Wave MiniBOSS Manual

Wave MiniBOSS MEPC 107(49)
110 / 240v AC 24v DC
Monitored Oil Removal System
OPERATION & MAINTENANCE MANUAL
Tel: [phone]
[email protected]
www.waveinternational.co.uk

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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

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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

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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

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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.

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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.

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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