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BOSS 107 SEPARATOR SYSTEM

OPERATIONS & MAINTENANCE MANUAL

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O&M MANUAL
VOLUME I TABLE OF CONTENTS SYSTEM DESCRIPTION: .......................................................................................... 3 1.1. Components by System.......................................................................................... 3 1.1.1. BOSS Oil Water Separation System .................................................................. 3 1.1.2. Separator BOSS 107 filter system ...................................................................... 3 1.1.3. Oil Content (TPH) Monitoring .......................................................................... 3 1.1.4. Electrical/Controls.............................................................................................. 3 1.2. Process Description................................................................................................ 4 1.2.1. Process pump:..................................................................................................... 4 1.2.2. Pre-filtration: ...................................................................................................... 4 1.2.3. Oil-water separation:.......................................................................................... 4 1.2.4. TPH or oil content monitor ................................................................................ 5 1.2.5. Filter.................................................................................................................... 6 1.2.6. Additional Post Filter ......................................................................................... 9 1.2.7. Heater (Optional).............................................................................................. 10 1.2.8. Hi Flow Option ................................................................................................. 11 1.2.9. Zone 2 (Class I, Div II) or Zone 1 (Class I, Div I) Option:.............................. 11 1.3. Optional System Features: .................................................................................. 13 1.4. System Specifications........................................................................................... 14 1.5. Fault Alarms and Remote Monitoring Capabilities ........................................... 15 2. STARTUP................................................................................................................... 16 2.1. Factory Testing/Delivery ..................................................................................... 16 2.2. Installation ........................................................................................................... 16 2.3. Power Test............................................................................................................ 16 2.4. Initial Water Filling:............................................................................................ 17 2.5. Set Flow Rate: ...................................................................................................... 18 2.6. Verify Suction: ..................................................................................................... 18 2.7. TPH TEST: .......................................................................................................... 18 3. TROUBLE SHOOTING:........................................................................................... 20 4. OPERATION ............................................................................................................. 22 4.1. Normal Operation................................................................................................ 22 4.2. Alarm and Action Conditions.............................................................................. 22 4.3. Draining the Separator ........................................................................................ 23 4.4. Factory Startup and Acceptance Test Procedures ............................................. 23 5. MAINTENANCE ....................................................................................................... 24 6. PARTS LIST AND RECOMMENDED SPARE PARTS ......................................... 26 ATTACHMENT 1 - P&ID DRAWING........................................................................... 30 ATTACHMENT 2 - PIPING CONNECTIONS .............................................................. 31 ATTACHMENT 3 PARTS IDENTIFICATION O&M Manual.................................. 32 ATTACHMENT 4 ELECTRICAL SCHEMATICS .................................................... 33 1.

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1. SYSTEM DESCRIPTION: The BOSS-107 oil water separation system includes the following basic components: 1.1. BOSS Oil Water Separator - fluids A&B Post Separator Filter for fluid C Oil Content (TPH) Monitoring

Components by System

1.1.1. BOSS Oil Water Separation System F-101 CV-101 S-101 P-101 G-101 LS-101 V-001 SV-101 MOV-101 or CV-102 F-102 FI-101 V-003 HTR Pre-filter y-strainer Inlet check valve BOSS oil separator Main process pump Vacuum gauge Oil level switch BOSS separator vent manual valve BOSS make-up water inlet control valve Oil discharge valve Oil discharge Y strainer Flow indicator Flow control valve Heater (optional)

1.1.2. Separator BOSS 107 filter system G-102 V-002 F-103 G-103 CV-103 SV-102 SV-103 Pump discharge pressure gauge Filter vent valve Fluid C post filter Pressure gauge after filter Discharge check valve Discharge water control valve Recycle water control valve

1.1.3. Oil Content (TPH) Monitoring V-005 V-006 V-007 TPH-102 TPH clean water inlet manual valve TPH sample inlet manual valve TPH return manual valve TPH monitor

1.1.4. Electrical/Controls P1 BOSS Control panel

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1.2. Process Description 1.2.1.Process pump: 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 (S101). This placement reduces the formation of mechanical emulsification. The standard pump will pull up to 10 feet (3 meters) of negative head or vertical suction lift and still provide the design flow through the unit. The high lift or L model can pull up to 16 feet (5 meters) of negative head. 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. The separation system operates in a negative pressure condition or vacuum. It is critical that ALL connections to the oil water separator are airtight and properly sized for the installation. If the connections are not air tight, air will be pulled into the separator or if the inlet is restrictive it will cause the unit to cycle between fill and discharge in a less than 30-minute cycle. The larger the leak or greater the restriction the faster the cycle time. 1.2.2. 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 (Y-strainer). This 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. 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. 1.2.3. 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

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the collected oil to a predetermined low 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 SV101and MOV-101 (if applicable) to close. The main pump (P-101) turns on and SV-102 or SV-103 opens and normal operation resumes. 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. The pass through the second stage of 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 filter unit.

1.2.4. TPH or oil content monitor There are 2 different technologies for monitoring Total Petroleum Hydrocarbons. The most common monitor uses light refracting technology. The three primary suppliers are Deckma, Brannstrom and Rivertrace. REI uses either Deckma or Brannstrom. These monitors are relatively inexpensive. However, turbidity in the water will be measured as oil since the light refracts off the particles the same as it refracts off oil. If the turbidity in the water is greater than 35 NTU, the monitor will go into alarm even if there is no oil present. If your system has turbidity then it possible that a secondary filter will be needed to remove the turbidity before the TPH. If the TPH alarms it does not necessarily mean that the system is not removing oil or that the oil content is > 15 ppm. If the post filter back pressure is increasing it is likely plugging up with solids, which indicates the presence of turbidity. If the oil content increases without an increase in back pressure then the post filter is removing oil and the issue is likely emulsions of high concentrations of oil coming through the system. 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. The primary supplier for this technology is Turner Design. Turner monitors are much more expensive than the other type of monitors but they are not impacted by turbidity. If the application has a lot of turbidity and a sand filter or other form of sediment filter is not practical, a Turner monitor is the best solution. The cost of a Turner monitor is about 8 to 10 times greater than the other type of monitor. The BOSS 107 includes a Total Petroleum Hydrocarbon meter (TPH, also sometimes called an Oil Content Monitor or OCM) that has been certified to meet the MEPC 107(49) regulations. Unless otherwise specified the TPH monitor will either be Deckma or Brannstrom (at the discretion of REI). The TPH monitor has

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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 (TPH) control the recycle action. The TPH unit is a 15 PPM oil content alarm monitor that has been tested and approved in accordance with IMO Resolution MEPC.107 (49). The TPH monitor is continually sampling the process stream and is designed to react quickly to any changes in the oil content. 1.2.5. Filter 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 BOSS 107 system includes a polyglass (Models 2T-107, 5T-107 and 10T-107) or steel (Models 25T-107 and 45T-107) filter vessel designed to hold bulk media. The BOSS system is also certified to use standard cartridge filters or Mycelx filters. The primary types of media are activated carbon and organoclay. Each type has advantages and disadvantages depending on your specific needs. Carbon generally works better than organoclay for most emulsions. Organoclay works better than carbon for any free oil, BTEX, heavy metals or turbidity. The mix of media can be adapted to fit any specific requirement. If you have a mix that does not fit your specific requirements or is not performing as you think it should, call the factory and we will work with you to design a mix that meets your specific needs. Bulk filters have certain advantages over cartridge filters. A cartridge filter for a 2 gpm system will hold about 5 ounces of oil. The same size cartridge filter that has been treated with Mycelx coating will hold about 1.5 lbs. of oil. The BOSS bulk media filter for a 2 gpm system using organoclay will hold about 30 lbs. of oil or about 100 times more than a 2 gpm cartridge. The other advantage is that the media can be adapted easily to any situation. We can put sand in the bottom to help remove turbidity. 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 filter 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 filter loaded with a base of sand covered by organoclay. There are 2 types of filter housings that are supplied. The 2, 5 and 10 gpm systems use a polyglass filter 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 pumps are oversized so that the same pump will work in most all situations. The systems are designed to handle up to 12 mercury suction vacuum and approximately 80 feet of discharge head. 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 65 psig pressure. The pumps are sized to give no more than 65 psig under normal operating conditions. If the situation demands a high suction lift and a high discharge head

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and a stronger pump is needed then a higher pressure filter will be required to accommodate the increased pressure. The polyglass filter can either be configured in a Down Flow (water goes down through the media and up the inner tube) or Up Flow (water goes down through the inner tube and up through the media) mode. a. Down Flow: 1. With a down flow configuration the inlet to the filter needs to have a vent valve so the filter can be vented during the initial fill up of the system. This valve is only needed when the filter is filled. 2. The back pressure across the filter is lower in a down flow configuration. 3. The filter will remove more turbidity from the water than with an up flow configuration. Since the TPH monitor picks up turbidity a down flow configuration will result in a slightly lower oil content reading if there is any turbidity present. 4. The organoclay will remove more oil in a down flow configuration. 5. The back pressure can be reduced by filling the filter with coarse sand (40 mesh or coarser--#20) up to about 8 above the top of the bottom strainer basket. Do not use fine sand because it will go through the strainer and could possibly get into the discharge valves and cause the valves to stick. If you have more turbidity you can use more sand and less media. You should not go above 50% sand, otherwise the media will not have enough time to absorb the oil. 6. In a down flow configuration the top strainer is not critical. Up Flow: No vent valve is necessary because the filter tank will vent through the separator. The back pressure across the filter is higher than with a down flow configuration. The organoclay media does not remove the turbidity as well so if there is turbidity in the water the TPH monitor will read higher in an up flow configuration. The filter will remove less oil. Coarse sand will reduce the back pressure in the filter. Once again you should not use fine sand. In an up flow configuration the system will not work without the top strainer. Without the strainer, organoclay particles will carry over and plug up the valves and piping.

b. 1. 2. 3.

4. 5. 6.

The system will work either way but the down flow has a couple of advantages. In order to accommodate either configuration all systems come from the factory with the top strainer in the filter, with a vent valve and with coarse sand at the bottom of the filter. Since the downflow configuration is considered to have more advantages, the standard factory configuration will be downflow. The steel filter can only be piped up one way, as marked on the filter.

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With organoclay, when the system first starts the back pressure across the filter may gradually climb. This happens because the fines in the organoclay wash through the organoclay to the sand interface and form a layer of fines on top of the sand. This will depend on the type of organoclay that is used and how course it is. If the backpressure goes up, you should reverse the flow and backwash up through the media. This will cause the back pressure to come back down and stabilize. To do this remove the flexible hoses at the top of the filter and reverse them and then run the system as normal. After 20 or 30 minutes turn the system off and change the flexible hoses back to their original position. You should notice a drop in the back pressure. There is no particular time when this procedure should be done and only needs to be done if the pressure drop is too high and the design flow is not being achieved. (NOTE: The systems with polyglass filters come from the factory prepiped with the flexible hoses. The systems with the steel filters do not come with the filter piped up and it is the customers responsibility to connect the filter to the separator if the customer wants to be able to backwash. Backwashing is not necessary, however, it is an effective tool to reduce pressure drop and extend the life of the media and is recommended.) During normal operation it is not uncommon for the water to form channels through organoclay. Channeling can cause the TPH monitor to show higher oil content readings than it should. If the oil content climbs you can backwash the system to remove the channeling. This can be done in the same manner used to backwash the system. Periodic backwashing of the filter will reduce both the pressure drop and the channeling of the media and will extend the life of the media. There is no set time to perform this procedure. It should be done when the media is not meeting the required removal level. If the TPH has a high oil content reading after the backwashing then it is time to replace the media. It is not necessary to discharge the backwash water. You are not trying to remove anything from the filter. You are simply mixing up the media to stop channeling or to reduce pressure drop. Activated carbon will have a lower pressure drop than organoclay and will not channel like organoclay. With a carbon filter you will likely not need to backwash the filter. The advantage of organoclay over carbon is that organoclay will absorb about 5-7 times more oil and will therefore last longer between media changes. c. Startup During the initial fill of the system with water, the air in the filter has no way of venting itself. The air is pressurized when the pump runs and pushes back to the pump when the pump is turned off causing the pump to lose its prime. Since a vacuum is formed in the separator the vent valve on top of the separator will need to be opened to allow water back into the pump... Therefore the procedure for getting the air from the filter is to run the pump until water comes out of the filter vent valve, close the vent valve, stop the pump, open the separator and filter vent valves, wait for the water to settle, turn the pump back on until the air is released from the filter. Once water comes out close the valve and repeat the process. Repeat this

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process as many times as needed until no more air comes out of the filter vent valve. d. Recharging the Media The media will need to be replaced when the system will no longer keep the oil content within acceptable limits. To remove the media it will be necessary to vacuum out the media with a shop vac or a vac truck. 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 is generally best to add coarse sand (40 mesh or coarser--#20) in the bottom of the filter to a level of about 8 above the top of the basket strainer. Fill the rest of the filter with media up to about 8 from the top for the fiberglass filters and just below the top distributor for the steel filters. e. Expected Results: You can expect the following results from the system: 1. 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 ppm. If you use an up flow configuration the monitor will read from 5 to 10 ppm. Assuming no emulsions and carbon the oil content in the discharge will be higher than organoclay. 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. It will run 50% oil continuously. 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 organoclay filter will take out whatever the primary separator does not remove. The more oil in the separator discharge the faster the post filter media will be consumed but the system will accommodate such conditions. Organoclay does not remove emulsions as well as carbon. Based on testing done by REI, the organoclay filter removed fluid C to < 10 ppm, whereas carbon removed fluid C to < 5 ppm. A combination of carbon and organoclay with a sediment cartridge filter removed fluid C to <2 ppm. These results will vary depending on the type of emulsions.

2.

3.

1.2.6. Additional Post Filter An additional post filter may be required for the following purposes: a) Remove turbidity. A sand filter can be used to remove turbidity out of the water. If the water has an NTU of more than 35 it could cause the TPH monitor to give a false alarm.

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Removal of the turbidity should help the TPH monitor provide more accurate readings. If turbidity is a problem the most economical solution is a post filter to remove the turbidity. A cartridge filter can also be used to remove turbidity. b) Other. Filters can be used to achieve other post separation objectives, such as the removal of iron, H2S, mercaptans, metals and other contaminants. Such other filter options are offered on a project specific basis and will vary from project to project. If there are space limitations, it is also possible to combine multiple media types in the same filter vessel to create a multimedia filter. c) Non detect oil content New organoclay will generally remove free oil to a non-detect level. If emulsions are present it will require a combination of carbon and organoclay to achieve non-detect levels. This can sometimes be done by combining carbon and organoclay in the same filter. To do this load sand in the filter first, then carbon and then organoclay on top. It may also require a sediment filter because turbidity will read the same as oil and to have the monitor read zero there cant be any turbidity. 1.2.7. Heater (Optional) 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 filter 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 filter media. The heater can come with a variety of configurations, including a single heater or multiple heaters working together. 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. 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

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the heater elements. Setting the thermostat in the heater to higher than 80 degrees C could cause damage to the separator. 1.2.8. Hi Flow Option 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. 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. 1.2.9. Zone 2 (Class I, Div II) or Zone 1 (Class I, Div I) Option: 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). If this option is selected the following changes take place: 4. 5. 6. 7. The pump motor is explosion proof. The solenoid valves, motorized ball valve (if applicable) and level controller are rated for Zone 2 or Zone 1, as applicable. The control panel is an aluminum NEMA 7/4X enclosure. The external wiring is armored cable with the appropriate connectors

The Oil Content Monitor does not come rated itself for Zone 1 or Zone 2, so a separate purged enclosure is provided for the Oil Content Monitor. The purge control is rated for Zone 1 or Zone 2, as required. 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. 1.2.10. Rig Unit Option: The system normally comes with a polycarbonate control panel and marine rated cable. Where more rugged conditions exist the Rig Unit Option can be selected.

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This option includes a stainless steel panel, a motorized ball valve on the oil discharge instead of a check valve, armored cable, sample ports and other minor features. 1.2.11. High Lift Option: The system is normally rated for a 10 ft. (3 meter) suction lift. A dual suction/pressure gauge is provided on the inlet of the separator that reads in inches of Hg. 8.8 inches of Hg is equal to 10 ft of suction lift. If the inlet vacuum gauge is reading more than 8.8 in. Hg then the system may not be able to achieve full design flow. This will handle most situations. In cases where the suction lift is more than 3 meters but less than 5 meters some minor changes can be made to the system to achieve up to 5 meter lift (16 ft or 14 inches Hg). If the suction lift is more than 5 meters then a progressive cavity pump and other changes are required and the price will go up significantly. If the vacuum gauge is reading more than the design rate you should first look for factors that could be causing the high suction lift. These may include too small inlet piping, restrictions in the line, to many fittings or too many valves. 1.2.12. Dry Bilge Option: 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 we can include an option to install a timer that will automatically turn the system on at some interval using clean water. If water is allowed to just sit in the separator it can grow bacteria or other bugs. By cycling the system on a timed basis the system will stay clean and fresh and available for use when needed. System Features: a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. NEMA 4X controls and electrical TEFC motor Stainless Steel pump and impeller Automatic operation Completely self contained and operationally tested at the factory IMO approval and US Coast Guard certification under MEPC 107 (49). system also has ABS type approval. All piping is marine grade red brass, bronze fittings or stainless steel. Total petroleum hydrocarbon monitoring. Pressurized oil discharge with level control Automatic control valves Flow indicator Marine grade paint coating system All mounting hardware and panels are stainless steel. Operates up to 30 deg out of vertical for ship board application Post filter for removing emulsions

The

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1.3. Optional System Features: a. Rig Unit. The Rig Unit includes in addition to the standard features a motorized ball valve on the oil discharge, a stainless steel control panel, sample ports and armored cable. Class I Div. II option. The system can be designed for a Class I Div. II hazardous area classification. In this situation the control panel is NEMA 7/4X, the pump motor is explosion proof and the instruments are all properly rated for this area classification. The electrical wiring is armored cable with the properly approved connectors and seal offs. The TPH monitor is mounted in a stainless steel purged panel with a properly rated purge system. Class I Div I option. The system can be designed for a Class I Div I hazardous area classification. Turner Designs monitor for turbidity. The Turner monitor can also be Class I Div II or Class I Div I. If the inlet has a positive head then an MOV is required for the oil discharge. Otherwise this feature is optional. A skid is optional unless a Turner monitor is selected in which case it is required. Capacitance level switch. Filter Options. Various filter options are available including multiple filters, sand filter for removing turbidity, sediment filter for removing turbidity, activated carbon, combination of activated carbon and organoclay, Mycelx Heater Option. A heater can be added 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 heater helps break an emulsion by increasing the temperature in this section of the separator to 140 degrees F. Yacht Unit. This option is smaller in dimensions and is coated with Awl Grip painting system using Matterhorn White paint. High Lift Option. The system is normally designed for 10 ft of suction lift (8.8 inches Hg). If more lift is required it is possible to go higher. Hi Flow Option. This option is designed for a situation where the customer has a large volume of water in a tank with some oil on the top. 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. 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. Dry Bilge Option. 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 we can include an option to install a timer that will automatically turn the system on at some interval using clean water. If water is allowed to just sit in the separator it can

b.

c. d. e. f. g. h.

i.

j. k. l.

m.

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grow bacteria or other bugs. By cycling the system on a timed basis the system will stay clean and fresh and available for use when needed. 1.4. System Specifications
Specifications Height (inch/cm) Width (inch/cm) Depth (inch/cm) Dry Weight (lbs./kilogram) Capacity gpm (M3/hr) Organoclay charge (lbs./kg) 2 GPM 48 (91) 24 (61) 42 (107) 500 (227) 2 (.5) 60 (27) 5 GPM 60 (152) 28 (71) 48 (122) 900 (408) 5 (1.0) 130 (59) 10 GPM 80 (203) 36 (91) 60 (152) 1500 (680) 10 (2.5) 250 (114) 25 GPM 84 (213) 40 (102) 72 (183) 1900 (862) 25 (5.0) 500 (227) 45 GPM 84 (213) 48 (122) 96 (244) 2600 (1180) 45 (10.0) 1000 (454)

ALL UNITS
Specification IMO MEPC Compliance Test PSIG Operating Pressure Operating Temp Range Max Free Oil Concentration Max Fluid C Oil Concentration (with Filter) Oil in Water Discharge with TPH Single Phase Power Options Three Phase Power Options Value 107(49) 45 15 PSIG 5-60 C 35% 6% <15 ppm 110/120vac 220vac 210/220vac 360/380vac 460/480vac 575/600vac 12 or 24 50 or 60 Hz < 15 amps 35 NTU 9 (2.8) 15 PSIG Conductance Centrifugal w SS Housing Polypropylene / HDPE Nema 4X or Class I Div II Epoxy/Urethane Bronze / Red Brass Marine Coated Carbon Steel

DC Power Options Frequency Max Amperage Max Turbidity for Accurate TPH Reading Design Negative Inlet Head (Ft/M) Positive Inlet Head Design Pressure (Motorized Valve Required) Level Sensor Pump Coalescing Media Hazardous Area Classification Coating Specification Piping and Manual Valves Vessel Metallurgy

NOTES: Custom designs are available to vary specifications Combinations of specs may have pricing implications Oil Discharge Pressure equals the pressure of the makeup water inlet, but should be restricted to less than 15 lbs.

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1.5. Fault Alarms and Remote Monitoring Capabilities The TPH monitor is designed to alarm if the oil content exceeds the set limit or if the TPH system fails or if the blue handle on the detector is in the test mode position. If the oil content exceeds the set limit the TPH alarms internally and causes the system to go into recycle mode until the alarm condition no longer exists. The alarm will show on the TPH display and will be recorded by the TPH data logger. Under a system fault alarm the alarm will show on the TPH display. Any TPH alarm or fault condition will automatically put the system into the recycle mode. Potential causes of the TPH 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 TPH O&M manual for a more detailed explanation of the TPH monitor.) The customer can connect directly to the TPH and obtain the following information at a remote location: a. 4-20 ma signal showing the ppm oil content in the water (0-20 ppm) b. Voltage free contact for the TPH alarm c. Voltage free contact for the TPH system fault The customer can connect to the main control panel and obtain the following: a. 120 v signal showing whether the system is in normal operation mode (pump is running and either discharging water or recycling water) b. 120 v signal 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.

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2. STARTUP 2.1. Factory Testing/Delivery Prior to delivery the system is tested in the manufacturers shop to verify that the system is watertight and that all the pumps, valves, instrumentation and controls are operational. When the system arrives at it final destination it should be carefully checked for damage that may have been sustained during shipping. All damage should be noted and reported to the shipping company and to the manufacturer. If replacement parts or components are needed the manufacturer should be informed immediately. 2.2. Installation The BOSS Oil Water Separator is a self-contained system that is fully tested and operated under normal operating conditions at the factory. Within the system battery limits no piping or wiring will be necessary unless the units are to be mounted separate from each other. All that is normally required is to mount the system, make the necessary piping connections to your application and bring power to the main panel, as explained below. The power connections to the main power disconnect (see figure 1) are shown on the electrical schematics attached as Attachment 5. The unit has been set up for the proper voltage requirements at the factory as specified by your purchasing department. Please insure that the voltage you are supplying matches the voltage that the unit is designed to operate on. The voltage requirements are listed on the wiring diagram supplied with the unit. This schematic is found inside the control panel as well as within the attachment section of this manual (see attachment 5). All piping connections to the system are listed in Attachment 2. It is critical that the connecting pipe runs are sized to permit unrestricted operation of the unit. Piping that is undersized can impair the operation of the system. To facilitate service and testing procedures it is recommended that the customer install isolation valves at all piping connections to the separator unit. 2.3. Power Test Before applying power to the unit, be sure all isolation valves to and from the system are closed with the exception of the oil out valve after CV-102. Turn on the disconnect located on the control panel, and turn the selector switch to on to begin operation. The REM position of the BOSS selector switch is for remote on/off control. This would be for a remote controller or for a remote level switch in the bilge sump. The unit comes from the factory with a jumper on the REM position so that the system will operate the same at the ON or REM positions. For any remote operation, the customer will need to connect to the terminals provided. When the power disconnect on the BOSS unit is turned on, the power light should come on, and the system should go into FILL & OIL DISCHARGE mode. Leave the make up water isolation valve closed until it has been verified that the pump is operating in the correct direction. (see figure 2 on next page) The TPH monitor on the 107 unit should power up and perform its self test mode. When the switch on the BOSS 107 is turned to ON, the recycle valve should open and will stay open until the TPH unit senses less than 15 PPM oil content in the water flow.

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If your system is wired for 115 or 240 VAC SINGLE PHASE operation the following procedure is NOT required. Follow this procedure ONLY if your system is wired for 3 PHASE operation. Power Test:

After the installation of power and BEFORE ANY WATER IS PUT IN THE SYSTEM the pump should be checked for proper direction of rotation. If pump rotation is checked after the system is filled, starting the pump in the incorrect direction can cause the pump impeller to rotate off the motor shaft. If this should occur remove the pump head and re-attach the impeller to the shaft.

WARNING!!
An experienced and trained electrician or controls technician should do this procedure, as potentially lethal voltages are present in the control panel.
Energize the pump by opening the control panel turning on the power disconnect by rotating the disconnect shaft clockwise approx. 90 degrees. Momentarily push the contactor button with a pencil or other non-metallic item. At the same time, watch the direction of the fan on the rear of the pump. It should rotate in a clockwise direction as viewed from the back end of the motor (see figure 2).

Power Connections
Disconnect Shaft

Contactor Figure 1

2.4. Initial

Watch the direction of the fan on the rear of the pump. It should rotate in a clockwise direction as viewed from the back end of the motor.

Figure 2 Water Filling:

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Before the initial filling and testing isolate the supply of oily water. It is important that the system is tested BEFORE any oily water is admitted into the separator. 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. The separator will automatically start to fill and the Fill & Oil Discharge light should be on. Open the separator vent valve (V001) at the top of the separator. When the separator is full the fill valve and oil discharge valve (MOV-101) will close (if your unit has the MOV option) and the pump will come on. The separator is now full. With the pump running close the discharge and recycle isolation valves to allow the pressure to build up. When the pressure builds up, turn off the pump and open the filter vent. This will release air and water. To avoid spraying of water connect the vent to a hose. When there is no more release of air and water shut the valve and turn the pump on and repeat the process as many times as necessary. When the system pressurizes quickly that is an indication that the air is gone. Once the air is evacuated open the isolation valves. 2.5. Set Flow Rate: Turn the system on. Establish proper flow by adjusting the flow control valve until the flow indicator shows the proper system flow rate. Observe the pressure gauge located on the pump outlet. 2.6. Verify Suction: Check the suction by reading the suction gauge on the inlet pipe. If the suction pressure reads 0 there are most likely leaks in the piping. If the suction pressure is > 10 inches Hg there are either restrictions in the suction piping or the suction lift is too high. If you have removed all restrictions and the vacuum gauge still reads > 10 inches Hg the system could have difficulty achieving the design flow rate. In most cases the pump is oversized and the system will accommodate a somewhat higher than normal suction head. If there is no foot valve in the sump the system will drain every time it is shut off and will have a hard time priming. Verify that there is a foot valve in the sump. 2.7 Separator Level Switch: No adjust is required for the level switch. The system is set at the factory. 2.7. TPH TEST: While the system is running on clean water the TPH needs to read zero. If the TPH is not reading zero this may be caused by air in the sample lines or turbidity in the water. After a few minutes of running with clean water the air will work itself out of the system and any turbidity from the system should be eliminated. It is possible you may need to clean the cell with the brush. When the unit returns with a display of 0 PPM the unit is ready for operation. If the monitor continues to read > 0 it may need to be reset. For further explanation of the TPH see the vendor O&M manual.

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2.8

STARTUP CHECKLIST

1. Connect piping. Make sure to install isolation valves before and after the unit and a foot valve in the sump. 2. Connect power to the system. Verify proper voltage. 3. Check pump rotation 4. Turn the system switch to the ON position 5. The system will automatically fill with clean water. Make sure no oily water is allowed into the system. 6. Open the separator vent valve (V001) 7. Close the discharge and recycle isolation valves so the system will pressurize. This is to help evacuate the air from the system. 8. Evacuate all air from the system. This may require running the pump one or more times. 9. Open the isolation valves. 10. Turn system on. 11. Set the design flow rate. 12. Verify proper vacuum. Fix any piping leaks or remove any obstructions. 13. Open the valves to the TPH and verify proper operation of the TPH 14. The system is now ready for full operation and the oily water isolation valve can be opened and normal operations can commence. 15. Observe several cycles of the system. You can shorten the cycle time by opening the separator vent valve. This will pull air into the oil chamber and cause the system to go into the fill mode.

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3. TROUBLE SHOOTING: Pump disassembly The following suggestions are provided for situations that have been encountered in the past: 3.1 Solenoid Valve 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. 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. 3.2 MOV 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. 3.3 Filter There are a number of situations that can occur with the filter: a. If there is turbidity in the water the TPH monitor can give a false oil content reading. If this happens a sediment filter may be needed to remove turbidity. You can either add a sand filter or cartridge filter to remove the turbidity. You can also change the loading in the filter to include more sand in the bottom of the filter and less media. 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 emulsions and organoclay will work better for free oil. 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. 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 25% or more on a continuous basis. However, the water coming out of the separator will also go up in oil content. This is generally not a problem because the

b.

c.

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d.

e.

f. g.

organoclay filter will remove the oil. However, the organoclay media will fill up faster and the media will need to be changed more often. The organoclay works best in a downflow configuration, where the water goes down through the media. The oil content will be at least 5 ppm lower in a downflow configuration. In most situations the organoclay will remove 100% of the free oil that goes through the filter. As the organoclay fills up with oil the ppm oil in the discharge will rise until the monitor goes into alarm. When this happens reverse the hoses and go up through the organoclay for 10-15 minutes and then reverse them back again. Sometimes the organoclay will channel. This will loosen up the organoclay, reduce the back pressure and get rid of the channels. In most cases this process can be repeated several times, which will extend the life of the organoclay. When this process no longer reduces the oil content below 15 ppm it is time to change the media. In the case of carbon there is no channeling and when it no longer will stay below 15 ppm it is time to change the media. When it is time to change the media open the top of the filter housing and vacuum out the media. This can be done with a shop vacuum. You will need to keep the media wet in order to vacuum it out. To replace the media, dump sand in the bottom up to about 6 above the bottom distributor, then add organoclay to about 8 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. You can also hire a local filter company (such as US Filter) to change the media. They will come out and vacuum out the filter and replace the media. You can also order a replacement filter, swap out the new filter for the old filter and return the old filter for a credit to the factory or to your distributor.

h.

Sometimes a high TPH reading has nothing to do with the filter and is simply caused by a dirty TPH 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.

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4. OPERATION 4.1. Normal Operation After all of the specified testing has been completed and the system has run satisfactorily with the water flowing through the filter, then the system can be put in normal operation. Turn the switch to ON and open the sample lines to the TPH. 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. 4.2. Alarm and Action Conditions The only alarm condition that requires operator action is when the filter has reached maximum hydrocarbon saturation. This is determined by the inability of the separator and filter to remove oil below 15 PPM. At this point, the TPH monitor will not be discharging water overboard but is in a continuous recycle mode. The TPH should be cycled several times through the clean water and clean the cell glass with the brush located on the side of the panel by removing the cell plunger located on the top of the cell, before it is determined that the filter is full. You should also backwash the filter to make sure there is no channeling in the organoclay. If, after cleaning the cell, the TPH level is still above the 15-PPM limit and you have backwashed the filter to remove any channeling, it is time to change the filter media. There is 1 alarm condition and 4 action conditions that require operator response. a. Oil in Discharge Water AlarmIf the oil in the discharge water is greater than 15 PPM the TPH monitor will alarm. A TPH alarm will cause the system to automatically go into recycle mode until the condition no longer exists. The alarm light on the TPH panel indicates that the system is in recycle and that oil greater then 15 PPM has been detected in the water. There is an adjustable 0-20 sec. delay timer in the TPH that is met before the recycle valve is actuated. Plugged filterIf the pre-filter or post-filter (if applicable) are plugged the pump will not pull the design flow of water through the system. When this happens it is time to clean the filter(s). A better approach would be to set up a routine schedule to clean the filter(s). The timing for cleaning the filters will be determined by the customer based on operating conditions. Short-cycle conditionIf the inlet pump is pulling air into the system from leaks in the piping, air will collect in the top of the separator and force the oil down. This will cause the level sensor to read hi oil level and will cause the system to short cycle between oil discharge and normal operation. A cycle time of less than 30 min. in most cases is an indication of this problem This is also a possible indicator 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

b.

c.

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system flow rate. If the inlet line is plugged, or the pre-filter is plugged, the separator will likely short cycle. Remove the restriction. If the process flow is greater than the design it can also cause a short-cycle condition. d. Excess flow conditionThe 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 (V003) must be adjusted to the designed separator flow rate for your unit. Processing more 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 if there is a possibility that the position of the flow adjustment valve V-003 has been changed.

4.3. Draining the Separator Before draining the separator, 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 F101 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 30 60 seconds. 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. 4.4. Factory Startup and Acceptance Test Procedures A factory startup and acceptance test is not required for the system, however, it is a good idea and one that we highly recommend. If we do a factory startup we will perform the following procedures. If the customer does their own startup they will need to follow these same procedures. If the customer initially elects to do their own startup and then changes their mind the factory startup can be done at any time. The cost for a factory startup is $2,400 plus out of pocket expenses in North America and $2,800 plus out of pocket expenses elsewhere for any of the standard systems. The factory startup can also be performed by your distributor if they have a factory trained technician. Check with your distributor to determine if they have a factory trained technician. The fee charged by the distributors technician will be determined by the distributor. 1. 2. 3. 4. 5. Verify that the installation of the system has been done properly. Make any installation corrections required. Verify the power and voltage to the system Proceed through the startup procedures as described above. Pressure test the system from the inlet valve to the discharge valve. This has already been done at the factory but it should be checked again to make sure nothing has changed during shipment and installation.

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6. 7. 8.

Set the discharge flow to the design gpm. Proceed through the startup procedures for the TPH Once everything has been tested satisfactorily with clean water the system is ready to introduce process water. 9. Operate the system at design conditions for the required test period. 10. Simulate alarm and warning conditions to verify that they function properly. 11. Make any adjustments that are appropriate. 12. Provide a training class for the system operator(s). This training will include theoretical training on the system, functional training and training on how to maintain the equipment. 5. MAINTENANCE The separator system may require periodic maintenance on or replacement of the components shown in the spare parts list below in section 5. The following items may require periodic maintenance at specific intervals. A. PumpThe pump installed on the system does not require lubrication. The mechanical seal should be replaced periodically or when it fails. B. ValvesThe valves installed on the system are high quality marine grade valves and do not require lubrication. If sand particles get into the solenoid valves it can cause them to leak and they will need to be cleaned. The coils and gasket will need to be replaced periodically or when they fail. NEVER remove the solenoid from the valve with the power on. This will IMMEDIATELY destroy the coil and will void any warranty on the valve. C. TPH MonitorThe TPH will need a periodic check of zero against clean water, and frequent cleaning of the glass sample cell. The dessicator will need to be replaced whenever the color indicator is not blue. It is possible to bake out the dessicators in an oven at low temperature. A spare parts kit is recommended for the TPH. Anything not covered by the standard spare parts kit for the TPH will require the unit to be sent back to the factory for repair. D. Coalescing MediaThe coalescing media in the separator should last for several years. It does not require specific maintenance or replacement under normal operating conditions. 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: 1. Remove 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. 2. The replacement media should come packaged with an inner section and an outer section. The inner section should come partially shoved inside the outer section. Remove the inner section. 3. 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 but not too tight. If the section is too large you may need to trim a small amount off the roll. To do this just cut off the excess with a utility knife.

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4.

5.

It is easier to push the media into the vessel with 2 people. Both people can help get the media started about 1/3 of the way. Then use the round piece of wood to put on top of the media and push down uniformly. Repeat the same process for the other section of media. The inner section should be pushed down about 1-2 inches below the weir. The outer section should be pushed down just below the weir.

E.

Filter MediaThe filter media will need to be changed when the oil content monitor will not go below 15 ppm AND you have cleaned the cell AND you have backwashed the post filter. High oil content can be caused by using surfactants and other cleaning chemicals that cause hard to remove chemical emulsions. We recommend the use of cleaners that do not cause emulsions. See more detailed discussion of the filter media above under the troubleshooting section. Controls componentsThe 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.

F.

G. Flow IndicatorThe flow indicator is a low-cost direct reading industrial class flow 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. The disadvantage of the flow indicator is that it is not as rugged as more expensive meters might be. The flow indicator is made from high impact polysulfone plastic and has excellent structural integrity for a plastic device. However, it will break if put under too much stress or if impacted directly. To replace a broken flow indicator, remove the broken indicator. Apply pipe thread compound liberally to each end of the flow indicator. Make sure to use pipe thread compound that is compatible with plastic. We recommend Blue Magic Industrial Grade made by Whitlam. We have found that teflon tape does not work as well and is hard to seal. Do not over tighten. Over tightening will cause the indicator to break. Tighten until snug--you should have 4-5 thread showing when you are done. If you use the right pipe thread compound you will get a good seal without over tightening. We also highly recommend that you maintain a spare flow indicator at all times. If the flow indicator breaks and you do not have a spare, simply replace the indicator with a similar length threaded nipple, order a replacement and install the new indicator when it arrives. The system will function perfectly fine without the flow indicator. The only impact is that you will not know exactly what the flow rate is.

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6. PARTS LIST AND RECOMMENDED SPARE PARTS

The following lists show the recommended spare parts for each model of separator to be kept on hand for routine maintenance and repair of the Recovered Energy Boss oil/water separator. In the case of pumps, valves and TPH, we recommend that the customer spare a complete assembly plus rebuild components. That way if a component breaks down the spare assembly can be installed and the rebuild kit can be used to repair the component that failed and the customer will always have a functioning spare. Description (*) indicates this is a recommended spare. Pumps 6.1. BOSS 2-5 a. Complete pump assembly including motor: P-101 Separator pump (3 phase) JEU 806 .......... (*) (110 vac single phase) SBS 1200511........... (*) Pump repair kit for 3 phase (complete pump assembly kit minus seal) (*) Mechanical seal for 3 phase pump ......... (*) Minimum repair parts (o-ring, impeller, plug kit) ......... (*) Pump repair kit for 110 V (standard kit, including seal) ......... (*) Part Number (*)

b.

6.2. BOSS 10 a. b. Complete pump assembly including motor: P-101 Separator pump (3 phase) ........ JEU 1506 or CDU 120 (*) Pump repair kit for 3 phase (complete pump assembly kit minus seal) (*) Mechanical seal for 3 phase pump ......... (*) Minimum repair parts (o-ring, impeller, plug kit) ......... (*)

6.3. BOSS 25 a. b. Complete pump assembly including motor: P-101 Separator pump (3 phase) CDU120 ........ (*) Pump repair kit (complete pump assembly kit minus seal) ......... (*) Mechanical seal for 3 phase ......... (*) Minimum repair kit (o-ring, impeller, plug kit) ......... (*)

6.4. BOSS 45 a. b. Complete pump assembly including motor: P-101 Separator pump (3 phase) CDU200 ........ (*) Pump repair kit (complete pump assembly kit minus seal) ......... (*) Mechanical seal for 3 phase ......... (*) Minimum repair parts (o-ring, impeller) ......... (*)

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For Class I Div I and II the pumps are the same but the motors are explosion proof. Valves 6.5. BOSS 2 a. Complete valve assembly for each type of valve SOV-101 18N42 1/2 .......(*) SOV-102, SOV-103 18A42 1/2 ........(*) MOV-101 DM9933-FTTS-075/ER1-2.5-4-120/60 ........(*) Valve repair/rebuild kits: Solenoid coil only: SOV-101,102,103 Valve gasket: SOV-101 Valve disc and gasket: SOV-102,103

b.

A2-120vac ........(*) 18N42 1/2-S .......(*) 18A42-3/4-S ....(*)

6.6. BOSS 5 a. Complete valve assembly for each type of valve SOV-101 18N42 1/2 ....... (*) SOV-102, SOV-103 18A43 3/4 ........(*) MOV-101 DM9933-FTTS-075/ER1-2.5-4-120/60 ............ Valve repair/rebuild kits: Solenoid coil only: SOV-101,102,103 Valve gasket: SOV-101 Valve disc and gasket: SOV-102,103 MOV switch

b.

A2-120vac ........(*) 18N42 1/2-S .......(*) 18A43-3/4-S ....(*) (*)

6.7. BOSS 10 & 25 a. Complete valve assembly for each type of valve SOV-101 18A42 1/2 ....... (*) SOV-102, SOV-103 18A44 1 ........(*) MOV101 DM9933-FTTS-075/ER1-2.5-4-120/60 ............ Valve repair/rebuild kits: Solenoid coil only: SOV-101,102,103 Valve disc and gasket: SOV-101 Valve disc and gasket: SOV-102,103 MOV switch A2-120vac ........(*) 18A42 1/2-S .......(*) 18A44-1-S .......(*) ....... (*)

b.

6.8. BOSS 45 a. Complete valve assembly for each type of valve SOV-101 18A43 3/4 ....... (*) SOV-102, SOV-103 35A46 1.5 ........(*) MOV101 DM9933-FTTS-075/ER1-2.5-4-120/60 ....... (*) Valve repair/rebuild kits:

b.

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Solenoid coil only: SOV-101 Solenoid coil only:SOV-102,103 Valve disc and gasket: SOV-101 Valve disc and gasket: SOV-102,103 MOV switch 6.9 Class I Div I and II:

A2-120vac ........(*) A3-120vac ........(*) 18A43 3/4-S .......(*) 35A46-1.5-S ....(*) ....... (*)

For Class I Div II and Class I Div I units the valves are all rated Class I Div I Group C and D so the same valves are used for both applications. SOV F18A42 ............ SOV F18A43 ............ 1 SOV F18A44 ............ 1.5 SOV F35A46 ............ MOV DM9933-FTTS-075/ER 1-2.5-7-120/60 ............ 6.10 a. Monitoring Equipment (all units are the same) Complete units: Conductance level probe Conductance level relay Flow indicator

3E3B 16MM1A0001 (*) FI-101 ....... (*)

b.

Controls Parts List and Recommended Spares (standard units): Contactor ....................................................... GH15BN-3-10A Circuit breaker (if used) .......................................... WMS1D03 Control box 10x8x6 w/ subpanel................. HW-100806CHQR Control box 12x10x6 .................................. HW-121006CHQR Control box 14x12x8 .................................. HW-141208CHQR Control box sticker ................................................................... Disconnect handle ......................................................SD-HRY Disconnect shaft .......................................................... SD-200 Disconnect switch ................................................. SD1-025BR Fuses (set) (if used).........................................................HCTR Fuse holders.............................................................................. Lights (set of 1 green and 1 red)................................................ Motor starter ....................................................................MS25 Relay -set (if used)...............................................782-2C or 4C Switch 3 position selector ....................................E22XBG1RR Surge suppressors (set of 4) ............................ GH15BN-3-10A Terminal kit .............................................................................. Transformer .............................................................................. TPH monitor (Dekma) .............................................................. TPH repair kit (Dekma) (dessicator (2), O-ring, fuses (2), brush) TPH dessicator.......................................................................... TPH brush ................................................................................ Stainless tube fitting kit (4 ferrule & connector set).................. (*)

(*) (*) (*) (*) (*) (*) (*) (*) (*)

(*) (*) (*) (*)

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c.

Controls Parts List and Recommended Spares (Class I Div I & Class I Div II): Armored cable ......................................................................... Cable glands (set of 2) ...............................................711A 1/2 Contactor ....................................................... GH15BN-3-10A Circuit breaker ....................................................... WMS1D03 Circuit breaker molded case ....................................... G Frame Conduit box ............................................................................. Control box NEMA 7X..................................... EXB12188N34 Control box mounting pan ........................................................ Control box labels (set) ............................................................. Fuses (set) ................................................................................ Fuse holder ............................................................................... Lights (set of 1 green and 1 red)................................................ Motor starter ....................................................................MS25 Switch disconnect handle.......................................................... Switch 3 position selector ......................................................... Surge suppressors (set of 4) ............................ GH15BN-3-10A Terminal kit .............................................................................. Transformer .............................................................................. Stainless tube fitting kit (4 ferrule & connector set)...................

(*) (*)

(*) (*) (*) (*) (*) (*)

(*)

6.11

Miscellaneous BOSS filter media Maintenance paint quart kit urethane and hardener.....SW14109 Top flange gasket for 2 GPM separator.................1210.02NEO (*) Top flange gasket for 5 GPM separator 1620.05NEO .......(*) Top flange gasket for 10 GPM separator 2025.10NEO ........(*) Top flange gasket for 25 GPM separator 3035.25NEO ........(*) Top flange gasket for 45 GPM separator 4247.45NEO .......(*) Pressure gaugeLiquid filled (*) Vacuum gaugeLiquid filled (*)

6.12 i.

Filter BOSS 2, 5 and 10 Filter tank (polyglass) Filter basket strainers (set of 2) Filter riser Filter top distributor Charge of media

(*) (*) (*) (*)

b.

BOSS 25 and 45 Filter tanksteel Distributor Charge of media

(*)

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ATTACHMENT 1 - P&ID DRAWING

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O&M Manual Volume I

ATTACHMENT 2 - PIPING CONNECTIONS

BOSS SYSTEM PIPING CONNECTIONS

PIPE SIZE Description OILY WATER INLET From COLLECTION SUMP
Connection

2 GPM

PIPE PIPE PIPE SIZE SIZE CONNECTION 5SIZE & 10 GPM 25 GPM 45 GPM DESTINATION

F-101

3/4" NPT

1" NPT 1.5"NPT

2" NPT

Notes RUNS OVER 100' OR MORE THAN (5) 90DEG FROM BILGE ELBOWS MAY OR SUMP REQUIRE LARGER PIPE RETURN TO USED VERY SUMP INFREQUENT RETURN TO USED VERY SUMP INFREQUENT F-103 inlet PIPE SIZE IS SAME AS F-103 INLET SIZE

SEPARATOR DRAIN SEPARATOR DRAIN PUMP DISCHARGE OIL DISCHARGE

SEPARATOR CENTER SEPARATOR OUTER RING PUMP OUTLET SEPARATOR OIL HEAD

NPT PLUG NPT PLUG P-101 MOV-101

3/4" NPT 3/4" NPT

1" NPT 1.5" NPT 2" NPT 1" NPT 1.5" NPT 2" NPT

3/4" NPT 3/4" / 1"NPT 1.5" NPT 1.5" NPT 3/4" NPT 3/4" NPT 3/4" NPT 3/4" NPT

PRODUCTION OR USED OIL OIL HEADER ST0RAGE TANK MUST BE 15 PSI OR GREATER, IF SOURCED FROM CULINARY WATER, AN ANTI SIPHON/BACK FLOW PREVENTER VALVE SHOULD BE USED

MAKE UP WATER

PRESSURIZED WATER

SOV-101

1/2" NPT 1/2" NPT 3/4" NPT 3/4" NPT

PROCESS WATER

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O&M Manual
ATTACHMENT 3 PARTS IDENTIFICATION

LS-101 Oil Level Switch

V-001 Separator Vent Manual Valve MOV-101 Motorized Oil Discharge Valve G-102 Pre-filter Pressure Gauge

S-101 Oil Separator Tank

TPH-101 TPH Monitor G-103 Post-Filter Pressure Gauge SV-102 Separator Discharge Control Valve P-1 Control Panel

V-004 Flow Control Valve

CV-101 Prefilter Check Valve F-101 Pre-Filter (Y-Strainer) P-101 Process Pump

SV-103 Separator Recycle Control Valve

FI-101 Flow Indicator

Outer Drain SV-101 Fresh Water Inlet Control Valve

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ATTACHMENT 4 ELECTRICAL SCHEMATICS

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