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O&M Manual rev M1.

1 January 1, 2016

Website: www.recoveredenergy.com
Email: oilwatersales@recoveredenergy.com

BOSS 107 Separator System


Operations & Maintenance Manual

BOSS 2.2T/107 BOSS 11T/107

BOSS 5T/107

BOSS 45T/107
BOSS 25T/107 1
O&M Manual rev M1.1 January 1, 2016

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 mediagenerally
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 polishernormally 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 valvepolisher inlet/backwash
V-107 Backwash 3-way valvepolisher 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 rpms 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 15 / 45 PSIG
Polisher Vessel Design / Test Pressure 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) 13 / 4 (with CDU Pump with Size 1 or 3 Impeller)
Design Negative Inlet Head (Ft/M) 16 / 5 (with JEU, 2CDU or CDU Pump with Size 5 Impeller)
Positive Inlet Head Design Pressure 15 PSIG
(Motorized Valve Required)
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 Bronze Body, Solenoid Type, Rated for Salt Brine
Oil Out Valve Check, Bronze Body (Motorized Valve with MV Option)
Backwash Valves 3-Way Manual, Bronze Body (Motorized with AB Option)
Bag Filter Valves 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 < 15 amps
Hazard Area Classification 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
manufacturers 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 continuouslyonly 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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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 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.

PLUNGER O-RING BORE


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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.

COIL BASE COIL SPRING BONNET


WASHER

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.

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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:

Sample fitting
Flow Restrictor

Sample return

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 doesnt 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 rollseither 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 problemjust 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 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 doesnt 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 25gpm 45gpm


24 30
Sand 0.5 1 2 4 8 10
Buckets
Sand 30 50 100 200 400 500
Weight
Organoclay 2 4 7 14 14 28
Buckets
Organoclay 60 120 210 420 420 840
Weight
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 EPAs
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
Annuali
Maintenance zed
Maintenance Activity Hours Frequency 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 s
is below 15 ppm. 4-8 variable 48

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

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. Dont 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 OPTION DESCRIPTION CODE


No.
A Area Classification AC
NEMA 4X Rated for NEMA 4X area (Standard) 4X
Hazardous area -- Rated for Class I Div I hazardous area, NEMA 7
Class I Div I enclosure X1

Hazardous area -- Rated for Class I Div II hazardous area, purged


Class I Div II enclosure X2
B Pressure Classification PC
Vacuum -- Standard vacuum inlet, separator 15 psig pressure,
VS
Standard suction polisher 75 psig pressure (Standard)
Vacuum -- High High lift vacuum Inlet, separator 15 psig pressure,
HL
Suction polisher 75 psig pressure (for CDU pumps)
Vacuum -- Medium High Lift vacuum Inlet, Sep 50 psig pressure,
VM
Pressure Polisher 75 psig pressure
Vacuum -- High High Lift vacuum Inlet, Sep 150 psig pressure,
VH
Pressure Polisher 150 psig pressure
Positive Pressure --
Positive inlet, Sep 50 psig, Polisher 75 psig PL
< 15 psig
Positive Pressure --
Positive inlet, Sep 50 psig, Polisher 75 psig PM
15-50 psig
Positive Pressure --
Positive inlet, Sep 150 psig, Polisher 150 psig PH
50 - 150 psig
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
In Line Filtration (Bag
BF
D Filter)
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
Dual 304 SS bag filter--manual valves S2
Bag filter

Dual 304 SS bag filter--automatic valves S3


Bag filter
E Polisher Vessel PV

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

Bulk Media
Polisher Organoclay bulk media polisher (standard) OP
Bulk Media
Polisher Automatic Backwash AB
Bulk Media
Polisher 2nd polisher EF
Mycelx Dual cartridge filters (2 or 5 gpm systems
Cartridge Filter only) MF
Organoclay dual cartridge filters (2 or 5 gpm systems
Cartridge Filter only) OF
Wave International dual cartridge filters (2 or 5 gpm
Cartridge Filter systems only) WF
Enhanced Performance
F
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
Oil Content Monitor
G
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
Imbedded PLC level control, polycarbonate
Poly enclosure 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
Threaded flanges for each inlet / outlet with
Flanges counterflange FC
Certificates CCS certificate CCS

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

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 (2 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 (2
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, lets 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 (lets 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 medias 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

Yachts, 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

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