Reference_-_Oil_Refurbishment_Ops_Manual_2022_2f_3.pdf

Operation and Maintenance of Ohmsett Contract E17PC00014

Oil Refurbishment Operations Manual

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

TABLE OF CONTENTS

1. REQUIREMENT

2. APPROACH

3. TEST FLUID RECOVERY TANKS

3.1. PRINCIPLE OF OPERATION

3.2. MAINTENANCE

4. TEST BASIN SKIMMER

4.1. PRINCIPLE OF OPERATION

4.2. SKIMMING

4.3. MAINTENANCE

5. EQUALIZATION PITS

5.1. PRINCIPLE OF OPERATION

5.2. EQUALIZING

5.3. MAINTENANCE

6. OIL PROCESSING

6.1. PRINCIPLE OF OPERATION

7. HEALTH AND SAFETY

7.1. SLIPPERY WORK SURFACE

7.2. WORKER EXPOSURE TO LIQUID PROCESS OILS

7.3. WORKER EXPOSURE TO HYDROGEN SULFIDE

TABLE OF FIGURES

Figure 1. Cross Section of the Recovery Tank Showing Two Components

Figure 2. Cutaway Elevation View of the Ohmsett Test Basin Skimmer

Figure 3. Plan View of the Ohmsett Test Basin Equalization Tanks

Oil Refurbishment Operations Manual

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

Refurbishment of used test oils is an integral part of the oil-handling procedure at Ohmsett. The high cost of replacing used test fluids with new fluids necessitates the reuse of test fluids. In addition, disposal costs associated with test fluids that contain more than five percent water justifies treating these fluids even if they are not suitable for further test.

Just like fluids recovered from real oil spills, used Ohmsett test fluids contain oil, water, and 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 wood chips. 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 of 10 to 50,000 centipoise. Oil production, of course, depends on the percent water and debris in the used test fluid and the amount of modified oily substance.

The system consists of the following five units.

• Test Fluid Recovery Tanks

• Test Basin Skimmer

• Equalization Pits

• Equalization Pit Skimmer

• Oil Processing to the Tank Farm

3. TEST FLUID RECOVERY TANKS

3.1. PRINCIPLE OF OPERATION

An eight-compartment test fluid recovery tank (Figure 1) located on the Ohmsett auxiliary bridge is used to contain and measure the fluid volumes recovered by a test device. At the bottom of each compartment are two ports with ball valves. One port enters a water discharge manifold, the other, an oil discharge manifold. During tests, gravity-separated water is removed through the water ports until oil reaches the port. At that time, the water port is closed, and the oil port opened allowing the oil to drain into the manifold, whereby it is offloaded to a storage tank or the equalization pits.

3.2. MAINTENANCE

The recovery tank requires little maintenance, other than leaving the ports open when the tank is not in use. This is especially true during the winter months; however, these valves have had to be replaced when broken or worn.

Figure 1. Cross Section of the Recovery Tank Showing Two Components

4. TEST BASIN SKIMMER

Oil spilled in the test basin but not recovered by a test device will remain on the tank surface. This oil is moved toward the north end of the basin using a boom suspended from the auxiliary bridge across the full width of the basin. An adjustable overflow pipe weir located in the northeast corner of the test basin is then used to skim the oil into equalization pits.

4.1. PRINCIPLE OF OPERATION

The overflow pipe weir has two basic components as shown in Figure 2; (1) a horizontal "half-pipe" that can be adjusted by rotating and controlling the rate of oil flow into the pipe and (2) a scum pipe that controls the direction of flow from the weir to either of two equalization pits. The weir is adjusted by a lever above the weir adjacent to the wash pad. The scum pipe adjustment lever is accessible from the catwalk above the equalization pits.

4.2. SKIMMING

This operation requires three operators to follow the procedure below.

• Raise the steel plate in front of the weir using the winch-and-purchase system located by the railing at the northeast corner of the test basin.

• Open the 16-inch isolation valve.

• With the auxiliary bridge in its southern most position, lower the skirt boom under the bridge to the water surface.

1. The boom should float on its own in the water with enough slack in the winch to reduce unnecessary tension in the system.

2. Pilot the auxiliary bridge north slowly (0.3–0.5 knots) to skim surface oil to the north end of the test basin. (See the Bridge System Operational Procedures Manual for proper operating procedures for the test basin bridges.)

3. Stop the auxiliary bridge in its northern most position.

4. At this point, two technicians create a current to push/consolidate the oil towards the weir using spray nozzles and fire hoses.

5. Begin with a full hose stream from the west deck to drive the fluid to the east, where the weir is located; use a partial hose stream from the west and south direction to push oil north to the weir.

The operator using the hose on the east deck needs to be cautious that he does not "fight" the efforts of the other hose operator.

6. The third operator maintains the most efficient adjustment for the weir pipe so the maximum amount of oil (and minimum amount of water) flows over the weir. The rate of flow is controlled by the skimming weir and will affect the ratio of oil-to-water entering the weir, as well as the oil thickness. Since oil thickness is a function of how well the operation is going, all three operators must work together to efficiently skim oil.

7. When the skimming is finished, rotate the weir to the upright position so the lip is above the test basin water level.

8. Close the 16-inch isolation valve.

9. Rotate the scum pipe so the elbow is vertical with the opening pointing up.

10. Properly store the fire hoses.

Figure 2. Cutaway Elevation View of the Ohmsett Test Basin Skimmer

4.3. MAINTENANCE

Regular maintenance of the skimmer involves keeping the test basin water level at eight-feet, one-inch height and lubricating the weir plate hoist and 16-inch valve every six months.

5. EQUALIZATION PITS

The test basin weir empties into a concrete holding tank, divided by a concrete wall as shown in Figure 3.

The 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 the north and south equalization pits.

Figure 3. Plan View of the Ohmsett Test Basin Equalization Tanks

5.1. PRINCIPLE OF OPERATION

The equalization pits are used for primary separation and to prepare a uniform feed for subsequent treatment. Oil and water enter one of the pits as determined by the scum pipe valve. Any coarse debris such as sorbent pads, polypropylene rope, and windblown refuse are caught in a rectangular debris basket. Fluid flows through the basket and can equilibrate over time, leaving oily product on the surface layer and water beneath. As one pit fills and the top layer reaches the concrete walls crown, oily product spills into the other equalization pit.

When large quantities of oil and water are involved, both equalization pits become full. This needs to be kept in mind when pumping fluid for further treatment.

5.2. EQUALIZING

• With the weir pipe adjusted for optimum oil collection, tip the scum pipe, and allow fluid to flow into the debris collection basket. Adjust the weir pipe only enough to provide adequate flow for good oil collection.

• Allow the oil to equilibrate as needed.

• Pump the oil from the surface using a double diaphragm pump with a two-inch skimmer attached to the end of the suction hose.

• Pump the skimmed fluid directly to an interim oil process tank.

• When all the oil is removed, pump the remaining water to the test basin.

5.3. MAINTENANCE

The equalization pit requires periodic cleaning. Operators must enter the pits to do this, so a confined space entry plan/permit must be obtained. The use of a tripod with safety harnesses are necessary when entering the pits. At no time should the operators tie off to the pipe railing. After the 2021 refurbishment, a safety cabling system was left in place to protect workers as well as customers from entering the pits.

6. OIL PROCESSING

6.1. PRINCIPLE OF OPERATION

Floating oil and oily emulsion are pumped from the equalization pits to the tank farm where they are separated using heat and gravity separation. Because debris in the oil includes fine materials (such as seeds) that are blown into the test basin, a fine mesh screen is used to filter out particulates greater than approximately 1/8 inch. To maintain a good process flow, the filter should be cleaned when the pressure differential is 20 pounds per square inch (psi). 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.

7. HEALTH AND SAFETY

In addition to hazards addressed in the Ohmsett Health and Safety Plan, the refurbishment process presents health and safety hazards specific to the operation that must be recognized and controlled to minimize the impact on personnel. These hazards include slippery work surfaces, worker exposure to liquid process oils, and worker exposure to hydrogen sulfide, a toxic gas.

7.1. SLIPPERY WORK SURFACE

The possibility exists of oil deposits on walking and climbing surfaces. Since the operator must walk on the grated surface to access the ladder to the equalization pits, it is necessary to ensure that all surfaces are kept free of grease or oil residue, which may lead to slips and falls. The operator should inspect all surfaces and ladders frequently and should immediately clean up any oil or greasy residue that may be present.

7.2. WORKER EXPOSURE TO LIQUID PROCESS OILS

Some of the oils processed at Ohmsett are identified as carcinogens. Extended exposure to all the oils may result in skin disorders such as folliculitis, oil acne, or general contact dermatitis. Prolonged contact with the skin should be avoided. Operators should wear oil resistant neoprene gloves when a possibility of exposure is likely. Any oil residue that contacts the skin should be promptly washed off.

If the possibility of splashes exists, such as during transfer of oil from the equalization pits to the surge tank, goggles and face shield should be used to prevent exposure of oil to eyes and face.

All hazards and effects of exposure to specific oils at Ohmsett may be found in the Ohmsett Hazard Communication Program and are communicated to staff personnel annually through the OSHA HAZWOPER refresher course.

7.3. WORKER EXPOSURE TO HYDROGEN SULFIDE

Hydrogen sulfide is a toxic gas that may be present during processing. The gas has a characteristic odor of rotten eggs. Air monitoring will be performed by the Health and Safety Officer, at open discharge points where personnel may be exposed, to determine if and at what level hydrogen sulfide exists. All personnel performing refurbishment operations shall be trained in the hazards and protective measures for hydrogen sulfide. Specific monitoring requirements may be found in Section 2.4 of the Liquid Transfer Manual.