Reference_-_Liquid_Transfer_Ops_Manual_2022_2f_3.pdf

Operation and Maintenance of Ohmsett Contract E17PC00014

Operating Manual for Liquid Transfer

Prepared for:

Bureau of Safety and Environmental Enforcement (BSEE) Contracting Officer’s Representative (COR)

Frank Jurado BSEE Oil Spill Preparedness Division

45600 Woodland Road Sterling, VA 20166

Email: Frank.Jurado@bsee.gov Ph. 571-279-7896

Prepared by:

Applied Research Associates, Inc.

Operating Contractor

Ohmsett Facility Naval Weapons Station Earle (NWSE)

Waterfront Route 36 P.O. Box 150, Leonardo, NJ 07737

Date: September 30, 2022

Operation and Maintenance of Ohmsett Contract E17PC00014 i

TABLE OF CONTENTS

1. Requirement

2. Approach

2.1. Personnel Training

2.1.1. Hazards of Liquid Products

2.1.2. Liquid Transfer Methods and Equipment

2.1.3. HAZWOPER

2.2. Hose Assemblies

2.2.1. Minimum Design Burst Pressure

2.2.2. Maximum Allowable Working Pressure

2.2.3. Chemical Compatibility

2.2.4. Hose Connections

2.2.5. Hose Labeling

2.2.6. Visual Inspections

2.3. Hose Clearing and Cleaning

2.4. Control and Safety Requirements

2.5. Oil Transfer Record

3. Pumps

4. Tanks

4.1. Horizontal 10,000 Gallon Tanks

4.2. Vertical 10,000 Gallon Tanks

4.3. Mixing Tank

4.4. Main Bridge Storage Tank

4.5. Portable Storage Tanks and Containers

5. Bulk Delivery

5.1. Preparation

5.2. Bulk Delivery Product Transfer

6. Oil Transfers within the Facility

6.1. Transfers

6.2. Ohmsett Tank Farm Status

7. Transfers to Containers and Portable Tanks ii

TABLE OF FIGURES

Figure 1. Ohmsett Oil Transfer Piping

Figure 2. Empty Height-to-Volume Conversion for Ohmsett Horizontal Tanks

Figure 3. Empty Height-to-Volume Conversion for Ohmsett Vertical Tanks

Figure 4. Main Bridge Storage Tank Capacities

LIST OF TABLES

Table 1. Hose Connections Pressure Rating

Table 2. Maximum Allowable Size of Containers and Portable Tanks

Operating Manual for Liquid Transfer

1. REQUIREMENT

Contract E17PC00014, Task Order E17PD00117, Section 2.4.1.12.E Detailed Operations Manuals. These manuals detail required routine activities and are to be used as references by the Contractor in operating the systems described. These manuals also guide the routine operations and maintenance of the facility.

The Contractor shall update the manuals as needed when major changes occur.

2. APPROACH

The Ohmsett facility provides a testing and training venue using refined and crude oils to simulate real spill scenarios. Transferring these oils to the facility, within the facility, and to outside entities requires special piping and hose configurations. Certain parts of the Ohmsett oil storage system are connected by steel pipe; however, temporary connections with flexible hose are used periodically at key locations to adjust for various testing and training conditions. The key locations are at pumps, meters, mixers, loading and off-loading valves. By using temporary connections and flexible hoses, many different configurations are created to increase flexibility; at the same time, it increases the likelihood of a spill. The purpose of this manual is to instruct operators in the proper ways to handle oil and other liquid transfers in a safe and efficient manner. Most transfers take place within concrete secondary containment areas. In those rare instances when a transfer takes place outside a containment area, special precautions must be taken to prevent and capture any potential discharge product.

The information that follows is intended to provide guidelines for proper use of liquid transfer equipment, and safe and efficient procedures for performing liquid transfers at the Ohmsett facility.

2.1. PERSONNEL TRAINING

Each employee that transfers oil or hazardous material receives classroom and hands-on training in the following areas.

2.1.1. Hazards of Liquid Products

Using information from Ohmsett Safety Data Sheets (SDS), each type of hazard is listed as described in Standard SDS Sections IV through VIII.

• Fire and Explosion Hazards

• Health Data

• Reactivity Data

• Special Protection

• Environmental Data

2.1.2. Liquid Transfer Methods and Equipment

The general methods used at Ohmsett to transfer liquids are described during classroom training. The topics include transfer to metal containers, electrical bonding, labeling, containing drips, pump selection, hose selection, and record keeping requirements. Using information from manufacturers’ publications, the proper selection, use, maintenance, and storage of liquid transfer equipment are described.

2.1.3. HAZWOPER

Each technician involved in liquid transfers must complete Hazwoper qualifications training.

2.2. HOSE ASSEMBLIES

These requirements are adapted from Title 33 of the Code of Federal Regulations Parts 154 and 156. Each hose assembly used for transferring oil or hazardous material must meet the following requirements.

2.2.1. Minimum Design Burst Pressure

The minimum design burst pressure for each hose assembly must be at least 600 pounds per square inch (psi) and at least four times the sum of the pressure of the relief valve setting (or four times the maximum pump pressure when no relief valve is installed) plus the static head pressure of the transfer system at the point where the hose is installed.

2.2.2. Maximum Allowable Working Pressure

The Maximum Allowable Working Pressure (MAWP) for each hose assembly must be at least 150 psi; and more than the maximum pressure of the relief valves in series. Service valve to pressure relief valve will be open.

2.2.3. Chemical Compatibility

Each hose must be compatible with the fluid being pumped. This includes compatibility with the fluid at the existing concentration and temperature.

2.2.4. Hose Connections

Hoses at Ohmsett are fitted with quick connect, cam, and groove couplings. These couplings are made of aluminum, steel, brass, or bronze. There are more than one brand used, and five different sizes: 1-, 2-, 3-, 4-, and 6-inch. In general, the larger size has, a lower working pressure rating (Table 1).

Table 1. Hose Connections Pressure Rating

Coupler Material Pressure Rating (psi)*

1” 2" 3" 4" 6" Aluminum, Bronze 250 250 125 100 75 Cast Iron 125 125 100 100 -- Stainless Steel, Steel 250 250 200 100 -- Monel 250 250 200 100 -- Polypropylene 100 100 50 -- --

* Source: P.T. Coupling Co., Inc.

2.2.5. Hose Labeling

Each hose used for oil transfer is labeled with the words "oil service" with the maximum working pressure "MWP XXX psi" displayed. Each oil use hose is labeled with a number to identify that hose and the date of purchase.

2.2.6. Visual Inspections

Each hose must have no unrepaired loose covers, kinks, bulges, soft spots, or any other defect that would permit the discharge of oil through the hose material; and no cuts, or slashes that penetrate the first layer of hose reinforcement. "Reinforcement" means any strength member of the hose consisting of fabric, cord, and/or metal. To the extent internal inspection is possible with other ends of the hose open, no internal deterioration should be observed.

Hoses are inspected annually. If any sign of abrasion, slices, outer laminate deterioration, kinks, bulges, leaks, or abnormality is observed, the hose will be taken out of service. Couplings will be removed, and the hose discarded. In the event the cam-lock coupling shows any sign of corrosion, deformation or degradation to the locking mechanism, the cam-lock will be replaced.

Prior to use, each hose shall be inspected to ensure the female cam-lock is equipped with a ring seal compatible with the fluid being transferred.

2.3. HOSE CLEARING AND CLEANING

When done properly, clearing a hose prior to disconnecting is the most important deterrent to minor spills. Therefore, when setting up each transfer, an air blow-out fixture must be included at one end of the transfer line. The main bridge is equipped with an air compressor and an air supply valve connected to the oil transfer line. At the end of a transfer operation to or from the main bridge, the supply pump is reversed, and air is supplied to the transfer line to aid in the evacuation of the line. When tank truck deliveries are completed, the lines are blown into the tank farm storage tank, usually with compressed air from the delivery truck. Air compressors are in the filtration area and the oil recovery area. When assembling temporary transfer set-ups, an adapter is always included at one end of the system to provide compressed air to aid in evacuating the hose prior to disconnection.

Hoses designated for oil service generally do not require internal cleaning. Prior to storing oil transfer hoses, they should be coiled and connected to keep residual oil inside the hose. The outside of the hose should be washed if needed. When hanging the coiled hose, the connectors must be vertical to prevent drips.

2.4. CONTROL AND SAFETY REQUIREMENTS

For oil transfers at Ohmsett:

• Ohmsett engineer-in-charge must be notified prior to transfer operations.

• Only testing or training oils are transferred within the facility.

• Hoses are maintained and visually inspected before use.

• Pumping pressures are maintained below 100 psi (75 psi for four-inch and larger hoses).

• At each transfer operation, ensure the connection is over an impervious surface; if not, use drip pans under each connection.

• Always have sorbent pads/rolls/towels/rags present to prevent spills.

• Wipe drips at connections when disconnecting and prior to stowing.

• Two operators are required: one as a pumper to control pump operation and one as a tank monitor to inspect for leaks and monitor the receiving tank; they communicate via two-way radios.

2.5. OIL TRANSFER RECORD

For each oil transfer into and out of the tank farm, the following information is recorded.

• Date and time

• Transfer operators’ names

• The type of transfer (e.g., delivery, off-site shipment for recycle)

• Type of oil

• The initial and final volumes of oil in the storage tank

3. PUMPS

Portable pumps are routinely used at Ohmsett for small volume transfers. Depending on the application, assigned pumps are used exclusively for oil, oil and water, or exclusively for water.

Pumps designated for exclusive use must not be used on other type liquids. As none of the motors or engines that power the pumps are rated for flammable liquids, Ohmsett pumps are prohibited from use for this purpose, and should pump only combustible oils. All pumps are fitted with guards around couplings and belt drives; these safety devices must be in place during operation.

4. TANKS

The Ohmsett “tank farm” contains nine storage tanks (Figure 1) that can store up to 58,000 gallons of fluid, as well as the 1,500-gallon main bridge oil distribution tank and two portable tanks (not shown).

4.1. HORIZONTAL 10,000-GALLON TANKS

Two cylindrical horizontal tanks are baffled at the center to form two compartments of 5,000 gallons each.

They are insulated, and each of the four compartments have thermostatically controlled electric heaters.

To measure the volume of product within these tanks requires "sticking the tank": measuring the free space in inches from the oils surface to the inside of the man way. Since oils expand when heated, expansion space should be calculated for anticipated temperature changes. The maximum effective storage capacity is approximately 4,500 gallons. Figure 2 shows the relationship between "empty height" and tank contents.

4.2. VERTICAL 10,000-GALLON TANKS

Four 10,000-gallon vertical steel cylindrical tanks are grouped 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 the empty height (Figure 3).

4.3. MIXING TANK

One 2,000-gallon mixing tank is located at the western edge of the tank farm secondary containment area.

Ohmsett refers to this tank as Number 7 (#7); with US Navy tank Inventory #117. The vertical tank is single-walled and is located on an impervious concrete base. The tank is used to blend different oils utilizing a vertical mixer that can be piped to the main bridge distribution tank for testing or training events.

4.4. MAIN BRIDGE STORAGE TANK

The storage tank on the main bridge has a 1,500-gallon capacity and is used for oil distribution on the tank water surface during tests. It is a cylindrical tank with a conical bottom; each inch within the straight wall portion equals 19 gallons. A sonic meter measures the liquid in the tank with a read-out meter on the bridge control panel; it can also be recorded on the data computer in the Building R-26 control tower. The meter read-out is between 0% and 100%; a conversion table is used to equate percent to gallons. Figure 4 shows the tank capacities and corresponding gallons.

4.5. PORTABLE STORAGE TANKS AND CONTAINERS

Ohmsett has multiple portable totes (330-gallon capacity); they typically hold smaller volumes of test oils and low viscosity oils that are used as diluents. These containers are stored in Building R-41, or if in use, in secondary containment areas.

Five-gallon and one-gallon capacity steel-spring loaded safety cans for engine fuels, gasoline, diesel, and gas/oil mixtures for two-cycle engines are stored in in flammables cabinets, and used for facility vehicle, and support equipment.

Figure 1. Ohmsett Oil Transfer Piping

Figure 2. Empty Height-to-Volume Conversion for Ohmsett Horizontal Tanks

Figure 3. Empty Height-to-Volume Conversion for Ohmsett Vertical Tanks

Figure 4. Main Bridge Storage Tank Capacities

5. BULK DELIVERY

5.1. PREPARATION

Each of the two Ohmsett oil transfer operators will review the product SDS, obtain two-way radios, and alert the senior contractor representative that the delivery is arriving. Prior to receiving oil, the senior representative should compare the carrier’s bill of lading with the original order. Bulk deliveries are received at the east gate of the tank farm. The tanker is positioned enabling the delivery valves to be lined up over the tanker transfer pad. An appropriate transfer hose (two-inch or three-inch diameter) is connected to the storage tank fill line then, connected to the delivery tanker.

5.2. BULK DELIVERY PRODUCT TRANSFER

One of the operators, designated as the Storage Tanks Monitor, ensures the delivered product is

(1) pumped to the correct storage tank, (2) there is room in the tank for the delivered product, and (3) that the tank is not over filled. The Storage Tank Monitor is in radio communication with the second operator.

The second operator is the Pumper. This person either operates the product pump or coordinates with the tank truck driver when using a truck-mounted pump for delivery. The Pumper checks each cargo compartment for volume and content. If necessary, a sample of the cargo would be taken at this time.

During the transfer, both operators check for leaks in the delivery hose and liner. If a leak occurs, pumping stops and valves are closed. The leaked product is cleaned up and the leak is repaired.

The delivery set up is not a gravity feed; hoses must be blown dry before disconnecting. There is still a chance of oil dripping, sorbent pads are used to catch the oil. When blowing the lines clear, there must be enough space in the storage tank to allow for splashing, bubbling, and anticipated expansion due to temperature changes. Pressure in the lines must be bled-off to atmospheric pressure before disconnecting and removing the hose.

6. OIL TRANSFERS WITHIN THE FACILITY

6.1. TRANSFERS

Two operators are used when oil is transferred within the facility. One monitors the receiving tank, while the other operates the pump and monitors the supply tank. The contractor’s senior representative must be notified prior to transfer operations. Prior to making the transfer, the following should be known.

• Product name, location (tank number), and quantity to be transferred

• Receiving tank or container and the available space in the tank or container

• Hose and pipe connections and the pump to be used

• Health and safety precautions

• A general knowledge of oils

6.2. OHMSETT TANK FARM STATUS

After oil transfers take place either into or from the tank farm, the change in product volume is documented on the tank farm status sheet. This document is kept in the technical staffs office so it maybe reviewed when necessary.

7. TRANSFERS TO CONTAINERS AND PORTABLE TANKS

Depending on the type of liquid, containers and portable tanks of various sizes can be used when smaller quantities are required for a particular job. The maximum allowable sizes presented in Table 2 are specified in 29 CFR Part 1910.106.

Table 2. Maximum Allowable Size of Containers and Portable Tanks

Container Type Flammable Liquids Combustible Liquids

Class IA Class IB Class IC Class II Class III

Glass or approved plastic

Metal (other than DOT drums)

1 pint

1 gal

1 pint

5 gal

1 gal

5 gal

1 gal

5 gal

1 gal

5 gal

Safety Cans 2 gal 5 gal 5 gal 5 gal 5 gal

Metal Drums (DOT specifications) 60 gal 60 gal 60 gal 60 gal 60 gal

Approved Portable Tanks 660 gal 660 gal 660 gal 660 gal 660 gal

At Ohmsett, gasoline and diesel fuels are kept in clearly and properly labeled metal safety cans. The cans are inspected, and a decal is placed on each can by the NWS Earle Fire Inspector. When taking material from its original container and putting it into a secondary container, the secondary container must have a Hazardous Material Identification System (HMIS) label. These are available from the on-site Health and Safety Specialist. An exception to using the HMIS label occurs when the contents are immediately used, such as when an oil can is used to dispense crank case oil.

Samples taken for analysis during test programs require a sample label that lists test number, sample number, sample date/time, and sampling person. Samples are stored in either portable or fixed secondary containment.

7. Transfers to Containers and Portable Tanks