Reference_-_E_System_Tests_Report_2022_v4f_3.pdf

Operation and Maintenance of Ohmsett Contract E17PC00014

Ohmsett Systems Test Report

Prepared for:

BSEE Contracting Officer’s Representative (COR) Frank Jurado

BSEE Oil Preparedness Division 45600 Woodland Road

Sterling, VA 20166 Email: Frank.Jurado@bsee.gov

Phone: (571) 279-7896

Prepared by:

Applied Research Associates, Inc.

Ohmsett Facility P.O. Box 150

Leonardo, NJ 07737 www.ara.com

(732) 866-7183

Date: October 27, 2022 mailto:Frank.Jurado@bsee.gov http://www.ara.com/

Operation and Maintenance of Ohmsett Contract E17PC00014 i

Table of Contents

1. Requirement

2. System Descriptions and Tests

2.1. Main Bridge Towing System

2.1.1. System Description

2.1.2. System Tests

2.2. Oil Distribution System and Tank Farm

2.2.1. System Description

2.2.2. Tank Farm System Inspection

2.2.3. Main and Auxiliary Bridge Tank Inspection

2.3. Oil Recovery System

2.3.1. System Description

2.3.2. Test Fluids Recovery Tank

2.3.3. Equalization Pit

2.3.4. Equalization Pit Weir Pipe

2.3.5. Surface Oil Management

2.4. Oil Refurbishment System

2.4.1. System Description

2.4.2. System Tests

2.5. Wave Generator and Beaches

2.5.1. System Description

2.5.2. System Tests

2.6. Computer System, Tank Instrumentation, Video System, and Weather Station

2.6.1. System Description

2.6.2. System Status

2.7. Testing Laboratory

2.7.1. Total Petroleum Hydrocarbon in Water—NDIR

2.7.2. Total Petroleum Hydrocarbon in Water—Fluorometric Method

2.7.3. Measurement of pH

2.7.4. Salinity by Refractory Measurement

2.7.5. Salinity by Conductivity Meter

ii

2.7.6. Specific Gravity by Hydrometer

2.7.7. Density by Hand-Held Ultrasonic Densitometer

2.7.8. Surface and Interfacial Tension

2.7.9. Water and Sediment Petroleum

2.7.10. Turbidity

2.7.11. Viscosity

Hazardous Waste Disposal Requirements Report

1. Requirement In response to Contract 14E17PC00014 Task Order E17PD00117 Section 2.8.E, Applied Research Associates, Inc. (ARA) submits the System Test Report as part of the Annual Deliverables requirement, and includes a summary of testing the:

• Main bridge towing system

• Oil distribution system and tank farm, including main and auxiliary bridges leak tests

• Oil recovery system

• Oil refurbishment systems

• Wave generator and beaches

• Computer, electronic instrumentation, and video systems

• Chemistry laboratory to ensure that all analytical systems are functional

2. System Descriptions and Tests Applied Research Associates, Inc. (ARA) Ohmsett staff performed comprehensive assessments of all the systems and developed a detailed list of upgrades and repairs provided in the Facility Upgrade Proposal. The operational status of each subsystem is listed below.

2.1. Main Bridge Towing System

2.1.1. System Description

The Main Bridge, which is the primary bridge, is cable driven and can attain speeds up to 6.0 knots or 10.1 ft/s. The secondary bridges, auxiliary and vacuum, are north and south of the main bridge, respectively, and can be attached to the main drive cable. The design permits the respective bridges to be positioned a relative distance from, and travel at the same velocity as, the main bridge. Flexibility of the bridge location is ideally suited for strategically locating test equipment and instrumentation for documenting the test as defined in experimental designs.

The Bridge Control System includes two DC motors, DC drives, PLC-based controls with sensors, safety switches, warning devices, and a Human Machine Interface (HMI). To provide redundancy, the cable system is driven by two 500-HP DC motors connected to a common shaft with separate encoders for synchronization of the motors.

Four red warning beacons are installed around the deck at access points indicating when the bridge is active and can move at any time. For safety reasons, getting on and off the bridge is prohibited when these beacons are lit.

The bridge can be accelerated from 0 to 6.5 knots in 15.2 meters in a minimum of eight seconds.

In the normal “Stop,” a regeneration sequence is used to decelerate the bridge(s) from 6.5 to 0 knots in 9.1 meters over a period of seven seconds. In an emergency “Stop” sequence, the power is shut off to the motors—a process that could potentially damage the drive system. It is advisable to use slower acceleration rates to reduce the stresses on the equipment.

2.1.2. System Tests

The main bridge towing system, including the cable, was removed during 2021–2022 as a part of the most recent tank refurbishment. The bridge itself was refurbished, including repair to extensive structural damage to the underside of the bridge. The refurbished bridge was reinstalled, and new cables were installed. During initial operation, the new cable appeared to have undergone stretching during a customer test, and it tangled on its spool. The cable and cable system were adjusted and made operational. Going forward, the addition of a strain gauge system to monitor cable tension is recommended for operational integrity and as a safety system.

System tests were conducted following the cable repair including position and speed accuracy measurements as follows:

• Position: The bridge control system moved the bridge from 100 meters to 175 meters;

the actual position was 175.03 meters.

• Speed: North-to-south speed test was conducted with the system set to 0.75 knots; the travel time for the respective test was measured using a stopwatch and for the average velocity of 0.77 knots.

• Speed: South-to-north speed test was conducted with the system set to 0.75 knots; the travel time for the respective test was measured using a stopwatch and for the average velocity of 0.75 knots.

2.2. Oil Distribution System and Tank Farm

2.2.1. System Description

The oil storage tank farm has several tanks used to store various test oils:

• Two tanks at Ohmsett are horizontal, cylindrical, and baffled at the center to form two compartments that are 5,000 gallons each. Each of the four insulated compartments has thermostatically controlled electric heaters. The maximum effective storage capacity is approximately 4,500 gallons but is de-rated to provide headspace for thermal expansion of the oil. The oil level is manually measured by inserting a stick in the top of the tank and measuring the distance to the oil surface (i.e., a well-known process known as “sticking”).

• Four 10,000-gallon vertical steel cylindrical tanks are grouped to the west of the horizontal tanks in the tank farm. They measure 10 feet in diameter and are 18 feet high. All four tanks manifold into a single four-inch feed and fill pipe. Like the horizontal tanks, the vertical tanks are "sticked" by measuring to the oil surface.

• One 2,000-gallon mixing tank is located at the western edge of the tank farm secondary containment area. The tank is designated as Ohmsett #7 and listed on the Navy Tank Inventory #117. The single-walled vertical tank is located on an impervious concrete base that serves as a secondary containment. The tank is used to blend different oils utilizing a vertical mixer that can be piped to the main bridge holding tank for tests.

2.2.2. Tank Farm System Inspection

The oil tanks were thoroughly inspected by an outside firm in September 2021, and although there was a loss in wall thickness due to some isolated pitting in the lower quadrant of the tank, they were still within code. The interiors of the tanks were sandblasted and painted with an epoxy coating system. Tank wall thickness was again measured during September to October 2022, this time by Ohmsett staff, as part of an annual process. The oil distribution system was visually inspected throughout the year and is fully operational at this time. The in-line oil heater and controller were replaced during the past year and are fully functional.

The following future improvements are recommended:

• Installation of tank fluid level gauges (such as Banner ultrasonic gauges). This would enable continuous monitoring of levels for oil usage tracking and minimize the need for manual “sticking” to measure the level.

• Evaluation of the mezzanine between the two horizontal tanks. It is supported by welds on each of the tanks, a grandfathered structural connection that does not comply with current ASME tank code.

2.2.3. Main and Auxiliary Bridge Tank Inspection

Tanks on the Main Bridge and North (Auxiliary) Bridge were visually inspected and do not have any leaks.

It is recommended that an oil flow meter on the main bridge tank be installed on the top of the tank to provide Ohmsett users with the ability to directly measure oil use during testing.

2.3. Oil Recovery System

2.3.1. System Description

As is the case in real-world oil spills, recovered Ohmsett test fluids contain oil, water, and possibly, debris. Combinations of the three can take several forms. A stable oil/water emulsion with finely dispersed solids presents different treatment challenges than oil with free water containing particulates. The Ohmsett oil refurbishment system was designed and used to treat emulsions, emulsions with debris, and emulsions with free water, over a fluid viscosity range between 10 and 50,000 centipoise. Oil recovery depends on the percent of water and debris in the used test fluid and the amount of modified oily substance.

The system includes the following units.

2.3.2. Test Fluids Recovery Tank

A recovery tank with eight compartments is located on the Ohmsett North (Auxiliary) Bridge and is used to accumulate recovered fluid during a test or training. At the bottom of each compartment is a three-way valve with one port connected to a water discharge manifold and the second port to an oil discharge manifold. Following recovery, gravity separates the water and oil, allowing the water to be decanted through the water ports. Switching to the second port, the remaining fluid is allowed to drain to the storage tank or the facilities equalization pits. Operational status is as follows.

• The recovery tank was addressed during the 2021–2022 tank refurbishment project, a process that included painting the tank and replacing the valve manifold. The recovery tanks are fully operational.

2.3.3. Equalization Pit

Oil is recovered from the test basin surface using an overflow weir at the northeast corner of the tank and collected in a two-compartment concrete holding tank. A compartment dividing wall is 54 inches tall and can be used as an overflow weir. The two holding tanks formed by the wall are referred to as the North and South Equalization Pits. Each pit can hold 5,000 gallons of fluid.

Operational status is as follows.

• During the past year, restoration of the reinforced concrete walls of the pit was completed during the tank refurbishment project, and the walls were painted with durable, oil-resistant epoxy. The pits are fully operational.

2.3.4. Equalization Pit Weir Pipe

Oil released in the test basin and not recovered during a specific test is transported to the north end of the basin for removal from the tank. A manually operated pipe weir located in the northeast corner of the test basin is then used to skim the oil into equalization pits. Operational status is as follows.

• The weir pipe is operational and leak free, but the swing pipe used to direct the recovery oil to the respective pit has a leaking swivel joint that allows tank water into the oil separation pits. Although the extra water requires additional processing time, the system is operational. The swivel joint should be replaced at some future time, e.g., the next time the tank is drained.

2.3.5. Surface Oil Management

Surface oil is managed using an oil curtain deployed from the North (Auxiliary) Bridge to sweep the water surface and collect the oil at the north end of the tank. Spray nozzles and fire monitors are used the move the oil to the equalization pits for possible disposal or to a drum skimmer for collection. Operational status is as follows.

• New sidewall wiper seals were installed on the North (Auxiliary) Bridge during tank refurbishment and are working well with the new smooth tank walls.

• The oil containment curtain system was updated, and a motorized hoist system was installed during the tank refurbishment project. The mechanical system is fully operational.

2.4. Oil Refurbishment System

2.4.1. System Description

Using new test oil for each test could potentially waste resources and lead to higher costs to Ohmsett clients. As an alternative, used refined oils are processed to remove dirt, debris, and water, thereby allowing the fluids to be available for other testing or training activities. Ohmsett refined oils can be refurbished up to three times using one or more of the following processes.

• Settling: The used fluid is allowed to separate gravimetrically from the water by remaining in a separation tank.

• Heating: The fluid is heated in a series of electrical coil heaters to reduce the viscosity and to promote separation of any oil/water emulsion. The oil is tested in Ohmsett’s lab and, if appropriate, sent back to the tank farm for reuse. Recovered water is discharged back into the test basin.

For estimating purposes, about 0.75 cubic meters per hour of No. 2 fuel oil or about 0.57 cubic meters per hour of heavier lube oil can be processed to bring the water content below 0.2%. A testing customer who chooses to use stock Ohmsett oil, when available, will be responsible for the cost of returning the oil to its original condition and the cost of oil replacement due to losses through use and reprocessing. Users who authorize purchase of new test oils and desire reprocessing before reuse will also be assessed reprocessing costs. Reprocessing is done for approximately 38% of new oil cost. Crude oil is not suitable for re-use and is disposed of in accordance with environmental, health, and safety guidelines.

Test fluid that cannot effectively be removed from the test water is authorized to be used in the tank. Hazardous waste disposal costs are the financial responsibility of the tank users as a part of funded task orders.

Oil and oily emulsions are pumped from the equalization pits to the tank farm, where they are separated using heat and gravity, as discussed above.

Because debris in the oil may include a variety of fine particulates that could be blown into the test basin, a fine mesh screen is used to filter out particulates greater than approximately 1/8 inch during oil transfer. To maintain a sufficient process flow, this filter should be cleaned when a pressure differential of 20 pounds per square inch (psi) occurs. After close monitoring of the processed oil’s physical characteristics (viscosity, surface/interfacial tension, and density), oils are either retained in the tank farm for re-use or disposed of through a local recycler.

2.4.2. System Tests

The oil refurbishment system is fully operational.

2.5. Wave Generator and Beaches

2.5.1. System Description

A key feature of the Ohmsett test facility is the wave generator. Waves are generated at the south end of the tank via two articulated wave flaps that pivot on the bottom, while the top is moved by dedicated hydraulic pistons. Displacement of the hydraulic piston, and the subsequent creation of waves, are controlled by a computer for the generation of sine waves, harbor chop, and more complex waves.

An adjustable wave attenuating beach system is located at the north end of the tank. With the beaches raised, wave energy is dissipated to reduce reflections. When the beach is lowered, wave energy is nearly completely reflected off the concave north wall.

2.5.2. System Tests

The beach was removed and reinstalled following the refurbishment of the reinforced concrete tank this past year. A new, safer system to raise and lower the upper beach section was also installed. The beaches can be raised and lowered manually at the present time; lifting winches have been unavailable but will be installed as soon as possible.

The PLC wave generation control system was updated over the past year to replace end-of-life (discontinued) components. The PLC system is functional, but the current system is outdated and is the subject of discussion.

The wave flaps were removed, sandblasted, painted, and reinstalled over the past year.

2.6. Computer System, Tank Instrumentation, Video System, and Weather Station

2.6.1. System Description

The user computer systems, servers, and networking equipment were purchased in 2019 to support staff computing needs, data collection on the tank and in the laboratory, and data storage on the server in the main building.

The electronic instrumentation data acquisition and analysis system at Ohmsett is a Windows PC-based system with LabVIEW software user GUI interface and related data acquisition hardware (primarily National Instruments). The primary sensors include ultrasonic wave height sensors and bridge position/speed sensors, which are digitized and logged on the computer system in the

Bridge and/or Tower control rooms. During data acquisition, the staff monitors the data as it is displayed on the LabVIEW interface, and it is logged on hard disk. The stored data file can be retrieved for analysis in Excel or Matlab, for example. Near real-time analysis of the test results are often used to determine which of the later tests in a series will be carried out or modified.

To support the Ohmsett scientific mission of providing a consistent and accurate weather database, the facility’s weather station includes the following:

• Campbell Scientific Inc. (CSI) CR6 datalogger and support software

• Volt 16 CDM

• Multi-section weather station tower, 30-feet total height

• Setra 278 barometer

• Temperature/relative humidity probe

• METSPEC 10 plate solar radiation shield

• TE525 Rain gage

• Solar radiometer

• Apogee Digital thermopile pyranometer

• Gill 2-D sonic wind sensor

2.6.2. System Status

• Computers: As approved by BSEE, the Ohmsett computer system was transitioned to

ARA IT systems that meet relevant DFARS requirements in mid-2022.

• Servers: Servers have enough storage, and all user computers are operational and effective. All networking equipment is functional and sufficient for the facility.

• Tank Instrumentation: The R-26 tower instrumentation computer, operating system, and data acquisition software are outdated but operational. Replacement will require updating and installing LabVIEW measurement automation software and replacing association data collection hardware. Some data collection hardware and cabling are obsolete. ARA recommends replacing the data acquisition hardware, updating the LabVIEW data acquisition software and displays, and implementing a capability to monitor additional sensors in the tank farm, filter house, wave generator room, etc.; a proposal will be submitted to address these issues.

• Video: The Ohmsett video systems are functional but outdated and less than optimal.

Camera housings are weathered, have reduced video quality, and are in need of replacement. The video control system is functional but generally will not support newer equipment. Additional wired underwater cameras are needed to increase live test monitoring and viewing. Facility-monitoring cameras require upgrade or replacement to restore and increase utility. Additional camera placements are being considered for enhanced site operation. Networking setup and configuration of IP cameras is required to provide customers with remote viewing, both onsite and offsite.

2.7. Testing Laboratory

The Ohmsett facility laboratory provides the capability for various physical and chemical analyses to be performed in support of operations and testing programs. These analyses support specification verification of raw materials, QA/QC of testing and research activities, analysis of samples, and small-scale pilot proofing of procedures and processes prior to large-scale programs in the test basin. There are a number of laboratory-based instruments and systems. A description of function, operational readiness, and necessary upgrades or repairs follows.

2.7.1. Total Petroleum Hydrocarbon in Water—NDIR

This method includes the measurement of solvent-extractable hydrocarbons from fresh and saline waters, as well as industrial and domestic aqueous wastes. It employs a non-dispersive infrared analyzer (NDIR), the Horiba OCMA-500. It also involves standard “wet chemistry” techniques and vessels for sample preparation through quantitative solvent extraction. Presently, the Horiba OCMA-500 is operational and located at its own workstation in the laboratory. Ancillary apparatus and the necessary solvents for extraction, dilution, and cleaning are maintained in inventory.

2.7.2. Total Petroleum Hydrocarbon in Water—Fluorometric Method This method includes the measurement of solvent-extractable hydrocarbons from fresh and saline waters, as well as industrial and domestic aqueous wastes. As opposed to the NDIR method described above, this method uses fluorescence to determine the presence and concentration of total petroleum hydrocarbon in water. The method meets the requirements of EPA Test Method 1664 and uses a Turner Designs TD-3100 laboratory fluorimeter, as well as ancillary apparatus and the necessary solvents for extraction, dilution, and cleaning. The TD-3100 is operational and located at its own workstation. All required solvents are maintained in inventory.

2.7.3. Measurement of pH

Measurement of pH as it relates to hydrogen ion activity was performed using an Orion 3-Star Plum pH Meter. This instrument recently failed and is in the process of being replaced. Fresh cleaning and reconditioning solutions, and pH buffers (standards) are maintained in inventory for calibration as needed.

2.7.4. Salinity by Refractory Measurement

Tank water salinity may be determined by measuring the refractive index at a standard temperature. Two Atago 2442 refractometers are kept in the laboratory cabinets to use for this analysis. Salinity standards are maintained for calibration as needed.

2.7.5. Salinity by Conductivity Meter

Tank water salinity and specific conductivity may be determined by measuring the conductivity of a water sample using a YSI Model 30 Conductivity/Temperature meter. The meter is kept in the laboratory cabinets for this analysis. Salinity standards are maintained for calibration as needed.

2.7.6. Specific Gravity by Hydrometer

A set of hydrometers, a measuring cylinder, and specific gravity standards are kept in the laboratory for this analysis. This method is used only as backup validation of other methodologies.

The set of hydrometers should be supplemented to cover a full range of specific gravities.

2.7.7. Density by Hand-Held Ultrasonic Densitometer

The density of liquids at room temperature is measured using a handheld Mettler-Toledo Model 30-PX densitometer. Two densitometers are kept in the Ohmsett laboratory, and both are fully operational. In addition, fresh density standards are also maintained in inventory to affect calibration.

ARA recently purchased a Mettler-Toledo Excellence D4 digital densitometer that offers fast measurements with automatic temperature control from 0°C to 95°C, and accuracy of up to

0.0001 g/cm³.

2.7.8. Surface and Interfacial Tension

A Fisher Model 20 tensiometer is located at its own workstation in the laboratory. This instrument employs a DuNouy Ring method to determine the surface tension of a liquid at its interface with air. The instrument may also be used to measure the interfacial tension between two immiscible liquid phases. Calibration is accomplished through a mechanical process of comparison to a known torsion standard. A new DuNouy Ring was recently obtained.

2.7.9. Water and Sediment Petroleum

This method involves a solvent extraction and centrifugation technique to determine the total volume of water and solids in a petroleum sample. A centrifuge is kept in the laboratory to affect this analysis. In addition to the centrifuge, a number of centrifuge tubes and specific solvents are kept in the laboratory. All equipment is maintained in good working order. No direct calibration is necessary.

2.7.10. Turbidity

Liquid turbidity is measured on a scale of 0 to 1000 Nephelometric Turbidity Units (NTU). An Oakton/Eutech Instruments T-100 portable turbidimeter is kept in the laboratory for this measurement. The instrument is in good working order, and fresh calibration standards are maintained.

2.7.11. Viscosity

To measure the viscosity of liquids and perform basic rheological determinations, a ThermoFisher Haake Viscotester iQ Air viscometer was recently purchased and is in the laboratory at its own workstation. The new viscometer has an integrated heating and cooling capability that allows for viscosity measurements over a range of temperatures to support testing and research requirements. The viscometer is being set up and calibrated on site by a factory representative.

Calibration is performed using viscosity calibration standards in inventory.