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REPORT NO. C6-D-40-76

TASK NO. 4305.2/12

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USC6 OILY WATER SEPARATOR SYSTEM

CARTRIDGE USAGE DATA SURVEY

ROBERT L. SKEWES

U. S. CfAST GUARD (6-DET-l)

OFFIU OF RESEARCH AND DEVELOPMENT

WASHINGTON. DC 20590

NOVEMBER 1975-MARCH 1976

FINAL REPORT

Document Is available to the U.S. public through the NATIONAL TECHNICAL INFORMATION SERVICE.

Springfield. Virginia 22161

Prepared for

U

!H

S. DEPARTMENT OF TRANSPORTATION UNITED STATESiiDAST GUARD

OFFICE OF RESEARCH AND DEVELOPMENT "" WASHIMC^OC 20590

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This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The United States Government assumes no liability for its content or use thereof.

The contents of this report do not necessarily reflect the official view or policy of the Coast Guard, and they do not constitute a standard,

specification or regulation.

This report, or portions thereof, may not be used for advertising publica- tion, or promotional purposes. Citation of trade names and manufacturers does not constitute endorsements or approval of such products.

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Captain, U.\S. Coast Guard Chief, Environmental and Transportation Technology Division Office of Research and Development U. S. Coast Guard Headquarters Washington. D. C. 20590

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Technical Report Documtntation Pag*

(¥- ̂CG-^D-40-76! TitU and Subtitl«

1. Report No.

/

2. Government Accettion No.

45CG J^ILY WATER SEPARATOR SYSTEM CARTRIDGE USAGE' DATA SURVEY ':

)/

LTJCJROBERTL./kEWES^ USCG 9. PerforffW^^f^WuTeKo/Mom« and Address

U. S. COAST GUARD (G-DET-1) OFFICE OF RESEARCH AND DEVELOPMENT WASHINGTON. D. C. 20590

12. Sponsoring Agency Name and Address

DEPARTMENT OF TRANSPORTATION U. S. COAST GUARD OFFICE OF RESEARCH AND DEVELOPMENT WASHINGTON, D. C. 20590

3. Recipient's Catalog No.

j> I/' 'V->

/' >-. SämiStm. .

6. Performing Organization Code

8. Performing Organization Report No.

, _^1Q.. Work Unit No QRAIS)

I C l ^gp43(Ü5.2/12 / 11. Contract or Grant No.

IN-HOUSE -■ W* °' R»P°rt prtd Pe;iod Covered

41 NAL ■ ^/ « - -"——

14, Sponsoring Agency Code

15. Supplementary Notes

fAbilroct

Eighty U.S. Coast Guard cutters with Oily Water Separator Systems installed were surveyed. These cutters range in size from 65 foot river buoy tenders to 378 foot high endurance cutters. Filter-coalescer cartridge usage rate and cost data was obtained. Commencing with the installation of the first prototype oily water separator in September 1973, approximately 10,283,260 gallons of effluent have been processed, at a cost of $33,967.73 for cartridges. Installation costs for these systems totalled $1.368 million. Overall cost/gallon of effluent processed to date is 0.3497 cents; 100 GPM 0WS cost is 0.2371 cents/gallon; 10 GPM 0WS cost is 0.7537 cents/gallon and the 5 6PM 0WS cost is 1.2378 cents/gallon. (These figures represent only the cost of cartridges and do not reflect maintenance, installation or repair costs to the 0WS systems). Projected installation costs for all 261 active U. S, Coast Guard vessels is $3.5 million, and the projected annual cartridge cost for operating the 261 systems is $156,129. (Based on present cartridge prices and available data). The projected annual cartridge cost to equip the 125 confirmed 0WS systems for the coming year is $69,085.00. ^

n

17. Key Word«

Oily Water Separating Systems, Surveyed, Projected Costs, Cost/ Gallon of Effluent

19. Security Clatfil. (of thi» report)

UNCLASSIFIED

16. Distribution Statement

Document is available to the U.S. public through the National Technical Information Service, Springfield, Virginia 22161

20. Security CloMif. (of this page)

UNCLASSIFIED

21- No. of Pages 22. Pnee

Form DOT F 1700.7 (8-72) Reproduction of completed page outhoriied

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ACKNOWLECiGEMENTS

The author wishes to acknowledge and thank the following persons for

their contribution and support in this report:

G-ENE (Coast Guard Naval Engineering Division). Special

appreciation is extended to CW03 Carl Wade for his technical

assistance.

BM1 John Haran (G-DST; Coast Guard Marine Safety Technology

Division), for his assistance in the compilation of the

report.

G-DET (Coast Guard Environmental Transportation Technology

Division) for overall support.

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ABBREVIATIONS

OWS - Oily Water Separator

GPM - Gallons Per Minute

PPM - Parts Per Million

K - Thousand

GAL - Gallon

/\p - Change in Pressure (pressure differential)

SICP - Ship Inventory Control Point

QA - Quality Assurance

NAVSEC - Naval Ship Engineering Center

G-ENE - Coast Guard Naval Engineering Division

G-DET - Coast Guard Research and Development (Environmental and Transportation Technology Division)

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TABLE OF OWTENTS

PAGE

1.0 Introduction 1

2.0 Scope of OWS Installation Program 2

3.0 Cartridge Usage Rate Questionnaire 11

3.1 Trend Analysis 11

4.0 Cartridge Cost and Expenditure Data 13

5.0 Overall Cartridge Usage and Cost Data 23

6.0 Geographical Analysis 34

7.0 Summary 37

APPENDIX

PAGE

A. U. S. Coast Guard Oil-Water Separator Program Survey A-l

B. Oily-Water Separator System Cartridge Usage Data Questionnaire B-l

C. Individual Vessel Response to OWS Questionnaire (Cartridge Usage Rate Trends) C-1

D. Cartridge Usage Data for Individual Vessels U-l

E. Geographical Survey Analysis (Vessel Distribution and Cost Analysis Totals by Regions) E-1

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FIGURES

PAGE

1.0 Cost of Processing Effluent -v- Vessel Class 27

2.0 Overall Cost Distribution (Cost -v- No. of Occurrences) 28

3.0 100 GPM System Cost Distribution (Cost -v- No. of Occurrences) 29

4.0 10 GPM System Cost Distribution (Cost -v- No. of Occurrences) 30

5.0 5 GPM System Cost Distribution (Cost -v- No. of Occurrences) 31

6.0 Cartridge Lifespan (Gallons) -v- OWS Systems 32

7.0 Cartridge Lifespan (Hours) -v- OWS Systems 33

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TABLES

PAGE

1.0 Vessel Homeport and Installation Data 3

2.0 Oily Water Separator Installation Costs 6

3.0 Separator System Installations Not Surveyed 10

4.0 OWS Questionnaire Response Summary 12

5.0 Filter Coalescer Element Price Listing 14

6.0 Cartridge Usage Data (CAT-A-SEP 100 GPM Automatic OWS) 15

7,0 Cartridge Usage Data (SRS 10 GPM \utomatic OWS) 16

8.0 Cartridge Usage Data (SRS 5 GPM Manual OWS) 17

9.0 Filter Coalescer Cartridges Expenditure Recovd (By Manufacturer) 22

10.0 Cartridge Usage Data; Vessel Class and OWS System Summaries 25

11.0 Geographical Distribution of Surveys 35

12.0 Distribution of OWS Systems (System Capacity) By Geographical Regions ,, 36

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1.0 INTRODUCTION

In response to a request fron Ccmmander, Naval Sea Systems Command,

the Coast Guard Naval Engineering Division and Research and Development

Office initiated a fleetwide survey of U. S. C. G. vessels to obtain

performance and cost related data on oily water separator systems.

The purpose of this request was to examine the suitability of utilizing

filter/coalescer type oily water separators on U. S. Navy vessels by

acquiring installation, operation, maintenance and logistics support

requirements of similar systems on U. S. C. G. ships.

The U. S. C. G. data obtained was then to be compared with avail-

able Navy test data on filter/coalescer OWS systems as well as opera-

tional and technical evaluations of the parallel plate type OWS system.

Appendix A of this report is a synopsis o^ the overall U. S. C. G.

OWS program, with respect to the above parameters, as requested by

Naval Ship Engineering Center (NAVSEC) .

As of 1 January 1976 there were 125 confirmed OWS installations

on board U. S. C, G. vessels. Questionraires were distributed to

105 of these vessels, and 89 vessels responded. Of these, 80 contained

sufficient data to be used in the cost and performance calculations in

this report. All of the original questionnaires are on file at the

Office of the U. S. C. G. Naval Engineering Division, Washington, D.C.

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2.0 SCPPE OF OWS INSTALLATION PROGRAM

The U.S.C.G. OWS program, managed by G-ENE, will encompass the

entire fleet of approximately 261 vessels. The systems installed are

filter coalescei systems and are categorized as follows:

a. 100 GPM, automatic, built by CAT-A-SEP (Prototype built by

SRS). These units are installed on vessels greater than 205 ft

in length which ballast.

b. 10 GPM, automatic, built by SRS (Prototype built by Facet).

These units are installed on vessels greater than 110 ft but

less than 205 ft in length, which do not ballast.

c. 5 GPM, manual, built by SRS (Prototype also built by SRS).

These units are installed on vessels from 65 ft to 110 ft in length,

To indicate the scope of the OWS program, a proportionate dis-

tribution of OWS capacity, and a listing of vessel honeport. and system

installation data is presented in Table 1.0. This table also represents

the 105 vessels which were initially surveyed.

Additionally, installation costs of the OWS systems with respect

to the various classess is presented in Table 2.0. A discussion of this

table follows:

a. Vessels per class colunn - the approximate nimber of active

vessels in class (variable)

b. Vessels surveyed column - the actual number of questionnaires

sent out to the fleet.

c. Confirmed OWS systems eclunn - those systems installed as of

1 January 1976.

d. Projected cost column - the projected costs of installation

as supplied by G-ENE. Actual installation costs have been lower

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than projected costs in most ca5.es, however, an insufficient

number of actual cost returns prevented conpletion of the table

in this manner.

e. Installed cost per class for cutters surveyed - vessels

surveyed x projected costs.

In an effort to update the CWS program as of 1 January 1976,

Table 3.0 was developed, reflecting those vessels with OWS installations

which were not surveyed. The total projected installation cost of the

125 confirmed OWS installations reflected in Tables 1.0 and 3.0 is

$1,625 million. Projecting these installation costs to the 261 active

vessels, as indicated in Table 3.0, the projected total OWS installation

program cost is $3.5 million.

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3.0 CARTRIDGE USAGE RATE QUESTIONNAIRE

In response to the NAVY's request, G-ENE and G-DET developed a

cartridge usage rate questionnaire (Appendix B) to be distributed to

the USCG fleet. The questionnaire was designed to obtain the following

information, and at the same time create minimum interference to ship-

board routine:

a. cost and expenditure data for cartridges

b. operating hours and installation date of system

c. trend of cartridge usage rate (questions D-G)

d. general remarks on system performance.

Data used in the calculations was obtained from responses re-

ceived prior to 16 January 1976.

3,1 TREND ANALYSIS

Table 4.0, which sunmarizes the cartridge usage rate trend

analysis for all vessels, proved to be inconclusive. Initially, it

was felt that questions D and F would reflect the trend of cartridge

usage, and thus, indicate an increase or decrease in OWS system

efficiency and cost of operation. As shown in Table 4.0, this was

not the case.

Appendix C, details this information by individual vessel

response.

11

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TABLE 4.0 - QWS QUESTIONNAIRE RESPONSE SUMMARY

QUESTION D - Cartridge rate higher during first 3 months of operation?

NUMBER OF RESPONSES YES NO N/A OR UNKNOWN

80 36 45.0%

35 43.8%

9 11.2%

QUESTION E - If yes, percent higher.

NUMBER OF RESPONSES <50%

36 15 41.7%

50-100% MORE THAN 2 X

18 50.0%

3 8.3%

QUESTION F - Current Usage Rate?

NUMBER OF RESPONSES DECREASING INCREASING

80 19 23.8%

5 6.2%

STEADY N/A OR UNKNOWN

51 63.8%

5 6.2%

QUESTION G - Data Accuracy Evaluation.

NUMBER OF RESPONSES GOOD FAIR

80 38 47.5%

38 47.5%

POOR

4 5.0%

12

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Question C of Appendix B (Questionnaire) requested the cartridge

expenditure of each vessel by manufacturer and model number. Con-

current with the submission of this data, cartridge manufacturers

were contacted to obtaiü information on cartridge costs. Table 5.0,

lists the prices of various filter-coalescer elements by manufacturer

and individual model number. In all cases, prices in effect prior to

1 November 1975 were used to calculate cost data in this survey.

Tables 6.0, 7.0 and 8.0 show total cartridge expenditure on an

individual ship and system capacity basis as obtained from response to

Question C. These tables present both individual ship expenditure and

total expenditure by system capacity. A discussion of these tables

follows:

a. Total cost is equal to the number of cartridges expended times

the individual price of cartridges as detailed in Table 5.0.

b. Numbers in lower right hand comer of pages are page totals,

and represent the totals for each system capacity.

c. Table 6.0 reflects those vessels equipped with 1Ü0 GPM systems.

Table 7.0 reflects 10 GPM installations and Table 8.0 reflects

5 GPM installations.

In the conputation of this data, as is the case in all computations,

it was assumed that the data supplied by the vessels was accurate and

complete to the date of submission.

As indicated on page 4 of Table 8.0, the overall cost of cartridges

expended to date is $33,962.73. This figure represents total expenditure

by the 80 vessels submitting usable data, regardless of installation

date of the systems. If the individual vessel data submitted is ad-

justed mathematically to reflect annual costs per vessel for cartridge

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expenditure, the following projections can be made:

a. projected annual cartridge cost of 80 surveyed vessels - $ 47,134.00

b. projected annual cartridge cost of 125 confirmed CMS system - $ 69,085.00

c. projected annual cartridge cost of 261 active USCG vessels - $156,129.00

These projections are based on data submitted to date, and may, in some

cases, be biased by the limited amount of data obtained for various

classes of vessels. Also, these projections do not reflect an anti-

cipated decrease in cartridge coalescer costs, nor do they reflect

anticipated increases in cartridge lifespans as a result of current

research being conducted by G-ENE.

Additionally, an analysis was conducted to depict overall cartridge

expenditure and cost by manufacturer and model number. Table 9, depicts

cartridge cost data on an individual cartridge model number and manu-

facturer basis. The totals in the right hand column represent the

total cost by the individual manufacturers.

Lastly, data from Table 9 was utilized to determine the average

cost per cartridge for each manufacturer. Results are as follows:

TOTAL NUMBER OF CARTRIDGES EXPENDED

MAPCO - 695

FACET - 357

SRS - 918

BALDWIN - 6

AVERAGE COST PER CARTRIDCE

$25.65

$14.30

$13.62

$ 7.88

The variance in cost is attributed to system capacity, (i.e.,

.WCO is used only in 100 GPM systems; SRS is used primarily in 10 and

5 GPM units, which are smaller, and less expensive to run).

21

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TABLE 9.0

FILTER COALESCER CARTRIDGES EXPENDITURE RECORD

(BY MANUFACTURED)

MAP CO TÜTTA-SEP)

FRAM (FACET)

SRS

BALDWIN

A-0648 A-0649

TEC-1684 (EXP) TEC-1715 (EXP) EB-11

EB-12 EB-12-CG-1 EB-12-CG-2 EB-13-CG-1 EB-13-CG-2 C-744 PC-11 CCK-11 CH-58PL

611-100 611-503 611-620-A 611-621-A 614-500 614-502 614-503 614-620-A 614-621-A 622-100 622-503 622-621-A 611-200 614-200-A

Pl-123-5

EXPENDITURE TOTAL

330 365

4 30 22

120 16

2 151

4 fi 2

190 6

109 188

35 70

6 88

40

180 6

COST PER TOTAL COST CARTRIDGE EXPENDITURE

22.50 7425.00 28.50 10402.50 17827.50

18.30 0.00 24.00 0.00 12.50 50.00 14.50 435.00 16.80 369.60 22,80 2736.00 4861 70

16.75 268.00 24.00 48.00 6.10 921.10

12.50 50.00 12.50 75.00 4.50 9.00

12.60 2394.00 16.80 100.80 16.80 1831.20 16.80 3158.40 8.75 305.75 8.75 612.50

16.80 100.80 i3126.25 16.80 1478.40 16.80 0.00 19.60 784.00 22.40 0.00 22.40 0.00 12.60 2268.00 15.40 92.40

: :■

47.28 47.28

TOTALS 1976 $35,962.73

22

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5.0 OVERALL CARTRIDGE USAGE AND COST DATA

Data presentation thus far has been devoted primarily to cartridge

cost and expenditure. An overall analysis of cartridge and system per-

formance is presented in Table 10.0, which shows overall cartridge

usage and cost data on a vessel class, system capacity and overall

basis.

Table 10.0 calculations were obtained as follows:

A. Columns A^B - obtained from questionnaire response.

B. Column B - obtained from Tables 6 through 8.

C. Column C - Column B divided by column A.

D. Column E - Column B divided by column D.

E. Column F - 80 percent of system capacity times number of

operating hours times 60 min/hr.

F. Column G - Column D divided by column A.

G. Column H - Column F divided by column A.

H. Column I - Column B divided by column F.

The number of responses listed reflects actual surveys returned,

while the number of data points reflects those responses utilized in

the calculations. Appendix D, is a complete listing by individual

ship, of cartridge data usage. It should be noted that the following

data from cutters do not represent a valid base because of (1) the

small number of cutters in the class and (2) the minimal amount of

operating hours of the OWS systems:

CUTTERS wim ows

1 1 1 1 2

CLASS

WLM 175 FT WLM 157 FT WLI 100 FT WLR 75 FT WER 65 FT

WYTL

' NAME

FIR RED CEDAR COSMDS CHEYENNE OBION SAMAGAMON CHOCK

CAPSTAN

OPERATING HOURS

20.0 50.0 20.0 5.0

15.0

16.0

COST/GAL GAL

1.7792 5.5000 1.4000 3. «167 4.2000

0.S750

23

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This data was included in all calculations, however, as the installation

date of some vessels dates back to 1974.

The cost of processing effluent data computed in Table 10.0 is

illustrated in Figure 1.0 as a function of class of vessel surveyed,

total system capacity, and overall cost. In addition. Figures 2.0

through 5.0 illustrate the number of occurrences for various costs in

cent per gallon, to process OWS system effluent. Figure 2.0 shows,

the overall distribution, Figure 3.0 shows, the cost distribution for

100 GPM systems. Figure 4.0 shows, the cost distribution for 10 GPM

systems, and Figure 5.0 shows, the cost distribution for 5 GPM systems.

Figures 6.0 and 7.0 illustrate the lifespan of filter coalescer

cartridges in gallons and hours, as presented in Table 10.0. An

explanation of these figures follows:

a. Total bargraph - depicts the overall lifespan figures for

the systems.

b. Remaining bargraphs - depict high, low, and average values

for each capacity system, as obtained in Appendix D.

c. See Appendix U for actual values obtained for each vessel.

24

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FIGURE 1.0 - COST OF PROCESSING EFFLUENT -.3- ,:^' CLASS

OVERALL

100 GPM OWS

WHEC 378 FT

WMEC 210 FT

WAGB 310/269

10 GPM OWS

WMEC 205 FT

WLB 180 FT

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>- o

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UJ WLM 133 FT

s UJ h-

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§ o

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_I UJ IS) IS) ÜJ >

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3.5000

3.8167

w!-i- 'y^-mmm.

H 2<t 3<t H

COST OF PROCESSING EFFLUENT (CENTS/GALLON)

27

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FIGURE 6.0 - CARTRIDGE LIFESPAN (GALLONS) -vs- OWS SYSTEMS

00

o

< a.

e3

25,000

24,000 "

15,000 "

10,000

9,000

6,000

5,000

2,000

1.000

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TOTAL 100 GPM OWS 10 GPM OWS 5 GPM OWS

OILY WATER SEPARATOR SYSTEMS

32

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63 "IGURE 7.0 - CARTRIDGE LIFESPAN (HOURS) -vs- OWS ;/STEMS

62.50

62

51

50

5 +

4 4-

HI LOW AVG HI LOW AVG

TOTAL 100 GPM OWS 10 GPM OWS

OILY WATER SEPARATOR SYSTEMS

33

HI LOW AVG

5 GPM OWS

^ — ..

6.0 GEOGRAPHICAL ANALYSIS

A geographical analysis of the data was performed to determine the

dependence of effluent processing cost on geographical location.

Table 11.0 details the geographical distribution of the ships sur-

veyed, and illustrates the breakdown of the survey into regions, as

defined by Coast Guard Districts. Table 11.0 also shows vessels not

responding to the survey, regional responses to the survey, and the

regional cost of processing effluent. Again, the number of surveys

plotted (80) depicts those responses containing sufficient data to

calculate the cost of processing effluent.

The results presented in Table 11.0 are inconclusive, with the

3rd region (Gulf Coast), the only possible exception. The low cost of

processing effluent occurring here may be attributed to the following

factors:

a. Climate

b. Vessel or district "housekeeping" or maintenance programs

c. Vessel or system distribution in region.

Table 12.0 is a geographic distribution of OWS systems by system

capacity. This table indicates that distribution of the OWS systems

is not a factor in the low cost of region 3 (Table 11.0).

No direct analysis is possible from the data, however the signi-

ficantly low cost figure is worth noting. Further investigation into

that region's OWS program could reveal factors or practices which

substantially reduce overall cost. Appendix E, is a breakdown of

regions into the individual vessel totals used to calculate cost per

gallon shown in Table 11.0.

34

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TABLE 11.0

GEOGRAPHICAL DISTRIBUTION OF SURVEYS

REGION 1 - INLAND _ USCG DISTRICTS 2 & 9 REGION 2 - EAST COAST - USCG DISTRICTS 1, 3 & 5 REGION 3 - GULF COAST - USCG DISTRICTS 7 & 8 REGION 4 - SOUTHWEST COAST - USCG DISTRICTS 13 8 17 REGION 5 - NORTHWEST ( :OAST - USCG DISTRICTS 11, 12 & 14

< SURVEYS SURVEYS SURVEYS AVERAGE COST/ DI 3TRIBUTED RECEIVED PLOTTED GAL EFFLUENT

REGION 1 10 9 8 0.6903 CENTS REGION 2 31 25 20 0.4026 " REGION 3 31 25 23 0.1614 " REGION 4 12 11 11 0.7753 " REGION 5 21 19 18 0.6191 "

TÖF "57

84.48% 76.19%

Ö.3497 CLNIS

VESSELS NOT RESPONDING TO SURVEY USCG DISTRICT

378 FT CLASS _ CGC MIDGETT 12 269 FT CLASS - CGC WESTWIND 9 210 FT CLASS - CGC RESOLUTE

CGC ALERT 12

3 128 FT CLASS - CGC PORTLAND 1 110 FT CLASS - CGC MOHICAN 5 95 FT CLASS

- CAPE FOX CAPE JELLISON CAPE HORN

7 13

1 82 FT CLASS

- POINT LOOKOUT POINT HIGHLAND POINT WARDE POINT ESTERO

8 5 7 (NOT INSTALLED) 8

75 FT CLASS

-

SLEDGE CLAMP HATCHET

5 8 8

i ■'

i 1 \

i 1

35

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r-r^-^.T iimwiiiiiwi^^—i^^BgiiaBa ■Mmw^———— nmsamiMni

TOTALS 80 13 15 52

TABLE 12.0 - DISTRIBUTION OF OWS SYSTEMS (SYSTEM CANtttTV) 6V GEOGRAPHICAL REGIONS

GEOGRAPHICAL REGION

USCG DISTRICTS

2 & 9

TOTAL NO OWS SYSTEM

RESPONSES

8

DISTRIBUTION OF OWS SYSTEMS BY CAPACITY 100 GPM 10 GPM

0 5

5 GPM !

1 1

2 1, 3 & 5 20 7 3 10 ' 1

3 7 & 8 23 4 3 16

4 13 & 17 11 0 3 8

5 11. 12 & 14 18 2 1 15

L ■— v--— - ^--.^g ^— ^...-■....- aaattMi—■"-■■■^i,l,'-- - •-■^■»■tnyi

36

|»..ww.J.,^rM,.,l,w.p,,.. ,'4..iH-W.M.,^.M.^'<iWW^J*^^ , ..i,,,,,,

7.0 SUNMARY

In the survey of 105 USCG vessels, 80 installations were utilized

as data points to compute usage and cost data. The following figures

represent the cost to process OWS system effluent:

a. overall (80 vessels) - 0.3497 cents/gallon

b. 1C0 GPM OWS systems - 0.2371 cents/gallon

c. 10 GPM OWS systans - 0.7537 cents/gallon

d. 5 GPM OWS systems - 1.2378 cents/gallon

(costs computed from cartridge expenditure cost; maintenance,

installation and repair cost are not included)

In addition, the following data applies to the overall OWS program:

a. average cost per cartridge - $18,20

b. cartridge cost per operating hour - $5.44

c. cartridge lifespan in hours - 3.35 hrs.

d. cartridge lifespan in gallons - 5204 gals.

Individual vessel, vessel class and system capacity totals are

included in the report.

It should be noted that several projects are being undertaken by

G-ENE to lower maintenance costs. These include (1) tests of larger

micron rating filter-coalescer elements, and (2) tests of a parallel

plate OWS on a 327 FT WHEC. If successful, modifications to replace

the first stage of existing units with a parallel plate separator would

extend cartridge life by removing most of the particulate matter with

oil in the first stage.

The data compiled in this report was obtained for the Office of

Naval Engineering (G-HNE) , the Naval Ship Engineering Center (NAVSEC)

and the Naval Sea Systems Command (NAVSEA) upon request. It must be

37

^.,....-,.^..^w, W...V.,,.,.,. V,,»«..Mt. „■ ^^^^^g^^^^g^lgl^illlllljllllg^^^ | jttMaafc ■• ■

ni^iu^-.i.i.mwin^» mi. JNIW BW ■^■^'^WWTfffqBPP«iPP!i II. ■ I'' ■——w^^^^»^^^^^^^^^^ "1 stressed thtt the projections and conclusions presented are based on a

limited amount of data, and that the various parameters involved in

assuring the reliability of this data were not controlled. Assumptions

made throughout the report were noted were applicable.

38

i i -- - Igflgg^jJllJjgll^g^g^gfl^Miafcäate

—■^—ww

-1

APPENDIX A

U. S. COAST GUARD OIL WATER

SEPARATOR PROGRAM SURVEY

A-l

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APPENDIX A - U.S. COAST GUARD OIL WATER SEPARATOR PROGRAM SURVEY

PURPOSE: To determine the suitability of utilizing a filter/coalescer type oil water separator on U. S. Navy vessels by accessing tne installation, operation, maintenance and logistics of a similar oil water separator on USCG ships.

I. SHIPBOARD PARAMETERS

1. How many ships are to receive OWS's? Ideally, the entire fleet (approximately 261 active vessels). As of 1 January 1976, 125 OWS 'ystems were installed.

2. What is the capacity of those OWS's? 5 GPM for vessels 65-110 FT in length, 10 GPM for vessels 110-205 FT in length and 100 GPM for vessels > 205 FT in length which ballast.

3. What is the propulsion system on those ships? Diesel and/or gas turbine.

4. What are the generation rates of oily waste on the ships? Variable - No data available.

b. What are the sources of oily waste? Lube oil and fuel oil leakoff, piping or machinery failure.

6. What are the dirt and oil concentrations? Variable - No data available.

7. What cleaning method is used to clean equipment and bilges? Spot cleaners, (spray on-wipe off); diesel oil and hot water washdown.

8. How frequently is cleaning accomplished? Weekly.

9. What is the method of dewatering bilges without OWS's? Only alternative is to pump into a tank truck or a barge ashore.

II. INSTALLATION

1. What is the cost to install and pipe up the OWS on various size ships? See Table 2.0

2. How is the OWS piped to drain all bilge spaces? Utilize existing bilge system (except in case of eductor bilge systems, where a separate system is installed).

3. What spaces that have bilge water are not piped? Non-oily spaces.

4. Is existing ships piping used? See II-2 above.

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APPENDIX A

5. What type deck connection is used? Hose; bibb

6. How are bilges cleaned to support installation? Bilges are cleaned commercially and flushed thorougly with fresh water.

7. Are bilges recleaned periodically? Flushed by ships force only,

8. What size of oily waste or waste oil tanks are provided? Varies with vessel size - use existing tanks in some cases. New designs are 100% of one (1) main propulsion engine sump.

9. Is ballast processed with OWS. Yes

III. OPERATION

1. Is OWS operated at sea? Yes

2. Is monitor bypassed? No

3. What are OWS operating instructions? Use each time bilges are pumped or tanks deballasted.

4. What effluent samples are taken, how taken, where analyzed and how? No samples are taken on a routine basis.

5. What type of elements perform best and how determined to be best? Not determined to date.

6. Are OWS's doing better performance-wise with cleaned bilges and how determined? Absolutely - filter usage rate is lower as reported by individual vessels.

• 7. Is performance of OWS dependent on type of bilge pump? Not when OWS is used in deballast mode. The efficiency of the OWS is dependent upon pump type.

8. Does OWS start automatically? No

9. When is OWS utilized - bilge level? Variable - (decision of 00D, Engineering Watch Officer, & Ship Standing Orders). Wet bilge is preferred.

10. How much oil concentrate is collected and what is it's concentration? Unknown - No data available.

11. Is concentrated oil remixed and if so, how is it controlled? Unknown.

12. What is flow rate of OWS? 5, 10 & 100 GPM. (100 GPM unit is operated at 20-40 GPM when pumping bilges).

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APPENDIX A

13. What is the pump used? Air diaphragm and progressing cavity pumps - when in deballast mode a centrifugal pump is used.

14. How often is monitor operable? Whenever system is operated.

15. How many gallons are processed daily, monthly? Variable - a function of oily waste generation rates, for which no data is available.

16. How is OWS used if monitor not working or if working and re- cycles, how are bilges pumped? Inport the OWS discharges to tank truck or barge - at sea, discharge is to dirty oil tanks and in an emergency - overboard. Monitor recycles effluent to bilge until PPM level is below discharge limit.

17. What is mode of operation - auto, manual? The 10 & 100 GPM systems are automatic - the 5 6PM systems are manual.

18. What time spent monitoring operation and rating? Variable - no data available.

IV. MAINTENANCE

1. How frequently are prefilter elements replaced?

a. Gallons processed - No available data.

b. Pressure drop - 25 psi.

2. How frequently are coalescer elements replaced?

a. Gallons processed - No available data.

b. Pressure drop - 25 psi.

3. Are elements replaced throughout OWS? No - only those elements which require replacement, as indicated by theAP reading.

4. How frequently is monitor window cleaned? Optional - cleaning is dependent upon the zero gain of the monitor.

5. What is maintenance required on OWS? Outlined in operating i ns tructi ons/manuals.

6. What is spent element disposition? Returned to new element carton, retained until inport and disposed of ashore.

7. How much operator time is required? Actual operator time is minimal (start up, shut down and occasional monitoring).

8. What rating maintains OWS? MK2 (Machinery Technician Socond Class) and above - occasional help is required of EMI (Electricians Mate First Class) and above.

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APPENDIX A

LOGISTICS

1. How are elements procured? Commercially, by the individual vessel.

2. How are OWS procured? By contract - Advertising on specifications,

3. Does ship buy elements? Presently, individual vessels procure elements. Eventually CG will stock the elements at CG YARD (SICP).

4. How are elements stored on ship? Elements are stored in vessel storerooms in their original cartons.

5. How many elements are stored? 90 day supply (except WAGB class vessels - 6 months supply).

6. What is projected usage rate? Variable. Cartridge lifespan (to date) in hours and gallons is outlined in Table 10.0, Appendix D and Figures 6.0 and 7.0.

7. What is QA on elements? G-ENE specifications dictate rating and size of elements, only.

8. Are different elements from various manufacturers interchanged? Yes, See Tables 5.0, 6.0, 7.0 and 8.0.

9. Are coalescer element costs decreasing? Yes. See Table 5.0.

10. What is price paid for elements? See Table 5.0.

Prepared by J. Powderly/D. Waters, NAVSEC 6159D 10/20/75

Answered by C. Wade, USCG, G-ENE and R. L. Skewes, USCG, G-DET-1/62, 1/22/76

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APPENDIX B

OIL WATER SEPARATOR SYSTEM

CARTRIDGE USAGE DATA QUESTIONNAIRE

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APPENDIX B - OIL WATER SEPARATOR SYSTEM CARTRIDGE USAGE DATA QUESTIONNAIRE

DEPARTMENT OF TRANSPORTATION

UNITED STATES COAST GUARD MAILING ADDRESS US COASTGUARD (G-ENE-4/64) 400 SEVENTH STREET SW WASHINGTON, D C 20590

PHONE 202-426-1302

9000

18 KOV 197c; 'From: Commandant To: Commanding Officer, USCGC Via: Commander,

Subj: Oily Water Separator System Cartridge Usage Data; request for

1. To facilitate planning and provide needed operational data on cart- rüqt v^qe rate, the enclosed questionnaire is forwarded for completion hy J January 1976, Questionnaires shall be prepared in duplicate. Submit original directly to Commandant(G-DET-1/62) and copy to cognizant district(e).

End: (1) Questionnaires ^KmX'Z. ROBERTS

By cfccc'ion

FIRST ENDORSEMENT

From: Commander, To: Commanding Officer, USCGC

Subj: Oily Water Separator System Cartridge Usage Data; request for

1. Forwarded; for submission as directed.

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APPENDIX B ~1

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QUESTIONNAIRE

Date of Cc -in1,ion

..'HERE REQUESTED INFORMATION IS NOT AVAILABLE, PLEASE USE Bhbi ESTIMATE,

a. Installation date of oily water separator systen

b. Operating hours of system to date

c. Cartridge information:

TYPE NUMBER USED (MANUFACTURER/MODEL NO.) TO DATE

FRAM EB 11 SRS 6U-620A FRAM EB-12-CG-1 SRS 611-621-A FRAM C-744 SRS 614-500 FRAM EB-13-CG-1 SRS 611-100 __ __ _ FRAM FB-12 SRS 614-621-A FRA,^ EB-12-CG-2

TYPE NUMBFR USED (MANUFACTURER/MODEL NO.) TO DATE

SRS 622-621 A CATA-SEP A-0649 FRAM EB-13-CG-2 SRS 622-100 CATA-SEP A-0648 SRS 614-503

OTHER (SPECIFY);

d. Was the cartridge usage rate higher during the first three months of operation than the current usage rate? YES NO

e. If the answer to "d" is yes, approximately how much higher:

less than 50« more 50 to 1002 more More than twice es much

f. Is the current usage rate steady, increasing or declining?

g. Assign an accuracy/reliability evaluation to the above data:

GOOD FAIR POOR

h. Remarks: [Include applicable operatkial data, cartridge availability and performance, problems, applications of separator (cleanin fuel oil tanks, bilges); etc.] (Continue on reverse).

Co"'*1:,! ^i-inn Officer's Sirraturo

Forward to: Coniiiandant(G-DET-l/62)

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APPENDIX B

QUESTIONNAIRE

Date of Completion

WHERE REQUESTED INFORMATION IS NOT AVAILABLE, PLEASE USE BEST ESTIMATE,

a. Installation date of oily water separator system

b. Operating hours of system to date

c. Cartridge information:

TYPE NUMBER USED (MANUFACTURER/MODEL NO.) TO DATE

FRAM EB 11 SRS 614-620A FRAM EB-12-CG-1 SRS 611-621-A FRAM C-744 SRS 614-500 FRAM EB-13-CG-1 SRS 611-100 FRAM EB-12 SRS 614-621-A FRAM EB-12-CG-2

TYPE NUMBER USED (MANUFACTURER/MODEL NO.) TO DATE

SRS 622-621 A CATA-SEP A-0549 FRAM EB-13-CG-2 SRS 622-100 CATA-SEP A-0648 SRS 614-503

OTHER (SPECIFY):

d. Was the cartridge usage rate higher during the f^st three months of operation than the current usage rate? YES NO

e. If the answer to "d" is yes, approximately how much higher:

less than 50% more 50 to 100/: more More than twice as much

f. Is the current usage rate steady, increasing or declining?

Assign an accuracy/reliability evaluation to the above data:

GOOD FAIR POOR

h. Remarks: [Include applicable operational data, cartridge availability and performance, problems, applications of separator (cleaning fuel oil tanks, bilges); etc.] (Continue on reverse).

Commanding Officer's Signature

Forward to: Commander, Coast Guard District^

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APPENDIX C

INDIVIDUAL VESSEL RESPONSE TO OWS

QUESTIONNAIRE (CARTRIDGE USAGE

RATE TRENDS)

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APPENDIX C INDIVIDUAL VESSEL RESPONSE TO QMS QUESTIONNAIRE (CARTRIDGE USAGE

RATE TRENDS P"

CLASS/ NAME VESSEL

VWEC 378 FT

HAMILTION CHASE SHERMAN GALLATIN MORGANTHAU MIDGETT RUSH

CARTRIDGE RATE HIGHER DURING FIRST 3 MONTHS OF OPERATION

NO YES

NO N/A YES

NO

IF YES. PERCENT HIGHER

N/A MORE THAN 2X

N/A N/A

50-100% NO RESPONSE-

<5or0

CURRENT USAGE

RATE

INCREASING STEADY STEADY DECLINING DECLINING

DATA ACCURACY

EVALUATION

GOOD GOOD GOOD GOOD FAIR

STEADY FAIR

WMEC 210 FT

DILIGENCE DECISIVE COURAGEOUS STEADFAST VALIANT VENTUROUS RESOLUTE ALERT

YES YES

UNKNOWN YES YES

50-100% <50%

N/A 50-100% 50-100%

■NOT INSTALLED- -NO RESPONSE- -NO RESPONSE-

STEADY STEADY STEADY STEADY STEADY

FAIR GOOD GOOD GOOD GOOD

WAGB 310 FT

GLACIER

WAGB 269 FT

NORTHWIND WESTWIND

YES

UNKNOWN

50-100% DECLINING

N/A STEADY ■NO RESPONSE

FAIR

POOR

WMEC 205 FT

CHILULA ■FLUID ANALYZER REPAIRS-

WLB 180 FT

BUTTONWOOD UNKNOWN

I RONWOOD NO MARIPOSA YES BLACKTHORN YES SALVIA YES BRAMBLE NO WOODRUSH N/A MESQUITE N/A SEDGE YES

N/A UNKNOWN

N/A INCREASING

<50% STEADY 50-100% DECLINING

<50% STEADY

N/A STEADY

N/A N/A N/A DECLINING

50-100« DECLINING

GOOD GOOD GOOD FAIR GOOD FAIR GOOD GOOD FAIR

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APPENDIX C

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CLASS/ NAME VESSEL

WLB 1/5 FT

FIR

WLM 157 FT

REC CEDAR

WLM 133 FT

CARTRIDGE RATE HIGHER DURING FIRST 3 MONTHS OF OPERATION

YES

NO

WHITE PINE YES WHITE HOLLY YES WHITE HEATH NO

IF YES, PERCENT HIGHER

<5üro

N/A

CURRENT DATA USAGE ACCURACY RATE EVALUATION

UNKNOWN

STEADY

GOOD

GOOD

50-100% DECLINING FAIR 50-100% STEADY GOOD N/A STEADY GOOD

WLR 114 FT

FOXGLOVE

WLV 128 FT

PORTLAND

WYTM 110 FT

MOHICAN

WLI 100 FT

NO

COSMOS YES BUCKTHORN

WPB 95 FT

CAPE CARTER NO CAPE WASH YES CAPE SMALL YES CAPE FOX CAPE KNOX NO CAPE NEWAGEN NO CAPE JELLISON - CAPE HORN CAPE YORK NO CAPE CORWIN YES CAPE CROSS NO CAPE GEORGE NO CAPE FAIRWEATHER

N/A

■NO RESPONSE-

•NO RESPONSE-

STEADY

< 50% DECLINING -NOT INSTALLED -

N/A DECLINING 50-100% DECLINING

< 50% DECLINING — NO RESPONSE -

N/A DECLINING N/A STEADY

—NO RESPONSE —NO RESPONSE

FAIR

GOOD

GOOD FAIR FAIR

FAIR FAIR

N/A STEADY POOR < 50% STEADY GOOD

N/A STEADY FAIR N/A STEADY GOOD

-NOT INSTALLED

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APPENDIX C

CARTRIDGE RATE HIGHER DURING IF YES, CURRENT DATA

CLASS/ FIRST 3 MONTHS PERCENT USAGE ACCURACY NAME VESSEL OF OPERATION HIGHER RATE EVALUATION

WPB 95 FT (CONT)

CAPE MORGAN YES < 50% STEADY FAIR CAPE SHOALWATER YES < 50% STEADY GOOD CAPE ROMAIN YES 50-100% STEADY FAIR CAPE CORAL NO N/A STEADY FAIR

WPB 82 FT

POINT THATCHER NO N/A STEADY GOOD POINT VERDE NO N/A STEADY FAIR POINT POINT

WELLS BROWN

-UNKNOWN _ Kin DATA QIIDDI Tm

YES < 50% STEADY FAIR POINT ROBERTS YES 50-100% INCREASING FAIR DnTMT UUTTCUnDW -UNKNOWN _ wn nflTfl CIIDDI Ten 1 ^/X11 1

POINT »11 1 i 1 Ul IVI\

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NO RESPONSE- l-u

POINT NOWELL YES 50-100% DECLINING FAIR POINT SAL YES MORE THAN 2X INCREASING FAIR POINT STEELE NO N/A N/A GOOD POINT DIVIDE NO N/A STEADY GOOD POINT JUDITH NO N/A STEADY FAIR POINT STUART NO N/A INCREASING FAIR POINT BONITA NO N/A STEADY GOOD POINT POINT

TURNER JACKSON

-UNKNOWN _ wn n/nv CIIDDI irn

NO N/A STEADY GOOD POINT HANNON NO N/A STEADY FAIR POINT BARROW NO N/A STEADY FAIR POINT HEYER YES MORE THAN 2X DECLINING FAIR POINT LEDGE NO N/A STEADY FAIR POINT BARNES NO N/A STEADY GOOD POINT CAMDEN YES < 50% STEADY GOOD POINT HOBART NO N/A STEADY GOOD POINT HARRIS YES 50-100% STEADY FAIR POINT DORAN NO N/A STEADY FAIR POINT ARENA N/A N/A STEADY FAIR POINT HIGHLAND NO RESPONSE- POINT HURON JNKNOWN N/A UNKNOWN POOR POINT CHARLES NO N/A STEADY FAIR POINT WARDE NO RESPONSE- POINT HOPE NO N/A STEADY GOOD POINT LOBOS YES UNKNOWN STEADY GOOD POINT ESTERO NO RESPONSE- POINT SPENCER N/A N/A STEADY FAIR POINT EVANS NO N/A STEADY FAIR POINT BENNETT YES 50-100% DECLINING POOR POINT COUNTESS YES <50% STEADY GOOD POINT GLASS YES <50% STEADY GOOD POINT RICHMOND YES 50-100% DECLINING GOOD

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APPENDIX C

CLASS/ NAME VESSEL

CARTRIDGE RATE HIGHER DURING FIRST 3 MONTHS OF OPERATION

IF YES, PERCENT HIGHER

CURRENT USAGE

RATE

DATA ACCURACY

EVALUATION

WLR 75 FT

CHEYENNE NO N/A DECLINING GOOD

WLR 65 FT

OBION SANGAMON

YES YES

< 50% 50-100%

STEADY DECLINING

FAIR FAIR

WLIC 75 FT

HAMMER SLEDGE CLAMP WEDGE MALLET HATCHET

NO

YES —NO

N/A STEADY -NO RESPONSE --NO RESPONSE

50-100% STEADY OPERATING HOURS -NO RESPONSE

FAIR

FAIR

WYTL 65 FT

CHOCK CAPSTAN

NO N/A

N/A N/A

DECLINING N/A

GOOD POOR

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APPENDIX D

CARTRIDGE USE DATA FOR

INDIVIDUAL VESSELS

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APPENDIX E

GEOGRAPHICAL SURVEY ANALYSIS

(VESSEL DISTRIBUTION AND COST

ANALYSIS TOTALS BY REGIONS)

E-1

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APPENDIX E - GEOGRAPHICAL SURVEY ANALYSIS (VESSEL DISTRIBUTION AND COST ANALYSIS BY REGIONS) —

REGION 1 - USCG DISTRICTS 2 and 9

VESSELS: MARIPOSA, BRAMBLE, WOODRUSH, MESQUITE, FOXGLOVE, CHEYENNE, OBION, SAN6AM0N (8)

CARTRIDGE COST:

TOTAL GALLONS:

$2,340.10

338,976

0.6903 Cents COST/GAL:

REGION 2 - USCG DISTRICTS 1, 3 and 5

VESSELS: HAMILTION, CHASE, SHERMAN, GALLATIN, MORGANTHAU, NORTHWIND, DECISIVE, RED CEDAR, WHITE PINE, WHITE HEATH, CAPE CROSS, CAPE GEORGE, POINT BROWN, POINT STEELE, POINT BONITA, POINT TURNER, POINT JACKSON, POINT HANNON, POINT ARENA, CAPSTAN (20)

CARTRIDGE COST:

TOTAL GALLONS:

COST/GAL:

REGION 3 - USCG DISTRICT 7 and 8

$17,709.80

4,398,424

0.4026 Cents

VESSELS: DILIGENCE, COURAGEOUS, STEADFAST, VALIANT, BLACKTHORN, SALVIA, WHITE HOLLY, COSMOS, CAPE KNOX, CAPE YORK, CAPE MORGAN, CAPE SHOALWATER, POINT THATCHER, POINT ROBERTS, POINT NOWELL, POINT SAL, POINT BARNES, POINT CHARLES, POINT HOPE, POINT LOBOS, POINT SPENCER, HAMMER, WEDGE (23)

CARTRIDGE COST:

TOTAL GALLONS:

COST/GAL:

$6,648.90

4.119,720

0.1614 Cents

E-2

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APPENDIX E

REGION 4 - USCG DISTRICTS 13 and 17

VESSELS: IRONWOOD, SEDGE, FIR, CAPE ROMAIN, CAPE CORAL, POINT VERDE, POINT DORAN, POINT BENNETT, POINT COUNTESS, POINT GLASS, POINT RICHMOND (11)

CARTRIDGE COST: $2,126.00

TOTAL GALLONS: 274,200

COST/GAL: 0.7753 Cents

REGION 5 - USCG DISTRICTS 11, 12 and 14

VESSELS: RUSH, GLACIER, BUTTONWOOD, CAPE CARTER, CAPE WASH, CAPE SMALL, CAPE NEWAGEN, CAPE CORWIN, POINT DIVIDE, POINT JUDITH, POINT STUART, POINT BARROW, POINT HEYER, POINT LEDGE, POINT CAMDEN, POINT HOBART, POINT HARRIS, POINT EVANS (18)

CARTRIDGE COST: $7,137.93

TOTAL GALLONS: 1,152,960

COST/GAL: 0.6191 Cents

OVERALL TOTALS: VESSELS: 80

CARTRIDGE COST: $35,962.73

TOTAL GALLONS: 10,283,280

COST/GAL; 0.3497 Cents

E-3

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