Wave MiniBOSS Manuel

Wave MiniBOSS MEPC 107(49)

110 / 240v AC 24v DC

Monitored Oil Removal System

OPERATION & MAINTENANCE MANUAL

Tel: +44 1476 861717

[email protected]

www.waveinternational.co.uk

MiniBOSS O&M Manual Rev 3 Page 2 9/25/2018

OPERATIONS AND MAINTENANCE MANUAL

TABLE OF CONTENTS

1. SYSTEM DESCRIPTION ...............................................................................................3

1.1. Options. ...........................................................................................................................3

1.2. Process Description........................................................................................................3

1.4. System Specifications . ...................................................................................................4

2. OPERATION ....................................................................................................................4

2.1. Alarm and Action Conditions. ......................................................................................5

2.2. Maintaining and Servicing the OCM...........................................................................5

2.3. Calibration of the OCM. ...............................................................................................6

2.4. Changing the OCM Alarm Limit. ................................................................................6

2.5. Special tools. ...................................................................................................................6

2.6. Shutdown procedures. ...................................................................................................6

2.7. Pre-screening. .................................................................................................................7

3. MAINTENANCE..............................................................................................................7

3.1. Component Maintenance. .............................................................................................7

4. TROUBLE SHOOTING..................................................................................................8

4.1. Reduced flow through the system ................................................................................8

4.2. Fault Alarms and Remote Monitoring Capabilities. ..................................................8

4.3. Solenoid Valve not working. .........................................................................................8

4.4. High oil content reading causing water to recycle and not discharge overboard....8

5. SAFETY.............................................................................................................................8

6. SPARE PARTS .................................................................................................................9

ATTACHMENT 1 – MECHANICAL DRAWINGS . .......................................................1 0

ATTACHMENT 2 – ELECTRICAL SCHEMATICS ......................................................1 3

MiniBOSS O&M ManualRev 3 Page39/25/2018

1. SYSTEMDESCRIPTION

TheMiniBOSS oil waterseparation systemis acompactIMOMEPC 107(49)certified system

utilizingeasyto change,disposablesedimentand oil removalcartridgefilters. Its small

footprintand designed tobewall mounted. Itis designed to meetthedischargerequirements

on smaller craftthathaveasmall amountofbilgewater with asmall amountofoil.

TheMiniBOSS oil waterseparation systemincludes thefollowingbasiccomponents:

•ControlPanel

•Pump/motor

•SedimentFilter

•2 XP420 Extremefilters

•Oil ContentMonitor(OCM)

•3 waysolenoid (ortwo 2-way)valves forrecycleordischarge

1.1. Options

TheMiniBOSS comes in two models with oneofthree voltageoptions:

1) ThebasicMini-BOSS requires 24VDCand hasacapacityof1 gpm(0.25 m3/hr)

2) TheMiniBOSS-110 requires either 110-120VACor220-240VAC. This unit has a

capacityof1.5 gpm(0.35 m3/hr)

1.2. Process Description

Oilywaterissuckedintothesystembytheprocess pumpP-101(positivedisplacement

diaphragmpump).ThedesigncapacityofthestandardMiniBOSS systemis1gpm(0.25

M3/hr.)at25 psigbackpressure and no vacuumon theinletor1.5 gpm(0.35 M3/hr) withthe

MiniBOSS-110. However,theactualflowrateachievedisafunction ofthesystempressure.If

thebackpressuregoesup theflowratewill godown. Theflowratewill fluctuatedependingon

pressure and vacuum. There is no waytoadjusttheflowrate.

Thewatergoesthroughasedimentfilter toremovesilt and suspendedsolids. Thewater then

goesto2XP420 Extremefilterstoremovefree oil and emulsifiedoil.Asampleofthe

dischargewatergoesthroughtheoil contentmonitorwhenever thesystemisoperating.Ifthe

samplewater has<15 ppmoil theOCMopens thedischargeportofthe3-waysolenoiddiverter

valve.Ifthesamplewater has>15 ppmoil theOCMshutsthedischargeportandopens the

recycleportofthe3-waysolenoiddiverter valveand thewater isrecycledbacktothebilge.The

systemis designed so thatnon spec waterwill notbeallowed overboard.

1.3. Oil ContentMonitor

TheMiniBOSS systemincludesanOil ContentMonitor(also calledan“OCM”or“bilge

alarm”) thathasbeencertifiedtomeettheMEPC107(49)regulations. TheOCMhastheability

MiniBOSS O&M ManualRev 3 Page49/25/2018

toautomaticallyreturnnon-conformingdischargewater backtothesumporbilge.TheOCMis

a15 ppmoil contentmonitorthathasbeentestedandapprovedinaccordancewithIMO

Resolution MEPC.107 (49).TheOCMiscontinuallysamplingtheprocess streamand is

designed toreactquicklyto anychanges in theoilcontent.

Ifthere isarequirementforamaximumof5ppmoil inthedischargewater,theOCMcanbe

adjustedtoonlyallowdischargewithless than5ppmoil byfollowingtheinstructions

referenced in 2.4 below

ThepumpintheMiniBOSS systemisdesignedtodischargeapproximately2gpmat20 psig.

Halfoftheflowisprocessedthroughtheseparatorand iseitherdischargedorrecycled,

dependingon theOCMreading.TheotherhalfgoesthroughtheOCMand isrecycledbackto

thebilge.Thenetflowthroughtheseparatorisapproximately1gpm.Ifthedischargepressure

changes, theflowratewill changeaccordingto thepump curve.

1.4. SystemSpecifications

ALL UNITS

Specification Basic MiniBOSS(24VDC) MiniBOSS-110 (110-240VAC)

IMOMEPCCompliance Monitor 107(49) certified Monitor 107(49) certified

Dimensions 30”x40”x10”deep 34”x43”x11”deep

DryWeight 82 lbs. 83 lbs.

Capacity, max 1gpm(0.25 M3/hr.) 1.5gpm(0.35 M3/hr.)

Filter Media XP420Extreme XP420Extreme

Test PSIG 55 55

OperatingPressure Upto50 PSIG Upto50 PSIG

OperatingTempRange 1-55 C1-55 C

Oil Content Monitor IMOMEPC107(49)certifiedmonitor IMOMEPC107(49)certifiedmonitor

PumpPositivedisplacementdiaphragm Positivedisplacementdiaphragm

ControlValve Solenoidtype3-waySolenoidtypedouble 2-wayvalves

Piping&Fittings Stainless steel pipe&fittings,

polytubing&fittings Stainless steel pipe&fittings,

polytubing&fittings

Single PhasePower Required

Three PhasePower Options 24 vdc

Available onlywithseparate transformer 110-120 vac or220-240 vac

Available onlywithseparate transformer

Frequency 50 or60 Hz 50 or60 Hz

MaxAmperage 8ampbreaker at 24 vdc 4ampbreaker @110vac, 1.6amp@220vac

2. OPERATION

Thedivertervalve(s)arecontrolleddirectlybytheOCM. Thecontrolpanelcontrolsthepower

to thesystemand thepump motorcontrol.

Turnon thesystemdisconnectand settheselectorswitchtothe“ON”position. Verifythatthe

OCMreads zeroppm.Ifit doesnotgodowntozeroinareasonableperiod oftimeyou may

needtoremovethecaptotheOCMcell and usethesuppliedbrush tocleanthecell.Thenturn

on thesystempumptopumpoilywaterthroughthesystem.Thedesignflowforthesystemis

1.0 gpm(.25 M3/hr)at25 psigbackpressure or1.5 gpm(0.35m3/hr) fortheMiniBOSS-110

MiniBOSS O&M ManualRev 3 Page59/25/2018

withno vacuum.Ifthebackpressurechangestheflowratewill varyslightly.Theflowrate

cannotbeadjusted.

There are pressure gaugeson theinletand outletofthesedimentfilter.Takenoteofthepressure

differentialwhenthecartridgesarenew.Thedifferentialwill increaseasthesedimentbuilds up.

WhentheINLET gaugeisreading25 psigorabove,theflowof1gpmhaspeaked. Itwill

continuetoprocess oilywater butasthepressure goesup theflowwill bereducedfurther.

WhentheINLET gaugehasreached50 psig,thepumphasnowreacheditsmaximumpressure

and will justbypass theflowinternally.Atthispointtheflowisessentiallyzero. Whenthis

happens it istimetochangethesedimentfilter.Theoil removalfiltersarenotdesignedtoplug

aslong asthesedimentfilter isproperlymaintained. Ifthesedimentfilterischangedand there

isstill too muchbackpressure,thenthatmeans theoil removalfiltershavealso beenpluggedand

needtobechanged.2)If theOCMconsistentlygoesintorecyclethentheoil removalfiltersare

full ofoil and need to bechanged.

2.1. Alarmand ActionConditions

Theonlyalarmcondition thatrequiresoperatoraction iswhentheoil removalfiltershave

reachedmaximumhydrocarbonsaturation. ThisisdeterminedbytheinabilityoftheXP420

Extremefilter toremoveoil below15 PPM. Atthispoint,theOCMwill notbedischarging

water overboard butwill bein acontinuous recyclemode.

When this happens it is timeto changetheoil removalfilters.

Oil inDischargeWater Alarm—Iftheoil inthedischargewaterisgreater than15 PPMthe

OCMwillalarm.AnOCMalarmwillcausethesystemtoautomaticallygointorecyclemode

until thecondition no longerexists. Thealarmlighton theOCMpaneldisplayindicatesthatthe

systemis in recycleand thatoil greater than 15 PPM has been detected in thewater.

2.2. Maintaining andServicing theOCM

DO NOTATTEMPTTOBREAK THESEALOROPENTHEOCMTODO ANY

MAINTAINENCEOFTHEOCM. BREAKINGTHESEALWILLVOIDTHE

CALIBRATION.

Theonlyworkyou cando on theOCMistochangethecell orcleanthecell orperformsome

other minorfunctions explainedintheoil contentmonitorinstruction manual.Anyother work

mustbedonebythefactory.Aseparateinstruction manualfortheoil contentmonitoris

provided.

TheOCMcell willneedtobecleanedon aregular basis. Refer totheOCMmanualfor

operatinginstructions fortheOCM.

MiniBOSS O&M ManualRev 3 Page69/25/2018

There are timeswhentheOCMcell canbecoatedwithmaterialthatishardtogetoff.You may

needtousesoaporvinegarorsomeothernon-abrasivecleanertogetthecell cleanifit hasbuilt

up too much to getaclean readingon themonitor.

2.3. CalibrationoftheOCM

AtIOPP certificaterenewaltimeevery5years, thecalibration oftheOCMhastobecurrent.

Theoriginalcalibration certificateisgood for5years. TheOCMcalibration canbecheckedat

anytimeusinganapprovedcalibration testkit.Once thecell calibrationdatehasexpired(5

yearsfromthecertificatedate),thecell will needtobereplaced. Checkthecalibration

certificatethatcomeswiththesystemintheO&Mmanualtoverifythecalibration date.Ifyou

havelostyourcalibrationcertificateRecoveredEnergyoryourdistributorcanprovideyou with

acopy. Replacementcells are keptin stock.

Shouldyou wish todo acalibration check, atestkit thatcanbepurchasedeither fromyour

distributororthefactorytoverifythecalibration ofthemonitor.Itisnotnecessarytotestthe

calibration aslongasthecell hasavalidcalibration certificate.Theinstructions forcheckingthe

calibration will beincluded in thecalibration kit.

2.4. Changing theOCMAlarmLimit

In someareas thelimit fordischargeis lower (usually5 ppm). Ifthis is thecase, thealarm

limit can besetto 5 ppmoranyother amountin therangeof1-15 ppm. Pleaserefer to the

BrannstromOCM manualforinstructions on changingthealarmvalue.

2.5. Specialtools

There are no specialtools, testequipmentormaterials neededforservicing and maintainingthe

systemexceptthefollowing:

a. Calibration testkit totestthecalibration ofthemonitor.Thisistotallyoptionaland is

generallynotrequired.

2.6. Shutdownprocedures

Ifashutdown is requiredforanymaintenance thatrequires servicingan electricalcomponent,

makesure thattheunit isunpluggedand thesystemis locked outand tagged accordingto

standard lock-out, tag-outprocedures.

To clean thecell, do notunplugtheunit. You willneed power to thesystemto operatetheoil

contentmonitorduringthecleaningprocess.

MiniBOSS O&M ManualRev 3 Page79/25/2018

2.7. Pre-screening

Theseparatorisnotdesignedtohandleheavysolids. AY-strainer orother suitablepre-

screeningfilter needs tobeinstalledbythecustomer infrontoftheseparatortokeeplarger

particlesoutofthesystem.A5micron sedimentfilter isincludedinthesystemtohandle

someturbidityand to protecttheoil/emulsion filters.

3. MAINTENANCE

Thesystemdoesnothaveinstalledredundancy.Thegeneralmaintenance philosophyformost

ofthecomponents is to replacethecomponents astheyfail. Wehavenotdevelopedameantime

betweenfailureformostofthecomponentsbecauseeverysituation isdifferent.Thesystem

doesnotgenerallyrun continuously—onlywhenthebilgelevelincreasestoadesignatedlevel.

Ingeneral,thereisadequatetimetomakeanyrequiredrepairwithoutimpactingthebilgewater

level.Werecommend maintainingcriticalspare partsininventoryso thatifthere isafailure the

partcan bereplaced quickly. Everycomponentcan bechanged within afewminutes.

Componentsare fairlyinexpensiveand it isless expensivetoreplace theentire componentthan

it istobuythepartand overhaulthecomponent.Theonlyexception tothisistheoil content

monitor,whichisthemostexpensivecomponenton thesystem.Inthecaseoftheoil content

monitor,it isagainstIMOregulations forthecustomer todo anymaintenance on thesystem

other thancleaningthecell.Ifthemonitorfailsitgenerallyhastoreplaced. Anyattemptbythe

customer to break thesealand open themonitorwill void thevalidityofthemonitor.

Therearesomeroutinemaintenancefunctions thatneedtobeperformedtokeepthesystem

runningatpeak performance:

3.1. ComponentMaintenance

3.1.1. Valve—Thesolenoidvalvecanbecleanedifit getsdirtinit.Ifthevalvefails, it will need

to bereplaced with anewvalve, it cannotberepaired..

3.1.2. OCM—TheOCMwillneedaperiodiccheckofzeroagainstcleanwater,and frequent

cleaningoftheglass samplecell.TheOCMmeasuringcell hasalife of5years. Atthe

end ofthatperiod themeasuringcell will need tobereplaced.

3.1.3. Filters— Thefilterswill need to bereplaced whentheybecomespent.

3.1.4. Controlscomponents—Thecontrolsare minimal.Anymaintenance canbedonewhenthe

componentfails.

3.1.5. Pump—Thepumpisadiaphragmpump. You cannotpurchaseindividualcomponentsof

thepump, and arepairkit isnotavailable.Thepumpisratedforcontinuous dutywitha

life expectancyofabout5,000 hours. Thepumpwill self-primeup to 9 feetverticallift.

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4. TROUBLE SHOOTING

Thefollowingsuggestions are providedforsituations thathavebeenencountered in thepast:

4.1. Reducedflowthroughthesystem

Iftheflowthroughthesystembecomesreducedit couldbecausedbyapluggedsedimentfilter.

Removeand replace thefilter.

4.2. FaultAlarms and Remote Monitoring Capabilities

TheOCMisdesignedtoalarmiftheoil contentexceeds thesetlimit oriftheOCMsystemfails.

Iftheoil contentexceedsthesetlimit theOCMalarmsinternallyand causesthesystemtogo

intorecyclemodeuntil thealarmcondition no longerexists. Thealarmwill showon theOCM

displayand will berecordedbytheOCMdatalogger.Under asystemfaultalarmthealarmwill

showon theOCMdisplay.AnyOCMalarmorfault condition will automaticallyputthesystem

into therecyclemode. Potentialcauses oftheOCM systemfault include:

a. looseorimproperlyinserted datacard

b. loss ofcommunication between thedisplayand thedetector(loosecable)

c. internalboard orpower supplyfailure

(See separateOCM O&M manualforamoredetailed explanation oftheOCM.)

4.3. SolenoidValvenotworking

Ifasolenoidvalvedoesnotwork, themostlikelycauseisafailureofthecoil oraloosewireor

it needs to becleaned. You can verifytheelectricalcontinuityfromthecontrolpanel.

4.4. Highoil contentreading causing water to recycleand notdischargeoverboard.

a. Ifyou arerunninghigh concentrations ofoil thefilter maypass more than15 ppmoil.

b. SometimesahighOCMreadinghasnothingtodo withthefilter and issimplycausedbya

dirtyOCMcell.Theglass inthecell shouldbecleanedon aregularbasis.Thisshouldbe

thefirstthingcheckedwhen themonitoris in alarmmode.

5. SAFETY

a. 29 CFR,Part 1910

There are no exposed movingparts on thesystem

b. FederalProtectionStandards

There are no hazardous substancesorchemicalsusedinthesystem.Thesystemisdesignedto

separateoil fromwater.Ifthereare other chemicalsorsubstancesintheoilywater sumpthey

should beevaluated individuallyto determinetheimpact.

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6. SPAREPARTS

ITEMDESCRIPTION ITEM# VERSION

CPParts-Disconnect,Handle and ShaftMRX-130 40011 24V/110V

LIGHT -GREEN-24VDC 40183 24V/110V

LIGHT -RED-24VDC 40072 24V/110V

LIGHT -WHITE-24VDC 40150 24V/110V

LinkModule-Small -CP-ECCMP 40152 24V/110V

MotorStarter/Overload-4.0-6.3A-CP-MPW25-6 40158 24V/110V

MotorStarter/Overload-2.5-4.0A-CP-MPW25-4 40157 220V

MOTOR CONTACTOR-7 A-24VDC 40209 24V/110V

CPParts-Side Switch-CP-SS 40182 24V/110V

RELAY -24VDC-8 A 41204 24V/110V

CIRCUIT BREAKER-1P-2A-CCURVE 41070 24V/110V

GAUGE-PRESSURE -100PSI/BAR-BRASS STEM -GLYCOL 40371 24V/110V

Measuring Cell (Sensor) forBilgMon-488 -TPH-488MC 40456 24V/110V

Cleaning BrushforBilgMon488Measuring Cell 40466 24V/110V

DIAPHRAGMPUMPWITH24VDCMOTORMPU24V 42016 24V

DIAPHRAGMPUMP– 110-120 VACMOTOR 42501 110V

DIAPHRAGMPUMP– 220-240 VACMOTOR 42574 220V

SOLENOID,3 WAY,1/4"NPT,316 STAINLESS,24VDC. 42022 24V

SOLENOID,2WAY-NC-1/2"NPT-24VDC, DIN 42465 110V

Housing -Filter/Polisher-Poly -Cartridge Size2.5x20in 40264 24V

HOUSING-CARTRIDGE-20"BIGBLUE, 1"IN/OUT41269 24V/110V

Cartridge -Filter-2.5x20 in,5 Micron 40267 24V

CARTRIDGE -SEDIMENT -4 1/2"X20",5MICRON 42682 110V

Cartridge -Polisher-4.5x20 in,BOSS XP420 41270 24V/110V

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