residual waste.
XBSY automated tank cleaning combines a Zone 0 tank cleaning robot with surface transfer, conditioning and oil–water–solids treatment. The robot enters through the manway, excavates and suctions tank-bottom sludge, then pumps it to the downstream process units.
- Zone 0 tank cleaning robot is designed for in-tank sludge extraction where an explosive gas atmosphere may be continuously present. Surface modules follow the site classification.
- Non-entry tank cleaning equipment reduces routine worker exposure inside the tank during tank-bottom sludge removal.
- Pumped transfer to treatment modules moves extracted sludge to the surface system for conditioning and separation.
- Integrated oily sludge treatment produces a hydrocarbon-rich phase, an aqueous phase and concentrated solids for testing, further treatment, owner-approved reuse or disposal.
From tank-bottom sludge to separated streams
This four-stage overview is not an operating procedure. Project-specific process design, settings and control logic remain protected and are finalized through an approved method statement.
Assess & prepare
Tank geometry, stored product, access, sludge data and utilities define the configuration. Isolation, atmosphere testing, inerting where required, and owner-approved HSE controls are prerequisites for deployment.
Excavate & transfer
The tank cleaning robot enters through the manway, excavates tank-bottom sludge and suctions it to the intake. Transfer pumps move the recovered sludge to the surface treatment units.
Condition & separate
Recovered material passes through project-specific coarse separation and, where required, thermal or chemical conditioning before staged phase separation.
Recirculate & verify
Compatible process liquid may be recirculated before the separately agreed final washdown and cleanliness verification scope.
Built around the priorities of tank owners and contractors
The system connects the defined bulk-sludge recovery and treatment stages; owner responsibilities and final-cleaning deliverables are agreed separately.
Reduced personnel exposure
The Zone 0 tank cleaning robot shifts the principal sludge-removal activity away from routine confined-space entry and direct sludge contact.
Recoverable product value
Staged separation is designed to recover oil that would otherwise remain mixed with water and tank-bottom solids.
Lower disposal volume
Concentrating solids and recirculating compatible process liquid can reduce residual solids and off-spec liquid requiring disposal or further treatment.
Vapor-management options
Where specified, closed-transfer and vapor-management provisions can reduce open handling. Emission performance depends on the selected configuration and site controls.
Faster mobilization
A compact modular layout supports efficient transport, installation and adaptation to the available site footprint.
Process visibility
Remote observation and monitored operating conditions support more consistent execution and informed decisions.
Built for large crude oil storage tanks
The system is intended for crude oil tank cleaning on above-ground storage tanks and selected heavy-oil tanks.
Large crude oil storage tanks
Tank-bottom sludge extraction and treatment as a defined stage before separately scoped inspection, repair or a change of service.
Refinery tank farms
Integrated tank cleaning support where shutdown control, oil recovery and waste reduction are critical.
Terminals & depots
Fixed- or floating-roof crude and selected heavy-oil tanks, subject to manway access (typically DN600-class), floor condition, internal obstructions, working radius and hose reach.
Selected heavy-oil tanks
Primary duty is crude-oil tank bottoms. Selected heavy residues may be reviewed separately. Volatile, high-H₂S, pyrophoric or debris-laden service requires additional engineering review.
Compact capacity for field deployment
These values provide an initial basis for discussion. West Petroleum configures the system after reviewing your sludge sample, tank layout and recovered-stream specifications.
Get a Project-Specific Proposal- In-tank robot hazardous-area rating
- Zone 0
- Indicative treatment throughput*
- 5–12 m³/h
- Reference hydrocarbon recovery*
- Typically ≥96%
- Reference wet-sludge volume reduction*
- ≥75%
- Reference residual oil in treated solids*
- <1%
- Reference oil in separated aqueous phase*
- ≤0.3%
- Indicative core-equipment area*
- <80 m²
- Indicative system operating crew*
- Approx. 6 / shift
- Core-module rig-up at a prepared site*
- As little as 5 hours
*Reference values for selected, pre-characterized feed and a defined system configuration—not universal guarantees. The Zone 0 rating applies to the in-tank cleaning robot; surface process and utility modules are selected to the site hazardous-area classification. Throughput depends on viscosity, temperature, solids loading and selected modules. Recovery and recovered-stream values require agreed sampling, test methods and a mass-balance basis. The aqueous phase may require further treatment before reuse or discharge. Area excludes access, safety clearances, auxiliaries and temporary storage. Crew excludes owner and specialist HSE resources. Rig-up time excludes permitting, lifting readiness, utility connection, testing and commissioning.
Separation expertise behind the cleaning system
XBSY automated tank cleaning is backed by solids control, centrifugation, oily sludge treatment and modular process equipment—from sludge recovery to phase separation.
Planning a crude oil tank cleaning project
What tanks can the West Petroleum system clean?
The system is designed for large crude oil storage tanks and selected heavy petroleum storage tanks. Suitability depends on the stored product, manway access (typically DN600-class, subject to site survey), tank-floor condition, internal columns, heating coils, roof legs, sumps, other obstructions, sludge properties and hazardous-area requirements.
Is this non-entry tank cleaning equipment?
The Zone 0 tank cleaning robot handles tank-bottom sludge extraction without routine personnel entry. Entry may still be required for preparation, contingency work, final cleaning or inspection. Every project remains subject to tank isolation, atmosphere testing, inerting where required, permit-to-work, confined-space and site-specific HSE controls.
Is the tank cleaning robot suitable for Zone 0?
Yes. The in-tank tracked tank cleaning robot is designed for Zone 0 hazardous areas. Surface process and utility modules are selected to the site hazardous-area classification. Certification documents can be shared during technical review. A Zone 0 robot rating does not replace tank isolation, atmosphere testing, inerting where required, permit-to-work or other owner HSE controls.
Can the system recover oil from tank-bottom sludge?
Yes. A configured separation train can produce a hydrocarbon-rich phase, an aqueous phase and concentrated solids. Hydrocarbon recovery is typically 96% or higher under defined feed and operating conditions. Project performance, if guaranteed, is established from sludge characterization and an agreed sampling, testing and mass-balance basis.
Is the system suitable for different tank sizes and sludge types?
It is modular rather than one-size-fits-all. West Petroleum selects the cleaning, transfer, conditioning, separation, monitoring and utility modules after reviewing the tank and sludge data for each project.
Does the system deliver an inspection-ready or gas-free tank?
Not unless expressly included in the agreed scope. Tank-bottom sludge removal, removal of pumpable residues, final washdown, manual touch-up, gas-freeing and preparation for visual or NDT inspection are separate project endpoints with different HSE and acceptance requirements.
What safety conditions apply before operation?
The in-tank robot is designed for Zone 0. Surface modules follow the site classification. Operation still requires an owner-approved method statement covering tank isolation, atmosphere testing, inerting where required, grounding and bonding, vapor management, emergency response, and applicable permit-to-work and confined-space controls.
What information is needed for a technical proposal?
Please provide the tank data sheet and general arrangement drawing, dimensions, previous-product SDS, manway details, tank-floor and internal-obstruction information, estimated sludge depth and volume, available sludge analysis, site utilities, hazardous-area classification, target schedule, required cleaning endpoint and destination criteria for each recovered stream.
Start with your tank and sludge data.
Send the tank data sheet, layout, manway details, sludge analysis, hazardous-area classification and required project endpoint. Our engineers will identify preliminary suitability, data gaps and the recommended scope.
