POLLUTION CONTROL INSTRUMENTATION FOR

OIL AND EFFLUENTS

POLLUTION CONTROL INSTRUMENTATION FOR

OIL AND EFFLUENTS

H. D. Parker ITOPF

and

G. D. Pitt

Renishaw Transducer Systems Ltd

Graham &> Trotman A member of the Kluwer Academic Publishers Group

LONDONIDORDRECHT/BOSTON

First published in 1987 by

Graham & Trotman Limited Sterling House 66 Wilton Road London SWIV tOE UK

© G. D. Pitt and H. Parker, t987

Graham & Trotman Inc. Kluwer Academic Publishers Group 101 Philip Drive Assinippi Park Norwell MA 0206 1 USA

Softcover reprint of the hardcover I st ed ition 1987

ISBN-13: 978-94-010-7951-8 DOl: 10. 107/978-94-009-3233-3

e-ISBN-13 : 978-94-009-3233-3

British Library ell' Data and Library of Congress CIP Data are available

This publication is protected by international copyright law. All rights reserved. No pan of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the publishers.

Typeset in Great Britain by Acorn Bookwork, Salisbury

CONTENTS

Acknowledgements XIll

Preface xv

CHAPTER 1 Introduction 1

1.1 Background 1 1.2 The role of IMO and the progress of Marine Pollution

Legislation 4 1.2.1 International Convention for the Prevention of

Pollution of the Sea by Oil, 1954 5 1.2.2 MARPOL 73178 6

1.3 Oil Sources and Marine Transportation for Hydrocarbons 7

1.4 Operational Discharges at Sea 9 1.4.1 Tankers 9 1.4.2 Cargo Ships and Tankers 10 1.4.3 Other Operational Discharges 10

1.5 Fate and Environmental Impact of Oil Discharges at Sea 10

1.6 Scope of the Book 13 References 16

CHAPTER 2 Oil pollution control and international legislation 17

2.1 Introduction 17 2.2 The Development of MARPOL 73178 17 2.3 Operational Procedures 24

2.3.1 Load-on-Top (LOT) Tank Cleaning System 25 2.3.2 Dedicated Clean Ballast Tanks (DCBT) (also

referred to as CBT) 29 2.3.3 Segregated Ballast Tanks (SBT) 31 2.3.4 Crude Oil Washing (COW) 33

v

VI CONTENTS

2.4 Bilge and Fuel Oil Discharges 35 2.5 Reception Facilities 37 2.6 Enforcement 37

References 38

CHAPTER 3 Technical requirements of the IMO international performance and test specifications for shipboard oil pollution instrumentation for oily water separation monitoring and control 40

3.1 Introduction 40 3.2 Performance and Test Specifications concerning Oily

Water Separators and Oil Filtering Equipment 41 3.2.1 Terminology 41 3.2.2 Preamble and General Provisions 42 3.2.3 A.393(X)-Test Specifications for Oily Water

Separating Equipment 43 3.2.4 Resolution A.444(XI) 45

3.3 Performance and Test Specifications for Oil Content Meters 45 3.3.1 Resolution A.393(X) 48

3.4 The Control System 54 3.4.1 Regulations 54 3.4.2 Early Resolutions 55 3.4.3 Resolution A.586(14) 57

3.5 Overboard Discharge Arrangements with Part Flow Presentation 63

Appendix 3.1 Unified Interpretation-Annex II MARPOL 73/78 64

CHAPTER 4 Oil content monitors-a technical appraisal of the state of the art 66

4.1 Introduction 66 4.1.1 Practical Considerations 66 4.1.2 Monitor Types 67 4.1.3 System Requirements 69

4.2 Techniques for Measurement of Oil-in-Water 70 4.2.1 Ultraviolet Fluorescence 75 4.2.2 Ultraviolet Absorption 76 4.2.3 Photo-Optical Detection and Gas Evaporation 77 4.2.4 Solvent Extraction-Infrared Absorption 77 4.2.5 All-optical Fibre Solutions 78 4.2.6 Direct IR Absorption in Water 80 4.2.7 Scatter and Turbidity 80 4.2.8 Intelligent Turbidity (Light Scatter) Measurements 86

CONTENTS VII

4.3 Shipboard Installation of Monitor Systems 89 4.3.1 Ballast Monitors 89 4.3.2 Bilge Monitor 92

4.4 Conclusions 93 References 96

CHAPTER 5 Problems of testing oil content monitors to the MARPOL 73/78 specifications 97

5.1 Introduction 97 5.2 General Test Rig Requirements and Operational

Problems 100 5.2.1 Pipework 102 5.2.2 Flow 102 5.2.3 Pressure 102 5.2.4 Injection 102 5.2.5 Burettes and Heavy Oils 103 5.2.6 Water 103 5.2.7 Oil Fouling Tank (i.e. for Test 3.2.9 in A.393(X)) 104 5.2.8 Particulate Test Equipment (i.e. Test 3.2.10 in

A.393(X)) 104 5.2.9 Salinity Test 108 5.2.10 Oil Droplet Size Variation (Test 3.2.11) 109 5.2.11 Temperature Variations (Test 3.2.13 ) 109 5.2.12 Pressure and Flow Regulation (Test 3 .2.14) 110 5.2.13 Utilities (Test 3.2.15) 110 5.2.14 Long Term Drift (Test 3.2.16) 111 5.2.15 Shut-down (Test 3.2.17) 111 5.2.16 Additional Instrumentation 111 5.2.17 Waste Products 112

5.3 Monitor Tests 113 5.3.1 Ballast Monitor (0-1000 ppm) 113 5.3.2 Bilge Monitor (0-100 ppm) 116 5.3.3 Bilge Alarm (15 ppm alarm-no recorder) 117

5.4 Grab Samples and Infrared Analysis 117 5.4.1 Sampling 118 5.4.2 Validation Test on the IMO A.393(X) method for

the Determination of Oil Content 119 5.5 The Full Control Systems and Functional Testing 124

References 126

CHAPTER 6 Oil content monitors-a review of available equipment 127

6.1 Introduction 127 6.2 General Review 131

VIll CONTENTS

6.3 Installation 132 6.4 Available Monitor Systems 135

6.4.1 Babcock-Bristol Ltd. (Croydon, UK) 136 6.4.2 Biospherics Inc (Maryland, USA) 137 6.4.3 Quantek (a Facet subsidiary) (USA) 139 6.4.4 Horiba Ltd. (Kyoto, Japan) 140 6.4.5 ITT Oilcon (Netherlands, UK, Japan) 141 6.4.6 Monitek (USA) 143 6.4.7 Oili-AEG Telefunken (Finland-W. Germany) 143 6.4.8 Salen and Wicander (Sweden) 145 6.4.9 SERES (Les-Milles, France) 147 6.4.10 Yamatake-Honeywell (Tokyo, Japan); Shimadzu

Seisakusho Ltd. (Kyoto, Japan); Fellow-Kogyo Co. Ltd. (Tokyo, Japan) 151

6.5 Shipboard Experience 151 6.5.1 Ballast Monitors 152 6.5.2 Bilge Monitors 155

6.6 Flowmeters 155 6.6.1 Installation 157 6.6.2 Flowmeters-Analysis 160 References 161 Appendix 6.1 162

CHAPTER 7 A technical review of the principles of oil-tVater separation 175

7.1 Introduction 175 7.2 Principles of Oil-Water Separation 175

7.2.1 Definitions 175 7.2.2 Generation of Oily Water Mixtures 178 7.2.3 Stabilisation 178 7.2.4 Separation 180

7.3 Oil-Water Separation Technology 185 7.3.1 Gravity Separation 185 7.3.2 Enhanced Gravity Separation 186 7.3.3 Enhanced Coalescene 188

7.4 Summary 193 References 193

CHAPTER 8 Problems of laboratory testing oil-water separators 195

8.1 Introduction 195 8.2 Resolution A.393(X) 196

8.2.1 Technical Specification-Part II of Annex to A.393(X) 196

CONTENTS

8.3 8.4

CHAPTER 9

9.1 9.2 9.3

9.4

IX

8.2.2 'Test Specification' (from Part II of the Annex to A.393(X)) 197

8.2.3 'Installation Requirements' (Part II of the Annex to A.393(X)) 201

Resolution A.444(XI) 202 The Test Rig 203 8.4.1 Capacity 203 8.4.2 Layout of Test Rig 204 8.4.3 Test Equipment 206 8.4.4 Other Test Facilities 208 References 209

Technical requirements of the IMO international performance and test specification concerning oily water separators and process units 210

Introduction 210 Separation Processes-The Practical Problems 211 Separator Systems 215 9.3.1 Alexander Esplen (UK) (COMYN) 216 9.3.2 Alsthom-Atlantique (France) 218 9.3.3 SEREP (France)-formerly also Butterworth (US)

Units 219 9.3.4 Facet (Netherlands, Italy, Spain, UK, USA) 225 9.3.5 Heishin (Japan) 228 9.3 .6 Hodge Separators (UK) 228 9.3 .7 Howaldtswerke-Deutsche Werft (FRG) 229 9.3.8 Keene Corporation (US)/Oil Pollution

Engineering Co. Ltd (Japan) 230 9.3.9 National Fluid Separators, Inc. (USA) 231 9.3.10 Salen and Wincander (Sweden) 232 9.3.11 RWO (FRG) 232 9.3 .12 Separation and Recovery Systems Inc (USA) 233 9.3 .13 Stork Services (Netherlands) 233 Conclusions 233 References 235

CHAPTER 10 Interface detection 236

10.1 10.2

10.3 10.4

Introduction and Requirements Test Specification for Oil/Water Interface Detector (MEPC XIII/9 Annex 3) Interface and Level Detection, System Implications Available Interface Detectors 10.4.1 Ultrasonic 10.4.2 Electrolytic

236

238 239 245 245 256

x

10.5 Conclusions-and the Future Appendix 10.1 Resolution MEPC.5(XIII) Annex 3 specification for oil/water interface detector Appendix 10.2 Department of Trade Certificate of Inspection and Tests: The Bestobell-Mobrey 'Sensall' Oil/Water Interface Detector

CONTENTS

259

262

265

CHAPTER 11 Large scale treatment of oil-contaminated water-

11.1 11.2

11.3

11.4 11.5

11.6

reception facilities 268

Introduction 268 Sources of Oily Water: Quantities and Characteristics 270 11.2.1 Ballast Water 270 11.2.2 Ballast Water Characteristics 272 11.2.3 Fuel Oil Sludge and Bilge Oil 273 11.2.4 Refineries 275 Available Techniques for the Treatment of Oily Water 277 11.3.1 Primary Treatment 277 11.3.2 Secondary Treatment 282 11.3.3 Tertiary Treatment 292 Environmental Impact of Oily Water Discharges 292 Examples of Different Reception Facilities 293 11.5.1 Oily Waste-Water Treatment Plant in DaIian New

Port 294 11.5.2 Small Floating Reception Facilities (PRC) 298 11.5.3 Large Floating Reception Facilities (Guangzhou) 300 11.5.4 Tank Washing Facility (Lisnave-Portugal) 302 11.5.5 Combined Refinery and Ballast Water Reception

Facilities 302 Discussion 307 References 307

CHAPTER 12 Methods of disposal of recovered oil and sludge 309

12.1 12.2 12.3

12.4

Introduction Methods of Oil Recovery from Operational Activities Disposal of Recovered Oil 12.3.1 Removal of Water Sludge Disposal 12.4.1 Landfill 12.4.2 Incineration 12.4.3 Land Farming 12.4.4 Conclusions

References

309 309 310 310 311 311 312 313 314 316

CONTENTS XI

CHAPTER 13 Offshore production platforms 317

13.1 Introduction 317 13.2 Operational Discharges from Platforms 319

13.2.1 Drilling Muds and Cuttings 320 13.2.2 Production Water 320 13.2.3 Displacement Water (Ballast) 320 13.2.4 Platform Drainage 321

13.3 Controls 321 13.4 Production Water Separation Processes 322

13.4.1 The Overall System 322 13.4.2 Enhanced Gravity Separation 323 13.4.3 Hydrocyclones and On-Line Monitoring 326

13.5 Separation of Displacement Water and Platform Drainage 330

13.6 Discussion 332 References 333

Appendix A Resolution A.393(X) 337

Appendix B Resolution A.441 (XI) 373

Appendix C Resolution A.586(14) 387

Index 429

Acknowledgements

This book originated from a series of lectures given on an IMO-sponsored Technical Symposium and Study Tour on Prevention of Marine Pollution in China in September 1980. The authors would particularly like to thank their hosts for their excellent hospitality, and also for the comprehensive nature of the tour. On the study tour there were several representatives from Asian countries; perhaps this book will remind them of an enjoyable experience.

Since 1980, the subject has moved on, and MARPOL 73/78 has come into force. The impetus to install and develop systems for approvals has involved Governmental Authorities, Installers, Classifications Societies, Testing Houses, Manufacturers and Operators. All have contributed to this book, and their many inputs (too diverse to mention individually) are gratefully acknowledged. This book is not intended to reflect the views of IMO or of other Authorities. Nor is any endorsement intended for any of the manufacturers' equipment described. Within the text due acknowledgement has been given for diagrams and references which have been kindly supplied by several manufacturers. Several extracts are taken from IMO publications, and instrumentation specifications are reproduced. The permission of IMO to include these is also gratefully acknowledged.

During the preparation of this book, considerable help was provided by colleagues at STC Technology Ltd. (Harlow) and Warren Spring Laboratories (Stevenage). The inputs of Messrs. S. E. Avis, A. M. E. Dooley, D. Gray, S. I. N. Gregorig, D. Sne!, Mr M. T. Thew of Southampton University and J. C. Woodhead are gratefully acknowledged. The assistance of R. G. Woodgate in reviewing parts of the manuscript is particularly acknowledged. The authors thank the Directors of STC Technology Ltd. for their cooperation in allowing access to drawing office files at their Harlow Laboratories for the purpose of illustrating this book.

xiii

Preface

The scale of global transportation of oil cargoes has led to a demand for increased control and international legislation to combat accidental and operational dis­charges of oily wastes and residues at sea. Since 1954 the International Maritime Organisation (IMO)* has provided the international forum for the development of several proposals for controlling oil pollution from shipping, which culminated in the 1973 International Convention for Prevention of Pollution from Ships and the 1978 Protocol relating to this Convention, together known as MARPOL 73178.

Apart from the requirement for improvements in the constructional design of tankers, and operational procedures to enhance both safety and pollution control in the carriage of oil and other noxious substances at sea, MARPOL 73178 called for the extensive installation of oil discharge monitoring, control and separating equipment on board ships and offshore platforms. The 1973 Convention came into force in October 1983, twelve months after sufficient countries had ratified it and agreed to abide by the international rules and regulations. As a result, a large number of systems have now been installed and are operational. The demand to separate oil from water to give an oil content of less than 15 parts per million (ppm) and measure this on-line in an extremely difficult environment has pro­vided a considerable impetus for the development of novel and robust instrumen­tation and systems.

The theme of this book is based on an original series of lectures given by the authors, acting as consultants to IMO during a lecture and study tour of China in September 1980. At that time, MARPOL 73/78 had not come into force, and the whole field was in a state of development. The compilation of these lectures, suitably updated in 1987, provide a comprehensive overview of the subject. The delay has allowed the latest information on practical full shipboard control systems to be included.

An attempt has been made to provide a balance between the different legis­lative, environmental and economic views expressed. With respect to the equipment, the approach has been to examine the problems from a fundamental scientific position, and then to extend this to the practical shipboard applications and systems. The installation of such systems can be expensive, and under the difficult economic conditions which shipping has experienced in the 1980s, the users' stringent expectation of reliable equipment to meet the legislated requirements is fully acknowledged. It is significant, however, that since 1973, when IMO began

• International Maritime Organization (IMO), then known as the International Maritime Consultative Organization (IMCO).

xv

xvi PREFACE

PREFACE xvii

to ask for the installation of equipment on board tankers and ships, pollution levels have dropped. This can be partly attributed to the reduction in shipping itself, but also to increased awareness and the enforcement of the relevant international rules by port and harbour authorities which has given rise to a much more conscientious and widespread use of such equipment.

Technically, the demands made on the equipment manufacturers have led to new and innovative advances, which will also have an impact on other appli­cations for shipboard instrumentation; for example, fibre optics have been introduced on ships for the first time. When used correctly, apart from simply preventing and monitoring pollution levels, the new systems can also provide economic benefits, and an attempt is made to stress those aspects.

The IMO Technical Symposium on Prevention of Marine Pollution (Beijing, 13-28 September, 1980), and subsequent study tour of several Chinese ports, provided an excellent view of the many problems involved in defining and unifying such international legislation. The tour involved representatives from several South East Asian countries. Some of these representatives came from small islands where much of the pollution is relatively light, since few deep-water vessels enter harbour. Others came from countries having heavily polluted ports. The needs for pollution control therefore cover a wide spectrum, and the tour helped to point out the economic advantages, or otherwise, in providing reception facilities in various maritime regions.

This book is concerned with the control of operational discharges, as distinct from the specialised response measures which are required for accidental spil­lages. While the latter often lead to visible, and at times, disastrous effects to the sea and shore-lines, operational discharges are often a necessary adjunct to the carriage and production of oil. It can be argued that, in the case of tankers, operational discharges tend not to be concentrated locally, thus being readily dispersed by the elements away from the coastline. The concentration of shipping in ports and terminals, however, means that the relevant authorities must be active in enforcing legislation for the prevention and control of any pollution. The correct operation of discharge instrumentation and recording devices now pro­vi-des a basis for identifying a transgression.

The types of equipment required for new and existing ships provide an apparently bewildering array of potential options for the ship operator. Particu­larly confusing are the several interim solutions which have been applied at various times for installation of systems applying to ships of varying status and size. An attempt has been made to clarify this situation.

There are two relatively basic chapters on oil content measurement and separation for those with a more fundamental interest in the techniques used. A review of available equipment which has gained governmental approval is then provided, together with a review of applications, including use on offshore platforms and at reception facilities.

The book is therefore intended for use at several levels:

(a) to provide technical insight into Annex I of MARPOL 73/78. (b) to assist in defining criteria for the selection of equipment. (c) to describe the basic techniques of oil-in-water monitoring and separation

systems used on land, offshore and on board ship.

It is hoped that the book will not only prove useful to readers interested in general instrumentation and separator design, but also to those concerned with the

xviii PREFACE

effluent problems of land-based discharges and offshore. Several full systems and their design are described. While several helpful sources of information have included governmental departments, IMO, manufacturers, users and legislative bodies, the views expressed in this book are their own, and do not necessarily reflect those of any other authority.

G. D. Pitt H. D. Parker

May 1987