BOSS 107 Separator System Operations & Maintenance Manual

O&M Manual rev M1.1 January 1, 2016

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BOSS 107 Separator System

Operations & Maintenance Manual

Website: www.recoveredenergy.com Email: [email protected]

BOSS 5T/107

BOSS 11T/107

BOSS 45T/107 BOSS 25T/107

BOSS 2.2T/107

http://www.recoveredenergy.com

mailto:[email protected]


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1. System Description: ................................................................................................................. 6

A. Components ...................................................................................................................... 6

B. Process Description .......................................................................................................... 8

i. General Description of the Process: ................................................................................. 8

ii. Pump Location ................................................................................................................. 9

iii. Vacuum vs. Pressure..................................................................................................... 9

iv. Vacuum Applications -- Pump Located on the Discharge ......................................... 10

v. Pre-filtration ................................................................................................................... 11

vi. Oil Water Separation .................................................................................................. 11

vii. Post Separator Filtration (Bag Filter): ........................................................................ 12

vii. Oil Content Monitor (OCM)....................................................................................... 12

viii. Polisher ....................................................................................................................... 13

C. System Specifications .................................................................................................... 13

2. Operation ............................................................................................................................... 15

A. Initial Procedure ............................................................................................................. 15

B. Normal Operation ........................................................................................................... 15

C. Pump Design .................................................................................................................. 15

D. Turbidity or Silt Issues ................................................................................................... 16

i. Backwash System ........................................................................................................... 16

ii. Bag Filter ........................................................................................................................ 16

iii. Sand Filter................................................................................................................... 16

iv. Solids Separator .......................................................................................................... 17

v. Combo Separator ............................................................................................................ 17

E. Alarm and Action Conditions ............................................................................................ 17

i. Oil in Discharge Water Alarm ....................................................................................... 17

ii. Plugged Pre-Filter .......................................................................................................... 18

iii. Short Cycle Condition ................................................................................................ 18

iv. Excess Flow Condition ............................................................................................... 19

v. Expected Results ............................................................................................................ 20

F. Maintaining and Servicing the Oil Content Monitor (OCM) ............................................ 20

G. Calibration of the Oil Content Monitor (OCM) ............................................................. 21

H. Special Tools .................................................................................................................. 21


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I. Shutdown Procedures......................................................................................................... 21

J. Control Enclosure .............................................................................................................. 22

K. Circuit Board .................................................................................................................. 22

i. Serial Numbers B7190 to B41270: ................................................................................ 22

ii. Serial Numbers starting with B50101: ........................................................................... 22

iii. Custom Control Panel ................................................................................................. 22

3. Maintenance ........................................................................................................................... 23

A. Maintenance Philosophy ................................................................................................ 23

B. Component Maintenance................................................................................................ 23

i. Pump............................................................................................................................... 23

ii. Control Valves................................................................................................................ 23

iii. Oil Content Monitor (OCM)....................................................................................... 26

iv. Coalescing Media ....................................................................................................... 26

ii. Polisher Media................................................................................................................ 28

iii. Control Components ................................................................................................... 30

iv. Flow Indicator............................................................................................................. 30

C. Draining the Separator ................................................................................................... 31

D. Annualized Recommended Maintenance Schedule ....................................................... 31

i. OWS Time-Based Maintenance ..................................................................................... 31

ii. OWS Condition-Based Maintenance ............................................................................. 31

4. Troubleshooting ..................................................................................................................... 32

A. System Recycles into Fill Mode Frequently .................................................................. 32

B. System is not Getting Enough Lift ................................................................................. 32

C. Reduced Flow Through the System ............................................................................... 32

i. Plugged Pre-Filter .......................................................................................................... 32

ii. Plugged Polisher ............................................................................................................. 32

iii. Bacteria ....................................................................................................................... 33

D. Fault Alarms and Remote Monitoring Capabilities ....................................................... 33

i. Potential causes of the OCM system fault include:........................................................ 33

ii. Available signals from the OCM ................................................................................... 34

iii. Available signals from the Control Panel ................................................................... 34

E. Solenoid Valve Not Working............................................................................................. 34

F. System Goes into Fill Mode but the Fill Valve Does Not Open ....................................... 34

G. High Oil Content Reading Causing Water to Recycle ................................................... 34


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i. Turbidity ......................................................................................................................... 34

ii. High Emulsions .............................................................................................................. 35

iii. High Oil Concentrations ............................................................................................. 35

iv. Full Media................................................................................................................... 35

v. Dirty OCM Cell .............................................................................................................. 35

vi. High Flow Rate ........................................................................................................... 35

H. No Flow Through the OCM ........................................................................................... 35

I. Pulling Vacuum on the Filter ............................................................................................. 36

5. Safety ..................................................................................................................................... 37

A. Ignition Hazard Assessment ........................................................................................... 37

B. Electromagnetic .............................................................................................................. 37

C. 29 CFR, Part 1910 .......................................................................................................... 37

D. Dangers, Warnings, Cautions ......................................................................................... 37

E. Federal Protection Standards ............................................................................................. 37

6. Available Options .................................................................................................................. 38

A. Area Classification (AC) ................................................................................................ 40

i. Zone 2 (Class I, Div II): Option “X2” ............................................................................ 40

ii. Zone 1 (Class I, Div I): Option “X1” ............................................................................. 40

B. Pressure Classification (PC) ........................................................................................... 41

i. High Lift Suction: Option “HL”.................................................................................... 41

ii. Vacuum Operation with Higher Vessel Design Pressure: Options “VM and VH” ...... 41

iii. Low Positive Pressure: Option “PL” ......................................................................... 42

iv. Pump Located Before the Separator: Options “PM and PH” .................................... 42

C. Pre Filtration (PF)........................................................................................................... 43

i. Basket Strainer: Options “BS” and “DB” ..................................................................... 43

ii. Heavy Solids: Option “SS” ............................................................................................ 44

D. In Line Filtration (Bag Filter “BF”) ............................................................................... 44

i. Dual Poly Bag Filters: Option “P2” .............................................................................. 44

ii. Single Stainless Bag Filter: Option “S1” ...................................................................... 44

iii. Dual Stainless Bag Filters: Option “S2”.................................................................... 44

iv. Cascading Bag Filter: Option “S3” ........................................................................... 45

E. Polisher Vessels (PV) ........................................................................................................ 46

i. Additional Polisher: Option “EP” ................................................................................. 46

ii. Automatic Backwash: Option “AB” ............................................................................. 46


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iii. Mycelx Cartridge Filter: Option “MF” ...................................................................... 46

iv. Organoclay Cartridge Filter: Option “OF” ................................................................ 46

v. Big Blue Oil removal Cartridge Filter: Option “WF” ................................................... 47

F. Enhanced Performance “EP” ............................................................................................. 47

i. Heater: Option “HE" ..................................................................................................... 47

ii. High Flow: Option “HF” ............................................................................................... 48

iii. Harsh Environment: Option “HW” ........................................................................... 48

iv. 5 PPM Discharge: Option “5P” ................................................................................. 48

G. Oil Content Monitor (OCM) Options ............................................................................ 49

i. Light Refracting ............................................................................................................. 49

ii. Ultra Violet ..................................................................................................................... 50

H. Other Options ................................................................................................................. 50

i. Drip Pan or Skid: Options “DP”, “SK” and “SP” ......................................................... 50

ii. Stainless Steel Piping: Option “SS” .............................................................................. 51

iii. Confined Space: Options “YM” and “YO” ............................................................... 51

O&M Manual Attachment 1 – P&ID Drawing............................................................................. 52

O&M Manual Attachment 2 – Electrical Schematics ................................................................... 53


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1. System Description:

The BOSS line of oily water separators are designed and certified to remove oils, grease and other hydrocarbons from water in accordance with IMO standards as defined in MEPC 107(49). The BOSS system removes fluids A & B and other free oils with a coalescing separator. Fluid C and other emulsions are removed using a bulk media—generally organoclay. Fine particles are removed by using various filtering alternatives. Water quality is monitored with a certified oil content monitor. The BOSS system, if operated properly, will meet and exceed all the requirements of MEPC 107(49).

A. Components

A P&ID is attached to this manual that shows all the components of the system. All systems come with a standard design that meets MEPC 107(49) standards. Additional features are available to meet specific situations or to help improve the performance of the system to exceed MEPC standards. The list below shows the standard components plus the components that are part of a specific option. The system you have may or may not have some of the following components depending on how the system was originally ordered or modified since the system was installed. PID # Description CV-101 Inlet check valve CV-102 Oil discharge valve (not used with Option HW) CV-103 Discharge check valve F-101 Pre-filter Y-strainer / basket strainer F-102 Oil discharge Y strainer (not used with Option HW) F-103 Additional polishing vessel (Option EF) F-104A Bag filter #1 (Option P1) F-104B Bag filter #2 (Option P2) F-105 Fluid “C” polisher—normally organoclay F-106 Extra filter – organoclay, sand or carbon (Option EF) FI-101 Flow indicator FR-101 OCM flow restrictor FH-(XXX) Various flex hoses as required G-101 Vacuum/pressure gauge G-102 Pump discharge pressure gauge G-103 Pressure gauge after polisher G-104A Filter pressure gauge (for F-104A) G-104B Filter pressure gauge (for F-104B) H-101 Emulsion breaking heater (Option HE) LS-101 Oil level switch MOV 101 Oil discharge valve (Options X1, X2, PM, PH) MOV-102 Cascade Bag Filter control valve (Option S3) MOV-103 Cascade Bag Filter control valve (Option S3) MOV-104 Cascade Bag Filter control valve (Option S3)


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MOV-105 Cascade Bag Filter control valve (Option S3) MOV-106 BACKWASH control valve (Option AB) MOV-107 BACKWASH control valve (Option AB) OCM-101 OCM monitor P1 BOSS Control panel P-101 Main process pump PSV-101 Pressure safety valve, separator (Option VM, VH, PM, PH) PSV-102 Pressure safety valve, polisher (Options VM, VH, PM, PH) S-101 BOSS oil separator S0V-101 BOSS make-up water inlet control valve S0V-102 Discharge water control valve S0V-103 Recycle water control valve V-001 BOSS separator vent manual valve V-002 Polisher vent manual valve V-003 Flow control valve V-005 OCM clean water inlet manual valve V-006 F-104B isolation/control valve (P1) V-007 F-104A isolation/control valve (P1) V-008 Post polisher sample port V-009 Pressure gauge isolation valve (Option HW, X1, X2) V-010 Pressure gauge isolation valve (Option HW, X1, X2) V-011 Pressure gauge isolation valve (Option HW, X1, X2) V-012 Pre polisher sample port V-013 Post polisher sample port V-106 Backwash 3-way valve—polisher inlet/backwash V-107 Backwash 3-way valve—polisher outlet/backwash


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B. Process Description

i. General Description of the Process: The system is first filled with clean water. A centrifugal pump (P-101) pulls oily water from a sump, bilge or holding tank into the bottom center section of the coalescing separator (S-101) through a pre-filter Y strainer (F-101). The separator has an inner and outer section. As the oily water enters the inner center section, its velocity slows down and it rises up through the center section of the separator. As it rises up it passes through an oleophilic media (polypropylene). The media facilitates the

separation of the oil from the water by providing a surface area that attracts droplets of oil and holds them until they coalesce into larger droplets which then rise to the surface of the water in the separator.

The oil droplets rise to the top of the separator, collect, and then displace the water, forcing the water level in the separator downward. Any air or gas vapor that enters the separator will rise rapidly to the top of the

separator where it also collects with the oil. Air or vapor that collects in the separator will be discharged with the oil. The water then spills over the inner weir and flows down through another layer of media to the bottom of the separator. Passing through the second stage of coalescing media further removes residual oil droplets which rise to the top of the separator. Separated water exits the separator out the bottom of the outer section, through the pump (P-101), then is pumped under pressure through the flow meter (FI-101), the post separator bag filter (F-104), the post filter media and finally the flow control valve (V-003). The polisher is equipped with manual backwash valves (V-106 & V-107) to remove accumulated fines from the polisher media. The backwash discharge is normally directed back to the bilge or holding tank. A conductance level sensor (LS-101) located in the top of the separator detects the water/oil level in the separator. When the water is displaced by the collected oil-air-gas to a predetermined low water/oil interface level the system switches from normal separating called "PUMP &


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WATER DISCHARGE" mode to "FILL & OIL DISCHARGE" mode (see the lights on the panel. The pump (P-101) turns off, the discharge valve (SV-102 and or the recycle valve (SV-103) close, the water makeup valve (SV-101) and oil discharge motor operated ball valve (MOV-101, if equipped) open. Makeup water is allowed in, pressurizing the separator and raising the level of the water. The oil-air-gas is pushed out of the separator through the oil out valve. Once the water reaches the high level, the level sensor switch shuts the makeup water and oil out valves. Normal "PUMP & WATER DISCHARGE" mode resumes. The operation of the discharge and recycle valves is directly controlled by the oil content monitor (OCM). Various models and types of OCM units are available. The specific OCM O&M manual for your unit is included as an attachment to this manual. If the water flow at the discharge valve has oil content of less than 15ppm on a standard system (5ppm on some units) the water is allowed to be discharged over board or to another appropriate collection receptacle or drainage. If it is greater than the pre set oil content ppm level, it is directed through the recycle valve back to the oily water source.

ii. Pump Location The standard system is designed with the pump on the discharge side of the separator pulling water through the separator. Where the bilge or sump is located below the level of the separator the pump will pull a negative suction head. If the bilge or sump is located above the separator the system is pressurized. The separator will work in both conditions with minor differences explained below. The standard system uses a vacuum to pull the water through the system. This allows the use of a centrifugal pump. The centrifugal pump has a lower cost, less maintenance, better safety, more operational flexibility, a longer life span and the flexibility to adjust the flow rate. However, it cannot be used on the front of the separator without creating mechanical emulsions that negatively impact the efficiency of the separator. It also has less negative suction lift and is less effective for high lift situations.

In some cases the situation may warrant the pump to be located on the inlet side of the separator and the oily water is pushed through the separator. This requires a progressive cavity pump running at low rpm’s in order to minimize the formation of mechanical emulsions. The progressive cavity pump option is described in more detail in Section 6 of this manual.

iii. Vacuum vs. Pressure The standard system operates under vacuum. However, the primary equipment will operate either in a vacuum or pressure mode, although there are some differences in how the system operates. When the system is in a vacuum mode the oil discharge valve does not need to hold pressure so a simple check valve (CV-102) is used. The standard system comes with a check valve for the oil discharge valve. If there is pressure in the separator vessel this check valve will not work and needs to be replaced by a motorized control valve (MOV-101). It is important to understand whether the system will be operated in a vacuum or pressure mode. If the system is pressurized a motorized control


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valve (MOV-101) is MANDATORY for the oil discharge. WARNING: If the system is operated under pressure without MOV-101 it will allow water and oil out of the oil discharge check valve. For more discussion of the MOV option see Section 6.

iv. Vacuum Applications -- Pump Located on the Discharge • A process pump (P-101) is mounted on the outlet of the separator which pulls water

from the oily water sump through the pre-filter (F-101) and separator (S-101). This placement reduces the formation of mechanical emulsions. The standard CDU pump with a size 1 or 3 impeller will pull 10 – 13 feet (3 - 4 meters) (up to 11.5” Hg on the vacuum gauge) of negative head or vertical suction lift and still provide the design flow through the unit. The standard JEU pump, 2 stage CDU pump or CDU pump with a size 5 impeller will pull 5 meters (14” Hg on the vacuum gauge) of negative head or vertical suction lift and still provide the design flow through the unit. The suction of the pump is continuously flooded with a positive head so there is no need to prime the pump. The pump is a stainless steel centrifugal pump and therefore does not need a safety relief valve. Depending on suction and head requirements for a given installation, the process pump is generally capable of pumping more than the designed flow through the system. A manual flow control valve is provided to adjust the flow to the design level. This valve is located after the polishing filter where it can still control the overall system flow but also allow the full force of the pump on polishing filter backwash.

• It is critical that all connections to the oil water separator are airtight and properly sized for the installation. Any leaks in the inlet piping or piping restrictions will impact the amount of vacuum that the pump can pull.

• The system will still work up to as much as 16” Hg (5.5 meters or 18’ head) with a JEU pump or a 2-stage CDU pump or a CDU pump with a size 5 impeller (13” Hg with a CDU pump with a size 1 or 3 impeller), but the flow will be restricted. The flow indicator will still read full flow but what is happening is that the system is pulling part of the water from the bilge and part of the water is coming from the head of the separator. The system will short cycle and go into the fill mode more often than normal. The higher the vacuum the less water the system will pull from the bilge. If the actual lift is more than described above, the pump could stop pulling water from the sump or could pull very little and could cavitate.

• A high lift option (as described in Section 6 of this manual) is available for 11 gpm, 25 gpm and 45 gpm systems in situations with high suction lift. With this option the height of the oil reservoir is increased by 6” so that the system will run longer without going into the fill mode. The impeller size for the pump is also increased to a size 5 impeller or a 2 stage CDU pump is supplied. This will generally require the motor to increase in horsepower. These modifications allow the system to pull up to 16 feet (5 meters) of negative head or vertical suction lift and maintain a


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reasonably normal cycle time. The high lift option is not necessary for 2.2 gpm or 5 gpm systems.

v. Pre-filtration

When the unit is turned on the main process pump (P-101) pulls water from the sump through a pre-filter screen F-101. The standard unit comes with a Y strainer. A basket strainer (or dual basket strainers) is available as an option, as described more fully in Section 6 of this manual. The strainer will remove particulates larger than 1/20th of an inch in any dimension. The pre-filter screen system also includes a check valve (CV-101) to prevent water from back flowing from the system when the unit is off or in the fill/oil discharge mode.

vi. Oil Water Separation The oil water separator (S-101) is a coalescing type gravity separator that relies on the difference in specific gravity of oil and water. The separator will not remove aqueous fluids or fluids that have a specific gravity of near 1.0 or higher. The oily water flows from the pre-filter into the bottom of the separator. The separator has an inner and outer section. The water comes up through the center section of the separator through an oleophilic media (polyethylene or polypropylene). The media facilitates the separation of the oil from the water by providing a surface area that attracts droplets of oil and holds them until they coalesce into larger droplets which rise rapidly to the surface of the water in the separator. As oil collects in the top of the separator it displaces the water and forces the water level in the separator downward. Any gas vapor or air that enters the separator will rise rapidly to the top of the separator where it collects with the oil. Air or vapor that collects in the separator will be discharged with the oil. A level sensor (LS-101) in the top of the separator detects the water level in the separator. When the water is displaced by the collected oil to a predetermined low oil/water interface level, the pump P-101 turns off, SV-102 and SV-103 close, and SV-101 and MOV-101 (if applicable) open. Makeup water is allowed into the separator through SV-101 raising the level of water in the separator and pushing the oil out of the separator through the oil outlet valve (MOV-101 or CV 102). Once the water reaches the high level, LS-101 causes SV-101and MOV-101 (if applicable) to close. The main pump (P-101) turns on and SV-102 or SV-103 opens and normal operation resumes. The system operates slightly differently when the system is pressurized as discussed in Section 6. WARNING: When the system is pressurized an MOV-101 is required on the oil out line. The check valve will withstand a pressure of about 1 psig. Anything above that will push water and oil through the check valve and into the slop oil tank and could cause the oil tank to fill up and overflow. During normal operation oily water entering the system flows up through the center section of the separator and over the top of the inner section where most of the oil is separated from the water. The water then flows down through the outer section of the separator, which contains additional media. Passing through the second stage of


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coalescing media helps remove any residual oil and provides discharge water from the primary separator in most cases with less than 15 PPM oil content. Separated water exiting the separator comes out the bottom of the outer section and is pumped to the post separator bag filter and then to the polisher unit.

vii. Post Separator Filtration (Bag Filter):

The media in the separator is very porous and will allow suspended solids to pass through. If the silt is suspended then it will generally pass through the separator without plugging it up. However, these suspended silts and solids can create plugging problems in the Polisher stage. The standard BOSS separator comes with a single bag filter to remove the suspended solids prior to the Polisher. There are 2 reasons for the post filtration. First it will improve the overall removal of oil. Second, it will increase the life of the polisher media. The bag filter after the separator is used to remove silt and turbidity. The standard REI system comes with a bag filter because it dramatically improves the overall performance of the system. Earlier systems or special order systems may not have come with a bag filter. If your system does not have a bag filter it is easy to add one and highly recommended. The bag filter can either be a single bag filter or dual bag filters. If dual bag filters are used they can be piped either in series or parallel. In some cases, additional bag filter options may be desirable to improve the longevity of the bags, improve the removal of solids and/or to make the bag changing easier or less frequent for the operator. For other bag filter options see Section 6 of the manual. Warning: The system will not operate to its peak performance if suspended solids are present and they are not being filtered out. For this reason the bag filter is a standard feature unless specially ordered otherwise. We strongly recommend a bag filter if one is not already installed. The bag filter will increase the life of the polishing filter media and it will result in lower ppm oil being measured by the OCM monitor.

vii. Oil Content Monitor (OCM)

The BOSS 107 includes an Oil Content Monitor (“OCM”, also sometimes called a Total Petroleum Hydrocarbon Monitor (TPH) or bilge alarm) that has been certified to meet the MEPC 107(49) regulations. The OCM monitor has the ability to automatically return non-conforming discharge water back to the sump or bilge. The recycle solenoid valve (SV-103) and the oil in water monitor (OCM) control the recycle action. The OCM unit is a 15 PPM oil content alarm monitor that has been tested and approved in accordance with IMO Resolution MEPC.107 (49). The OCM monitor is continually sampling the process stream and detecting the amount of oil concentration. It is designed to react quickly to any changes in the oil content. The BOSS OWS can be ordered with any 107(49) certified monitor. See the Options in Section 6 for a discussion of the various OCM options. The standard OCM comes with a 15 ppm limit. The OCM allows the limit to be set in a range from 1 ppm to 15 ppm, but cannot be set above 15 ppm. In some cases there is


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a requirement for 5 ppm discharge. If this is the case it can be handled by either setting the standard OCM to 5 ppm or by ordering a special 5 ppm version of the OCM that cannot be set above 5 ppm. For instruction on how to reset the monitor to 5 ppm, consult the OCM manual. For further information on the 5 ppm operation and options refer to Section 6 of this manual. The sample water tubing to the OCM is installed with a flow-restricting orifice in the outlet port of the OCM-- just inside the end of the tube fitting. This will limit the flow through the OCM meter to a flow of approximately 0.5 l/m to 2.0 l/m. You cannot see the orifice without removing the tube fitting. The return line from the OCM does not come with a shut-off or restricting valve. Under no circumstances should a valve be installed on the OCM sample return line.

viii. Polisher

The primary purpose of MEPC 107(49) was to address the monitoring and removal of emulsified oil. A coalescing separator will not remove chemical emulsions and will only partially remove mechanical emulsions. Some form of post treatment is necessary. The standard BOSS 107 system includes a polyglass (Models 2.2T-107, 5T-107 and 11T-107) or steel (Models 25T-107 and 45T-107) polisher vessel designed to hold bulk media. The standard bulk media used is organoclay. This media has the advantage of being efficient and long lasting. Activated carbon can also be used as an option but does not last as long. For discussion of this option see Section 6 of this manual. There are 2 types of polisher housings that are supplied. The 2, 5 and 11 gpm systems use a polyglass polisher with a tube that goes down the center. The inlet and outlet are both handled through the top distributor. These vessels are rated for 125 psig pressure. The 25 and 45 gpm systems use a steel vessel with an inlet distributor at the top and an outlet distributor at the bottom. These vessels are rated for 75 psig pressure. For higher pressure options see Section 6. The advantage of the bulk media is that it lasts a long time relative to other forms of media. The disadvantage is that it is hard to vacuum out the old media. The bulk organoclay media is by far the lowest cost alternative for removing emulsions. An option for cartridge filters is available and is discussed more fully in Section 6 of this manual.

C. System Specifications Specifications 2.2 GPM 5 GPM 11 GPM 25 GPM 45 GPM


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Height (inch/cm) 50 (127) 56 (142) 69 (175) 73 185) 75 (191) Width (inch/cm) 27 (69) 28 (71) 36 (91) 41 (104) 55 (140) Depth (inch/cm) 40 (102) 49 (124) 56 (142) 77 (196) 100 (254) Dry Weight (lbs./kilogram) 450 (204) 750 (340) 1250 (567) 2600 (1080) 3550 (1610) Capacity gpm (M3/hr) 2.2 (.5) 5 (1.1) 11 (2.5) 25 (5.6) 45 (10.2) Organoclay/sand charge (lbs./kg) 90 (41) 170 (77) 310 (141) 680 (308) 1240 (562) Specification Value IMO MEPC Compliance 107(49) certified by ABS, USCG, BV, CCS and MED(EC) Vessel Metallurgy Marine Coated Carbon Steel Exterior Coating Specification SSPC-10 Blast with Epoxy/Urethane Paint System Coalescing Media Polypropylene (Mycelx Snippets Added with 5P Option) Separator Vessel Design / Test Pressure Polisher Vessel Design / Test Pressure

15 / 45 PSIG 75 / 98 PSIG for Steel Vessels 125 / 125 PSIG for Fiberglass Vessels

Operating Pressure < 0 PSIG (Up to 15 PSIG with Pressurized Option) Water Operating Temp Range 5-60 C Design Negative Inlet Head (Ft/M) Design Negative Inlet Head (Ft/M)

13 / 4 (with CDU Pump with Size 1 or 3 Impeller) 16 / 5 (with JEU, 2CDU or CDU Pump with Size 5 Impeller)

Positive Inlet Head Design Pressure (Motorized Valve Required)

15 PSIG

Max Free Oil Concentration 35% Max Fluid “C” Oil Concentration (with Polishing) 6% Oil in Water Discharge <15 ppm (<5 ppm with 5P Option) Control Panel NEMA 4X Polycarbonate (SS304 with RO or X2 Options) OCM (Oil Content Monitor) IMO MEPC 107(49) Certified Monitor with Data Logging Max Turbidity for Accurate OCM Reading 35 NTU (Higher with TD-107 OCM) Level Sensor Conductance with 304 Stainless Steel Probes Discharge, Recycle, Fill Valves Oil Out Valve Backwash Valves Bag Filter Valves

Bronze Body, Solenoid Type, Rated for Salt Brine Check, Bronze Body (Motorized Valve with MV Option) 3-Way Manual, Bronze Body (Motorized with AB Option) Manual, Bronze Body (Motorized with BFM Option)

Pump Centrifugal with 304 Stainless Steel Housing (Progressive Cavity with PC Option)

Motor TEFC NEMA 56 (IP 55) (Exp. Proof with X1 or X2 Options) Piping & Fittings Marine Grade Red Brass Pipe, Bronze Fittings (304 Stainless

Steel with SS Option) Flow Indicator Visual Mechanical, Bronze Body with Glass Window Single Phase Power Options 110/120vac, 208vac, 220/240vac Three Phase Power Options 208vac, 220/240vac, 380/415vac, 440/480vac, 575/600vac Frequency 50 or 60 Hz Max Amperage Hazard Area Classification

< 15 amps NEMA 4X (Not Rated) (Class I Div I or II with X1, X2 Options)

Figure 1: Various options are available that may modify some specifications and may have pricing implications. Specifications for some of the options are shown in parentheses. See Section 6 for additional discussion of the options. Oil Discharge Pressure equals the pressure of the makeup water inlet, but should be restricted to less than 15lbs.


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2. Operation A. Initial Procedure

Installation procedures outlined in the installation manual should be followed before this initial procedure. Verify that the clean water source has been turned on. It is recommended that the pressure of the clean water should not exceed 15 psig (the vessel design pressure). Turn the system switch to ON and follow the startup procedure in Section 4 of the Installation Manual.

B. Normal Operation

After all of the specified testing has been completed and the system has run satisfactorily with the water flowing through the polisher, then the system can be put in normal operation. Turn the switch to ON and open the sample lines to the OCM. The unit will then monitor the outlet stream and automatically switch between discharge and recycle as needed. The system is designed to operate without operator interface except in certain conditions as described below. The systems are designed to handle up to 4 to 5 meters of suction lift (depending on the pump) and approximately 80 feet of discharge head with the standard centrifugal pump. If a progressive cavity pump is used in front of the separator it will handle up to 6 meters suction lift with approximately 80 feet of discharge head. For further information on the suction lift and high lift options see Section 6.

C. Pump Design One of the advantages of the BOSS OWS systems is the use of a centrifugal pump. This pump allows the user to control the flow through the separator by adjusting a manual flow control valve located after the polishing vessel. This position allows the system to restrict the flow while still allowing full pump capacity for backwashing the polishing filter. With other systems that have a positive displacement type pump, the pump does not have any flexibility. With a centrifugal pump, the pump is oversized so that the same pump will work in a variety of discharge pressure situations. The pump will operate from 10% of design up to > 100% of design without impacting the pump. The standard BOSS line of oily water separators with a centrifugal pump can be configured to any voltage from 110 vac to 575 vac and either 50 Hz or 60 Hz. If you have a pump that has been configured for a voltage or frequency that is different than what you expect, it is possible to change the voltage and frequency. Changing voltages or frequency can be done by following the table shown in the Installation Manual.


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D. Turbidity or Silt Issues One of the major issues the industry faces is solids and turbidity. It will plug the polisher and it will impact the accuracy of the OCM. We have designed several ways to deal with solids and turbidity.

i. Backwash System The system will come with a 3-way manual backwash valve assembly. This allows the operator to backwash the polisher whenever they want. This valve assembly will come installed for each system.

The timing of how often to do the backwash will be determined by the differential pressure across the polisher as measured by the inlet and outlet pressure gauges. When the differential pressure rises, simply change the valve positions to the backwash mode and let it run for about 5 minutes. You can pipe the backwash back to the bilge. This will cause silt to build up in the bilge. Periodically the bilge will need to be cleaned out to remove the silt. The bilge foot valve should never be located on the bottom of the bilge. Water should be pulled from a reasonable distance above the bilge so solids can settle to the bottom. It is also possible to pipe the backwash so that it goes through a filter to remove the silt. This will prevent the buildup of silt in the bilge. It is possible to automate the 3-way valves to make the backwash process automatic. The system will not come this way but this option can be added. To obtain a quote call the factory or a distributor. See Section 6 for more discussion about this option. It is important not to go for long periods of time without backwashing. If the silt is driven to deep into the organoclay bed it will not come out. We recommend that the backwash be done daily or after each batch process.

ii. Bag Filter A bag filter is generally included between the separator and the polisher. If you received a unit and there is no bag filter then it is because the shipyard or distributor ordered it that way. We highly recommend that the bag filter be added in ALL situations. It is a simple change. The bag filter will significantly increase the life of the organoclay media.

iii. Sand Filter Sand Filter: For situations with higher solids saturation of the inlet stream a separate sand filter can be added. We have developed a kit for this option that can be added to any existing separator. All of these options are simple to install and in most cases will address the silt issue and extend the life of the organoclay. We recommend that any operator that is experiencing silt issues should consider one of these options if not already part of the system. Please contact the factory or your distributor for more information about solids removal.


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iv. Solids Separator

Oily water separators are generally not designed to handle solids. Most solids removal systems such as bag filters, sand filters, hydrocyclones, DAF systems, flocculent systems, etc. generally cannot handle much more than 400 ppm solids. In order to handle large concentrations of solids up to as much as 30% solids, REI has developed a solids separator. The Solids Separator would be placed on the inlet of the separator to remove large quantities of solids. The solids separator is a gravity system that does not require any type of consumable. It will remove large volumes of solids down to as low as 20 micron particle size, depending on specific gravity. For more discussion on this option see Section 6.

v. Combo Separator REI has also developed a combination separator that combines the Solids Separator and the Oily Water Separator into a single vessel, which we call a “Combo Separator”. This system operates identical to the standard separator except that the vessel has an additional section for solids removal. The Combo Separator can be used for situations with as much as 30% solids. The Combo Separator cannot be added to an existing system. It has to be ordered that way.

E. Alarm and Action Conditions The only alarm condition that requires operator action is when the polisher has reached maximum hydrocarbon saturation. This is determined by the inability of the separator and polisher to remove oil below 15 PPM. At this point, the OCM monitor will not be discharging water overboard but is in a continuous recycle mode. Sometimes the OCM can indicate a high PPM condition when the polisher has not reached its maximum saturation. This condition is a result of the glass tube in the sampling cell having a buildup of contaminants from the effluent stream. To clear this condition cycle the OCM several times through using the OCM clean mode (see OCM manual for instructions on how to accomplish this) and clean the cell glass with the brush provided. Backwashing of the polishing filter should be done after each usage for 5 to 10 minutes if running batches, or at least once a day if running continuous. If there are high levels of solids it may be necessary to backwash longer or more often to keep the polisher media from plugging up. The flow control valve is located after the polishing vessel so as to allow the full pressure of the pump to be employed on backwashing. Prolonging the backwash operation allows solids that have collected in the polisher to solidify and become impossible to backwash out. If, after cleaning the cell and backwashing the polisher, the OCM level is still above the 15-PPM limit, it may be time to change the polishing media. There is 1 alarm condition and 4 action conditions that require operator response.

i. Oil in Discharge Water Alarm

If the oil in the discharge water is greater than 15 PPM (5 PPM with a “5P Option”) the OCM monitor will alarm. An OCM alarm will cause the system to automatically go into recycle mode until the condition no longer exists. The alarm light on the OCM


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panel indicates that the system is in recycle and that oil greater than 15 (5) PPM has been detected in the water. There is an adjustable 0-20 sec. delay timer in the OCM that is met before the recycle valve is actuated.

ii. Plugged Pre-Filter If the pre-filter (F-101) is plugged the pump will not pull the design flow of water through the system. This is indicated when the rated design flow of the system as indicated on the flow indicator (FI-101) cannot be reached when the flow regulating valve (V-003) is opened fully and the inlet vacuum gauge (G-001) is abnormally high. When this happens it is time to clean the filter. A better approach would be to set up a routine schedule to clean the filter. The timing for cleaning the filter will be determined by installation specific operating conditions.

iii. Short Cycle Condition Short cycle condition is indicated when the system goes from normal separator operation to "FILL" and back to normal operation in a frequency less than an hour of duration. This condition can occur for any of the following reasons:

• Air Leaks

The most common cause of short cycling is because the inlet of the separator is pulling air into the separator with the oily water. The air collects in the top of the separator and displaces the oil, driving down the internal water/oil level interface. This in turn activates the level sensor which tells the system it is time to discharge oil. If the inlet piping connections are not air tight, air will be pulled into the separator. The larger the leak the faster the cycle time. This situation can be corrected by making sure there are no leaks in the inlet piping.

• Foot Valve If there is no foot valve in the bilge or if the foot valve is not interlocked with the system the system can suck air and go into fill mode. The correction is to install a foot valve that is interlocked with the system to shut off when the bilge level goes below the foot valve.

• Suction Lift The system will also short cycle if the suction lift is too great. A standard 2.2 gpm or 5 gpm system with a JEU jet pump has a suction lift of 5 meters (16 feet) as it comes from the factory without any modifications. Any system with a CDU pump has a standard lift of 3-4 meters (10-13 ft.) In order to achieve a 5 meter (16 ft.) lift with a CDU pump the high lift (HL) option must be exercised and following modifications must take place: (i) the pump has to have a larger impeller and motor or (ii) it has to be a 2 stage pump (2CDU). (ii) The oil reservoir has to be larger. With a large suction lift the vacuum expands any air space in the top of the separator. If there are any leaks in the inlet piping air will accumulate in the top of the oil reservoir and any vacuum will expand the air space leaving no room for water or oil. The system will short cycle if this happens. To address this issue the oil reservoir is increased by 6” to increase the length of time the system will operate


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before going into “fill mode”. If the suction lift exceeds these levels the system will continue to process water at a reduced flow up to about 6 meters for a JEU pump or the hi-lift option and 5 meters for a CDU pump without the hi-lift option. After that the pump will just deadhead and nothing will be coming out of the sump.

• Sump Level Switch

If your system is equipped with a remote start/stop it is possible that the external sump low level switch is faulty, and the system is sucking the sump dry. Check the sump level switch or adjust the system flow rate.

• Plugged Line

If the inlet line or the pre-filter are plugged the separator will likely short cycle. Remove the restriction.

• Excess Flow

If the process flow is greater than the design it can also cause a short-cycle condition. Check the flow rate and make sure it is not above the design flow. Any of these conditions could cause the level sensor to read low water level (high oil level) and will cause the system to go into “oil discharge/fill mode” in a shorter cycle than normal. A cycle time of less than 30 min. in most cases is an indication of this problem. If this happens one of the above conditions exist. You will need to find and fix the problem. In some cases a “hi-lift” option may be required to fix the problem. See Section 6 of this manual for a discussion of the hi-lift option.

iv. Excess Flow Condition

The system is designed to process the oily water at a specific flow rate. The pump is capable of pumping more than the design flow rate to accommodate many possible variables with suction and discharge lift that may be encountered with each application or installation. The flow adjustment valve (V-003) must be adjusted to the designed separator flow rate for your unit. Processing at a flow rate higher than the design flow will reduce the efficiency of the separator. An excessive flow rate could also cause other problems in the system such as a short cycle condition. When the system is initially started up the flow rate should be adjusted to achieve the design flow, and periodically checked. As the polisher back pressure increases it will reduce the flow. As an operational note the slower the flow through the separator the more efficient it will remove the free oils in the oily water stream. This will in turn increase the life of the polishing media. Anytime you want to improve the performance of the system or extend the life of the organoclay you can reduce the flow rate through the system. In most cases the system will not be running continuous and slowing it down will not seriously impact vessel. A good practice is to slow the system down during normal conditions and then in


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situations with abnormally high water levels in the bilge run at full design or maybe even higher than design.

v. Expected Results Operating properly the BOSS 107 Separator system will reduce the oil in your discharge water to below the 15 ppm limit set by the IMO MEPC regulation 107(49). In many situations the oil content will be significantly lower than the 15 ppm. With the 5 ppm option the oil content will be below 5 ppm. You can expect the following results from the system: a. With no emulsions present and using organoclay in a down flow configuration, the

system will generally remove any free oil and the monitor will generally read 0-1 ppm.

b. The higher the volume of oil in the oily water the more oil the primary separator will discharge. For example, in most situations the primary separator will remove free oil to < 15 ppm. However, with high concentrations of oil the primary separator will pass more than 15 ppm oil. The separator will handle 100% oil for short periods of time. However, as the oil concentration goes up so will the amount of oil in the water leaving the separator. This is generally not a problem because the polisher will take out whatever the primary separator does not remove. The more oil in the separator discharge the faster the post polisher media will be consumed but the system will accommodate such conditions.

c. If the separator is not being used all the time or is not running full time at the design rate, the performance can be improved by slowing down the separator. The flow control valve can be used to restrict the flow to less than the design rate. This will improve the performance of the separator and allow the coalescing separator to remove more oil, making the Polisher media last longer. This can be an effective tool for managing discharge levels of oil.

F. Maintaining and Servicing the Oil Content Monitor (OCM) WARNING: DO NOT ATTEMPT TO BREAK THE SEAL OR OPEN THE MONITOR TO DO ANY MAINTAINENCE OF THE MONITOR. BREAKING THE SEAL WILL VOID THE CALIBRATION. The only work you can do on the monitor is to change the cell, clean the cell or perform some other minor functions explained in the oil content monitor instruction manual. Any other work must be done by the factory. A separate instruction manual for the oil content monitor is attached. The oil content monitor cell will need to be cleaned on a regular basis. To clean the cell, follow the instructions in the attach OCM manual. Do not use toothbrushes or other brushes that do not have a soft end. Brushes can be ordered from your distributor or the factory. Once the cell is brushed, screw the top on the cell and push the water button again to flush clean water through the cell again. The system can now be turned back on. Do not shut off the disconnect. The monitor will need power in order to control the solenoid valve and go through its functions. You should read and refer to the separate OCM manual for more details on how to operate and maintain the OCM.


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There are times when the cell can be coated with material that is hard to get off. You may need to use soap, lime away or vinegar or some other cleaner that is non abrasive to get the cell clean.

G. Calibration of the Oil Content Monitor (OCM) At IOPP certificate renewal time every 5 years, the calibration of the OCM has to be verified. The IMO MEPC 107(49) regulation states “The accuracy of the 15 ppm Bilge Alarms should be checked at IOPP Certificate renewal surveys according to the manufacturer’s instructions. Alternatively the unit may be replaced by a calibrated 15 ppm Bilge Alarm. The calibration certificate for the 15 ppm Bilge Alarm, certifying date of last calibration check, should be retained onboard for inspection purposes. The accuracy checks can only be done by the manufacturer or persons authorized by the manufacturer.” Check the calibration certificate that comes with the system in the O&M manual to verify the calibration date. If you have lost your calibration certificate or if the cell is ready for recalibration either contact your distributor or the factory. The most common practice is to purchase a new measuring cell (sensor) that has a recent calibration and replace the old one. We recommend purchasing a new cell. Do not try to keep a spare measuring cell on the shelf because it will be using up its life while sitting on the shelf. A better practice is to order a new cell a month or so before the life of the old cell expires. It is possible to check the calibration of the cell. There is a test kit that can be purchased either from your distributor or the factory to verify the calibration of the monitor. It is not necessary to test the calibration as long as the cell has a valid calibration certificate. The instructions for checking the calibration will be included in the calibration kit. If this check is done by an authorized representative they should provide you with a certificate indicating the date that the test was completed and the results. In some cases, this check provided by an authorized representative can satisfy the IMO requirement at IOPP. This will need to be verified with your local inspector.

H. Special Tools

There are no special tools, test equipment or materials needed for servicing and maintaining the system except the following: • Brush to clean the cell on the oil content monitor • Wrench for removing bag filter housing • Calibration test kit to test the calibration of the monitor. This is totally optional and is

generally not required by local authorities.

I. Shutdown Procedures If the system is connected to a level control in the bilge sump the separator will automatically turn on and off according to the high and low settings on the level control and no manual intervention is required. If there is no level control in the bilge then the system will need to be started and stopped manually. Startup procedures are shown above. To shut the system off simply turn the 3 position selector switch on the face of the control panel to the off position.


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If the shutdown is required for any maintenance that requires opening the panel or servicing an electrical component, make sure that the disconnect on the separator AND the main breaker is turned off and the system is locked out and tagged according to standard lock-out, tag-out procedures. The disconnect in the main panel will shut off all power to the pump and internal control board but lethal voltages are still present in the control panel. To clean the cell, do not shut off the disconnect. You will shut off the 3 position switch but not the disconnect. You will need power to the system to operate the oil content monitor during the cleaning process. Any time the system is shut down all isolation valves should be shut.

J. Control Enclosure

The control enclosure is a NEMA 4X IP 68 polycarbonate box. There following pictures show the outside and inside of the control enclosure.

K. Circuit Board i. Serial Numbers B7190 to B41270:

These circuit boards are a relay based circuit board unless noted otherwise. All of the logic and control is done through relay logic. A level control relay is plugged into the board in order to control level and can be swapped out if the level relay is faulty. The level relay is the only user repairable component on the circuit board. We recommend having a spare relay in inventory. The OCM is wired to these circuit boards and communicates through status relays. Special features can be added to these systems by adding separate control devices such as timing relays. These separate control devices will not be added directly to the circuit board, but are mounted on DIN rail inside the control enclosure. There are 4 status signals that are available to the customer. These status signals indicate the following states of the system; Power, Fill (Oil Discharge), Discharge (Pump), and Recycle (PPM Alarm).

ii. Serial Numbers starting with B50101: These circuit boards are a microchip (PIC) based circuit boards. These boards have been designed to incorporate the level control and a number of other functions not previously available on the older board. The additional functions are: automatic backwash, common fault, and emergency shutdown (ESD). There are 4 status signals that are available to the customer. These status signals indicate the following states of the system; Common Fault, Fill and Oil Discharge, Pump and Water Discharge, and Alarm (PPM). The new circuit boards are completely backwards compatible and can be installed in place of the older circuit boards back to serial number B7190.

iii. Custom Control Panel

A custom control panel can be designed to meet custom requirements. This can be done by using a circuit board or a programmable logic controller (PLC) such as Allen


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Bradley or Do-more. When a PLC is used the controls can be completely customized. The human machine interface (HMI) can be lights and switches or it can be a touch screen that will use software such as Wonderware or Factory Talk View. If your system includes a custom control panel and HMI see the separate electrical and control drawings for an explanation of your system.

3. Maintenance A. Maintenance Philosophy

The standard system does not have installed redundancy, although it can be ordered with any level of redundancy the customer wishes. The general maintenance philosophy for most of the components is to replace the components as they fail. We have not developed a mean time between failures for most of the components because every situation is different. The system does not generally run continuously—only when the bilge level increases to a designated level. In general there is adequate time to make any required repair without impacting the bilge water level. We recommend maintaining critical spare parts in inventory so that if there is a failure the part can be replaced quickly. Most components can be changed within a few minutes. There are no components that need to be overhauled. In most cases the components are fairly inexpensive and it is less expensive to replace the part than it is to overhaul or repair the part. The only exception to this is the oil content monitor, which is the most expensive component on the system. In the case of the oil content monitor it is against IMO regulations for the customer to do any maintenance on the system other then cleaning the cell and other minor service. If the monitor fails it generally has to be replaced. Any attempt by the customer to break the seal and open the monitor will void the validity of the monitor. There are some routine maintenance functions that need to be performed to keep the system running at peak performance.

B. Component Maintenance i. Pump

The standard centrifugal pump installed on the system does not require lubrication. The mechanical seal should be replaced periodically or when it fails. At least one spare seal should be kept in inventory.

ii. Control Valves The control valves installed on the system are high quality marine grade solenoid or actuated ball valves and do not require lubrication. a. Solenoid Valve: If a solenoid valve fails to open the actuating coil could be at fault

and will need to be replaced. If a valve fails to close properly, there may be foreign objects lodged in the plunger assembly. The valve must be disassembled and cleaned. NEVER remove the solenoid coil from the valve with the power on or apply power with the coil not on the plunger stem. This will IMMEDIATELY destroy the coil and will nullify any warranty on the valve. If you need to service


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PLUNGER O-RING BORE

the valve, loosen the large nut at the base of the coil and remove the entire coil assembly. This will expose the plunger and allow you to replace the o-ring and valve disc or clean out any sand. If you need to change the coil you will need to disconnect the power before removing the cover. In most cases actuated ball valves have electric actuators, although air actuators are available and are used in some conditions. There is very little maintenance required for actuated valves. A spare actuator should be maintained in inventory in the event of a failure.

Occasionally a Magnatrol valve will “hang” open and not shut off the flow of water either on the fill water inlet or one of the outlet valves. The repair procedure is the same for all sizes of valves. There is an inner core that slides in the main bore of the valve that can get a particle of sand or other debris lodged which can cause the valve not to close. Or a particle may scratch the surface of the core and raise a burr on the surface, this will also hang open the valve.

Here is a photo of a ½”A42 solenoid valve CAUTION! NEVER POWER THE COIL TO “TEST” IT UNLESS IT IS INSTALLED ON THE CORE, IT WILL BURN OUT IN LESS THAN 30 SECONDS. Begin by removing the bonnet, spring washer, coil, and coil base. The core stem can then be removed from here. The location of where the main problem generally occurs is located between the stem plunger and the bore SEE BELOW

Generally a good cleaning here will solve the problem, sometimes it may be necessary to clean the inside and outside surfaces of the plunger and the bore with a FINE grit 320 or 400 sand paper to remove any burrs that may have formed. Reassemble the unit making sure the o-ring is in place.


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ALSO be sure the spring washer is on the top of the coil on the core stem and all components are positioned as shown below.

b. MOV. The system will generally not come with an MOV on the oil discharge line unless the whole system is pressurized. An MOV is required with a positive inlet pressure. If the separator is delivered without an MOV and you have a positive pressure, or if you decide for any reason that you want an MOV on the oil discharge an MOV will need to be installed as follows:

• Disconnect the oil discharge piping at the elbow. • Install the MOV in the oil discharge line in place of the check valve. • Drill a 7/8” hole in the bottom of the control panel enclosure. Put this hole

2” to the right of the hole with the level switch wire. Note: You may need to use an angle drill or drill from the inside of the enclosure.

• Run the wire along the back of the panel down to the bottom and tie wrap to unistrut.

• Run the wire around the bottom left edge of the panel and into the enclosure. Tie wrap.

• Install connector into enclosure using a cable gland provided in the kit. • Connect the wires as shown in the instructions that come with the MOV. • Clip the jumper on the circuit board J1.

COIL BASE COIL SPRING WASHER

BONNET


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Sample fitting Flow Restrictor

Sample return

iii. Oil Content Monitor (OCM) The OCM will need a periodic check of zero against clean water, and frequent cleaning of the glass sample cell. For Deckma monitors, the desiccators will need to be replaced whenever the color indicator is not blue. A spare parts kit is recommended for the Deckma OCM. The Brannstrom and Rivertrace monitors do not require desiccators and there are no spare parts required other than brushes. There are no user serviceable parts to the OCM control unit or cell. If any defective operations of the OCM are determined, call your service rep or Recovered Energy.

Without a restriction the system will generally flow more water to the OCM than is necessary or recommended. The system comes with a very small flow restrictor installed inside the return line fitting. If the flow restrictor is ever lost for any reason a new one will need to be installed as follows:

Remove the return fitting and insert the flow button in the threaded end and reinstall the return fitting. You may need to replace the Teflon tape on the threads. Do not use petroleum based pipe dope on the plastic fittings.

An automatic cleaning attachment is available that can be added to the monitor. See Section 6 for a discussion of this option.

iv. Coalescing Media

The coalescing media inside the separator is not to be confused with the polisher filter media. The coalescing media does not need periodic cleaning. It rarely will need replacing. Under normal circumstances we expect the coalescing media will need changing only once every 5-10 years. It does not require specific maintenance or replacement under normal operating conditions. The media can be destroyed by strong acids or bases. If the media is damaged by adding chemicals to the water or for some unusual reason you should do the following in order to change out the media:


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a. Remove the head on the separator vessel. b. Remove the clips and the old media. This is easier if you make a hook using a

small diameter rod. Shove the rod down the side of the media. Turn 90 degrees so the hook part is under the media and use the hooked rod to pull the media up. (It is easier with 2 hooks.) For larger systems the media may have to be cut out in pieces. Hooks can be ordered from the factory or your distributor as a spare part but in most cases it is simply easier to cut it out.

c. The replacement media comes packaged in rolls with an inner section and an outer section. Both sections are supplied a little over sized. It will be necessary to test fit and possibly remove a few inches of the roll for the proper fit. The roll may seem to be too large, however the media will be somewhat compressed as it goes into the pipe. The first 6-10” should go in with moderate pressure and get harder as it slides in. The last 4 inches should be fairly hard, and require some heavy pressure to get all the way in.

d. It doesn’t matter which section you install first. Place the media in the proper section and get it started, making sure not to damage the edge of the media trying to force it in place. The media should be tight as possible but still allow it to be inserted into the separator without rushing the roll. The center section will compress more than the outer section and it can be a little tighter. If the outer section is too tight it will be hard to push down and could buckle. You may need to trim a small amount off the rolls—either the inside of the roll or the outside or both. To do this just cut off the excess with a utility knife. If you cut too much that is not a problem—just add some back. If you have to add any back unroll the media bundle a little and insert the small piece and re-roll the bundle.

e. It is easier to push the media into the vessel with 2 people. Both people can help get the media started and then push it down uniformly. If there is only 1 person it is easier if you can use a piece of wood to put on top of the media and push down uniformly. We have found that when the media is almost in place it gets hard to push down. We use a couple of short pieces of 2 x 4 to help us push down the last little bit. On the larger systems we find that it works well to walk around on the media and use your weight to push it down. You should be able to jump up and down on the media to help push it down on the large units.\


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f. The inner section should be pushed down about 1-2 inches below the weir on 2 and 5 gpm units and about 4-6 inches on the larger units. The outer section should be pushed down just below the weir

g. If you cut off too much and the media is too loose it can float up in operation and will interfere with the operation of the level probes. If the media is loose pull it out. Roll back ½ layer of the roll and sandwich in a small section of the excess that was cut off and re roll. See picture below. This will make it tighter fitting in the pipes. It is not likely that the media in the outer section will ever come up because the water pressure is pushing it down.

(The black section is only colored for contrast) h. A small clamp is provided with the unit. This should be installed at the top of

the center pipe to prevent the possibility of the media from rising up and interfering with the level probes. This will normally only happen if the center media was not rolled tight enough.

ii. Polisher Media

The polisher media will need to be changed when the oil content monitor will not go below 15 ppm (5 ppm if the 5P option has been supplied) AND you have cleaned the cell and backwashed the media. High oil content (maximum saturation of the media) is will eventually happen with each charge of media but can be premature by using surfactants and other cleaning chemicals that make hard-to-remove chemical emulsions. We recommend the use of cleaners that do not cause emulsions. The media can last up to a year with proper care and bilge management. The used media can generally be thrown away in the same manner a spent oil filter is discarded or with the other municipal waste from the vessel or facility. It can also go into an incinerator. (Note that the ash content will be high if it is put into the incinerator.) Check with the incinerator manufacturer to verify that the incinerator will handle the high ash/sand content. a. Recharging the Media The procedure for recharging the organoclay or carbon media is as follows:


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2gpm, 5 gpm and 11 gpm Units: • Remove the flexible hose to the unit. • Remove the top distributor. Vacuum the old media from the unit using a shop vacuum. You will need to keep the media wet in order to vacuum it out. • In some cases the center tube will come out easily as long as the

media is wet. In some cases it may be hard to remove initially. If this is the case the vacuum hose will need to be small enough to go down alongside the tube or you can put the vacuum over the tube.

• Rinse out the housing. (Skip the first 5 procedures if you are using a new filter housing.)

• Place the center tube into the housing, making sure it is centered. Plug up the tube so nothing goes down the center of the tube.

• Place the funnel to the side of the tube. DO NOT ALLOW SAND OR MEDIA TO GO INSIDE THE TUBE. Pour the sand into the funnel. The sand should cover the bottom distributor basket about 6”. This can vary depending on what objective you are trying to achieve. If you tend to have problems with turbidity it is better to have more sand and less media. Turbidity or sediment will plug up the media and shorten its life. The organoclay may still have plenty of life but the media could be plugged. If this is a problem then use more sand and less organoclay or carbon. The sand should be coarse sand (40 mesh or courser).

• Pour the organoclay or carbon into the housing using the same funnel. Fill the vessel to about 10” from the top.

• Any combination of sand, carbon and organoclay is possible depending on your situation. If you have a lot of turbidity add more sand (up to half). If you have more emulsions add more carbon. If you have high concentrations of oil use more organoclay. You can purchase pre-measured buckets of sand/carbon/organoclay from the factory or your distributor.

25gpm and 45 gpm Units: • The procedure is basically the same as with the smaller units except that the

housing has a manway cover that will be removed. The new sand and organoclay or carbon is dumped into the manway opening. The sand should be filled at least 5” above the bottom distributor but not more than 50% full of sand. Organoclay and/or carbon should be loaded at least 6-8” below the top distributor.

• If the manway cover gasket is damaged you may need to replace the gasket. • In some cases the vessel will come with a bottom 10” manway to make it easier to

remove the media. This normally only comes when specifically requested. The following table shows the number of buckets that should be used for each size vessel. Do not overfill the polisher vessels. In some cases there will be a little


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more media than is required because the vessel size doesn’t match exactly with the buckets. If you overfill the vessel vacuum out the excess. You can also hire a local filter company or your distributor to change the media. They will come out and vacuum out the polisher and replace the media.

2gpm 5gpm 11gpm 25gpm

24” 25gpm

30” 45gpm

Sand Buckets

0.5 1 2 4 8 10

Sand Weight

30 50 100 200 400 500

Organoclay Buckets

2 4 7 14 14 28

Organoclay Weight

60 120 210 420 420 840

Figure 2: Weights are all shown in lbs.

b. Disposing of Spent Organoclay Media:

Laboratory testing of spent organoclay has shown that BTEX and other volatile hydrocarbons are adsorbed tightly enough for the spent product to pass the EPA’s Toxicity Characteristic Leachate Procedure (TCLP) test and be disposed as a non-hazardous waste. The TCLP is used to identify the presence or absence of toxic chemicals that might be able to leach into groundwater after disposal. This is an amazing accomplishment, given that the product may adsorb up to 88% of its own weight in hydrocarbons or 100% by volume. Being classified as a non-hazardous waste allows the spent product to be landfilled, land farmed, or otherwise disposed in an economical manner.

iii. Control Components The control components are designed for marine application. They should be replaced when they fail. We have indicated on the spare parts list which items we recommend to spare.

iv. Flow Indicator The flow indicator is an industrial class, direct reading indicator that is simple to use and install. It provides an excellent way to measure the flow through the system without having to use an expensive meter. If the glass gets cloudy or breaks, the cover is easily removed and a replacement glass can be installed. The spring inside the indicator is specific to each size unit and is not interchangeable. The spring can be changed by removing the cover. The separator system will function perfectly fine without the flow indicator. The only impact is that


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you will not know exactly what the flow rate is. If the flow indicator fails the system can be operated normally until a replacement can be procured. In this situation the system can be operated based on its performance. If there is too much flow going through the separator, the efficiency will decrease. If the oil content in the discharge goes up, slow down the flow and the efficiency will improve. As long as the separator is meeting IMO requirements it is not critical to know the exact flow rate during a temporary situation but lower flow is always safest in these situations.

C. Draining the Separator

The separator is designed to hold water all the time. Should it become necessary to drain the separator for any reason you should cycle the system between fill and normal operation several times in succession to eject as much oil as possible from the top of the separator. To cycle the unit place the system in normal operation, close the inlet valve that is located on the inlet side of F-101 and open the vent valve (V001). The unit will go into fill mode as soon as the fluid level in the top of the unit is pumped down to the low-level sensor. This should happen in approximately 60 seconds to 5 minutes, depending on your separator size. The unit will cycle between fill and normal operation as long as the vent is open and the inlet is closed. Three cycles should be enough to dilute and reject as much oil as possible. Then proceed to open the drain plugs D1 & D2. This will drain both of the internal sections of the unit. Leave the vent open to facilitate the draining process. To refill the unit follow the procedure outlines in 2.4.

D. Annualized Recommended Maintenance Schedule

i. OWS Time-Based Maintenance

Maintenance Activity Maintenance Hours Frequency

Annualized Hours

Clean OCM monitor glass 0.05 Daily or weekly 5 Purge the air in the OCM Monitor cell 0.05 daily or weekly 5 Verify normal operation of the system 0.05 daily or weekly 5 Clean the “Y” strainer screen 0.15 daily or weekly 15 Test the operation of pump 0.1 monthly 1.2 Test the operation of the control valves 0.1 monthly 1.2 Verify design flow rate 0.05 monthly 0.6 Check the OCM desiccators (Deckma only) 0.05 monthly 0.6

Verify mechanical seal on the pump 0.05 semi annual .1

ii. OWS Condition-Based Maintenance

Replace the organoclay media in the filter when the system will not keep the oil content sis below 15 ppm. 4 - 8 variable 4 – 8


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Replace the desiccators on the OCM monitor,when it is no longer blue (Deckma only) 0.1 Variable 0.1

Replace mechanical seal and o-ring on pump,and valve o-rings .5 When they leak .5

Replace other components as required 2 variable 2

4. Troubleshooting The following suggestions are provided for situations that have been encountered in the past: A. System Recycles into Fill Mode Frequently

The BOSS system is designed to go into fill mode (Cycle) when the oil water interface reaches the low level. If conditions are normal this should not happen more than once per hour. If the system is cycling more often than that, several problems may exist. For further discussion of this condition see Section 2(E) (iii).

B. System is not Getting Enough Lift

If the vacuum gauge is reading more than the design rate you should first look for factors that could be impacting the suction lift. These may include too small inlet piping, restrictions in the line, to many fittings or too many valves. If the application demands a high suction lift refer to the Hi Lift Option in Section 6.

C. Reduced Flow Through the System i. Plugged Pre-Filter

If the flow through the system becomes reduced it could be caused by a plugged pre-filter. To unplug the filter, remove the screen, clean it and reinstall the screen.

ii. Plugged Polisher

Low flow can also be caused by a plugged polisher. In some cases suspended solids in the bilge water will collect on top of the organoclay and cause the polisher to plug. The system will normally come with a bag filter located between the separator and the polisher. The purpose of the bag filter is to remove fine sediment and turbidity that could plug up the polisher or impact the OCM reading. If your system does not have this bag filter it is because the shipyard or distributor specifically ordered the system without a bag filter. The factory strongly recommends a bag filter. The system will work significantly better with a bag filter. If your system does not have a bag filter it can be ordered from the factory or the closest distributor and can be installed very easily. The bag filter will significantly reduce any plugging of the post polisher. A sand filter can also be installed prior to the organoclay polisher instead of the bag filter to remove these suspended solids before they reach the organoclay polisher.


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The system comes with backwash valves to remove sediment or turbidity that collect in the Polisher. The system should be backwashed daily with continuous operation or at the end of each batch with a batch process. If the sediment is allowed to go deep into the polisher it will be too embedded to remove. Once the organoclay polisher is plugged with solids the media will need replacing.

If the bag filters are being replaced too often or in situations with high levels of sediment the Y strainer and bag filters may not be adequate to remove the solids. In this situation a solid separator can be installed on the front of the system. This is a gravity separator that will remove high levels of solids down to a particle size of about 20 micron, depending on the specific gravity of the material. If you are struggling with high solids please call the factory or your distributor and ask about the various options for handling solids.

iii. Bacteria

In some cases we have found that the bilge is full of bacteria that are growing in the bilge. This will plug the polisher and will also cause the OCM to not work because it will discolor the water and cause the OCM to alarm. If there is bacteria in the bilge it must be removed with chlorine or something else that will kill the bacteria and keep it from returning. Neither the bag filter nor the polisher will remove bacteria. If the separator is not used for long periods of time it can go anaerobic and clog the media. The separator should be run at least weekly. There are times when the vessel operates a dry bilge and rarely if ever uses the separator. This is not good for the separator and could cause problems when it is used. If the unit is not going to be used on a regular basis it should still be run at least weekly. This can be done manually or REI can provide a timer that will automatically turn the system on at some interval using clean water. By cycling the system on a timed basis the system will stay clean and fresh and available for use when needed.

D. Fault Alarms and Remote Monitoring Capabilities

The OCM monitor is designed to alarm if the oil content exceeds the set limit or if the OCM system fails or (for a Deckma monitor only) if the blue handle on the detector is in the test mode position. If the oil content exceeds the set limit the OCM alarms internally and causes the system to go into recycle mode until the alarm condition no longer exists. The alarm will show on the OCM display and will be recorded by the OCM data logger. Under a system fault alarm the alarm will show on the OCM display. Any OCM alarm or fault condition will automatically put the system into the recycle mode. i. Potential causes of the OCM system fault include:

a. loose or improperly inserted data card b. loss of communication between the display and the detector (loose cable) c. internal board or power supply failure

(See separate OCM O&M manual for a more detailed explanation of the OCM monitor.)


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ii. Available signals from the OCM a. 4-20 ma signal showing the ppm oil content in the water (0-20 ppm) b. Voltage free contact for the OCM alarm c. Voltage free contact for the OCM system fault

iii. Available signals from the Control Panel

a. Dry contact showing whether the system is in normal operation mode (pump is running and either discharging water or recycling water)

b. Dry contact showing whether the system is in fill mode (pump is not running, the system is filling and oil is being discharged)

c. The customer can remotely start or stop the system with an external voltage free contact. The above control features are standard with the system. Any other control features that the customer would like to have can probably be done for an additional fee.

E. Solenoid Valve Not Working

If a solenoid valve does not work, the most likely cause is a failure of the coil or a loose wire. You can verify the electrical continuity from the control panel. To replace the coil, turn off the power to the system, disconnect the wiring, remove the cover and replace the coil as shown in the Maintenance Section. NEVER remove the coil with the power still connected. You will destroy the coil instantly if the coil is separated from the valve and the power somehow is either left on or gets turned on. If the valve needs a new gasket or O-ring turn off the power and make sure there is no power to the coil. Then loosen the nut just above the valve and remove the coil section. Replace the gasket/O-ring and reassemble the valve. Do not turn the power back on until the valve is fully reassembled.

F. System Goes into Fill Mode but the Fill Valve Does Not Open For systems with the optional MOV valve on the oil discharge, the MOV and the fill valves should open when the system goes into fill mode. If the MOV opens but the Fill Valve does not open then it is possible that the MOV switch is faulty. If the switch does not make complete contact then the MOV will open but SOV 101 will not do anything. If this happens you have a bad switch on the MOV and need to replace the switch.

G. High Oil Content Reading Causing Water to Recycle i. Turbidity

If there is turbidity in the water the OCM monitor can give a false oil content reading. If this happens, a better filtering system will be needed to remove turbidity. If you do not have a bag filter or sand filter, you can add one. If this is done it is recommended to be placed just prior to the organoclay polisher in line. If the system already has a bag filter and there is still a sediment problem then a solid separator on the front of the


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system should be considered. Contact the factory or your distributor to discuss this situation.

ii. High Emulsions If you have high levels of emulsions and the organoclay is not removing the oil adequately, you may need to use carbon instead of organoclay or you can use a combination of carbon and organoclay. Carbon will work better for some emulsions and organoclay will work better for free oil and other types of emulsions. If you use the combination you should load a bed of sand first, then carbon and then organoclay. The water goes down through the media. It is best to go through the organoclay first and then the carbon.

iii. High Oil Concentrations If you are running high concentrations of oil the primary separator may pass more than 15 ppm oil. The system will handle up to 100% slugs of oil and will handle 35% for longer periods of time. However, the water coming out of the separator will also go up in oil content. This is generally not a problem because the organoclay polisher will remove the oil. However, the organoclay media will fill up faster and the media will need to be changed more often.

iv. Full Media In most situations the organoclay will remove 100% of the free oil that goes through the polisher. As the organoclay fills up with oil the ppm oil in the discharge will rise until the monitor goes into alarm. When this happens it is time to change the media.

v. Dirty OCM Cell Sometimes a high OCM reading has nothing to do with the polisher and is simply caused by a dirty OCM cell. The glass in the cell should be cleaned on a regular basis. This should be the first thing checked when the monitor is in alarm mode.

vi. High Flow Rate One important thing to check is to make sure the flow rate is not over the design rate. Letting the water flow through the separator at a higher rate than the design rate will reduce the efficiency of the 1st stage separation because the residence time is not sufficient. Lowering the flow rate will increase the residence time and flux rate and the efficiency of the separation and will lower the oil content of the water to the polishing filter.

H. No Flow Through the OCM

The flow through the OCM is based on the differential pressure across the system since the OCM recycle is discharged back into the separator. In a vacuum situation there is always a differential pressure and therefore there is always a flow through the OCM. If the system has a positive pressure then the pump will create a differential pressure across the system. However, it is possible in rare situations for the discharge pressure to be very close to the inlet pressure. This would be caused by high discharge head or a plugged Polisher vessel. If this happens the flow of water through the OCM could be restricted or possibly even stop


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because the drain from the OCM goes back into the vessel and if everything is at the same pressure nothing will flow. One way to correct this is to make sure the polisher vessel is not plugged. If the polisher is not plugged then there will always be a differential pressure. Another way is to pipe the recycle water from the OCM to a non-pressurized drain and then flow will start again. It is also possible to install a flow switch that will interlock with the OCM so that the system will shut down if there is no flow through the system. Please contact the factory or your distributor for this option.

I. Pulling Vacuum on the Filter In rare situations it is possible to pull high enough vacuum and collapse a fiberglass Polisher vessel. There are 3 situations where this is possible: i. If the operator is pulling high vacuum and shuts off the inlet ball valve and then shuts

off the unit. In this case the separator will be under full vacuum and if the inlet is restricted it will not allow the separator to pull water from the bilge so it will pull from the filter. If the pressure in the filter is low at the time then it is possible to pull enough vacuum to collapse the fiberglass filter.

ii. If the Y strainer is plugged or there is some other obstruction in the inlet piping and the unit is shut off then you will have the same condition described in “a”.

iii. If the filter vessel is tightened down too tight it is possible for the filter clamp to flatten the filter so that when there is vacuum pulling it is easier to collapse the filter where the filter clamp is located.

These conditions are rare but possible. There are several ways to address this situation: i. Don’t shut off the inlet isolation valve until after the separator has had a chance to

relieve the vacuum. ii. Keep the Y strainer clean.

iii. In order to prevent this from happening we have located a check valve (CV-103) on the inlet side of the filter tank. This will prevent the separator from pulling vacuum from the filter and will prevent the collapse of the fiberglass Organoclay tanks on the 2, 5, and 11 GPM units. It is not an issue for 25 or 45 gpm units. If for any reason your unit does not have a check valve on the inlet line to the filter you should install a check valve or ask the factory or your distributor for a check valve. The factory will provide this check valve at no charge.


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5. Safety

A. Ignition Hazard Assessment The transformer generates up to 100 watts, which is not enough to generate an ignition source. In the case of a dead short, the transformer would trip and the source of heat would cease. If the transformer got too hot it would automatically trip and the heat would cease. The system is protected by a primary and secondary fuse. The system cannot generate sparks, shock waves, exothermic reactions, electrical arcing or adiabatic compression. There is no ignition hazard.

B. Electromagnetic The system has been tested under EN Standard 61000-6-2:2005 and EN 61000-6-4:2007 for electromagnetic compatibility by an independent laboratory and was found to have no EMI or EMC interference or hazard to the operator.

C. 29 CFR, Part 1910

There are no moving parts on the system except the pump which is close coupled, TEFC and IP 55 rated. There are no guards necessary because the pump is close coupled. The pump meets all the requirements of 29 CFR, Part 1910, as do all the other components.

The control panel has an IP 66 rating. All components in the control panel are finger safe.

The separator operates under vacuum so there are no pressure issues. Even through the separator vessel operates under vacuum it has been designed according to ASME Section VIII standards at 15 psig pressure and has been tested at 45 psig pressure or higher.

The system does not require hand rails, ladders, scaffolds or any other devices for access to the separator or post polisher. The system has its own disconnect, which must be turned off in order to open the control panel enclosure. The system is protected by fuses. The system is not processing any hazardous chemicals.

D. Dangers, Warnings, Cautions

The system will have a warning label showing the electrical voltage coming to the disconnect. When the system is shut down for maintenance the power coming into the system should be turned off at the breaker with proper lock-out, tag-out procedures being followed.

E. Federal Protection Standards There are no hazardous substances or chemicals used in the system. The system is designed to separate oil from water. If there are other chemicals or substances in the oily water sump they should be evaluated individually to determine the impact.


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6. Available Options The basic separator meets the requirements of MEPC 107(49) and will work fine in most situations. However, there are a number of situations where existing conditions require some type of modification from the standard package in order to enhance the performance of the system or to meet specific requirements. A list of the available options is shown below. Most of these options can be added to an existing system. Option

No. OPTION DESCRIPTION CODE

A Area Classification AC NEMA 4X Rated for NEMA 4X area (Standard) 4X

Hazardous area -- Class I Div I

Rated for Class I Div I hazardous area, NEMA 7 enclosure X1

Hazardous area -- Class I Div II

Rated for Class I Div II hazardous area, purged enclosure X2

B Pressure Classification PC

Vacuum -- Standard suction

Standard vacuum inlet, separator 15 psig pressure, polisher 75 psig pressure (Standard) VS

Vacuum -- High Suction

High lift vacuum Inlet, separator 15 psig pressure, polisher 75 psig pressure (for CDU pumps) HL

Vacuum -- Medium Pressure

High Lift vacuum Inlet, Sep 50 psig pressure, Polisher 75 psig pressure VM

Vacuum -- High Pressure

High Lift vacuum Inlet, Sep 150 psig pressure, Polisher 150 psig pressure VH

Positive Pressure -- < 15 psig Positive inlet, Sep 50 psig, Polisher 75 psig PL

Positive Pressure -- 15-50 psig Positive inlet, Sep 50 psig, Polisher 75 psig PM

Positive Pressure -- 50 - 150 psig Positive inlet, Sep 150 psig, Polisher 150 psig PH

C Pre Filtration PF Light solids Y Strainer (standard) Y Light solids Basket strainer B Light solids Dual basket strainer D Heavy solids Solid separator S

D In Line Filtration (Bag Filter) BF

Bag filter Single poly bag filter (standard) P1

Bag filter Dual poly bag filter--manual valves P2 Bag filter Single 304 SS bag filter S1

Bag filter Dual 304 SS bag filter--manual valves S2

Bag filter Dual 304 SS bag filter--automatic valves S3

E Polisher Vessel PV


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Bulk Media Polisher Organoclay bulk media polisher (standard) OP

Bulk Media Polisher Automatic Backwash AB

Bulk Media Polisher 2nd polisher EF

Cartridge Filter Mycelx Dual cartridge filters (2 or 5 gpm systems only) MF

Cartridge Filter Organoclay dual cartridge filters (2 or 5 gpm systems only) OF

Cartridge Filter Wave International dual cartridge filters (2 or 5 gpm systems only) WF

F Enhanced Performance Options EP

Heater Insertion heater mounted in side of separator HE High Flow Allows clean water to be discharged at a higher rate HF Harsh Environment For rigs or other harsh environment conditions HW 5 PPM Meets 5 ppm discharge standard 5P

G Oil Content Monitor Options OC

Brannstrom Bilgmon 488 (standard) B Brannstrom Bilgmon 488 with autoclean A Rivertrace Smartcell R Deckma OMD-2008 D NAG TD-107 T

H Automation Options AU

Poly enclosure Imbedded PLC level control, polycarbonate enclosure (standard) 1

SS enclosure Imbedded PLC level control, 304 SS enclosure 2 PLC Control Panel PLC control, polycarbonate enclosure 3

PLC Control Panel PLC control, 304 SS enclosure 4

I Other Options OC Drip Pan System mounted on a drip pan and fully piped DP Skid System mounted on a skid and fully piped SK Skid with pan System mounted on a skid with a pan and fully piped SP

SS Piping Stainless steel piping and fittings SS

Confined space Yacht size with cartridge filters YM Confined space Yacht size with bulk organoclay YO SS Name Plate 304 SS nameplate, embossed SN Flanges Threaded flanges for each inlet / outlet FL

Flanges Threaded flanges for each inlet / outlet with counterflange FC

Certificates CCS certificate CCS


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Certificates ABS certificate ABS Certificates BV certificate BV Certificates ASME Section VIII Div I U Stamp AS

A. Area Classification (AC) The standard system comes with a NEMA 4X area classification (Code 4X). If the application requires a hazardous area classification then certain modifications are required. The system can be designed to meet a hazard area classification for either Zone 2 (Class I, Div II) or Zone 1 (Class I, Div I). i. Zone 2 (Class I, Div II): Option “X2”

a. The pump motor is explosion proof. b. The solenoid valves and motorized ball valve are rated for NEMA 7. c. The control panel is in a 304 SS NEMA 4X purged enclosure. d. The OCM is enclosed in a NEMA 4X purged 304 SS enclosure. e. The level relay is intrinsically safe with a Zener barrier. f. The external wiring is armored cable with the appropriate connectors and glands. g. The oil discharge line has a NEMA 7 MOV. h. The OCM has remote buttons located on the face of the enclosure to allow

operation of the OCM without opening the cover. i. The OCM has automatic washing of the cell. j. The tubing is all 304 SS.

ii. Zone 1 (Class I, Div I): Option “X1”

b. The pump motor is explosion proof. c. The solenoid valves and motorized ball valve

are rated for NEMA 7. d. The control panel is an aluminum NEMA

7/4X enclosure e. The OCM is located inside a NEMA 7

enclosure, with proper cable glands and fittings.

f. The level relay is intrinsically safe with a Zener barrier.

g. The external wiring is armored cable with the appropriate connectors.

h. The oil discharge line has a NEMA 7 MOV. i. The OCM has remote buttons located on the

face of the enclosure to allow operation of the OCM without opening the cover.

j. The OCM has automatic washing of the cell. k. The tubing is all 304 SS.


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The Oil Content Monitor does not come rated for Zone 1 or Zone 2, so a separate enclosure is provided for the Oil Content Monitor. The enclosure for Zone 1 is NEMA 7, using an ex.d protection method. The enclosure for Zone 2 is a NEMA 4X 304 SS enclosure with purge control, using an ex.p protection method. The level control is protected inside the enclosure with a Zener barrier (ex.i method). The purge panel is designed so that if the panel is opened power to the OCM is immediately shut off. The rest of the system can continue to run in a safe mode but the valves will automatically fail to the recycle position when the purge panel is opened. The purge panel can be set to allow time to purge each time the door is opened. For instructions on how to do this see the separate purge control manual.

B. Pressure Classification (PC) The standard system is designed to operate in a vacuum condition with the pump pulling through the separator from a bilge that is LOWER than the separator. The separator vessel is designed for 14.5 psig vacuum and 15 psig pressure. The polisher vessel is designed for 14.5 psig vacuum and 125 psig pressure for a fiberglass vessel (2.2, 5 and 11 gpm systems) or 75 psig pressure for a steel vessel (25 or 45 gpm systems). The maximum pump pressure is 35 to 45 psig, depending on the pump and frequency. A standard 2.2 gpm or 5 gpm system with a JEU jet pump has a suction lift of 5 meters (16 feet) as it comes from the factory without any modifications. Any system with a CDU pump with a 1 or 3 impeller size has a standard lift of 3-4 meters (10-13 ft.). WARNING: If you have a positive inlet pressure you need to verify that your system is configured properly for positive pressure. i. High Lift Suction: Option “HL”

A higher suction lift than normal is available on systems with a CDU pump. This option will allow the separator to pull up to 16 feet (5 meters) of negative head. In order to achieve a 5 meter (16 ft.) lift with a CDU pump the high lift option must be exercised and following modifications must take place: (i) the pump has to have a size 5 impeller and matching motor or (ii) it has to be a 2 stage pump (2CDU) and (iii) The oil reservoir has to be larger. With a large suction lift the vacuum expands any air space in the top of the separator. If there are any leaks in the inlet piping air will accumulate in the top of the oil reservoir and the vacuum will expand the air space leaving no room for water or oil. The system will short cycle if this happens. To address this issue the oil reservoir is increased by 6” to increase the length of time the system will operate before going into “fill mode”. If the suction lift exceeds 5 meters, the system will continue to process water at a reduced flow up to about 6 meters for a JEU pump or the hi-lift option and 4.5 meters for a CDU pump without the hi-lift option. After that the pump will just deadhead and nothing will be coming out of the sump. If the suction lift is more than 5-6 meters then a progressive cavity pump and other changes are required (see Options PM and PH). Contact the factory or your distributor to determine what changes need to take place.

ii. Vacuum Operation with Higher Vessel Design Pressure: Options “VM and VH” A system may operate in both a vacuum condition or a pressure condition at different times for different reasons. Alternatively, the specifications may call for a higher


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pressure rating. In such cases the vessel design needs to be modified. Option VM includes a separator pressure rating of 50 psig and a polisher vessel rating of 150 psig. Option VH includes a separator pressure rating of 150 psig and a polisher vessel rating of 150 psig.

iii. Low Positive Pressure: Option “PL” In some cases the system will have a low positive pressure part or all of the time. This usually happens when the bilge or holding tank is slightly higher than the separator. In this condition the pump is still located on the discharge side of the vessel and is pulling through the system. The following changes are necessary for this condition:

• The oil out line needs a motorized discharge valve. The check valve that comes standard will only hold about 1 psig pressure. If the head pressure is greater than this the check valve will allow fluids through that would end up on the oil slop tank.

• A check valve is installed just prior to the discharge valve to create a differential pressure across the system. Without this check valve it is possible in rare situations for the system to not have any differential pressure. The water feed to the OCM is dependent upon differential pressure across the system. If there is no differential pressure no water will flow to the OCM.

• A flow switch is installed on the OCM. If there is no flow through the OCM the system alarms.

iv. Pump Located Before the Separator: Options “PM and PH”

In some cases it is necessary to locate the pump on the inlet of the separator and push through the system. This would normally be required to meet a specific pump specification or if the suction lift is higher than 5 meters. In this situation the system is pressurized and additional modifications are required. There are 2 pressurized options. Option HP is a high pressure system with both the separator and the polisher rated at 150 psig. Option MP is a medium pressure system with the separator rated at 50 psig and the polisher rated at 75 psig. With this option, a progressive cavity process pump (P-101) is mounted on the inlet of the separator which pulls water from the oily water sump and then pushes the water through the pre-filter (F-101) and separator (S-101). A progressive cavity positive displacement type pump is necessary to reduce the formation of mechanical emulsions. The flow rate of the pump is determined by the pressure and the rpm at which the pump operates. A pressure regulator protects the pump in case of over pressure. It is critical that ALL connections to the oil water separator are airtight and properly sized for the installation. The flow rate from the pump will vary somewhat depending on the inlet and discharge pressures and other factors. A progressive cavity pump is designed for a narrow flow


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rate range which is set by the rpm of the motor and the pressure. If the pressure changes the flow rate will change within a narrow range. In order to control the flow rate, the standard system includes a manual bypass valve back to the inlet of the separator so the flow rate can be adjusted or controlled by bypassing any excess flow. An option for an automated system to control the frequency (rpm) of the pump motor is also available at an extra cost. The VFD option is automated but much more expensive. A manual flow control valve is provided to adjust the flow to the design level when a VFD is not used. A motorized valve on the oil discharge is required. For vacuum situations a check valve is used to keep anything from coming back into the separator. However, with positive pressure the check valve will not hold enough pressure and a motorized valve is required. Since the pump is on the inlet of the system, the separator will always be under pressure. In this situation it is MANDATORY that the system includes a motorized control valve on the oil discharge. A positive pressure setup has a few differences from the standard vacuum pressure setup. With positive pressure:

• The vessel has a higher pressure rating. • The pump is a progressive cavity pump with a pressure relief valve and bypass. • The oil out line needs a motorized discharge valve. • A check valve is installed just prior to the discharge valve to create a differential

pressure across the system. • A flow switch is installed on the OCM. • The system includes a PSV.

All the fabricated vessels are designed according to ASME Section VIII Div I. However, they do not come with a U Stamp unless specifically requested and ordered that way. Any system can be ordered with an ASME U Stamp (Option “AS”) for an additional fee. However, this is not an option that can be added later. The system has to be ordered with a U Stamp before it is built.

C. Pre Filtration (PF)

The standard system comes with a Y strainer on the inlet. The Y strainer has an 80 mesh screen and will take out large particles but will not do anything for fine silt or turbidity. In some cases the standard Y-strainer may not provide adequate pre-filtration. Silt or turbidity in the system can impact the accuracy of the oil content monitor and will plug up any type of oil water separator or polishing vessel to remove emulsions. Drilling rigs or dredges generally have significant problems with silt. If the polisher plugs up quickly or if the monitor is consistently reading high then you could have turbidity or silt issues that require better pre-filtration. i. Basket Strainer: Options “BS” and “DB”

Basket strainers will generally provide better filtration than a Y strainer depending on the mesh size of the strainer. The advantage of a dual basket strainer is that the system does not need to be shut down to clean out the screen.


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ii. Heavy Solids: Option “SS”

REI has developed a Solids Separator to remove large volumes of solids. The Solids Separator can either be a separate vessel or it can be combined into one vessel with the oil water separator in what we call a “Combo Separator”. The individual Solids Separator would be used in situations where an existing system is already in place. The Solids Separator can be installed on the front end of any oil water separator. The Combo Separator would be used for new installations or to replace an existing oily water separator. The Combo Separator does not change the function of the oily water separator. The only operating difference is that the Combo Separator requires the addition of a blowdown system (pump, valve, solids level control) for the solids, a larger vessel, the BF option with 2 bag filters, the HP or MP Option and the PS Option. Most situations do not require a pre-filter other than a Y strainer or basket strainer to remove large particles. If your system has more solids than a Y strainer or basket strainer can handle then you should seriously consider a Solids Separator or Combo Separator. You can contact REI directly or go through your distributor.

D. In Line Filtration (Bag Filter “BF”)

The standard system comes with a single poly bag filter located between the oily water separator and the polisher, unless specifically requested not to have one. REI highly recommends the use of a bag filter to remove solids before the polisher. The bag filter will increase the life of the polishing media and improve the performance of the OCM. The following additional configurations and control options are available for the bag filters: i. Dual Poly Bag Filters: Option “P2”

In place of the standard single bag filter, a set of dual poly bag filters are installed with a set of manual valves. The valving is set to operate the bags in series to achieve the highest performance or in parallel to achieve the least maintenance cost.

ii. Single Stainless Bag Filter: Option “S1” This option includes a single 304 SS bag filter.

iii. Dual Stainless Bag Filters: Option “S2” In place of the standard single bag filter, a set of dual 304 SS bag filters are installed with a set of manual valves. The valving is set to operate the bags in series to achieve the highest performance or in parallel to achieve the least maintenance cost.


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iv. Cascading Bag Filter: Option “S3” As a unique feature the BOSS separator can be configured using a PLC based automatic bag filter cascading system. The cascade filter system works as follows: a. Theory--The Cascade System has been designed to take full advantage of the bag

filters in the process. Typically there are two configurations that bag filters are placed in; series or parallel. Series filtration will provide the highest water quality due to fluid passing through each filter sequentially. This is an optimal condition when filters are in a new and clean state. Parallel filtration will provide a larger filter surface area due to the splitting of the fluid streams. This provides an optimal condition when filters are in a dirty state. Parallel configuration also makes it easier to do maintenance because the system can still be running while one of the filters is changed. Cascade technology uses a series filter configuration under clean conditions and a parallel configuration under dirty conditions to extend the life filtration media and reduce operator maintenance.

b. Auto Mode--In “Auto Mode” the cascade system will be controlled by the differential pressure sensed across the cascade system. The initial state in “Auto Mode” will have the bag filters in a series configuration. The flow of process will enter one bag filter and then the next in a line or “series” type flow. As the differential pressure increases and eventually hits a predetermined set point the bag filters will then be changed to a parallel configuration or CASCADE. The flow of process will enter and exit both bag filters at the same time in a “parallel” type flow. The parallel configuration will cause the differential pressure to drop because of the reduced resistance to flow through the bag filters. As the differential pressure increases again it will hit another predetermined set point. Once this set point is achieved, process flow will stop, and a light will indicate that the filters need to be changed. After the operator has changed the bag filters the system will be notified via a pushbutton, and “Auto Mode” will resume from the beginning.

c. Manual Mode--In “Manual Mode” the operation of the system is totally controlled by the operator. They will have full control over all valves and pumps. Two additional states are available in “Manual Mode” that are not available in “Auto Mode”. The operator will be able to run each bag filter separately and completely independent of the other bag filter.

The chart to the left shows the valve configuration with a dual bag filter operating in a cascade format.


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E. Polisher Vessels (PV) The standard system comes with a polishing vessel designed to hold bulk organoclay media. The 2.2, 5 and 11 gpm systems are supplied with fiberglass vessels with a pressure rating of 125 psig. The 25 and 45 gpm systems are supplied with carbon steel vessels with a pressure rating of 75 psig. The advantage of bulk media is that it lasts longer between changes. The disadvantage is that it is harder the change. Overall the cost of bulk organoclay is the most cost effective approach. i. Additional Polisher: Option “EP”

There may be situations where an additional bulk polisher vessel is warranted. This option would be warranted in situations where there are lots of emulsions or difficult types of emulsions. The second polisher vessel mounts next to the first polisher and the media flows from one to the next in series. The standard media supplied with a second polisher is activated carbon. The second polisher is the same size as the first one.

ii. Automatic Backwash: Option “AB”

It is important to backwash the polisher vessel media in order to extend the life of the media. The system comes with manual backwash valves for the polisher vessel. Automating the backwash function can provide assurance that it is being done on a regular basis. This option includes actuators installed on the existing valves and minor changes to the control system. This can either be done when the unit is ordered or at any later date as an upgrade to the existing system.

iii. Mycelx Cartridge Filter: Option “MF” In some situations cartridge filters may be preferred. In these situations a sediment filter with a 5 micron cartridge would first be installed followed by 2 polisher filters (2½” poly housing) operating in series. Cartridge filters are generally used for 2.2 or 5 gpm systems. This option uses a Mycelx filter for the polishing filter.

iv. Organoclay Cartridge Filter: Option “OF” This option is the same as MF, except that it uses 2 polisher filters (2½” poly housing) operating in series with an organoclay cartridge filter.


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v. Big Blue Oil removal Cartridge Filter: Option “WF”

The option is the same as MF, except that it uses 2 Big Blue sized polisher filters (4” Big Blue size) in series. These hold more oil that the smaller cartridges

Bulk polishers have certain advantages and disadvantages over cartridge filters. A carbon cartridge filter for a 2 gpm system will hold <5 ounces of oil. The same size cartridge filter that has been treated with Mycelx coating will hold about 1.2 lbs. of oil. A cartridge organoclay filter will remove about 1.5 lbs. of oil. The Wave International cartridge will remove about 4 lbs. of oil. The BOSS bulk media polisher for a 2 gpm system using organoclay will hold about 25 lbs. of oil. The other advantage of bulk media is that the media can be adapted easily to any situation. We can mix carbon and organoclay to address a wider variety of situations. We can use all carbon or all organoclay. The disadvantage of the bulk polisher is that changing the media is more difficult than with a cartridge. There are certain situations where we recommend using a cartridge filter but in most cases the system will come with a bulk media polisher loaded with a base of sand covered by organoclay.

F. Enhanced Performance “EP” i. Heater: Option “HE"

A heater can be added as an optional feature. The heater is located in the top section of the separator just above the weir in the oil storage section of the separator. If there are emulsions in the oily water, some of the emulsions can collect on top of the water but below the free oil. If the emulsions have a high water content it is possible for the emulsion to act more like water than oil and can possibly be detected by the level sensor as water. Sometimes these emulsions can exit the separator with the water. The post polisher is designed to remove the emulsions that make it through the separator without being removed. Another way to break an emulsion is to heat the emulsion to a temperature above 140 degrees F. The heater is located in the section of the separator where emulsions can collect. By heating this section of the separator it is possible to achieve a better separation of emulsions and increase the life of the post polisher media. The standard heater comes with a single heater in the 2.2, 5 and 11 gpm sizes and 2 heaters in the 25 and 45 gpm sizes. The heater has an internal thermostat that can be set anywhere from 10 degrees C to 120 degrees C, although it should not be set above 80 degrees C. The heater is controlled by a circuit breaker located in the panel. If the heater is to be used the circuit breaker is turned on and will heat the affected zone of the separator to the set temperature and then turn off. As long as the heater switch is turned on the heater will maintain the set temperature in the upper section of the separator.


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WARNING! The heater should not be operated unless the separator is filled with water. Operating the heater without water in the separator could cause damage to the heater elements. Setting the thermostat in the heater to higher than 80 degrees C could cause damage to the separator.

ii. High Flow: Option “HF”

The hi-flow option is designed for a situation where the customer has a large volume of water in a tank with some oil on the top or in situations where there is a heavy rainfall and large volumes of water need to be discharged quickly. The hi-flow system allows the operator to pump the tank at a high rate (no real maximum limit). The BOSS continually samples the water through the oil content monitor. Once oil is detected above a given set point, the system closes the main valve and diverts the water through the separator at a slower rate. For example, let’s say that the main pump is discharging 600 gpm of water and is able to empty 95% of the tank before oil is detected. This water is discharged at a rate of 600 gpm. The last 5%, which contains oil goes through the separator at the design rate of the separator (let’s say 45 gpm for illustration purposes). This option allows the customer to pump large volumes of water, knowing that the system will automatically switch to the separator when oil is detected.

With a hi-flow option the separator works exactly the same as a normal separator. The difference in the system is that there is a control valve on the main line and additional control valves coming in and out of the separator to control the two different modes of operation. A Stand Alone Monitor (SAM) can be used to do the same things as the Hi-flow Option. A SAM is a free standing monitor that controls a discharge and recycle valve just like a separator. A sample of the water goes through the SAM. If the oil content is below the set point the water is allowed to go overboard. If the oil content is above the set point the water goes back to the bilge and has to be processed by the oily water separator.

iii. Harsh Environment: Option “HW”

The system normally comes with a polycarbonate control panel and marine rated cable. Where more rugged conditions exist the “Harsh Weather Option” can be selected. This option includes a 304 SS stainless steel enclosure, a motorized ball valve on the oil discharge instead of a check valve, armored cable with matching cable glands and 304 SS sample tubing.

iv. 5 PPM Discharge: Option “5P”

The industry is moving towards a 5 ppm oil discharge limit. The BOSS system will accommodate a 5 ppm upper limit with minor modifications. There are 3 ways to achieve assurance of 5 ppm operation. In each alternative the OCM can be adjusted. The standard 15 ppm OCM can be reset to alarm at 5 ppm. In this case the monitor is


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still certified for 15 ppm but is set to alarm at 5 ppm. Alternatively, a monitor can be supplied that is factory set and certified at 5 ppm with no ability to raise the setting. • Option 1:

This option is based on providing better coalescing and removal of suspended solids. Additional coalescing media is placed in the separator that works in conjunction with the standard media. The two media’s work slightly different and impact the oily water differently. The combination of two different types of media helps cover a broader spectrum of treatment. If the system does not already have a bag filter, a bag filter is added between the separator and the polisher. It is difficult to consistently reach 5 ppm discharge if there is silt or suspended solids that could impact the accuracy of the monitor.

• Option 2: This option is based on providing a second polishing filter loaded with activated carbon. Organoclay and carbon remove different hydrocarbons and emulsions. The combination fills in any gaps and provides better assurance of removal to 5 ppm.

• Option 3: This option is based on a simple operational adjustment. The efficiency of the oil water separator is impacted by the velocity of the water going through the system and the retention time. The slower the velocity the easier it is for oil particles to float to the top. One option to reduce velocity is to reduce the flow through the separator. In most applications the separator is not running all the time. In these cases, the separator can be slowed down which will improve the oil water separation. All that is required for this approach is to close the control valve until 5 ppm is achieved and to reset the alarm monitor. As an example a 5 gpm separator can be run at 2 or a 25gpm at 10-15 gpm. You can keep slowing the flow until you reach the optimum result for your situation.

Our recommendation to achieve 5 ppm is to do Option 1 with a 5 ppm factory set OCM. When a unit is ordered from the factory as a 5 ppm unit this is the option that will be provided. If a unit is already in the field and needs to be changed to a 5 ppm unit, then option 2 is normally used. Option 3 can be used at any time with any system. In difficult situations slowing the system down is a failsafe procedure that can be used when needed.

G. Oil Content Monitor (OCM) Options

There are 2 different technologies for monitoring oil content. i. Light Refracting

The most common monitor uses light refracting technology. There are typically 3 sources of light shown at different angles. The cell measures the refraction of the light as it bounces off hydrocarbon particles. The refraction can accurately measure the level of hydrocarbons present by the amount of refraction. However, 3 sources of light are not adequate to get all the angles that are required when there is a lot of turbidity present. When turbidity particles are present they can hide the oil and the light does not see all the oil. In these situations the monitor goes into alarm mode. If the turbidity in the water is greater than 35 NTU, the monitor will go into alarm even if there is no oil


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present. This can be corrected with more light sources. Brannstrom has a monitor that has 8 light sources that will work well in high turbidity, but it is not certified under MEPC 107(49). Consequently, the current light scattering monitors are not accurate when there is high turbidity. The light scattering type monitors are as follows:

• Brannstrom (Option “B”) (This is the standard) • Brannstrom with an automatic cleaning device (Option “A”) • Rivertrace (Option “R”) • Deckma (Option “D”)

If your system has turbidity then refer to the options above dealing with solids. If the OCM alarms it does not necessarily mean that the system is not removing oil or that the oil content is > 15 ppm. If the polisher back pressure is increasing it is likely plugging up with solids, which indicates the presence of turbidity. This can usually be addressed by using the various methods discussed above for dealing with solids. If the oil content increases without an increase in back pressure then the polisher is removing oil and the issue is likely emulsions with high concentrations of oil coming through the system. In these situations one way to improve the life of the polisher media is to slow down the flow rate.

ii. Ultra Violet The second technology uses ultraviolet light to shine through the water. Hydrocarbons will fluoresce when ultraviolet light is present. Each hydrocarbon has a defined color. The spectrum for various hydrocarbons is known and is measured based on the intensity of the color. There are 2 primary suppliers for this technology-- Turner Design and Advanced Sensor. Turner has several models including a model TD-107, which is specifically designed for ships operating under MEPC 107(49). The TD-107 model is the least expensive of the UV monitors and is the one most often used by REI. The advantage of the TD-107 is that it will not be fooled by turbidity. The disadvantage is that it is only programmed to recognize the UV frequency for certain hydrocarbons. If the hydrocarbon in the waste stream is one that is included in the TD-107 programming then it will accurately measure it. However, if the hydrocarbon in the waste stream is not one that has been programmed into the TD-107 then it will not measure it at all. If the application has a lot of turbidity and a sand filter or other form of sediment filter is not practical, a UV monitor is the best solution. The cost of a UV monitor is significantly greater than a light scattering monitor.

H. Other Options

i. Drip Pan or Skid: Options “DP”, “SK” and “SP” Boss systems can come with or without a drip pan or skid or a skid with a drip pan, depending on how they are ordered by the distributor. There are several different types of skids or drip pans depending on the specific application and requirements.


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ii. Stainless Steel Piping: Option “SS”

The standard system comes with marine bronze and red brass fittings and pipe. With this option the bronze piping and fittings are replaced by 304 SS piping and fittings. The valves, flow indicator, Y strainer and level probe base continue to be supplied in bronze.

iii. Confined Space: Options “YM” and “YO”

Yacht’s, fishing vessels, submarines, Navy or Coast Guard fast boats, confined mechanical rooms or other situations where space is a limiting factor, require smaller separators. For these situations REI has developed a shorter separator with a smaller footprint. The unit is still rated at 2.2 gpm (.5 M3/hr) and has the same flux rate and oil separation capability as the standard unit. However, it will not hold as much oil and the polisher media has to be changed more frequently.

This unit comes in 2 varieties. The YM version comes with cartridge filters. The first filter is a sediment filter followed by either a Mycelx filter or organoclay filter. This unit has the smallest footprint and lightest weight. The YO version comes with a small bulk organoclay polisher vessel. In situations where weight is an issue, such as for fast boats, REI uses several aluminum parts and other features to keep the weight as low as possible. Either of the versions can also be ordered for a Yacht application with a white AWL Grip paint system, instead of the standard green color. In some situations with smaller vessels gasoline can be used for various applications on the vessel. The normal jet pump has some plastic parts that react with gasoline. The pump for these options does not have any plastic parts. The pumps in these systems do not have as much suction lift or discharge head as the standard pumps.


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O&M Manual Attachment 1 – P&ID Drawing


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O&M Manual Attachment 2 – Electrical Schematics

BOSS 107 Separator System Operations & Maintenance Manual

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Transcript of BOSS 107 Separator System Operations & Maintenance Manual