TANK WASHING

TECHNOLOGY

CTG TT20 BR

Tank Cleaning Technology

Version: 456B (Abridged)

Index
Preface

page

Common Tank Cleaning Methods

page

Tank Cleaning Devices

page

Cleaning Dynamics

page 11

CIP (Clean In Place) Systems

page 16

Cleaning Validation and CIP Optimization

page 17

Technical Publications
PNR manufactures a complete range of spray nozzles for
industrial applications, as well as products and systems specially
designed for specific industries. Information about our Company
and our product range is available through the following
publications
PRODUCT RANGE

CTG TV BR

GENERAL PURPOSE SPRAY NOZZLES

CTG UG BR

AIR ASSISTED ATOMIZERS

CTG AZ BR

COMPLEMENTARY PRODUCTS
AND ASSEMBLY FITTINGS

CTG AC BR

INDUSTRIAL TANK WASHING SYSTEMS

CTG LS

EVAPORATIVE COOLING LANCES

CTG LN BR

FIRE FIGHTING PRODUCTS

CTG FF

PAPERMILL PRODUCTS

CTG PM BR

STEELWORK NOZZLES

CTG SW BR

SPRAYDRY NOZZLES

CTG SP BR

BR
BR

Our Company has

qualified its Quality
Management System
according to the ISO
9001/2000 Norms.

DNV

Cert. 04111-99-AQ
MIL SINCERT
Copyright: Troy Humphries

Tank Cleaning Technology

Version: 456B (Abridged)

01 - Preface
PNR is active in the tank washing business since 1968 and
developed since then a quite wide product range to cope with the
ever increasing requirements of the industry. The success of each
cleaning process inside a tank depends upon a number of different
factors, each one of them requiring to be carefully considered.
While PNR sales personnel will always give their best advice and
assistance to our Customers, we considered it would be useful
to publish this booklet in order to give our Customers a
comprehensive view into this fascinating technology.
The Science of Tank Cleaning Technology is a culmination of
various disciplines and includes but is not limited to the application
of mechanical function, hydraulics, physics, chemistry, and
instrumentation. The application of these various disciplines for a
given Tank Cleaning requirement will also vary from the simplistic
to the very complex.
The safe, efficient, and economic cleaning of tanks and vessels has
become a major consideration for a number of industries. Today,
less than adequate cleaning can result in...
Off-Spec Products
Lost production
Excessive waste
Excessive energy consumption
Unsafe working conditions
All of these factors can result in lost revenues and in some cases
loss of consumer confidence. The purpose of this paper is to make
you aware of the factors to be considered when analyzing a tank
cleaning requirement. This paper should not be considered
conclusive as the available technologies are ever changing. You
will, however, receive information about various types of cleaning
devices, CIP Design Considerations, Cleaning Dynamics, Validation
Methodologies and more.
Cleaning of vessels and tanks is not a new requirement. In ancient
Egypt, manual cleaning of large wine amphorae was very common.
However, it is amazing that today this method of cleaning is still
quite prevalent. It is estimated that approximately 40% of the tank
cleaning accomplished worldwide today is manually achieved and
another 15%-20% is accomplished inefficiently compared to the
technology available. The primary reason is due to insufficient
knowledge and understanding of today's cleaning technologies.

Tank Cleaning Technology

Version: 456B (Abridged)

02 - Common Tank Cleaning Methods

Most all Tank Cleaning Methods fall into the following categories:
Manual
The process whereby a human being is placed in the tank or
external to the tank and cleaning is accomplished by either
hand/brush or with wash hose (high and low pressure).
Fill and Dump (Floatation)
The process whereby a tank or process vessel is filled with the
required cleaning fluid. Agitation and heat may be applied.
Automated - Portable
The process whereby an automated cleaning device is placed in
the tank; either static or dynamic; then removed after the
cleaning process has been completed.
Automated - Fixed In Place
The process whereby an automated cleaning device is placed
permanently in the tank; either static or dynamic; and is not
removed during process, storage or transportation.

03 - Tank Cleaning Devices

The most optimal cleaning process is the one which brings back
the tank or vessel into satisfactory operating
condition by using:
the shortest possible time
the least volume of cleaning liquid
the least amount of chemicals
the least amount of energy
while at the same time being..,
Reliable
Safe
Economical
To accomplish this, a properly engineered and installed system
along with the proper selection and placement of the
automated cleaning device is imperative.

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

03.01 - Types of Automated Cleaning Devices

Automated cleaning devices fall into the following primary
categories:
Static
Dynamic
Static Devices
Figure 1

Static devices are any cleaning device that does not move and has
no moving parts (Figure 1). Devices within this category are:
Spray Balls
Spray Rings
Static Nozzles
There are variations of these devices in that they can be directional
and vary in their pressure and flow rates. Primary advantages and
disadvantages of these devices are as follows:
Advantages
- Mechanically they are not complicated
- Low purchase cost
- Little to no maintenance required
- Disassembly and inspection process by regulatory authorities is
easy
Disadvantages
- High flow rates compared to other technologies
- Low transference of energy to tank surfaces
- Blockage of cleaning ports more prevalent
- Limited tank size capability
- Validation of device operation is difficult compared other
technologies

Figure 2

Dynamic Devices - RJH Non-Integrated Fluid Drives

(Auxiliary)
Non-Integrated fluid driven rotating jet-heads (RJH) and spheres
are those which require a power source to operate the gear
mechanism other than the cleaning media (Figure 2). In other
words, to rotate the head or sphere a pneumatic, electric, or
hydraulic power source is required.
A rotating jet-head lays a cleaning pattern by rotation of its main
body axis (the horizontal plane) while at the same time rotating its
nozzle hub (the vertical plane). A full 360 degree or directional
indexing can be accomplished (Figure 3).

5
Figure 3

Tank Cleaning Technology

Version: 456B (Abridged)

Dynamic Devices - Rotating Spray Head (RSH)

A rotating sphere is either a rotating ball or disc with strategically
drilled ports or slots for the expulsion of the cleaning fluid (See
Figure 4). An RSH is normally set into rotation by reaction of the
fluid flow against the sphere or disc. As the fluid is discharged
through the device, the reaction of the fluid force will set the ball
of the RSH or disc in rotation. Some rotational values on some
types are controlled; but in most cases it is not.
Advantages
- Good transfer of energy to tank surfaces
- Lower flow rates
- Reduced cleaning times compared to static devices
- Reduced chemical usage compared to static devices
- Normally improved cleaning results compared to static
devices
- Broader range of tank sizes compared to static device

Figure 4

Disadvantages
- Mechanically more complicated
- Higher purchase cost
- Self cleaning can be more difficult to accomplish

Dynamic Devices - Integrated Turbine Fluid Drives

An Integrated Turbine Fluid Drive is powered by the cleaning fluid
that flows through it. In the case of a rotating jet-head (RJH),
normally a turbine is set in rotation by the passing of fluid across
the turbine vanes (See Figure 5). This in turn rotates the turbine
shaft and associated gears. The device is then set into rotation.
Advantages
- Excellent transfer of energy to tank surfaces
- Low flow rates; relative to tank size capabilities
- Reduced cleaning times
- Reduced chemical usage
- Improved cleaning results
- Validation of operation is easy
- Broadest range of tank sizes
- Normally offers the best cost-to-benefit ratio in terms of
cleaning cost.

Disadvantages
- Mechanically more complicated
- Highest purchase cost of all dynamic devices
- Unless properly designed, self-cleaning is difficult

Figure 5

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

03.02 - How Automated Cleaning Devices

Function

Figure 6

Figure 7

2 A shielded or shadow area is the

surface within a tank or vessel that
cannot be projected upon directly
from a given position of the cleaning
device.
3 The track width is the area between
where the center of the jet impinges
upon the tank surfaces and the next
adjacent jet track.

Static Devices
Static devices predominantly clean the host tank or vessel by
cascading the cleaning media on the surfaces of the subject structure.
This is commonly referred to as sheeting. The most common device
used is a spray ball. A spray ball atomizes the fluid flow within a few
centimeters of the device and a dense mist is projected onto a portion
of the subject structure. Solubility of the soil in water or the CIP
solution is relied upon to provide the cleaning action required. There
is little to no impact values onto the surfaces as a whole. Static
nozzles basically accomplish cleaning in a similar way except that they
can offer increased impact and cleaning radius due to nozzle design
but is usually very localized. These devices rely more heavily on fluid
flow, chemical assistance, time, and temperature than dynamic
cleaning devices. However, in many cases, this is all that is required to
place the subject tank or vessel back into a satisfactory operating
condition. Installation of these devices can be accomplished in a
number of ways. The most common for the hygienic industry is the
slip-joint or tri-clamp fitting (See Figure 7). Placement of the static
device is predominantly located in the upper areas of the vessel (See
Figure 6) so that the fluid flow will come in contact with these upper
surfaces, thus allowing gravity to assist in dispersing the media to the
other portions of the vessel. Directional units are available if only a
portion of the vessel is desired to be cleaned. This is many times the
case for open-top tanks or process vessels.
Dynamic Devices - Rotating Jet-Heads (RJH) and Rotating
Spray Heads (RSH)
As the basic cleaning operation of Auxiliary and Integrated Turbine
Fluid Drives are similar, we will not segregate the two in this section.
Rotating Jet-Heads clean the host tank or vessel by projecting a preprogrammed or programmable cleaning pattern on to the internal
structures of the tank (See Figure 3). This pattern is a series of jet
projections onto the vessel structures. Pattern build-up and density
can vary from one manufacturer of the device to another. Complete
cleaning patterns can be developed in as little as 5-6 minutes or as
long as several hours. It is many times not necessary to complete a
pattern in order to render a tank clean. Shielded (shadow) areas2 to
the cleaning device can many times be cleaned with a deflective jet
(See Figure 8). Automatic indexing and the deflective quality of the
jet is the primary advantage of the rotating jet-head over that of the
static device and that of the rotating sphere or disc. The track width3
is cleaned by the jet spread that occurs upon impingement. Rotating
spheres and discs do not develop patterns in the same way as the
RJH. In most cases, these devices project either a vertical or horizontal
sheet or stream of cleaning fluid. The sphere or disc rotates 360

Tank Cleaning Technology

Version: 456B (Abridged)

degrees and projects the cleaning fluid throughout the structure.

Rotating jet-heads, spheres and discs can project onto only a designated
portion of the subject vessel (directional devices) or offer 360 degree
coverage.
Principal factors to be considered in the success of a Rotating JetHead are:
P (Delta P) across the cleaning device.
The differential pressure loss from the entry of the cleaning media to its
exit at the nozzle is an important factor. Should the device consume an
inordinate amount of the hydraulic energy, jet impacts and distances will
be negatively affected. An easy way to check this is to note the start-up
pressure and flow. A lower start-up is a good indication of the RJH
mechanical efficiency and hence less mechanical losses through the
machine. When evaluating input values the following example might
occur:
RJH 1
Pressure @ discharge pump: 6.9 BARG
Pressure @ inlet to RJH:
6.55 BARG
Pressure @ nozzle entrance:
5.17 BARG
P across machine:
1.38 BARG
RJH 2
Pressure @ discharge pump: 6.9 BARG
Pressure @ inlet to RJH:
6.55 BARG
Pressure @ nozzle entrance:
6.2 BARG
P across machine:
0.35 BARG

Figure 8

In this case RJH 2 with its lower P would result in a more efficient transfer of energy. It does not
necessarily mean that RJH 2 would offer an overall better cleaning ability over RJH 1 as number
other factors must be considered.

Machine and nozzle design.

The internal design of the machine and nozzles
has a direct effect on achieving laminar flow when
the fluid exits the nozzle as the jet stream. Laminar
flow will result in a high density jet-stream with
longer distance and impact capabilities resulting
in the reduction of cleaning devices, flow
requirements, and enhancing the ability to clean shielded areas. The
more turbulence created within the cleaning device, the more difficult
the task of achieving optimized laminar flow values. Within an RJH;
turbulence is created but can be minimized with proper design criteria. In
most all designs turbulence is abated primarily within the nozzle hub
(Figure 10) and the nozzle (Figure 9). In the case of smaller nozzle designs
(Figure 11) little to no turbulence reduction will be achieved. This nozzle
body (Figure 10) employs a tangential offset design as opposed to 180
opposite angles. This allows for reduction of turbulence prior to nozzle
entry. The nozzle (Figure 9) employs a tubular bundle or flow straightener
to further reduce turbulence and hence improve laminar flow values.

Figure 9
Figure 10

Figure 11

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

Today, the two most common gear mechanisms used in a Rotating

Jet-Head are the Worm Wheel and Planetary Gear. Both are
effective and proven designs However the external appearance
and production requirements are reasonably different. The Worm
Wheel Design (Figure 13) will typically use approximately 30%+
fewer parts in the construction of the machine compared to the InLine or Planetary Gear (Figure 12) methodology and will typically
have less pressure drop (
P) across the machine. However,
externally the bottom of the machine will require enlargement (bell
shape) to allow for a horizontal shaft in the process of transferring
torque to the drive mechanism. As a result, the Planetary or In-Line
Gear design allows for a smaller profile taking on a cylinder type
of construction and many times reduces the size opening required
for entry of the RJH in to the tank.
Figure 12

The machine designs shown in Figure 13 and Figure 12 are

considered pre-programmed machines. In short this means that a
given cleaning pattern will be developed for a given XYZ location
within the tank being cleaned. Depending upon the gear ratio of
the Fixed Gear (the gear attached to the inlet connection) and the
moving gear typically the one attached to the hub a set
pattern matrix will be developed within the tank. For example;
should the fixed Gear employ 65 teeth compared to the hub gear
that has 63, it will take 65 axial revolutions to make one complete
pattern. After the 65th revolution, and for a given XYZ location
within a tank, the pattern matrix will begin all over again tracing
back over where it originally began. The pattern matrix of a two
nozzle for both a 65/63 and 45/43 gear ratio can be seen below in
Figure 14.

Figure 13

9
Figure 14

Tank Cleaning Technology

Version: 456B (Abridged)

Programmable Tank Cleaning Machines typically will use a single

nozzle design; similar that seen in Figure 15 below.
The cleaning patterns are mechanically programmed to start at a
given point in the tank and indexed based on a chosen degree
inclination per revolution.

Figure 15

A computer controlled tank cleaning machine does exist today in

the form of a product called the CyberJet. The cleaning jet, which
takes the form of a single nozzle machine with retractable down
pipe, is controlled by servos that operate via software working
from a geometrical representation of the tank being cleaned. See
Figure 16 for a visual representation of this device.

10
Figure 16

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

04 - Cleaning Dynamics - The Science of

Tank Cleaning
Jet Peripheral Velocity - JPV (RJH Devices)
The peripheral speed at which the jet-stream is traveling at the
farthest distance from the device is a critical factor, particularly in
larger or more difficult to clean tanks. See the formula in Figure 17
and illustration in Figure 18.

Figure 17

Figure 18

This is the most critical factor to consider when selecting and

applying an RJH to a given tank cleaning requirement.
As a general rule, the following peripheral speeds should be
observed:
Maximum impact requirements
0.15 to 0.45 m/sec
Standard impact requirements
0.45 to 1.5 m/sec
Low impact requirements
1.5 to 2.5 m/sec
Good washing and rinsing requirements
2.5 to 3.5 m/sec
Good wetting requirements
3.5+ m/sec
As the speed of the jet-stream increases, the duration time of the jet
on the surfaces is reduced. Additionally, the jetshear becomes more
prevalent. This serves to degrade the jet-stream and reduce its impact
and distance abilities.
Jet Density + Velocity = Impact.
The density of the jet is controlled by the volume of fluid in the jet and
to an extent by the specific gravity of the cleaning media. Velocity is
relative to the fluid pressure upon entrance to the nozzle and the
achievement of adequate laminar flow upon exiting the nozzle. As we
are dealing with a liquid, too great of a jet velocity will serve to
degrade the jet-stream prematurely. For example, a pressure of 10 bar
at the nozzle entrance where surface impact is 10 m from the
cleaning device will result in a higher impact than that of 30 bar at
the nozzle. Correspondingly, as the surface becomes closer to the
device, impact values will normally increase and higher pressure
values at the machine will become more efficient.

11

Tank Cleaning Technology

Version: 456B (Abridged)

Locating The Cleaning Device

Placement of the Rotating Jet-Head is not accomplished in the
same way as placement of the Rotating Spray-Head or disc. The
rotating sphere or disc is positioned in much the same way as the
static devices. Although these cleaning devices overcome distance
and impact limitations imposed by static devices, it is advantageous
to benefit from the cascading effect when installed in the upper
portion of the tank or vessel. When determining the position of the
rotating jethead, a geometrical study of the host vessel is
recommended.

Placeent Drawing - Profile View

Figure 19

Figure 20

Placeent Drawing - Plan View

Figure 22

Figure 21

12

As the rotating jet-head overcomes limitations of the other devices

mentioned, an improper location can result in less than
satisfactory results. A study of the jet-stream impact angles and
deflection requirements should be made. In doing this the number
of units, time, and flow rates required to accomplish the desired
cleaning can be optimized. See Figure 19, Figure 20, Figure 21
and Figure 22.

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

Validation of Cleaning Device Operation

Validation of operation for static devices and rotating spheres or
discs are for the most part limited to the monitoring of flow
meters, pressure gauges, or ultrasonics. It is difficult to validate that
all the ports of a spray ball are clear or that a rotating sphere or disc
is in rotation. Visual inspection by means of a sight glass is a
reasonably good method. However, in addition to the sight glass
method, a rotating jet-head can have its operation validated by the
rotation of the jet impinging upon a pressure sensor (See Figure
23). This signal can then be interpreted in various ways, subject to
the facility's requirements.

Figure 23

13

Tank Cleaning Technology

Version: 456B (Abridged)

Selection Of The Appropriate Cleaning Device

The selection of the appropriate cleaning device can involve a
number of factors. However, if due consideration is given to the
application, the process can be quite simple. When selecting the
cleaning device consider the following with regards to the
application at hand:
Dimensions and internal structures of the tank or process
vessel?
The size and number of internal structures of the tank or process
vessel will be a major factor in determining the type and quantity
of devices required.
Type of surfaces to be cleaned?
Electropolished stainless steel and glass lined vessels are far easier
surfaces to clean than carbon steel or certain types of coated
tanks. The condition of the lining can also be a factor. This is due
to the frictional resistance of the surface to the cleaning media
and its ability to absorb the product.
Are sanitary conditions required?
Sanitary cleaning devices, in most cases, are more costly and will
utilize more flow than a device that does not consider this
requirement. If you require a 100% self-washing device, make it
known in your cleaning design.
What openings are available for the installation of the
cleaning device?
In the case of new equipment, this consideration is more flexible.
A review of the vessel design can be made prior to construction
and the cleaning requirements determined. Installation is made
easier and usually less costly. However, in the case of existing
equipment, the desired location for the cleaning device may not
be available. This will have a bearing on the device selected and
its operating parameters.
What percentage of shadow4 areas are acceptable?
At present, there are no regulations governing the percentage of
shadow areas for any industry other than marine.
However, it is a factor that should not be overlooked when
selecting the proper cleaning device. This consideration is a
principal factor in determining the number of devices to be used,
the type, or both.

14

4 See footnote 1. A shadow area is the

same as a shielded area.

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

Desired cleaning time?

As production requirements may be a primary factor, the speed
at which the selected device or devices will render the tank or
vessel clean, would be a consideration.
Reason for cleaning?
What required the subject tank or vessel to be cleaned? To
prevent cross-contamination, sterilization, preparation for
maintenance, product recovery, etc.
5 A portable cleaning device is any
device that is placed into the tank or
vessel for cleaning then removed
once cleaning has been accomplished.
The device does not remain in the
vessel during process or storage of
the product.

Is it desired that the cleaning device be permanently

installed or portable?5
The installation assembly and cleaning device can be of different
natures if portable rather than fixed placement is desired. For
example, you may not normally require the device to be fully selfwashing if it is to be installed only for the cleaning process and
then removed.
Type of soil to be removed?
The device selected is largely influenced by the type and
condition of the soil to be removed. As a simple example,
consider the removal of methanol versus the removal of latex.
The methanol can be removed with simple cascading of the fluid
over the surfaces. A spray ball or rotating sphere/disc could be
employed, subject to tank size and capacity.
However, in the case of the latex you would be cleaning a long
time if you used a spray ball or rotating sphere. For latex, it would
be more prudent to use a rotating jet-head at the required
pressures and flows.
Budget considerations; capital cost and operational?
The cost of cleaning devices and their associated systems for a
given application can cost from $150.00 to $1,000,000.00+. The
purchase of the device is only part of the cost. In many cases, if
the proper cleaning system and device are selected, operational
savings can result in a favorable return on investment.
Operating parameters?
Pressure, flow rates, tank/vessel evacuation rates, cleaning media,
operating and at rest temperatures of the cleaning device are all
considerations in the selection process. These criteria will
determine, among others, the construction requirements of the
device.

15

Tank Cleaning Technology

Version: 456B (Abridged)

05 - CIP (Clean In Place) Systems

CIP Systems fall predominantly into the following three categories:
Single Use/Single Pass
Single Use/Recirculatory
Multi-Tank Solution Recovery
As this is an abridged version of this paper we will not go into
the depth required concerning CIP Systems.
However, in general it should be understood, that the CIP
Systems should never be designed until the cleaning
requirements have been determined. It should also be noted that
in addition to the cleaning of the lines, valves and other
associated wetted areas must be considered. This in many cases
could require multi-pumps or multiple pumps to achieve this
requirement. On determination of the in-tank cleaning design,
the in the CIP design process is the formulation of the P&ID
(Piping and Instrumentation Diagram).

16

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

06 - Cleaning Validation and CIP Optimization

Cleaning Validation is the process whereby the desired cleaning
is verified by means acceptable and repeatable for the given
cleaning requirement. CIP Optimization is the process of
streamlining the cleaning process so that operationally the
highest level of efficiency is achieved.
In brief, cleaning validation is accomplished today by the
following means:
Sight
Time and Temperature
Conductivity
Plate Counts
ATP (Adenosine Tri-Phosphate)
Prior to any Cleaning Validation Process, it is generally good
practice to validate coverage by means of establishing rinse
protocols so as to insure that all surfaces that require cleaning
receive the minimal fluid flow requirements. One of the best
methods is the Riboflavin Rinse Validation Process. This method
employs the spraying of a Riboflavin mixture onto the surfaces
to be cleaned and then validating coverage with a long-wave
ultraviolet light. On validation of that coverage the prescribed
cleaning arrangement is started and at set time intervals
checked and recorded until the surfaces are free of the
Riboflavin mixture. Riboflavin is readily miscible with water at
ambient temperatures and very accurately reveals if fluid flow
reaches the required areas of the tank, valves, pipes, and other
areas within the tank or process structure.

Figure 24

Figure 25
Application of Riboflavin Mixture

17

Tank Cleaning Technology

Version: 456B (Abridged)

Figure 26

Figure 27

Validation of Coverage with Long-Wave Ultra Violet Light

18

Figure 28

Figure 29

Photos After Rinsing

www.pnr-nozzles.com

Tank Cleaning Technology

Version: 456B (Abridged)

Once sufficient rinse coverage is established, validating cleanliness

by the taking of a rinse sample can then be considered viable.
Conductivity is a reasonable good way to monitor the absence of
certain fluids within the rinse water but is limited to those fluids
that possess a reasonably good conductivity value. Biologically, one
of the best methods is to measure bio-mass using the ATP
detection method. All organic matter possesses ATP (Adenosine TriPhosphate). When ATP is properly mixed with Lucifern Luciferase a
chemical light is produced that can be accurately read and
recorded by a properly balanced luminometer.

19

www.pnr-nozzles.com

CTG TT20 BR

Our products are distributed through the following Pnr Companies

PNR America
PNR Baltic
PNR Benelux

PNR Czech Republic

PNR Deutschland
PNR Italia

PNR Mexico
PNR Taiwan
PNR U. Kingdom

We are moreover represented in the following countries

Argentina
Australia
Austria
Brasil
Canada
China
Denmark
Finland
Greece

India
Indonesia
Iran
Ireland
Japan
Korea
Nepal
Norway
New Zealand

Pakistan
Poland
Portugal
Singapore
Slovenja
Spain
Sweden
Venezuela