Oily Water Separator Manual

Final Document
Oily Water Separator
Model: BOSS 25T/107
FOR
SHANHAIGUAN SHIPBUILDING INDUSTRY Co.,Ltd.(SHGSIC)

37,000DWT IMO TYPE II CHEMICAL/PRODUCT TANKER Tier III READY
Hull No.: CT370-01
M17104
Version ( A.0 )
2018.09.05

Oily Water Separator BOSS 25T/107 Rev: V2.0
CONTENTS
Chapter 1 System Description .................................................................................................... - 1 -
1.1 Components ......................................................................................................................... - 1 -
1.2 Process Description ............................................................................................................. - 1 -
1.2.1 General Description of the Process .............................................................................. - 2 -
1.2.2 Pump Location ............................................................................................................. - 2 -
1.2.3 Vacuum vs. Pressure .................................................................................................... - 2 -
1.2.4 Vacuum Applications -- Pump Located on the Discharge ........................................... - 3 -
1.2.5 Pre-filtration ................................................................................................................. - 3 -
1.2.6 Oil Content Monitor (OCM) ........................................................................................ - 3 -
1.2.7 Polisher ......................................................................................................................... - 4 -
1.2.8 Circuit Board ................................................................................................................ - 4 -
1.2.9 Expected Results .......................................................................................................... - 4 -
1.3 System Specifications .......................................................................................................... - 5 -
Chapter 2 Installation.................................................................................................................. - 7 -
2.1 Storing ................................................................................................................................. - 7 -
2.1.1 Remove Oil .................................................................................................................. - 7 -
2.1.2 Drain ............................................................................................................................. - 7 -
2.1.3 Shrink Wrap ................................................................................................................. - 7 -
2.2 Installation ........................................................................................................................... - 7 -
Chapter 3 Operation ................................................................................................................... - 9 -
3.1 Initial Procedure .................................................................................................................. - 9 -
3.2 Before Applying Power ....................................................................................................... - 9 -
3.3 Power Test ........................................................................................................................... - 9 -
3.4 Power ON & Initial Water Filling ..................................................................................... - 10 -
3.5 OCM Test .......................................................................................................................... - 11 -
3.6 Introduce Process Water & Set Flow Rate ........................................................................ - 11 -
3.7 Verify Suction ................................................................................................................... - 11 -
3.8 Simulate Alarm Conditions for Inspector or Verification of Valve Operation.................. - 11 -
3.9 Normal Operation .............................................................................................................. - 12 -
3.10 Backwash system............................................................................................................. - 12 -
3.11 Maintaining and Servicing the Oil Content Monitor (OCM) .......................................... - 12 -
3.12 Calibration of the Oil Content Monitor (OCM)............................................................... - 13 -
3.13 Shutdown Procedures ...................................................................................................... - 13 -
Chapter 4 Maintenance ............................................................................................................. - 14 -
4.1 Maintenance Philosophy.................................................................................................... - 14 -
4.2 Component Maintenance ................................................................................................... - 14 -
4.2.1 Pump .......................................................................................................................... - 14 -
I

4.2.2 Control Valves............................................................................................................ - 14 -

4.2.3 Oil Content Monitor (OCM) ...................................................................................... - 16 -
4.2.4 Coalescing Media ....................................................................................................... - 16 -
4.2.5 Polisher Media............................................................................................................ - 18 -
4.2.6 Control Components................................................................................................... - 19 -
4.2.7 Flow Indicator ............................................................................................................ - 19 -
4.3 Draining the Separator ....................................................................................................... - 19 -
4.4 Annualized Recommended Maintenance Schedule ........................................................... - 20 -
4.4.1 OWS Time-Based Maintenance ................................................................................. - 20 -
4.4.2 OWS Condition-Based Maintenance ......................................................................... - 20 -
Chapter 5 Troubleshooting ....................................................................................................... - 21 -
5.1 Short Cycle Condition ....................................................................................................... - 21 -
5.2 Reduced Flow Through the System................................................................................... - 21 -
5.2.1 Plugged Pre-Filter....................................................................................................... - 21 -
5.2.2 Plugged Polisher ......................................................................................................... - 22 -
5.2.3 Bacteria....................................................................................................................... - 22 -
5.3 Fault Alarms and Remote Monitoring Capabilities ........................................................... - 22 -
5.3.1 Potential causes of the OCM system fault include ..................................................... - 22 -
5.3.2 Available signals from the OCM ................................................................................ - 22 -
5.3.3 Available signals from the Control Panel ................................................................... - 22 -
5.4 High Oil Content Reading Causing Water to Recycle ...................................................... - 23 -
5.4.1 Turbidity ..................................................................................................................... - 23 -
5.4.2 High Emulsions .......................................................................................................... - 23 -
5.4.3 Full Media .................................................................................................................. - 23 -
5.4.4 Dirty OCM Cell .......................................................................................................... - 23 -
5.4.5 High Flow Rate .......................................................................................................... - 23 -
5.5 No Flow Through the OCM .............................................................................................. - 23 -
5.6 Common Fault Alarm ........................................................................................................ - 23 -
Chapter 6 Safety ........................................................................................................................ - 25 -
6.1 Ignition Hazard Assessment .............................................................................................. - 25 -
6.2 Electromagnetic ................................................................................................................. - 25 -
6.3 29 CFR, Part 1910 ............................................................................................................. - 25 -
6.4 Dangers, Warnings, Cautions ............................................................................................ - 25 -
6.5 Federal Protection Standards ............................................................................................. - 25 -
Chapter 7 Spare part list........................................................................................................... - 26 -
Appendix A: Drawing
Appendix B: OCM Instruction Manual
Appendix C: Certificates
II

Chapter 1 System Description

The BOSS line of oily water separators are designed and certified to remove oils, grease and other
hydrocarbons from water in accordance with IMO standards as defined in MEPC 107(49). The BOSS
system removes free oils with a coalescing separator. Emulsions are removed by using a bulk media—
generally organoclay. Fine particles are removed by using various filtering alternatives. Water quality is
monitored with a certified oil content monitor. The BOSS system, if operated properly, will meet and
exceed all the requirements of MEPC 107(49).
1.1 Components
A P&ID is attached to this manual that shows all the components of the system. All systems come
with a standard design that meets MEPC 107(49) standards. The list below shows the standard
components.
PID # Description
CV-101 Oily water inlet check valve
CV-102 Oil discharge valve
CV-103 Discharge check valve
F-101 Pre-filter Y-strainer
F-102 Oil discharge Y strainer
F-105 Polisher—normally organoclay
FI-101 Flow indicator
FR-101 OCM flow restrictor
FH-(XXX) Various flex hoses as required
G-101 Vacuum/pressure gauge
G-102 Pump discharge pressure gauge
G-103 Pressure gauge after polisher
LS-101 Oil level sensor
OCM-101 OCM monitor
P1 BOSS Control panel
P-101 Main process pump
S-101 BOSS oil separator
SV-101 BOSS make-up water inlet control valve
SV-102 Discharge water control valve
SV-103 Recycle water control valve
V-001 BOSS separator vent manual valve
V-002 Polisher vent manual valve
V-003 Flow control valve
V-004 Pre polisher sample port
V-005 OCM clean water inlet manual valve
V-009 Post polisher sample port
V-106 Backwash 3-way valve—polisher inlet/backwash
V-107 Backwash 3-way valve—polisher outlet/backwash
1.2 Process Description

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.
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1.2.1 General Description of the Process

The system is first filled with clean water. A centrifugal pump (P-101) pulls oily water from a
sump, bilge or holding tank into the bottom center section of the coalescing separator (S-101)
through a pre-filter Y strainer (F-101). The separator has an inner and outer section. As the oily
water enters the inner center section, its velocity slows down and it rises up through the center
section of the separator. As it rises up it passes through an oleophilic media (polypropylene). The
media facilitates the separation of the oil from the water by providing a surface area that attracts
droplets of oil and holds them until they coalesce into larger droplets which then rise to the surface
of the water in the separator.
The oil droplets rise to the top of the separator, collect, and then displace the water, forcing the
water level in the separator downward. Any air or gas vapor that enters the separator will rise
rapidly to the top of the separator where it also collects with the oil. Air or vapor that collects in the
separator will be discharged with the oil.
The water then spills over the inner weir and flows down through another layer of media to the
bottom of the separator. Passing through the second stage of coalescing media further removes
residual oil droplets which rise to the top of the separator. Separated water exits the separator out
the bottom of the outer section, through the pump (P-101), then is pumped under pressure through
the flow meter (FI-101), flow control valve (V-003). The water then flows into the polisher (F-105)
where the final adsorption of oils and emulsions occur. The polisher is equipped with manual
backwash valves (V-106 & V-107) to remove accumulated fines from the polisher media. The
backwash discharge is normally directed back to the bilge or holding tank.
A conductance level sensor (LS-101) located in the top of the separator detects the water/oil level in
the separator. When the water is displaced by the collected oil-air-gas to a predetermined low
water/oil interface level the system switches from normal separating called "PUMP & WATER
DISCHARGE" mode to "FILL & OIL DISCHARGE" mode (see the lights on the panel). The
pump (P-101) turns off, the discharge valve (SV-102) and the recycle valve (SV-103) close, the
water makeup valve (SV-101) opens. Makeup water is allowed in, pressurizing the separator and
raising the level of the water. The oil-air-gas is pushed out of the separator through the oil out valve.
Once the water reaches the high level, the level sensor switch shuts the makeup water and oil out
valves. Normal "PUMP & WATER DISCHARGE" mode resumes.
The operation of the discharge and recycle valves is controlled by the oil content monitor (OCM). If
the water flow at the discharge valve has oil content of less than 15ppm on a standard system the
water is allowed to be discharged over board or to another appropriate collection receptacle or
drainage. If the oil in the discharge water is greater than 15 ppm the OCM monitor will alarm. An
OCM alarm will cause the system to automatically go into recycle mode until the condition no
longer exists. There is an adjustable 0-10 sec. delay timer in the OCM that is met before the recycle
valve is actuated. The specific OCM instruction manual is included as an attachment to this manual.
1.2.2 Pump Location
The standard system is designed with the pump on the discharge side of the separator pulling water
through the separator. Where the bilge or sump is located below the level of the separator the pump
will pull a negative suction head. If the bilge or sump is located above the separator the system is
pressurized. The separator will work in both conditions with minor differences explained below.
The standard system uses a vacuum to pull the water through the system. This allows the use of a
centrifugal pump. The centrifugal pump has a lower cost, less maintenance, better safety, more
operational flexibility, a longer life span and the flexibility to adjust the flow rate. However, it
cannot be used on the front of the separator without creating mechanical emulsions that negatively
impact the efficiency of the separator. It also has less negative suction lift and is less effective for
high lift situations.
1.2.3 Vacuum vs. Pressure
The standard system operates under vacuum. However, the primary equipment will operate either
in a vacuum or pressure mode, although there are some differences in how the system operates.
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When the system is in a vacuum mode the oil discharge valve does not need to hold pressure so a
simple check valve (CV-102) is used. The standard system comes with a check valve for the oil
discharge valve. If there is pressure in the separator vessel this check valve will not work and needs
to be replaced by a motorized control valve (MOV-101). It is important to understand whether the
system will be operated in a vacuum or pressure mode.
If the system is pressurized a motorized control valve (MOV-101) is MANDATORY for the oil
discharge. WARNING: If the system is operated under pressure without MOV-101 it will allow
water and oil out of the oil discharge check valve. The check valve will withstand a pressure of
about 0.04MPa. Anything above that will push water and oil through the check valve and into the
slop oil tank and could cause the oil tank to fill up and overflow.
1.2.4 Vacuum Applications -- Pump Located on the Discharge
1. A process pump (P-101) is mounted on the outlet of the separator which pulls water from the oily
water sump through the pre-filter (F-101) and separator (S-101). This placement reduces the
formation of mechanical emulsions. The standard process pump will pull 5 meters of negative
head or vertical suction lift and still provide the design flow through the unit. The suction of the
pump is continuously flooded with a positive head so there is no need to prime the pump. The
pump is a stainless steel centrifugal pump and therefore does not need a safety relief valve.
Depending on suction and head requirements for a given installation, the process pump is
generally capable of pumping more than the designed flow through the system. A manual flow
control valve is provided to adjust the flow to the design level.
2. It is critical that all connections to the oil water separator are airtight and properly sized for the
installation. Any leaks in the inlet piping or piping restrictions will impact the amount of vacuum
that the pump can pull.
3. The system will still work up to as much as 16” Hg (6meters), but the flow will be restricted. The
flow indicator will still read full flow but what is happening is that the system is pulling part of
the water from the bilge and part of the water is coming from the head of the separator. The
system will short cycle and go into the fill mode more often than normal. The higher the vacuum
the less water the system will pull from the bilge.
If the actual lift is more than described above, the pump could stop pulling water from the sump
or could pull very little and could cavitate.
1.2.5 Pre-filtration
When the unit is turned on the main process pump (P-101) pulls water from the sump through a pre-
filter screen F-101. The standard unit comes with a Y strainer. The Y strainer has an 80 mesh
screen and 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.
1.2.6 Oil Content Monitor (OCM)
The BOSS 107 includes an Oil Content Monitor (“OCM”, also sometimes called a Total Petroleum
Hydrocarbon Monitor (TPH) or bilge alarm) that has been certified to meet the MEPC 107(49)
regulations. The OCM monitor has the ability to automatically return non-conforming discharge
water back to the sump or bilge. The recycle solenoid valve (SV-103) and the oil in water monitor
(OCM) control the recycle action. The OCM monitor is continually sampling the process stream
and detecting the amount of oil concentration. It is designed to react quickly to any changes in the
oil content.
The monitor uses light refracting technology. There are typically 3 sources of light shown at
different angles. The cell measures the refraction of the light as it bounces off hydrocarbon
particles. The refraction can accurately measure the level of hydrocarbons present by the amount of
refraction. However, 3 sources of light are not adequate to get all the angles that are required when
there is a lot of turbidity present. When turbidity particles are present they can hide the oil and the
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light does not see all the oil. In these situations the monitor goes into alarm mode. If the turbidity
in the water is greater than 35 NTU, the monitor will go into alarm even if there is no oil present.
The sample water tubing to the OCM is installed with a flow-restricting orifice in the outlet port of
the OCM-- just inside the end of the tube fitting. This will limit the flow through the OCM meter to
a flow of approximately 0.5 l/m to 2.0 l/m. You cannot see the orifice without removing the tube
fitting.
WARNING: The return line from the OCM does not come with a shut-off or restricting valve.
Under no circumstances should a valve be installed on the OCM sample return line.
1.2.7 Polisher
The primary purpose of MEPC 107(49) was to address the monitoring and removal of emulsified oil.
A coalescing separator will not remove chemical emulsions and will only partially remove
mechanical emulsions. Some form of post treatment is necessary.
There are 2 types of polisher housings that are supplied to hold bulk media. The 2.2T, 5T,11T and
25T systems use a polyglass polisher with a tube that goes down the center. The inlet and outlet are
both handled through the top distributor. These vessels are rated for 1.05MPa pressure.
The 45T systems use a steel vessel with an inlet distributor at the top and an outlet distributor at the
bottom. These vessels are rated for 0.5MPa pressure.
The standard bulk media used is organoclay. Its advantage is that it lasts a long time relative to
other forms of media. The disadvantage is that it is hard to vacuum out the old media. The bulk
organoclay media is by far the lowest cost alternative for removing emulsions.
1.2.8 Circuit Board
A. Serial Numbers B7190 to B41270
These circuit boards are a relay based circuit board unless noted otherwise. All of the logic and
control is done through relay logic. A level control relay is plugged into the board in order to
control level and can be swapped out if the level relay is faulty. The level relay is the only user
repairable component on the circuit board. We recommend having a spare relay in inventory. The
OCM is wired to these circuit boards and communicates through status relays. Special features can
be added to these systems by adding separate control devices such as timing relays. These separate
control devices will not be added directly to the circuit board, but are mounted on DIN rail inside
the control enclosure. There are 4 status signals that are available to the customer. These status
signals indicate the following states of the system; Power, Fill (Oil Discharge), Discharge (Pump),
and Recycle (ppm Alarm).
B. Serial Numbers starting with B50101 (January 2015)
These circuit boards are a microchip (PIC) based circuit boards. These boards have been designed
to incorporate the level control and a number of other functions not previously available on the
older board. The additional functions are: automatic backwash, common fault, and emergency
shutdown (ESD).
There are 3 status signals that are available to the customer. These status signals indicate the
following states of the system: Running Indication, Pump Fault Alarm, and ppm Over Limit Alarm.
The new circuit boards are completely backwards compatible and can be installed in place of the
older circuit boards back to serial number B7190.
1.2.9 Expected Results
Operating properly the BOSS 107 Separator system will reduce the oil in your discharge water to
below the 15 ppm limit set by the IMO MEPC regulation 107(49). In many situations the oil
content will be significantly lower than the 15 ppm. You can expect the following results from the
system:
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a. With no emulsions present and using organoclay in a down flow configuration, the system will
generally remove any free oil and the monitor will generally read 0-1 ppm.
b. The higher the volume of oil in the oily water the more oil the primary separator will discharge.
For example, in most situations the primary separator will remove free oil to < 15 ppm. However,
with high concentrations of oil the primary separator will pass more than 15 ppm oil. As the oil
concentration goes up so will the amount of oil in the water leaving the separator. This is generally
not a problem because the polisher will take out whatever the primary separator does not remove.
The more oil in the separator discharge the faster the post polisher media will be consumed but the
system will accommodate such conditions.
c. If the separator is not being used all the time or is not running full time at the design rate, the
performance can be improved by slowing down the separator. The flow control valve can be used
to restrict the flow to less than the design rate. This will improve the performance of the separator
and allow the coalescing separator to remove more oil, making the Polisher media last longer. This
can be an effective tool for managing discharge levels of oil.
1.3 System Specifications

Size
□2.2 T □5 T □11 T ☑25 T □45 T
Specifications
Height (mm) 1400 1570 1950 2000 2190
Width (mm) 755 952 1082 1109 1400
Depth (mm) 1050 1200 1500 2005 2600
Dry Weight (kilogram) 260 430 620 1110 1800
3
Capacity gpm (m /h) 2.2 (.5) 5 (1.2) 11 (2.5) 25 (5.7) 45 (10.2)
Organoclay/sand charge (kg) 41 82 147 290 630
Specification Value
107(49) certified by ABS, USCG, BV, CCS and
IMO MEPC Compliance
MED(EC)
Vessel Metallurgy Marine Coated Carbon Steel
Exterior Coating Specification Blast Sa2.5 covered with Epoxy/Urethane Paint
Coalescing Media Polypropylene
Separator Vessel Design / Test Pressure 0.11 / 0.33 MPa
Polisher Vessel Design / Test Pressure 1.05 / 1.05 MPa for Fiberglass Vessels
Operating Pressure < 0 MPa (Up to 0.1MPa when Pressurized)
Water Temp Range 5-60 ℃
Design Negative Inlet Head (m) 5
Positive Inlet Head Design Pressure
0.11 MPa
(Motorized Valve Required)
Max Free Oil Concentration 35%
Max Emulsion Concentration (with
6%
Polishing)
Oil in Water Discharge <15 ppm
Control Panel Enclosure NEMA 4X / IP55
-5-

IMO MEPC 107(49) Certified Monitor with Data

OCM (Oil Content Monitor)
Logging
Level Switch Conductance with 304 SS Probes
Discharge, Recycle, Fill Valves Bronze Body, Solenoid Type, Rated for Salt Brine
Oil Out Valve Brass Check Valve
Backwash Valves 3-Way Manual, SS Body
Pump Centrifugal with 304 Stainless Steel Housing
Motor TEFC IP 55
Piping & Fittings Marine Grade SS Pipe, SS Fittings
Flow Indicator Visual Mechanical, Bronze Body with Glass Window
Three Phase Power Options 3×440VAC
Frequency 60Hz
Max Amperage < 15 Amps
Hazard Area Classification NEMA 4X
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Chapter 2 Installation
2.1 Storing
If the unit is unpackaged or has been placed in operation and needs to be stored the following
should be done to protect the system from freezing or developing bacteria:
2.1.1 Remove Oil
If the unit has been in operation and is still in place, force the unit into the fill mode several times by
opening the separator vent valve. This will help make sure there is very little oil in the system. The
unit can also be forced into fill by disconnecting the level sensor. This is done by opening the
control panel and disconnecting the orange plug from the circuit board that controls the level switch.
This plug is located on the bottom left hand corner of the circuit board. Once the system has
removed all of the oil from the system, simply install the orange plug back into the circuit board.
2.1.2 Drain
1. Open the inner and outer separator drains and drain the system into the bilge. This will drain
most of the water.
2. Open the cap at the bottom of the pipe where the discharge and recycle valves are located.
3. Remove the pump plug.
4. Remove the OCM cap.
5.Drain the water from the separator into the bilge.
6. Blow air into the OCM, vent or any other openings to make sure as much water as possible has
been removed. Clean the cell with the brush provided using a mild, non-corrosive cleaning agent
and rinse with clean water. (See the separate OCM manual for cell cleaning instructions.)
2.1.3 Shrink Wrap
Wrap the unit in shrink wrap to protect it.
2.2 Installation
The BOSS Oil Water Separator is a self-contained system that is fully tested and operated under
normal operating conditions without oil at the factory. Each function of the system is tested and
verified. Within the system no piping or wiring will be necessary unless the separator and polisher
are to be mounted separate from each other. A FAT report is provided with the unit to show what
test procedures were performed.
Installation normally involves the following:
1. Move separator into place and mount the separator to the deck. This is accomplished by using
several M16 bolts.
2. Make the necessary piping connections to your application. All piping connections to the system
are listed in the table below.
Connection /
2.2T / 107 5T / 107 11T / 107 25T / 107 45T / 107
min pipe size
DN20,PN1.0 DN25,PN1.0 DN25,PN1.0 DN40,PN1.0 DN50,PN1.0
Oily Water Inlet
20mm 25mm 25mm 40mm 50mm
Fresh Water In
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Oil Out Discharge
Water Out Discharge
Water Recycle
Separator Inner Drain ¾” / na 1” / na 1” / na 1 ½” / na 1 ½” / na
Separator Outer Drain ¾” / na 1” / na 1” / na 1 ½” / na 1 ½” / na
3. 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 highly recommended that the customer install isolation valves at all piping
connections to the separator unit.
4. 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. This voltage is shown on the electrical drawing. This
schematic is found inside the control panel, as well as within the attachment section of this
manual. The power connections to the main power disconnect are shown on the electrical
schematics attached.
-8-

Chapter 3 Operation
3.1 Initial Procedure
The general steps for startup are listed here.
1. Verify that the installation of the system is complete before applying power.
2. Verify proper voltage to the system.
3. Verify that the clean water source has been turned on. It is recommended that the pressure of the
clean water should not exceed 0.11MPa (the vessel design pressure)
4. Connect power to the separator and verify the pump rotation direction.
5. Turn main power on and initiate clean water fill.
6. Fill the separator and piping completely with water.
7. Purge the air out of the system.
8. Verify suction & repair any air leaks.
9. Verify operation of the OCM (OCM power on, PPM reading, 3-way valve operation).
10. Verify operation of the recycle valve (valve is open when PPM > 15, closed when PPM < 15).
11. Verify operation of the discharge valve (valve is open when PPM < 15, closed when PPM >15).
12. Open the vent valve to force the system into fill mode. Verify operation of the fill valve and oil
out MOV (if applicable) (MOV is open when the fill valve is open, closed when the fill valve is
closed).
13. Turn the separator on and set the designed flow rate with the manual flow control valve.
14. Simulate alarm and warning conditions to verify that they function properly.
15. Make any adjustments that are appropriate.
3.2 Before Applying Power

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.
Verify that there is a foot valve. If there is no foot valve in the sump the system will drain every
time it is shut off and will have a difficult time priming.
Verify that the power is at the voltage and frequency indicated on the electrical drawing and
connected as shown on the electrical drawing. Connect power to the L1, L2 and L3 terminals on the
combination motor starter as shown on the electrical drawings. Do not remove the other wires on
these terminals.
3.3 Power Test

The pump has been supplied at the voltage that was specified when the system was ordered. Check
the pump voltage that was supplied to make sure that it agrees with the voltage that is required. If
the voltage supplied does not agree with what is required then it is possible to change the voltage or
frequency.
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.
Check rotation by manually energizing the pump. Open the control enclosure and turn the power on
by turning the disconnect shaft clockwise 90 degrees. Momentarily push the contactor button with a
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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). After testing rotation turn the disconnect off and close the enclosure door.
Figure 1
Power Connections
Ground
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
The unit is now ready to run by turning the disconnect to the ON position and turning the ON-OFF-
REM selector switch to the desired position.
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. The
OCM monitor on the unit should power up and perform its self test mode.
3.4 Power ON & Initial Water Filling

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
0.11MPa (the vessel design pressure). The next step is to fill both the separator and the filter.
Fill the separator by turning 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 will close and the pump will come on. When
the pump comes on it will automatically fill the polisher. With the inlet isolation valve closed the
pump will pull from the separator to fill the polisher. It will go into the fill mode several times
during this process but it will fill the polisher with clean water. In the normal mode air will be
trapped in the top of the filter. To evacuate the air you will need to switch the backwash valves (V-
106—polisher inlet-- and V-107—polisher outlet) to the backwash position for a short while. Open
the vent valve on the polisher to allow air to evacuate. This will push the air out of the polisher.
When water starts coming out the vent valve then the entire system if filled and the system is ready
to run.
- 10 -

IMPORTANT: If the polisher is not completely filled the OCM monitor will have problems due to
air in the polisher interfering with the oil ppm reading.
3.5 OCM Test

While the system is running on clean water the OCM needs to read zero. If the OCM 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 see the OCM
manual.
3.6 Introduce Process Water & Set Flow Rate

Once the system is filled with water and the OCM has been set to zero, keep the system on, open
the isolation valve to allow oily water into the system.
One of the advantages of the BOSS OWS systems is the use of a centrifugal pump. The pump is
oversized so that the same pump will work in a variety of discharge pressure situations. The pump
will operate from 10% of design up to > 100% of design without impacting the pump. This pump
allows the user to control the flow through the separator by adjusting a manual flow control valve
located next to a mechanical flow indicator. It is normally not necessary to adjust the flow rate
during operations once it has been set.
3.7 Verify Suction

Check the suction by reading the vacuum gauge on the inlet pipe. If the suction pressure reads 0
there are most likely leaks in the piping. If the suction pressure is >5m there are either restrictions
in the suction piping or the suction lift may be starting to get too high. If you have removed all
restrictions and the vacuum gauge still reads > 5m the system could have difficulty achieving the
design flow rate. With most new installations there is a significant amount of debris in the suction
line that gets caught in the pre filter. as a general rule clean the inlet strainer within the first hr of
normal oily water processing. observe the gauge pressure when the screen is clean. any rise in
suction pressure would indicate that the strainer is becoming clogged again.
3.8 Simulate Alarm Conditions for Inspector or Verification of Valve

Operation
The 107(49) monitors are factory calibrated by law and so no calibration is needed on startup.
When the inspectors come to verify the operation of the oil water separator, they will want to see
that the monitor will open the discharge valve when less than 15ppm and that the recycle valve will
activate when over the limit.
The proper operation of the monitor can be demonstrated by simulating the alarm conditions. This
is accomplished on the Brannstrom monitor by holding the back arrow key for 4 seconds. This will
simulate what happens when the unit is above its set point. The discharge valve will close and the
recycle valve will open.
You can check that the valves are actuating by shutting off the isolation valves (customer supplied)
and observing the pressure gauges on the separator. For example if the discharge is isolated and the
recycle is not, you will have pressure when it is trying to discharge and no pressure when it is
recycling.
- 11 -

The monitor can also be forced into alarm by emptying the cell by using the brush to push all the
water out. Then when you turn the separator on the air in the monitor will cause the alarm to go
above set point for a short period. This will show that above 15 ppm reading that the alarm works.
You can also simulate an alarm condition by using WD-40(which is an oil based product). This is
done by turning the three position selector switch to the “OFF” position, removing the plastic tubing
line that is for the sample inlet and spraying the WD-40 into the line. After spraying the WD-40
inside the line, reconnect the line to the plastic fitting and turn the system back on. The monitor will
read zero for a few seconds but as the WD-40 passes through, the ppm level will raise and then
lower as the WD-40 runs out.
You can cause the system to go into the fill mode to demonstrate the level control by opening the
vent valve while the system is running. This will pull air into the head of the separator and force the
water down until the level probe no longer senses water. This will cause the level control to think
there is oil in the oil reservoir and will cause the system to go into the fill mode.
3.9 Normal Operation

After all of the specified testing has been completed and the system has run satisfactorily with the
water flowing through the polisher, then the system can be put in normal operation. Turn the switch
to ON and open the sample lines to the OCM. The unit will then monitor the outlet stream and
automatically switch between discharge and recycle as needed. The system is designed to operate
without operator interface.
The systems are designed to handle up to 5 meters of suction lift and approximately 24 meters of
discharge head with the standard centrifugal pump.
3.10 Backwash system

The system will come with a 3-way manual backwash valve
assembly. This allows the operator to backwash the polisher
whenever they want.
The timing of how often to do the backwash will be determined
by the differential pressure across the polisher as measured by
the inlet and outlet pressure gauges. When the differential
pressure rises, simply change the valve positions to the
backwash mode and let it run for about 5 minutes. You can
pipe the backwash back to the bilge. This will cause silt to
build up in the bilge. Periodically the bilge will need to be
cleaned out to remove the silt. The bilge foot valve should
never be located on the bottom of the bilge. Water should be
pulled from a reasonable distance above the bilge so solids can
settle to the bottom. It is also possible to pipe the backwash so
that it goes through a filter to remove the silt. This will prevent
the buildup of silt in the bilge.
It is important not to go for long periods of time without backwashing. If the silt is driven to deep
into the organoclay bed it will not come out. We recommend that the backwash be done daily or
after each batch process.
3.11 Maintaining and Servicing the Oil Content Monitor (OCM)

WARNING: DO NOT ATTEMPT TO BREAK THE SEAL OR OPEN THE MONITOR TO DO
ANY MAINTAINENCE OF THE MONITOR. BREAKING THE SEAL WILL VOID THE
CALIBRATION.
- 12 -

The only work you can do on the monitor is to change the cell, clean the cell or perform some other
minor functions explained in the oil content monitor instruction manual. Any other work must be
done by the factory. A separate instruction manual for the oil content monitor is attached.
The oil content monitor cell will need to be cleaned on a regular basis. To clean the cell, follow the
instructions in the attach OCM manual. Do not use toothbrushes or other brushes that do not have a
soft end. Brushes can be ordered from your distributor or the factory. Once the cell is brushed,
screw the top on the cell and push the water button again to flush clean water through the cell again.
The system can now be turned back on. Do not shut off the disconnect. You will shut off the 3
position switch but not the disconnect. The monitor will need power in order to control the solenoid
valve and go through its functions. You should read and refer to the separate OCM manual for
more details on how to operate and maintain the OCM.
There are times when the cell can be coated with material that is hard to get off. You may need to
use soap, lime away or vinegar or some other cleaner that is non abrasive to get the cell clean.
3.12 Calibration of the Oil Content Monitor (OCM)

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

If the system is connected to a level control in the bilge sump the separator will automatically turn
on and off according to the high and low settings on the level control and no manual intervention is
required. If there is no level control in the bilge then the system will need to be started and stopped
manually. Startup procedures are shown above. To shut the system off simply turn the 3 position
selector switch on the face of the control panel to the off position.
If the shutdown is required for any maintenance that requires opening the panel or servicing an
electrical component, make sure that the disconnect on the separator AND the main breaker is
turned off and the system is locked out and tagged according to standard lock-out, tag-out
procedures. The disconnect in the main panel will shut off all power to the pump and internal
control board but lethal voltages are still present in the control panel.
Any time the system is shut down all isolation valves should be shut.
- 13 -

Chapter 4 Maintenance
4.1 Maintenance Philosophy
The standard system does not have installed redundancy, although it can be ordered with any level
of redundancy the customer wishes. The general maintenance philosophy for most of the
components is to replace the components as they fail. We have not developed a mean time between
failures for most of the components because every situation is different. The system does not
generally run continuously—only when the bilge level increases to a designated level. In general
there is adequate time to make any required repair without impacting the bilge water level. We
recommend maintaining critical spare parts in inventory so that if there is a failure the part can be
replaced quickly. Most components can be changed within a few minutes.
There are no components that need to be overhauled. In most cases the components are fairly
inexpensive and it is less expensive to replace the part than it is to overhaul or repair the part. The
only exception to this is the oil content monitor, which is the most expensive component on the
system. In the case of the oil content monitor it is against IMO regulations for the customer to do
any maintenance on the system other then cleaning the cell and other minor service. If the monitor
fails it generally has to be replaced. Any attempt by the customer to break the seal and open the
monitor will void the validity of the monitor.
There are some routine maintenance functions that need to be performed to keep the system running
at peak performance.
4.2 Component Maintenance

4.2.1 Pump
The standard centrifugal pump installed on the system does not require lubrication. The mechanical
seal should be replaced periodically or when it fails.
4.2.2 Control Valves
The control valves installed on the system are high quality marine grade solenoid or actuated ball
valves and do not require lubrication.
1. Solenoid Valve: If a solenoid valve fails to open the actuating coil could be at fault and will need
to be replaced. If a valve fails to close properly, there may be foreign objects lodged in the
plunger assembly. The valve must be disassembled and cleaned. NEVER remove the solenoid
coil from the valve with the power on or apply power with the coil not on the plunger stem. This
will IMMEDIATELY destroy the coil and will nullify any warranty on the valve. If you need to
service the valve, loosen the large nut at the base of the coil and remove the entire coil assembly.
This will expose the plunger and allow you to replace the o-ring and valve disc or clean out any
sand. If you need to change the coil you will need to disconnect the power before removing the
cover.
Occasionally a Magnatrol valve will “hang” open and not shut off the flow of water either on the
fill water inlet or one of the outlet valves. The repair procedure is the same for all sizes of valves.
There is an inner core that slides in the main bore of the valve that can get a particle of sand or
other debris lodged which can cause the valve not to close. Or a particle may scratch the surface
of the core and raise a burr on the surface, this will also hang open the valve.
- 14 -

Here is a photo of a ½”A42 solenoid valve
CAUTION! NEVER POWER THE COIL TO “TEST” IT UNLESS IT IS

INSTALLED ON THE CORE, IT WILL BURN OUT IN LESS THAN 30
SECONDS.
Begin by removing the bonnet, spring washer,

coil, and coil base.
The core stem can then be removed from here.

The main problem generally occurs between the stem
plunger and the bore.
Generally a good cleaning here will

solve the problem, sometimes it may be
necessary to clean the inside and
outside surfaces of the plunger and the
bore with a FINE grit 320 or 400 sand
paper to remove any burrs that may
have formed. Reassemble the unit
making sure the o-ring is in place.
PLUNGER O-RING BORE
ALSO be sure the spring washer is on the top of the coil on the core stem and all components are
positioned as shown below.
COIL BASE COIL SPRING WASHER BONNET

2. MOV. The system will generally not come with an MOV on the oil discharge line unless the
whole system is pressurized. An MOV is required with a positive inlet pressure. If the separator
is delivered without an MOV and you have a positive pressure, or if you decide for any reason
that you want an MOV on the oil discharge an MOV will need to be installed as follows:
 Disconnect the oil discharge piping at the elbow.
 Install the MOV in the oil discharge line in place of the check valve.
- 15 -

 Drill a 7/8” hole in the bottom of the control panel enclosure. Put this hole 2” to the
right of the hole with the level switch wire. Note: You may need to use an angle drill or
drill from the inside of the enclosure.
 Run the wire along the back of the panel down to the bottom and tie wrap to unistrut.
 Run the wire around the bottom left edge of the panel and into the enclosure. Tie wrap.
 Install connector into enclosure using a cable gland provided in the kit.
 Connect the wires as shown in the instructions that come with the MOV.
 Clip the jumper on the circuit board J1.
4.2.3 Oil Content Monitor (OCM)
The OCM will need a periodic check of zero against clean
water, and frequent cleaning of the glass sample cell. The
Brannstrom monitors do not require desiccators and there are
no spare parts required other than brushes. There are no user
serviceable parts to the OCM control unit or cell. If any
defective operations of the OCM are determined, call your
service rep.
Without a restriction the system will generally flow more water to the OCM than is necessary or
recommended. The system comes with a very small flow restrictor installed inside the return line
fitting. If the flow restrictor is ever lost for any reason a new one will need to be installed as
follows
Sample fitting
Flow Restrictor
Sample return
Remove the return fitting and insert the flow button in the threaded end and reinstall the return
fitting. You may need to replace the Teflon tape on the threads. Do not use petroleum based pipe
dope on the plastic fittings.
4.2.4 Coalescing Media
The coalescing media inside the separator is not to be confused with the polisher filter media. The
coalescing media does not need periodic cleaning. Under normal circumstances the coalescing
media will need changing only once every 5-10 years. It does not require specific maintenance or
replacement under normal operating conditions. The media can be destroyed by strong acids or
bases. If the media is damaged by adding chemicals to the water or for some unusual reason you
should do the following in order to change out the media:
1. Remove the head on the separator vessel.

- 16 -

2. Remove the clips and the old media. This is easier if you make a hook using a small diameter
rod. Shove the rod down the side of the media. Turn 90 degrees so the hook part is under the
media and use the hooked rod to pull the media up. (It is easier with 2 hooks.) For larger
systems the media may have to be cut out in pieces. Hooks can be ordered from the factory or
your distributor as a spare part but in most cases it is simply easier to cut it out.
3. The replacement media comes packaged in rolls with an inner section and an outer section. Both
sections are supplied a little oversized. It will be necessary to test fit and possibly remove a few
inches of the roll for the proper fit. The roll may seem to be too large, however the media will be
somewhat compressed as it goes into the pipe. The first 150~250mm should go in with moderate
pressure and get harder as it slides in. The last 100mm should be fairly hard, and require some
heavy pressure to get all the way in.
4. It doesn’t matter which section you install first. Place the
media in the proper section and get it started, making sure
not to damage the edge of the media trying to force it in
place. The media should be tight as possible but still
allow it to be inserted into the separator without rushing
the roll. The center section will compress more than the
outer section and it can be a little tighter. If the outer
section is too tight it will be hard to push down and could
buckle. You may need to trim a small amount off the
rolls—either the inside of the roll or the outside or both.
To do this just cut off the excess with a utility knife. If
you cut too much that is not a problem—just add some
back. If you have to add any back unroll the media bundle
a little and insert the small piece and re-roll the bundle.
5. It is easier to push the media into the vessel with 2 people. Both people can push the media down
uniformly. If there is only 1 person it is easier if you can use a piece of wood to put on top of the
media and push down uniformly. We have found that when the media is almost in place it gets
hard to push down. We use a couple of short pieces of 2 x 4 to help us push down the last little
bit. On the larger systems we find that it works well to walk around on the media and use your
weight to push it down. You should be able to jump up and down on the media to help push it
down on the large units.
6. The inner section should be pushed down about 25-50mm below the weir on 2T and 5T units and
about 100-150mm on the larger units. The outer section should be pushed down just below the
weir
7. If you cut off too much and the media is too loose it can float up in operation and will interfere
with the operation of the level probes. Pull it out. Roll back ½ layer of the roll and sandwich in a
small section of the excess that was cut off and re roll. See picture below. This will make it
tighter fitting in the pipes. It is not likely that the media in the outer section will ever come up
because the water pressure is pushing it down.
(The black section is only colored for contrast)
- 17 -

8. A small clamp is provided. It should be installed at the top of the center pipe to prevent the
possibility of the media from rising up and interfering with the level probes.
4.2.5 Polisher Media
The polisher media will need to be changed when the oil content monitor will not go below 15 ppm
AND you have cleaned the cell and backwashed the media. High oil content (maximum saturation
of the media) is will eventually happen with each charge of media but can be premature by using
surfactants and other cleaning chemicals that make hard-to-remove chemical emulsions. We
recommend the use of cleaners that do not cause emulsions. The media can last up to a year with
proper care and bilge management. The used media can generally be thrown away in the same
manner a spent oil filter is discarded or with the other municipal waste from the vessel or facility. It
can also go into an incinerator. (Note that the ash content will be high if it is put into the
incinerator.) Check with the incinerator manufacturer to verify that the incinerator will handle the
high ash/sand content.
a. Recharging the Media
The procedure for recharging the organoclay or carbon media is as follows:
2T, 5T,11T and 25T Units:
1. Remove the flexible hose to the unit.
2. Remove the top distributor.
3. Vacuum the old media from the unit using a shop vacuum. You
will need to keep the media wet in order to vacuum it out.
4. In some cases the center tube will come out easily as long as the
media is wet. In some cases it may be hard to remove initially. If
this is the case the vacuum hose will need to be small enough to
go down alongside the tube or you can put the vacuum over the
tube.
5. Rinse out the housing. (Skip the first 5 procedures if you are
using a new filter housing.)
6. Place the center tube into the housing, making sure it is centered.
Plug up the tube so nothing goes down the center of the tube.
7. Place the funnel to the side of the tube. DO NOT ALLOW
SAND OR MEDIA TO GO INSIDE THE TUBE. Pour the sand
into the funnel. The sand should cover the bottom distributor
basket about 150mm. This can vary depending on what objective
you are trying to achieve. If you tend to have problems with
turbidity it is better to have more sand and less media. Turbidity
or sediment will plug up the media and shorten its life. The
organoclay may still have plenty of life but the media could be
plugged. If this is a problem then use more sand and less
organoclay or carbon. The sand should be coarse sand (40 mesh
or courser).
8. Pour the organoclay or carbon into the housing using the same
funnel. Fill the vessel to about 250mm from the top.
- 18 -

9. 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
buckets of sand/carbon/organoclay from the factory or your distributor.
45T Units:
1. The procedure is basically the same as with the smaller units except that the housing has a
manway cover that will be removed. The new sand and organoclay or carbon is dumped into
the manway opening. The sand should be filled at least 125mm above the bottom distributor
but not more than 50% full of sand. Organoclay and/or carbon should be loaded at least 6-8”
below the top distributor.
2. If the manway cover gasket is damaged you may need to replace the gasket.
3. In some cases the vessel will come with a bottom 10” manway to make it easier to remove the
media. This normally only comes when specifically requested.
b. Disposing of Spent Organoclay Media
Laboratory testing of spent organoclay has shown that BTEX and other volatile hydrocarbons
are adsorbed tightly enough for the spent product to pass the EPA’s Toxicity Characteristic
Leachate Procedure (TCLP) test and be disposed as a non-hazardous waste. The TCLP is used
to identify the presence or absence of toxic chemicals that might be able to leach into
groundwater after disposal. This is an amazing accomplishment, given that the product may
adsorb up to 88% of its own weight in hydrocarbons or 100% by volume. Being classified
as a non-hazardous waste allows the spent product to be landfilled, land farmed, or otherwise
disposed in an economical manner.
4.2.6 Control Components
The control components are designed for marine application. They should be replaced when they
fail. We have indicated on the spare parts list which items we recommend to spare.
4.2.7 Flow Indicator
The flow indicator is an industrial class, direct reading indicator that is simple
to use and install. It provides an excellent way to measure the flow through
the system without having to use an expensive meter. If the glass gets cloudy
or breaks, the cover is easily removed and a replacement glass can be
installed. The spring inside the indicator is specific to each size unit and is
not interchangeable. The spring can be changed by removing the cover. The
separator system will function perfectly fine without the flow indicator. The
only impact is that you will not know exactly what the flow rate is. If the flow indicator fails the
system can be operated normally until a replacement can be procured. In this situation the system
can be operated based on its performance. If there is too much flow going through the separator, the
efficiency will decrease. If the oil content in the discharge goes up, slow down the flow and the
efficiency will improve. As long as the separator is meeting IMO requirements it is not critical to
know the exact flow rate during a temporary situation but lower flow is always safest in these
situations.
4.3 Draining the Separator

The separator is designed to hold water all the time. Should it become necessary to drain the
separator for any reason you should cycle the system between fill and normal operation several
times in succession to eject as much oil as possible from the top of the separator. To cycle the unit
place the system in normal operation, close the inlet valve that is located on the inlet side of F-101
and open the vent valve (V001). The unit will go into fill mode as soon as the fluid level in the top
of the unit is pumped down to the low-level sensor. This should happen in approximately 60
seconds to 5 minutes, depending on your separator size. The unit will cycle between fill and normal
operation as long as the vent is open and the inlet is closed. Three cycles should be enough to dilute
- 19 -

and reject as much oil as possible. Then proceed to open the drain plugs. 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 3.1.
4.4 Annualized Recommended Maintenance Schedule

4.4.1 OWS Time-Based Maintenance
Maintenance Annualized
Maintenance Activity Frequency
Hours Hours
Clean OCM monitor glass
Purge the air in the OCM Monitor cell 0.05 daily or 5
Verify normal operation of the system weekly
Clean the “Y” strainer screen 0.15 15
Test the operation of pump 0.1 1.2
Test the operation of the control valves 0.1 Monthly 1.2
Verify design flow rate 0.05 0.6
Verify mechanical seal on the pump 0.05 semi annual 0.1
4.4.2 OWS Condition-Based Maintenance

Replace the organoclay media in the filter when the system
4-8 Variable 4–8
will not keep the oil content below 15 ppm.
Replace mechanical seal and o-ring on pump, and valve o- When they
.5 .5
rings leak
Replace other components as required 2 Variable 2
- 20 -

Chapter 5 Troubleshooting
The following suggestions are provided for situations that have been encountered in the past:
5.1 Short Cycle Condition

Short cycle condition is indicated when the system goes from “PUMP & WATER DISCHARGE”
to "FILL & OIL DISCHARGE " and back to “PUMP & WATER DISCHARGE” in a frequency
less than half an hour of duration. This condition can occur for any of the following reasons:
1. Air Leaks
The most common cause of short cycling is because the inlet of the separator is pulling air into
the separator with the oily water. The air collects in the top of the separator and displaces the oil,
driving down the internal water/oil level interface. This in turn activates the level sensor which
tells the system it is time to discharge oil. If the inlet piping connections are not air tight, air will
be pulled into the separator. The larger the leak the faster the cycle time. This situation can be
corrected by making sure there are no leaks in the inlet piping.
2. No foot Valve interlocked with the system
If there is no foot valve in the bilge or if the foot valve is not interlocked with the system the
system can suck air and go into fill mode. The correction is to install a foot valve that is
interlocked with the system to shut off when the bilge level goes below the foot valve. If there is
no foot valve it is possible for the separator to empty the bilge and just suck air.
3. Suction Lift too great
If the suction lift exceeds the rated value, the system will continue to process water at a reduced
flow up to about 6 meters. But the flow will be restricted. The flow indicator will still read full
flow but what is happening is that the system is pulling part of the water from the bilge and part
of the water is coming from the head of the separator. The system will go into the fill mode more
often than normal. The higher the vacuum the more frequently system recycles into Fill Mode.
If the vacuum gauge is reading more than the design rate you should first look for factors that
could be impacting the suction lift. These may include too small inlet piping, restrictions in the
line, to many fittings or too many valves.
4. Plugged Line
If the inlet line or the pre-filter are plugged the separator will likely short cycle. Remove the
restriction.
5. Excess Flow
If the process flow is greater than the design it can also cause a short-cycle condition. Check the
flow rate and make sure it is not above the design flow. The flow adjustment valve (V-003) must
be adjusted to the designed separator flow rate for your unit.
Any of these conditions could cause the level sensor to read low water level (high oil level) and
will cause the system to go into “oil discharge/fill mode” in a shorter cycle than normal. If this
happens one of the above conditions exist. You will need to find and fix the problem.
5.2 Reduced Flow Through the System

5.2.1 Plugged Pre-Filter
If the flow through the system becomes reduced it could be caused by a plugged pre-filter. To
unplug the filter, remove the screen, clean it and reinstall the screen.
- 21 -

5.2.2 Plugged Polisher

Low flow can also be caused by a plugged polisher. In some cases suspended solids in the bilge
water will collect on top of the organoclay and cause the polisher to plug. A bag filter can be added
between the separator and the polisher. The purpose of the bag filter is to remove fine sediment and
turbidity that could plug up the polisher or impact the OCM reading. The system will work
significantly better with a bag filter. If your system does not have a bag filter it can be ordered from
the factory or the closest distributor and can be installed very easily. The bag filter will
significantly reduce any plugging of the post polisher.
A sand filter can also be installed prior to the organoclay polisher instead of the bag filter to remove
these suspended solids before they reach the organoclay polisher.
The system comes with backwash valves to remove sediment or turbidity that collect in the Polisher.
Backwashing of the polishing filter should be done after each usage for 5 to 10 minutes if running
batches, or at least once a day if running continuous. If there are high levels of solids it may be
necessary to backwash longer or more often to keep the polisher media from plugging up.
Prolonging the backwash operation allows solids that have collected in the polisher to solidify and
become impossible to backwash out.Once the organoclay polisher is plugged with solids the media
will need replacing.
5.2.3 Bacteria
In some cases we have found that the bilge is full of bacteria that are growing in the bilge. This will
plug the polisher and will also cause the OCM to not work because it will discolor the water and
cause the OCM to alarm. If there is bacteria in the bilge it must be removed with chlorine or
something else that will kill the bacteria and keep it from returning. Neither the bag filter nor the
polisher will remove bacteria. If the separator is not used for long periods of time it can go
anaerobic and clog the media. The separator should be run at least weekly. There are times when
the vessel operates a dry bilge and rarely if ever uses the separator. This is not good for the
separator and could cause problems when it is used. If the unit is not going to be used on a regular
basis it should still be run at least weekly.
5.3 Fault Alarms and Remote Monitoring Capabilities

The OCM monitor is designed to alarm if the oil content exceeds the set limit or if the OCM system
fails . If the oil content exceeds the set limit the OCM alarms internally and causes the system to go
into recycle mode until the alarm condition no longer exists. The alarm will show on the OCM
display and will be recorded by the OCM data logger. Under a system fault alarm the alarm will
show on the OCM display. Any OCM alarm or fault condition will automatically put the system
into the recycle mode.
5.3.1 Potential causes of the OCM system fault include
a. loose or improperly inserted data card
b. loss of communication between the display and the detector (loose cable)
c. internal board or power supply failure
(See separate OCM instruction manual for more explanation of the OCM monitor.)
5.3.2 Available signals from the OCM
a. 4-20 mA signal showing the ppm oil content in the water (0-30 ppm)
b. Voltage free contact for the OCM alarm
5.3.3 Available signals from the Control Panel
a. Dry contact showing whether the system is running.
b. Dry contact showing whether the pump is overloading.
c. The customer can remotely start or stop the system with an external voltage free contact.
- 22 -

5.4 High Oil Content Reading Causing Water to Recycle

5.4.1 Turbidity
If there is turbidity in the water the OCM monitor can give a false oil content reading. If this
happens, a better filtering system will be needed to remove turbidity. If you do not have a bag filter
or sand filter, you can add one. If this is done it is recommended to be placed just prior to the
organoclay polisher in line.
5.4.2 High Emulsions
If you have high levels of emulsions and the organoclay is not removing the oil adequately, you
may need to use carbon instead of organoclay or you can use a combination of carbon and
organoclay. Carbon will work better for some emulsions and organoclay will work better for free
oil and other types of emulsions. If you use the combination you should load a bed of sand first,
then carbon and then organoclay. The water goes down through the media. It is best to go through
the organoclay first and then the carbon.
5.4.3 Full Media
In most situations the organoclay will remove 100% of the free oil that goes through the polisher.
As the organoclay fills up with oil the ppm oil in the discharge will rise until the monitor goes into
alarm. When this happens it is time to change the media.
5.4.4 Dirty OCM Cell
Sometimes a high OCM reading has nothing to do with the polisher and is simply caused by a dirty
OCM cell. The glass in the cell should be cleaned on a regular basis. This should be the first thing
checked when the monitor is in alarm mode.
5.4.5 High Flow Rate
One important thing to check is to make sure the flow rate is not over the design rate. Letting the
water flow through the separator at a higher rate than the design rate will reduce the efficiency of
the 1st stage separation because the residence time is not sufficient. Lowering the flow rate will
increase the residence time and flux rate and the efficiency of the separation and will lower the oil
content of the water to the polishing filter.
5.5 No Flow Through the OCM

The flow through the OCM is based on the differential pressure across the system since the OCM
recycle is discharged back into the separator. In a vacuum situation there is always a differential
pressure and therefore there is always a flow through the OCM. If the system has a positive
pressure then the pump will create a differential pressure across the system. However, it is possible
in rare situations for the discharge pressure to be very close to the inlet pressure. This would be
caused by high discharge head or a plugged Polisher vessel. If this happens the flow of water
through the OCM could be restricted or possibly even stop because the drain from the OCM goes
back into the vessel and if everything is at the same pressure nothing will flow. One way to correct
this is to make sure the polisher vessel is not plugged. If the polisher is not plugged then there will
always be a differential pressure. Another way is to pipe the recycle water from the OCM to a non-
pressurized drain and then flow will start again. It is also possible to install a flow switch that will
interlock with the OCM so that the system will shut down if there is no flow through the system.
5.6 Common Fault Alarm

Starting in January, 2015 a revised circuit board will include a common fault alarm. There are 2
conditions that can cause a common fault alarm. The first condition (“short cycle”) occurs when air
is getting into the system or if the system is pulling too much vacuum. In both of these conditions
the system will build up air in the oil reservoir in the top section of the separator. The air forces the
- 23 -

water out of the space and causes the water level to go down and trip the oil level sensor. This will
cause the system to go into fill mode. If this condition occurs the operator will need to find and fix
the leaks in the suction piping. If the condition is caused by pulling too much vacuum the operator
will need to find a way to decrease the amount of vacuum. In an extreme condition a progressive
cavity pump may be required to pull enough vacuum.
The second condition (“long time running”) occurs when the system is left on by the operator
without anything in the bilge. If the bilge does not have a float interlocked with the system it is
possible for the bilge to run out of water without shutting off the system. If the operator is not
watching the system will continue to run and just pull in air. If the motor is running for a long time
without discharging any water the system will alarm.
If either of these conditions occur the common fault light will turn on and the system will alarm.
The alarm does not say which condition has occurred but it is easy to determine. If the bilge is dry
then condition 2 is the problem. If the bilge still has water then condition 1 is the problem.
- 24 -

Chapter 6 Safety
6.1 Ignition Hazard Assessment
The transformer generates up to 250VA, which is not enough to generate an ignition source. In the
case of a dead short, the transformer would trip and the source of heat would cease. If the
transformer got too hot it would automatically trip and the heat would cease. The system is
protected by a primary and secondary fuse. The system cannot generate sparks, shock waves,
exothermic reactions, electrical arcing or adiabatic compression. There is no ignition hazard.
6.2 Electromagnetic
The system has been tested under EN Standard 61000-6-2:2005 and EN 61000-6-4:2007 for
electromagnetic compatibility by an independent laboratory and was found to have no EMI or EMC
interference or hazard to the operator.
6.3 29 CFR, Part 1910

There are no moving parts on the system except the pump which is close coupled, TEFC and IP 55
rated. There are no guards necessary because the pump is close coupled. The pump meets all the
requirements of 29 CFR, Part 1910, as do all the other components.
The control panel has an IP 66 rating. All components in the control panel are finger safe.
The separator operates under vacuum so there are no pressure issues. Even though the separator
vessel operates under vacuum it has been designed according to ASME Section VIII standards at
0.11MPa pressure and has been tested at 0.33MPa pressure or higher.
The system does not require hand rails, ladders, scaffolds or any other devices for access to the
separator or post polisher. The system has its own disconnect, which must be turned off in order to
open the control panel enclosure. The system is protected by fuses. The system is not processing
any hazardous chemicals.
6.4 Dangers, Warnings, Cautions

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

There are no hazardous substances or chemicals used in the system. The system is designed to
separate oil from water. If there are other chemicals or substances in the oily water sump they
should be evaluated individually to determine the impact.
- 25 -

Chapter 7 Spare part list
Item Photo Part name Description Quantity Part No.
Electric part
1 Fuse 3A 1 1H5360027
2 Fuse 750mA 1 1H5360026
110V
3 Green Lights 2 1H5030011
XB2BVF3C
110V
4 White Lights 1 1H5030010
XB2BVF1C
Process pump
TS166T-5/8 +
5 Mechanical seal 1 1B2721020
G55-5/8
Pump O-ring
6 O-ring 1 1B2711090
Ф165×3.6mm
Solenoid valve
COIL-A2,
7 Solenoid coil 120V, 60Hz 1 1B3080005
class: B
Oil content monitor
CR1225
8 Button battery 1 1E1020058
3V
Special tools
With driver and
9 CD the log receiver 1 1E1020057
software
A type-A plug
10 USB Cable and a Mini 1 1E1020056
type-B plug, 2m
11 Brush 1 1F0028001
- 26 -

Appendix A – Drawing
Item Drawing No. Description Total Pages
1 32825-00LC P&ID Drawing 1
2 32825-00XS Assembly Drawing 1
3 32825-00MX Parts Identification Drawing 1
4 32825-00BZ Installation Diagram 1
5 32825-00WH Maintenance Access Drawing 1
6 30028-00ADL Electrical Schematics 2
7 20028-35-0 Overboard 3-way L-port Ball Valve 1

Appendix B – OCM Instruction Manual

15 ppm Bilge Alarm BilgMon 488 Rev: vAC
INSTRUCTION MANUAL
BilgMon488
15 ppm Bilge Alarm
-1-
CONTENTS
Chapter 1 Table of validity ........................................................................................................ - 4 -
Chapter 2 Introduction ............................................................................................................... - 5 -
Chapter 3 Construction .............................................................................................................. - 5 -
Chapter 4 Operation................................................................................................................... - 5 -
Chapter 5 Caution ...................................................................................................................... - 5 -
Chapter 6 Specification.............................................................................................................. - 6 -
6.1 General ........................................................................................................................... - 6 -
6.2 Specific 115/230 V AC model ....................................................................................... - 7 -
6.3 Specific 24 V AC/DC model ......................................................................................... - 7 -
Chapter 7 Installation................................................................................................................. - 8 -
7.1 Mechanical ..................................................................................................................... - 8 -
7.2 Tube arrangement ........................................................................................................... - 9 -
7.2.1 Alternative 1........................................................................................................... - 9 -
7.2.2 Alternative 2........................................................................................................... - 9 -
7.3 Electrical....................................................................................................................... - 10 -
7.3.1 General installation .............................................................................................. - 10 -
7.3.2 Fresh water flushing valve installation ................................................................ - 11 -
7.3.3 115 /230 VAC ...................................................................................................... - 12 -
7.3.4 24V AC/DC ......................................................................................................... - 12 -
Chapter 8 Calibration Check ................................................................................................... - 13 -
8.1 Schedule ....................................................................................................................... - 13 -
8.2 Calibration certificate expiry date ................................................................................ - 13 -
8.3 Calibration check requirements .................................................................................... - 13 -
8.4 Sensor unit replacement ............................................................................................... - 13 -
Chapter 9 Operating Instructions ............................................................................................. - 14 -
9.1 Start up sequence .......................................................................................................... - 14 -
9.2 Main menu and indication LEDs.................................................................................. - 14 -
9.2.1 Main menu ........................................................................................................... - 14 -
9.2.2 LEDs and indications ........................................................................................... - 15 -
9.3 Menu system ................................................................................................................ - 16 -
9.4 Contrast adjustment ...................................................................................................... - 17 -
9.5 Simulation .................................................................................................................... - 17 -
9.6 Force automatic stopping device activation ................................................................. - 19 -
9.7 Acknowledge alarm2 .................................................................................................... - 19 -
9.8 Information menu ......................................................................................................... - 20 -
9.8.1 Master info ........................................................................................................... - 20 -
9.8.2 Sensor info ........................................................................................................... - 20 -
9.9 Log ............................................................................................................................... - 21 -
9.9.1 Log menu ............................................................................................................. - 21 -
9.9.2 Step log ................................................................................................................ - 21 -
9.10 Cleaning & test ........................................................................................................... - 22 -
9.10.1 Clean cell (zero calibration) ............................................................................... - 22 -
9.10.2 Check 40NTU cal (calibration check)................................................................ - 22 -
9.10.3 Test outputs ........................................................................................................ - 23 -
9.11 Settings ....................................................................................................................... - 23 -
9.11.1 Valve settings (automatic stopping device) ....................................................... - 23 -
9.11.2 Alarm settings (bridge alarm) ............................................................................ - 23 -
9.11.3 Autoflush feature (automatic freshwater cleaning) ............................................ - 24 -
9.11.4 Set clock ............................................................................................................. - 24 -
9.11.5 Curro mode (Current output mode).................................................................... - 25 -
9.11.6 Curro 20mA cal. (Calibration of current output) ............................................... - 25 -
Chapter 10 Automatic stopping device test ............................................................................. - 26 -
-2-
10.1 While separator is active. ........................................................................................... - 26 -

10.2 While separator is not active. ..................................................................................... - 26 -
Chapter 11 Response test ......................................................................................................... - 26 -
11.1 Step 1 .......................................................................................................................... - 26 -
11.2 Step 2 .......................................................................................................................... - 26 -
11.3 Alternative .................................................................................................................. - 26 -
Chapter 12 Calibration check .................................................................................................. - 26 -
Chapter 13 Log entries............................................................................................................. - 27 -
Chapter 14 Maintenance .......................................................................................................... - 28 -
Chapter 15 Real Time Clock(RTC) ......................................................................................... - 28 -
15.1 Local time ................................................................................................................... - 28 -
15.2 Battery replacement .................................................................................................... - 28 -
15.3 RTC malfunction ........................................................................................................ - 29 -
15.3.1 Set UTC time ..................................................................................................... - 29 -
Chapter 16 Log data download via USB ................................................................................. - 30 -
16.1 Running the software.................................................................................................. - 30 -
16.2 Installing the VCP driver ............................................................................................ - 30 -
16.3 Download procedure .................................................................................................. - 30 -
Chapter 17 Troubleshooting .................................................................................................... - 33 -
-3-
Chapter 1 Table of validity

The following table describes the software and hardware versions on which this document was
based.
Doc version MASTER SW ver. MASTER PCB ver. SENSOR SW ver. SENSOR PCB ver.
vN A3 Bilgbas_H.1/ F Bilgemon H.1

Bilgbaslv_C.1
Bilgemaster L.1
vO, vP A4 Bilgbas_H.1/ B2 Bilgemon J.1
Bilgbaslv_D.1
Bilgemaster L.1
vQ, vR A4 Bilgbase_H.1/ B2 Bilgemon J.1
Bilgbaslv_D.1/
Bilgbasco_A
Bilgemaster L.1
vS, vT A9 Bilgbase_H.1/ B5 Bilgemon J.1
Bilgbaslv_D.1/
Bilgbasco_A
Bilgemaster N.1
vAA,VAB C3 Bilgbase_I.1/ B5 Bilgemon J.1
Bilgbaslv_D.1/
Bilgbasco_A
Bilgemaster K.1
vAC C9 Bilgbase_I.1/ B5 Bilgemon J.1
Bilgbaslv_D.1/
Bilgbasco_A
Bilgemaster K.1
-4-
Chapter 2 Introduction
The BilgMon488 bilge alarm has been designed specifically for use in conjunction with 15 ppm oil-
water separator units. BilgMon488 performance meets the requirements of the International
Maritime Organisation specifications for 15 ppm bilge alarms contained in resolution MEPC.
107(49).
BilgMon488 is equipped with 2 adjustable alarms that are triggered when the oil-content of the
processed sample exceeds the set limit (1 – 15 ppm, works-adjusted to 15ppm). Alarm outputs
consist of relays and indicator LEDs. Additionally a 0(4) – 20 mA current output signal
(corresponding to 0 – 30 ppm) is available to enable remote surveillance and recording of oil
contents.
Downloading the operating log of BilgMon488 can be done through a USB-interface. This requires
driver software and cables that can be supplied on demand.
Chapter 3 Construction
BilgMon488 consists of two main parts, the MASTER unit (housing with LCD, buttons and LEDs)
and the SENSOR unit (housing with pipe fittings).
The MASTER unit contains all the electronics used for control and data storage of the bilge alarm.
Mounted in the lid of the MASTER housing is the main memory containing the bilge alarm log.
The SENSOR unit contains electronics for measuring the sample stream. The SENSOR unit also
holds the measurement calibration data. Communication with the MASTER unit is done wireless
hence the SENSOR unit is hermetically sealed and shall not be opened.
Chapter 4 Operation
Optical sensors monitor the amount of light scattered and absorbed by the oil droplets in the sample
stream. Sensor signals are processed by a microprocessor to produce a corresponding oil content
(ppm) output. The output is communicated to the MASTER unit where it is processed. The
MASTER unit takes action, such as alarm activation, logging etc., depending on the oil content and
the separator signal.
Settings that affect the behaviour of the bilge alarm are described in detail in section 9 Operating
Instructions.
Zero point calibration can be re-adjusted on site whereas full sensor calibration according to IMO-
requirements is performed by manufacturer.
Chapter 5 Caution
Do NOT remove the internal battery for more than a couple of hours (see 15.2 Battery replacement)
DO NOT open the SENSOR unit as this will invalidate the calibration.
DO NOT open the MASTER unit when it is energized. Hazardous voltages are present inside.
-5-
Chapter 6 Specification
6.1 General
Measurement:
Oil range: 0 – 30 ppm
Resolution： 0.1 ppm
Accuracy： According to IMO MEPC.107(49)
Response time: < 3 sec
Alarms:
Alarm 1 (valve control) delay: 0-10 sec user adjustable
Alarm 2 (annunciation) delay: 0-60 sec user adjustable1
Alarm points 1 and 2: 1-15 ppm user adjustable
Alarm hysteresis: 0.5 ppm (below alarm point)
Data storage and retrieval:

Calibration storage: Stored in sensor housing.
Stored in BilgMon488 main housing (sensor housing
IMO required data:
may be replaced with data remaining on board).
Data retrieval via display.
Optional data retrieval:
Via USB port.
User interface:
LCD display: 2x16 alphanumeric display
Control: 4 button keypad
Environment:
Ambient temperature range: According to IMO MEPC.107(49),0～55℃
Enclosure ingress protection rating: IP65
Installation:
Recommended: 0.1-0.2MPa(200-300l/h)
Sample line inlet operating range:
Maximum: 0.3 MPa
1
0-600 sec on master unit software versions before C9, show on certificate and in “info” menu.
-6-
6.2 Specific 115/230 V AC model

Input /Output:
Current output: 0 – 20 mA or 4 – 20 mA for 0 – 30 ppm
USB serial communication (separate cable and
Communications:
software)
Alarm outputs: 2 x relays (0.25A)
Clean water solenoid valve output: 1 x relay (0.5A, supply voltage)
Switch input: 1 x switch input for separator status
System and supply:

Supply: 1 A, 115 or 230 V AC, 50 – 60 Hz
Power consumption electronics: 10 VA
Power consumption solenoid: 18 VA
6.3 Specific 24 V AC/DC model

Input /Output:
Current output: 0 – 20 mA or 4 – 20 mA for 0 – 30 ppm
USB serial communication (separate cable and
Communications:
software)
Alarm outputs: 2 x relays (1A)
Clean water solenoid valve output: 1 x relay (1A, supply voltage)
Switch input: 1 x switch input for separator status
System and supply:

Supply: 1.5 A, 24 V AC (50 – 60 Hz) or 24 V DC
Power consumption electronics: 10 VA
Power consumption solenoid: 18 A
-7-
Chapter 7 Installation
NOTE: If drain valve is fitted. It should always be closed while separator is running.
7.1 Mechanical
Legend
Item Qty Name Dimension Material
d1 4 Mounting screw M6×10 Steel
d2 4 Cable gland M20 Ф7-12mm Plastic
Illustration 1: Mechanical installation
-8-
7.2 Tube arrangement

7.2.1 Alternative 1
Illustration 2: Tube arrangement alt.1
7.2.2 Alternative 2
Illustration 3: Tube arrangement alt.2
-9-
7.3 Electrical
7.3.1 General installation
Bilgmon488 is manufactured in two base models, 115/230 VAC and 24 V AC/DC. The main
difference between these two models is the base PCB of the MASTER unit.
SW1: Voltage selection switch (115/230)
CN2: Terminals 1 – 9
CN3: Terminals 10 - 11
L8: Terminals 12 - 13
Illustration 4: Base PCB of 115/230 VAC MASTER unit.
CN4: Terminals 5 – 10
L8: Terminals 13 - 15
Illustration 5: Base PCB of 24 V AC/DC MASTER unit.
When installing the 115/230 VAC model be sure to put the voltage selection switch (SW1,
Illustration 4) in the correct position (marked 115 resp. 230).
Terminals 12-14 (L8, Illustration 4) resp. 13-15 (L8, Illustration 5) are coupled and can be used for
routing of external protective earth connections.
See sections 7.3.3 and 7.3.4 for detailed information of electrical connections.
- 10 -
7.3.2 Fresh water flushing valve installation

This section is valid for systems using a cleaning solenoid according to Illustration2: Tube
arrangement alt. 1 or similar installation.
115/230 VAC model: There are two coils delivered with

the BilgMon 488 one to be used with 115 VAC (marked
96 V) and one to be used with 230 VAC (marked 205 V).
Be sure to install the proper one for the chosen voltage.
24 VAC/DC model: Only one coil delivered with this

model (marked 24 V).
NOTE: Both models are equipped with a cable and

rectifier (in connection plug for solenoid). The rectifier is
necessary for all AC installations.
- 11 -
7.3.3 115 /230 VAC
Illustration 6： 115/230 VAC electrical connections
7.3.4 24V AC/DC
Illustration 7: 24V AC/DC electrical connections
- 12 -
Chapter 8 Calibration Check

8.1 Schedule
Two items needs to be addressed when setting up the maintenance schedule for the BilgMon488:
 Expiry date of the factory issued calibration certificate.

 Occasionally a calibration check is required within the validity period of the factory issued
calibration certificate.
The following two subchapters explain how to resolve these two items.
8.2 Calibration certificate expiry date

If the factory issued calibration certificate expires, the SENSOR unit must be replaced.
The SENSOR of BilgMon488 is designed to be easily replaced by the crew, see 8.4 Sensor unit
replacement. Replacement does not require any adjustments of the MASTER unit setup.
Each new SENSOR is accompanied with a new factory issued calibration certificate.
8.3 Calibration check requirements

On occasion ships may be required to perform a “calibration check” on their units. This might be
required to take place at shorter intervals than the validity period of the factory issued calibration
certificate.
Calibration check can be achieved in the following ways:
 Check calibration with a “calibration check kit”.

(Requires ordering a kit or consult a service agent)
 If the calibration check fails (calibration check values are not within limits), a new
SENSOR must be installed.
8.4 Sensor unit replacement

R e m o v in g S e n s o r U n it:
1. L o o se n fa ste n in g b o lts.
2. G e n tly p u ll S e n so r U n it
a w a y fro m M a ste r U n it.
M o u n tin g S e n so r U n it:
1. C le a n c o n ta c t su rfa c e s
u sin g w a te r a n d m ild
d e te rg e n t.
2. H o ld to g e th e r S e n so r
U n it a n d M a ste r U n it.
3. T ig h te n fa ste n in g b o lts.
M a s te r U n it p re p a ra tio n s:
N o p re p a ra tio n s n e c e ssa ry .
S e n so r U n it c o n ta in s a ll
S e n s o r u n it c a lib ra tio n d a ta .
S y ste m u p d a te s a u to m a tic a lly .
M a s te r U n it 2 x F a ste n in g b o lts
C o n ta c t su rfa c e s
Illustration 8: Sensor unit replacement procedure.
- 13 -
Chapter 9 Operating Instructions

9.1 Start up sequence
When BilgMon488 is powered up the LCD display will show an initialization sequence.
Sequence: 1.
1. Internal time reference (Real Time Clock, RTC) is
checked.
RTC check:
2. Information about unit setup is shown. In progress!
2.
Explanation of example shown in 2.:
BilgMon 488 00A9
BilgMon 488 - Product name. 1dec CO 15max
00A9 - Software version of master unit.
1dec - ppm value display precision.
CO - Current Output facility enabled.
15max - Maximum PPM level for alarm 2 and
automatic stopping device settings.
9.2 Main menu and indication LEDs

9.2.1 Main menu
After the initialization sequence is done the unit is ready for operation and the main menu will be
shown:
The main menu shows date and time followed by PPM

measurement and fresh water flushing valve selection. 140612 09:10:48
PPM=12.3 SPL
Date and time is set at factory to UTC time (Coordinated Universal Time) and is displayed on the
format:
YYMMDD hh:mm:ss (YY – year , MM – month, DD – day, hh – hour, mm – minutes, ss – seconds)
PPM measurement shows the latest measurement of oil content in parts per million as reported by
the sensor unit.
Fresh water flushing valve selection shows the current selection (control output) to the optional
fresh water flushing valve:
SPL – sample from separator selected
WTR – fresh water flushing input selected
If the internal clock battery backup voltage is too low

the display will display a warning (see right) every 2 WARNNG:
seconds. Change battery!
See Chapter15Real Time Clock (RTC) for further
information.
- 14 -
9.2.2 LEDs and indications

The LED lamps on the front panel indicate the status of the equipment. The straight/dashed lines
indicate if the lamps are lit continuously/flashing.
(green)
Bilgmon488 is in ACTIVE mode (separator is running).
ACTIVE BilgMon488 is in POWER mode (menu subsystem is active).

POWER
(red) (no signal) No alarm present.
Alarm.
ALARM
(yellow)
(no signal) Automatic stopping device activated (back to bilge tank).
VALVE Automatic stopping device NOT activated (overboard valve open).

OPEN
- 15 -
9.3 Menu system
Adjust LCD contrast.

Contrast
1) See 19.3
1)
Main Simulate PPM measurement and separator status.
Simulation See 19.5
1)
Force automatic stopping Temporarily activate automatic stopping device.
device activation See 19.6
Acknowledge alarm.
Acknowledge alarm See 19.7
1)
Info Master info Show information about MASTER unit.

1) See 1.19.8.1
Show information about SENSOR unit.

Sensor info
See 1.19.8.2
Step, search and download the log.

Log Step log
See 0
Cleaning & test Clean cell Zero calibration of SENSOR unit.

1) See 1.19.10.1
Check 40NTU Calibration check of SENSOR unit.

See 1.19.10.2
Relays and input test menu.

Test outputs See 1.19.10.3
Set PPM limit and delay of automatic stopping device.

Settings Valve
1) See 1.19.11.1
Set PPM limit and delay of alarm.

Alarm
See 1.19.11.2
Set interval and duration of fresh water autoflush feature.

Autoflush
1) See 0
Clock Adjust displayed time and date.

See 0
Select current output logic.

Curro mode
See 0
Curro 20mA cal. Calibrate 20mA output.

See 0
Navigation using or
Navigation using or
1) Transition only possible when BilgMon488 is in POWER mode (see 19.2 ). Navigation
Illustration 9: Menu layout.
- 16 -
9.4 Contrast adjustment

While in main menu press and hold .
Contrast: 010%
With held press / to increment/decrement
contrast setting by 10%.
9.5 Simulation
The simulation menu lets user simulate the PPM input from the sensor unit as well as the separator
status input state to verify that the installation of the unit is correct and that it responds as expected
to different oil content measurements.
Simulated events will be stored in the log starting with a SIM_ON event and ended with a
SIM_OFF event.
Enter simulation menu2:

From main menu press and hold . Simulation SPL
The LCD will now PPM>30.0 SEP_OFF
show something similar to the picture on the right.
Keep holding to stay in the simulation menu.
Leave simulation menu:

Release .
Toggle the simulated separator status input:

While still holding , press to toggle between
separator on/off (SEP_ON/SEP_OFF shown in LCD).
Increment/decrement simulated PPM value:
While holding , press / to increment/

decrement the simulated PPM value in steps of 1.0.
2
To enter the simulation menu the BilgMon488 needs to be in POWER mode. POWER mode
is when the unit is powered but separator is not running (separator status input is open, see 7.3
Electrical).
- 17 -
Example of simulation with explanations:
1) Start in main menu with separator off (separator

140613 09:50:24
status input open).
PPM>30.0 SPL
ALARM LED – OFF
VALVE LED – OFF (no discharge)
2) Hold (do not release until step #7 in this Simulation SPL

example). PPM>30.0 SEP_OFF
Automatic stopping device (ASD) is now active3
and the alarm2 is not active since the separator ALARM LED – OFF
is not running. VALVE LED – OFF (no discharge)
3) Press to simulate that the separator starts Simulation SPL

running (toggle to SEP_ON). PPM>30.0 SEP_ON
ASD and alarm2 is now active since the PPM
value is above 15 PPM and the separator is ALARM LED – ON
running. VALVE LED – OFF (no discharge)
4) Press repeatedly until PPM value is below Simulation SPL

15.0 ppm (14.0 or lower value shown). PPM=14.0 SEP_ON
ASD and alarm2 is now NOT active since the
PPM value is below 15.0 ppm and the separator ALARM LED – OFF
is running. VALVE LED – ON (discharge)
5) Press repeatedly until PPM value is above Simulation SPL

15.0 PPM (16.0 or higher value shown). PPM=16.0 SEP_ON
ASD and alarm2 is now active since the
separator is running and the PPM value is above ALARM LED – ON
15.0 ppm. VALVE LED – OFF (no discharge)
6) Press to simulate that the separator stops run Simulation SPL

ning (toggle to SEP_OFF). PPM=16.0 SEP_OFF
ASD is now active and the alarm2 is not active
since the separator is not running. ALARM LED – OFF
7) Release to return to main menu and end 140613 09:50:24

simulation. PPM>30.0 SPL
ALARM LED – OFF
3
The VALVE LED and the automatic stopping device output has reversed logic. Hence when
VALVE LED is lit the automatic stopping device is NOT active (overboard valve in discharge
position) and vice versa.
- 18 -
9.6 Force automatic stopping device activation

When the separator is running and the PPM value is below 15.0 ppm the automatic stopping device
can be temporarily activated by pressing and holding for approx. 2 sec.
After 10 seconds or on a press of BilgMon488 Force valve

returns to normal operation. close: 10s EXIT
9.7 Acknowledge alarm2

If separator is running (separator status input is closed, BilgMon488 in ACTIVE mode) and the
PPM value goes above 15.0 ppm the unit will generate an alarm2 (alarm2 output terminal and LED).
The alarm2 can be acknowledged4 by pressing , or . This means that the alarm2
output terminal will be put in no alarm position but the alarm LED on the front will still be lit.
4
Automatic stopping device output cannot be acknowledged (only alarm2 output).
- 19 -
9.8 Information menu

The information submenus will display5 information about the MASTER and the SENSOR unit of
BilgMon488 according to examples below:
9.8.1 Master info
Cycle 0: Master info

Menu name.
Cycle 1: Master ID:

Serial number. 000A-4567
Cycle 2: Master SW ver:

Software version. 00C3
Cycle 3: Master voltage:

Master unit lid power supply voltage. Should be approx. 5V. 5V supply=5.3V
Cycle 4: Master voltage:

RTC backup battery voltage. Should be approx. 3V. If lower RTC battery=3.0V
than 2.5V, replace battery.
Cycle 5:
Master UTC:
Internal time reference (RTC). Should be UTC time and date
(approximately). 140427 18:23:34
9.8.2 Sensor info
Cycle 0: Sensor info

Menu name.
Cycle 1:
Sensor ID:
Serial number. 000B-4325
Cycle 2:
Sensor SW ver:
Software version. 00B6
Cycle 3:
Sensor date:
Factory calibration date. 140112 13:23:10
Cycle 4:
Cal. checked:
Calibration check date. 140427 10:43:12
Cycle 5:
T:25.3 Dry:60
SENSOR internal measurements (temperature, moisture, V3:3.20 V03:.312
voltage etc.).
5
Information is continuously cycling (cycle 0, cycle 1, … , cycle n, cycle 0, …).
- 20 -
9.9 Log
The log menu enables the user to search and step the IMO-regulated log of the BilgMon488 as well
as download parts of or the entire log to file using the “BilgMon488 log download kit” (purchased
separately).
9.9.1 Log menu

The log menu shows the serial number stored in the log
memory (normally same as the serial number of the master Log (000A:4567)
unit) and the number of log items currently stored in log. 12343 entries
Press to enter the step log submenu.
9.9.2 Step log
First row of step log menu shows type of event and second
Log: PPM > 15
row shows date and time of occurance.
Stepping: 140601 23:12:33
Navigate the log by pressing resp. to step forwards
resp. backwards in the log.
Searching:
Log: PPM > 15
Press and a small cursor will appear in under the first 140601 23:12:33
entry in the date field. Press again to move the cursor c
yclically through the date/time fields. Use and to i
ncrease/decrease the digit marked by the cursor. Finish by ho
lding for approx. 3 seconds. The display will now show
the event that is closest in time to the date/time you entered.
Sending log via USB (download kit required):

Send log?
When leaving the step log menu ( ) user is asked
NO YES
to send log.
If user answers no ( ) the unit returns to log menu.
If user answers yes ( ) a follow up question is asked of Number of logs?
how many items from the current and forward (in time) is to 100 from current
be sent 100, 500 or all. Select with / and finalize b
y holding for approx. 3 seconds. Sending log!
LCD will show “sending log” while sending the log
followed by “sent xxxx” when download is complete.
Sending log!
Sent 100!
- 21 -
9.10 Cleaning & test

9.10.1 Clean cell (zero calibration)
The clean cell menu provides the facility to zero calibrate the BilgMon488. It is also a useful tool
for checking on dirt, layering and scratches on the sample tube inside the SENSOR unit.
Values shown range from 0% (clean, same values as factory calibration) to 100% (dirty) where 50%
or below is required to perform zero calibration.
Press to start zero calibration process. Clean cell:

START
Toggle fresh water flushing valve to position WTR by

6
Zero value: 045%
pressing . Make sure the fresh water supply line is
WTR ZERO
closed to prevent the liquid poured into the SENSOR is not
flushed out “backwards”.
Unscrew the top cap of the SENSOR, clean thoroughly
with mild detergent and soft brush, rinse and then pour in
some clean air free water.
When/if zero value goes below 50%, ZERO is shown.
Press enter to send zero calibration command to

SENSOR unit.
If zero value does not go below 50% see 18 Troubleshooting.
9.10.2 Check 40NTU cal (calibration check)

The check 40NTU cal lets the user perform a calibration check7 of the equipment. The calibration
check makes sure that the units sensors are still in good condition and that the measurements of the
oily water is still accurate.
Values range from 0% to 100% where 80% or above is considered acceptable (using calibration
check kit mixture).
Press to start calibration check process. Check 40NTU cal:

START
Toggle fresh water flushing valve to position WTR by Cal value: 093%
pressing 6
. Make sure the fresh water supply line is WTR OK
closed to prevent the liquid poured in to the SENSOR is not fl
ushed out “backwards”.
Unscrew the top cap of the SENSOR and fill with the
calibration check kit mixture.
When/if cal. value goes above 80%, OK is shown.
Press enter to set the calibration check date of the
SENSOR unit.
If cal. value does not go above 80% see 18 Troubleshooting.
6
Fresh water flushing is indicated also on ALARM2 (from master unit software version C9)
7
Doing a calibration check requires the “Bilgmon488 calibration check kit” (bought separately).
- 22 -
9.10.3 Test outputs

The test outputs menu is used for testing the function of the separator status input as well as the
alarm2, automatic stopping device and fresh water flushing valve outputs (see 7.3 Electrical).
Press to enter test outputs menu. Test outputs:

START
ALM: Press to toggle the alarm2 output8. ALM VLV WTR C

VLV: Press to toggle the valve (automatic stopping OFF 08 OFF EXIT
device) output.8
WTR: Press to toggle the fresh water flushing valve
output.
O/C: In the upper right corner the status of the separator status
input is displayed (O = Open, C = Closed).
9.11 Settings
9.11.1 Valve settings (automatic stopping device)
This menu allows the user to lower the detection level for valve output (automatic stopping device
output). This might be useful in cases where lower limits than 15 ppm oil content is requested.
There is also an adjustable delay (max 10 seconds) of the valve output. Factory defaults are 15 ppm
limit, 0 sec delay.
Press to display the cursor (under leftmost digit).

Valve settings
Press / to increase/decrease digit. ppm:15.0 t:000s
Press to move cursor right one digit (cursor moves
cyclically from left to right, one step per ).
Save setting by holding until cursor disappears.
Abort input at any time by pressing (cursor disappears,

previous values are filled in).
9.11.2 Alarm settings (bridge alarm)
This menu lets the user set the parameters for the alarm2 output.

Alarm settings
Press / to increase/decrease digit. ppm:15.0 t:000s

8
Fresh water flushing and Valve output can only be activated 10 seconds at a time and will always
generate an active alarm2 output. Seconds countdown is shown on LCD.
- 23 -
9.11.3 Autoflush feature (automatic freshwater cleaning)

If system is fitted with a freshwater flushing valve it is possible to let the unit clean itself at set
intervals with fresh water9 if the separator is not running. This menu lets the user set the interval at
which the cleaning should be performed (in hours) and the duration of the cleaning/flushing (in
seconds). If a duration of 0 seconds is chosen the feature is disabled (off).
Note: The autoflush feature is disabled when the separator is running (separator status input is
closed).

Autoflush ( on)
Press / to increase/decrease digit. t:10s int:24h
9.11.4 Set clock

The BilgMon488 has an internal timekeeping mechanism with a battery backup. This mechanism is
refered to as RTC (Real Time Clock). The RTC is set at production to UTC time (Coordinated
Universal Time).
The set clock menu lets the user adjust the local time of the unit (as shown in the main menu). The
local time is handled internally as an offset to the RTC time.
The local time setting affects the time and date shown in main menu as well as the log menu
according to the example below:
1. Set clock = local time:
Main menu will display local time and date.
Log items will be shown in local time and date.
2. Set clock = UTC time:
Main menu will display UTC time and date.
Log items will be shown in UTC time and date.
Note: Before inspecting the log, make sure the clock is set to the wished time frame (local time or
UTC).
9
Fresh water flushing is indicated also on ALARM2 (from master unit software version C9)
- 24 -

Press / to increase/decrease digit. Set clock:
140327 11:34:05
Abort input at any time by pressing
(cursor disappears, previous values are filled in).
9.11.5 Curro mode (Current output mode)

The current output of BilgMon488 can be altered between two modes, 0-20 mA and 4-20 mA.
These intervals correspond to 0-30 ppm oil content as displayed in the main menu.
The current output terminal can be used for external printing/logging of the momentary oil content
measurement.
Press to display the cursor.

Press / to alter mode. Curro mode
0 to 20 mA
9.11.6 Curro 20mA cal. (Calibration of current output)

If current output corresponds badly to the displayed oil content the current output can be calibrated
in this menu (one point calibration).
When entering this menu the BilgMon488 will try to output 20 mA (corresponding to 30 ppm).
Measure the output with ampere meter. If reading is not correct adjust the output according to below
instruction.
Press to display the cursor.

Press / to increase/decrease the current output Curro 20mA cal.
signal (adjust to 20 mA output). 59100
- 25 -
Chapter 10 Automatic stopping device test

10.1 While separator is active.
If the separator is active and the automatic stopping device is not activated (overboard valve open) it
is possible to force the activation of the stopping device for a short period of time (10 s) byholding
in the main menu. This allows testing that the automatic is correctly connected.
10.2 While separator is not active.

To check that the automatic stopping device is correctly connected see 11.2 Step 2
Chapter 11 Response test

11.1 Step 1
To check that the sensor responds to objects in the measuring path unscrew the cleaning cap (top of
SENSOR housing) and insert a long plastic rod or something similar into the measuring path. Do
not use anything that might scratch or in other ways damage the glass tube inside the SENSOR
housing (as for example screwdrivers). If the sensor is working properly the display should read
“PPM>30.0” (main menu). Note that the air-detection feature of the SENSOR requires the glass
tube to be filled with water during this test for it to work.
11.2 Step 2
Testing alarms and valves are done in simulation mode (see 9.5 Simulation) or in the test outputs
submenu of the cleaning & test menu (see 9.10.3 Test outputs) since this doesn't require opening the
MASTER housing.
11.3 Alternative
To make step 1 of the response test affect alarms and valves the apparatus needs to be active.
Bilgmon 488 is activated (flashing green led) when in main menu and the separator input signal is
active. Activation can be done by shorting the “separator status” input (see 7.3 Electrical). This
method is not recommended since there is an obvious risk of forgetting the strap and that it
requires opening the MASTER unit. It will also generate a false recording of OWS operation
(SEP_ON/SEP_OFF) in the log.
Chapter 12 Calibration check

Doing a calibration check requires the “Bilgmon488 calibration check kit” (bought separately). This
kit also contain detailed information on procedures and mixtures used in the calibration check
procedure.
See sections 9.10.1 Clean cell (zero calibration) and 9.10.2 Check 40NTU cal (calibration check).
Note: Complete calibration can only be performed by factory. Calibration check will perform a zero
calibration and a check of the units calibration values compared to those set at production.
- 26 -
Chapter 13 Log entries

Type Example Explanation
POWER ON Power was turned on at given date and
Log: POWER ON time (yymmdd hh:mm:ss).
060102 11:36:32
POWER OFF Power was turned off.
Log: POWER OFF
060102 14:06:10
SEP ON Separator signal input turned from not
Log: SEP ON activated to activated.
060102 12:10:12
SEP OFF Separator signal input turned from
Log: SEP OFF activated to not activated.
060102 12:23:34
ppm ABOVE Measured ppm went from below set
Log: PPM > 15 valve ppm level to above (in example
060102 12:15:13 valve setting is 15 ppm).
ppm BELOW Measured ppm went from above set
Log: PPM < 15 valve ppm level to below (in example
060102 12:17:42 valve setting is 15 ppm).
ppm AVG
Log: PPM AVG 04 PPM average when below set valve
051021 09:47:29 ppm limit since latest SEP ON signal
or latest PPM BELOW event.
ppm SET Valve ppm level setting was changed
Log: PPM SET 05 to indicated value (in example to 5
060102 13:10:07 ppm).
SIM ON Simulation was turned on.
Log: SIM_ON
060102 12:09:50
SIM OFF Simulation was turned off.
Log: SIM_OFF
060102 12:24:19
TIME SET Clock was altered (in settings menu).
Log: TIME OFFSET Offset to BilgMon builtin realtime
+0:59:46 clock in hours, minutes and seconds is
shown.
RTC SET BilgMon builtin realtime clock was
Log: RTC SET set (logged once at factory).
051021 09:47:29
NEW SENSOR A new sensor was attached.
Log: NEW SENSOR
051021 12:47:29
- 27 -
Chapter 14 Maintenance
The BilgMon488 can be set to autoflush (see 9.11.3 Autoflush feature (automatic freshwater
cleaning)). This means that the sensor tube is flushed with clean water at durations and intervals as
set in the settings menu. Autoflush is only active when in main menu and BilgeMon488 is not
active.
Cleaning the measurement unit should be done using a soft bottle-brush and mild detergent. Note
that there is a glass tube inside the SENSOR unit so don't use anything that might scratch or damage
the glass (i.e. metal objects). If the glass tube is layered with rust or similar try using low
concentrated acid (for example hydrochloric acid). Rinse well and make sure you protect your eyes,
skin and airways if using acidic substances.
Check the expiry date of the factory issued calibration certificate (8.2 Calibration certificate expiry
date).
Chapter 15 Real Time Clock(RTC)

The timekeeping mechanism in Bilgmon488 is referred to as the Real Time Clock (RTC). The RTC
is essentially a crystal oscillator backed up by a battery and a capacitor. The RTC keeps track of the
UTC time and date and is essential for keeping the log of Bilgemon488 correct.
15.1 Local time

In the settings of each Bilgmon488 there is a possibility to adjust the displayed time. This affects
how time and date are displayed on the display (main menu, log items etc.). This setting is stored
and used as an offset to the internal time (RTC-time).
The internal UTC time and date can be checked in one of the cycles of the master info menu (see
9.8.1 Master info).
15.2 Battery replacement

The RTC backup battery is coupled in parallel with a backup capacitor. This means that the
Bilgemon488 can keep its RTC running for a couple of hours without the battery present.
The RTC battery (type CR1225) is located on the backside of the master unit lid (see illustration).
Illustration 10: Master unit lid backside
Battery replacement procedure

1. Disconnect the power supply.
2. Open the lid of the master unit (loosen 4 screws in the corners of the lid).
3. Push on the metal clip (holding the battery) and pull the battery out of the socket.
4. Replace with new battery of type CR1225 as soon as possible (within a couple of hours).
- 28 -
15.3 RTC malfunction

In the event of the RTC stopping the following message will appear
ERROR: ERROR:
RTC malfunction! Press ENTER!
alternating with
When pressing the user enters the RTC recovery menu (see Illustration11: RTC recovery
menu layout).
Set UTC time: Set internal time reference.
1) See 15.3.1
Step, search and download the log.
Log Step log
1) 1) See 0
Navigation using or
Navigation using or
Illustration 11: RTC recovery menu layout

15.3.1 Set UTC time
If the battery voltage is too low (< 2.5 V) the following warning will be shown:
Batterylow:0.5V
Replace battery!
Follow the battery replacement procedure (15.2 Battery replacement).
When the battery is replaced and the voltage has increased to above 2.5V (might take a couple of
minutes if the backup capacitor is exhausted) the following menu will appear:
Set UTC time:

140703 13:00:23
Enter correct UTC time and date using same method as described in 9.11.4 Set clock.
After setting UTC the following will be displayed,
Checking RTC:
(4 sec)
Followed by,
Checking RTC:
RTC running OK!
- 29 -
Followed by,
140703 13:00:45
UTC ok? NO YES
Verify that display is showing the correct UTC date and time.
Press if UTC is correct or to go back to Set UTC time menu.
NOTE: After pressing the RTC recovery menu is left and user is returned to main menu.
Make sure that the UTC date and time is correct before pressing .
Chapter 16 Log data download via USB

Apart from inspecting the log via the LCD (see 9.9 Log) there is a possibility to download the log
via a USB-connection to a personal computer running Windows operating system.
NOTE: This procedure requires the “Bilgmon488 log data download kit” consisting of a CD with
software and a USB cable.
16.1 Running the software

Insert the CD and the BM488 log receiver program should start automatically after a short
period of time. If not, doubleclick ”BM488_log_receiver.exe” in the ”dist”-library of the CD to start
the log receiver.
16.2 Installing the VCP driver

The first time you connect your bilge alarm to your PC using the supplied USB-cable you will be
asked for a driver for the newfound hardware. Simply point to the CD and the operating system will
find the driver for you. To install the driver manually, doubleclick the ”CDM#.##.##.exe” in the
root directory of the CD.
The VCP (Virtual Com Port) – driver has to be installed for the connected bilge alarm to show up in
the log receiver software. Note that the VCP-driver installation is only necessary once per PC.
For the latest version of the VCP driver please visit:
http://www.ftdichip.com/Drivers/VCP.htm
16.3 Download procedure

The following steps will guide you through the process of downloading data from the log of your
bilge alarm. Instructions prerequisite that the CD is inserted in your computer, that the VCP-driver
is installed and that the ”BM488_log_receiver.exe”-program is started.
- 30 -
Illustration 12: Initial screen, waiting for connection Illustration 13: Connected (VCP3) and listening
140613 09:50:24 Number of logs?

PPM>30.0 SPL 100 from current
Log (000A:4567) Number of logs?

12343 entries All
”Long”
Log: PPM > 15 Sending log!

140601 23:12:33
”Wait”
Send log? Sending log!

NO YES Sent 12343!
Illustration 14: Send log data from Bilgmon488
Illustration 15: Log data download completed
- 31 -
Steps:
1. Initial screen is shown (see Illustration 12: Initial screen, waiting for connection). The
program is now waiting for a USB-connection.
2. Connect the BilgMon488 to your PC using the USB-cable. Note that the the bilge alarm
does not need to be connected to a power supply since it gets power from the USB-
cable.
The connected bilge alarm will show up last in the “Ports:” list.
3. Choose the latest appearing port from the list.
4. Click the “Start listening”-button. A dialogue will appear where you can choose an
output folder for the downloaded result.
5. The software is now listening for data from BilgMon488 (see Illustration 13: Connected
(VCP3) and listening).
6. On your BilgMon488 navigate to the log-menu and step in to the log. When exiting the
log you will be asked if you want to send the log. Answer yes and choose the amount of
data to download (see Illustration 14: Send log data from Bilgmon488). While the data
is sent it will show up in the “Received data” section of the log receiver.
7. When the download is finished the filename and position of the result can be found in
the “Status:” list (see Illustration 15: Log data download completed).
8. Close the application.
- 32 -
Chapter 17 Troubleshooting
Symptom Possible reason Servicing
BilgMon488 is switched on Power supply is erroneous. Check connections internally,

but LCD remains blank. externally and power supply
voltages.
LCD monitor is broken. Order replacement part.

Automatic fuses blown. Disconnect externals that might
have caused the short-circuit (f.ex.
water/sample-valve). Wait until
fuses have cooled down power up
the unit again.
ppm value remains high Dirty sensor tube Clean the sensor tube and re-zero.
Air present in sample Correct cause of air presence.

Clean sensor and re-zero.
Excessive contaminates Correct cause of contamination.

present in sample (rust, Clean sensor and re-zero.
bacteria etc...)
LCD display show: Memory malfunction Order replacement part.
MEMORY ERROR,
MEMORY WRITE ERROR, Memory chip not present Order replacement part.
ERASE ERROR
LCD display show: Dirty or damaged Part MASTER and SENSOR
Lost sensor com! MASTER-SENSOR contact units. Clean contact surface with
area. mild detergent.
LCD display show: Real time clock stopped. Order replacement part.
RTC check: FAILED!
- 33 -
Page 1 / 6
Certificate number: 43963/A0 EC

File number: ACM 201/2605/01
Annex A1 Item number: A.1/2.1
This certificate is not valid when presented without the full
attached schedule composed of 7 sections
www.veristar.com
Notified Body 0062 - MARINE EQUIPMENT DIRECTIVE 96/98/EC
EC TYPE EXAMINATION CERTIFICATE

as per Module B of European Union Council Directive 96/98/EC on marine equipment
as amended by Commission Directive (EU) 2015/559
This certificate is issued to

Recovered Energy, Inc.
Pocatello - UNITED STATES OF AMERICA
for the type of product
OIL-FILTERING EQUIPMENT (for an oil content of the effluent not exceeding 15
p.p.m.)
BOSS Oil Water Separation System
Models BOSS 2.2T/107, BOSS 5T/107, BOSS 11T/107, BOSS 25T/107 & BOSS 45T/107
Requirements:
- MARPOL 73/78 as amended, Annex I, Regulation 14
- IMO Res. MEPC.107(49)
- IMO MEPC.1/Circ.643
This certificate is issued on behalf of the French Maritime Authorities to attest that BUREAU VERITAS did undertake the relevant
type-examination procedures for the product identified above which was found to comply with the relevant requirements of the Council Directive
96/98/EC of 20 December 1996 as amended.
This certificate will expire on: 12 May 2021

For BUREAU VERITAS Notified Body 0062,
At BV PORT EVERGLADES CENTRE, on 12 May 2016,
Flavio Rosas
This certificate does not allow to issue the Declaration of Conformity and to affix the mark of conformity (wheelmark ) to the products corresponding
to this type. To this end, the production-control phase module (D, E or F) of Annex B of the Directive is to be complied with and controlled by a written
inspection agreement with a notified body.
This certificate remains valid until the date stated above, unless cancelled or revoked, provided the conditions indicated in the subsequent page(s) are complied with
and the product remains satisfactory in service. This certificate will not be valid if the applicant makes any changes or modifications to the approved product, which
have not been notified to, and agreed in writing with BUREAU VERITAS. Should the specified regulations or standards be amended during the validity of this
certificate, the product(s) is/are to be re-approved prior to it/they being placed on board vessels to which the amended regulations or standards apply. BUREAU
VERITAS is designated by the French Maritime Authority as a "notified body" under the terms of the French Regulations Division 140 Chapter 140-2. This certificate
is issued within the scope of the General Conditions of BUREAU VERITAS Marine & Offshore Division available on the internet site www.veristar.com. Any Person
not a party to the contract pursuant to which this document is delivered may not assert a claim against BUREAU VERITAS for any liability arising out of errors or
omissions which may be contained in said document, or for errors of judgement, fault or negligence committed by personnel of the Society or of its Agents in
establishment or issuance of this document, and in connection with any activities for which it may provide.
The electronic version is available at: http://www.veristarpm.com/veristarnb/jsp/viewPublicPdfTypec.jsp?id=nqslfc6mju

BV Mod. Ad.E 536 December 2014 This certificate consists of 6 page(s)
Page 2 / 6
THE SCHEDULE OF APPROVAL
1. PRODUCT DESCRIPTION
BOSS Oil Water Separation System
Models BOSS 2.2T/107, BOSS 5T/107, BOSS 11T/107, BOSS 25T/107 & BOSS 45T/107
Followed by options X1 and X2 for hazardous area classification.
1.1 Design
- The BOSS Oil Water Separation System mainly includes a coalescing type gravity separator, a process pump, a filter tank
made of steel or fiberglass material depending on models, a TPH monitor and an approved oil content meter (15 ppm bilge
alarm).
- The fiberglass filters are rated at 125 psig.
- The steel filters are rated at 75 psig.
1.2 Specifications
Models * BOSS 2.2T/107 BOSS 5T/107 BOSS 11T/107 BOSS 25T/107 BOSS 45T/107
Capacity gpm (m3/h) 2.2 (0.5) 5 (1.1) 11 (2.5) 25 (5.6) 45 (10.2)
Operating Pressure psig (bar) 15 (1) 15 (1) 15 (1) 15 (1) 15 (1)
Operating Temperature range (°C) 1/55 1/55 1/55 1/55 1/55
Supply Pump Capacity (m3/h) 2.2 5 11 25 45
Motor rating (kW) 0.56 0.56 1.12/1.49 1.12/1.49 2.24
Frequency (Hz) 50/60 50/60 50/60 50/60 50/60
Height inch (cm) 56 (142) 58 (147) 77 (195) 80 (203) 85 (216)
Width inch (cm) 27 (69) 32 (81) 39 (99) 47 (119) 54 (137)
Depth inch (cm) 42 (106) 48 (121) 58 (147) 78 (198) 100 (254)
Dry Weight lbs (kg) 480 (218) 775 (351) 1275 (578) 2475 (1123) 3875 (1758)
* For options (X1 and X2), refer to manufacturer's specification for electrical safe-type equipment.
1.3 Materials
- Components and electrical components per the manufacturer's part list
2. DOCUMENTS AND DRAWINGS

- Specification Sheet 107(49) update 2015
- Drawings list for all BOSS models rev. M1.1 Sheets 1 to 9
Title Sheet Model BOSS 2.2T/107 Model BOSS 5T/107 BOSS 11T/107
General Arrangement 1/9 No. 2.2TGNA001RM1.1 No. 5TGNA001RM1.1 No. 11TGNA001RM1.1
Option View 2/9 No. 2.2TOPT001RM1.1 No. 5TOPT001RM1.1 No. 11TOPT001RM1.1
Mounting 3/9 No. 2.2TMNT001RM1.1 No. 5TMNT001RM1.1 No. 11TMNT001RM1.1
Maintenance Access 4/9 No. 2.2TMAN001RM1.1 No. 5TMAN001RM1.1 No. 11TMAN001RM1.1
Installation Diagram 5/9 No. 2.2TINS001RM1.1 No. 5TINS001RM1.1 No. 11TINS001RM1.1
Connection Dimensions 6/9 No. 2.2TINS002RM1.1 No. 5TINS002RM1.1 No. 11TINS002RM1.1
P&ID - Standard 7/9 No. 2.2TPID001RM1.1 No. 5TPID001RM1.1 No. 11TPID001RM1.1
P&ID - Standard / Options * 8/9 No. 2.2TPID002RM1.1 No. 5TPID002RM1.1 No. 11TPID002RM1.1
P&ID - Identification 9/9 No. 2.2TPID003RM1.1 No. 5TPID003RM1.1 No. 11TPID003RM1.1

Page 3 / 6
Title Sheet Model BOSS 25T/107 Model BOSS 45T/107

General Arrangement 1/9 No. 25TGNA001RM1.1 No. 45TGNA001RM1.1
Option View 2/9 No. 25TOPT001RM1.1 No. 45TOPT001RM1.1
Mounting 3/9 No. 25TMNT001RM1.1 No. 45TMNT001RM1.1
Maintenance Access 4/9 No. 25TMAN001RM1.1 No. 45TMAN001RM1.1
Installation Diagram 5/9 No. 25TINS001RM1.1 No. 45TINS001RM1.1
Connection Dimensions 6/9 No. 25TINS002RM1.1 No. 45TINS002RM1.1
P&ID - Standard 7/9 No. 25TPID001RM1.1 No. 45TPID001RM1.1
P&ID - Standard / Options * 8/9 No. 25TPID002RM1.1 No. 45TPID002RM1.1
P&ID - Identification 9/9 No. 25TPID003RM1.1 No. 45TPID003RM1.1
Nota: The units are available with various options that are shown in the drawings (*). When any of these options are used the
2-digit code for that option should be added after the standard model number.
- Electrical Drawing Sample No. 2B4360 rev. 0 dated 21/09/2015. The electrical drawing is specific to each job.
- Installation and application manual rev. M1.1
- Operations and maintenance manual rev. M1.1
No departure from the above documents shall be made without the prior consent of the notified body named on this certificate.
The manufacturer must inform the notified body of any modification or changes to these documents and drawings.
3. TEST REPORTS
3.1 The 15 ppm bilge separator has been examined and type tested in accordance with the requirements of the specifications
contained in part 1 of the annex to the guidelines and specifications contained in IMO resolution MEPC.107(49).
Under type and model designation : BOSS 5T/107 & BOSS 25T/107 representing all BOSS XXT/107 Series, incorporating
- 15 ppm Bilge Separator manufactured by Recovered Energy, Inc. (USA) according to specification/assembly drawing listed
in 2 above
- Coalescer manufactured by Recovered Energy, Inc. (USA) according to specification/assembly drawing listed in 2 above
- Control equipment manufactured by Recovered Energy, Inc. (USA) according to specification/assembly drawing listed in 2
above
Note: An integral pump is fitted with this equipment.
3.2 Test carried out in TEi-Testing Services (USA) facilities (accredited laboratory by USCG). Samples were collected by
TEi-Testing Services (USA). Effluent/influent analysis were carried out by TEi-Testing Services (USA).
Collection method in accordance with ISO 9377-2:2000. Test reports No. TS-A-02866 dated 31/12/2006 (BOSS 5T/107) &
TS-A04186 dated 15/06/2010 (BOSS 25T/107) issued by the lab.
3.3 Environmental testing of the electric and electronic components was carried out in accordance with MEPC. 107(49), Part 3.
The tests were witnessed by TEi-Testing Services (USA) and were completed on 21/07/2015, test report No. 44817RSE.001.
Test reports No. TS-P00944 dated 02/11/2015 & TS-M00695 dated 30/10/2015. Inclination range up to 22,5° in any plane from
the normal operation condition.
EUT: New Control Panel with the replacement of the Analog Level Sensor Relay to an Integrated Circuit Digital Level Sensor
Controller
3.4 Additional test: IP testing for power box (IP65) and control box (IP55).
Note: Details of test data and results obtained are shown on the Appendix to this Certificate.
4. APPLICATION / LIMITATION
4.1 Operating media: Oil / water. Approved as an oil filtering equipment designed to produce an effluent with oil content not
exceeding 15 ppm. The equipment is to be fitted with an approved oil content meter (15 ppm bilge alarm).
4.2 The approval is not valid to options that are shown in the drawings (*) in 2 above if they are not part of the type-approved
unit.
4.3 Suitable for installation in non-hazardous area and in hazardous area when "X1 or X2" code comes after the standard model
number.
4.4 Electrical Equipment and/or components to be installed in Hazard areas are required to meet or exceed the requirements for
the specific area.

Page 4 / 6
4.5 The scope of the appraisal made by Bureau Veritas to issue this certificate is strictly restricted to the relevant requirements
stated on the front page of this certificate. Other requirements like Ship's Flag Administration Regulations and/or Classification
Societies Rules, typically for electrical equipment including control, safety devices and cables, are excluded from the scope of
this certificate.
4.6 The installation requirements on board ships will have to comply with the regulation 6.1 of MEPC.107(49).
4.7 A copy of this EC type-examination certificate should be carried aboard a ship with this separator at all times.
4.8 Each equipment is to be supplied with its manual for installation, use and maintenance in language accepted by the ship's
Flag Administration.
5. PRODUCTION SURVEY REQUIREMENTS

5.1 This certificate does not allow the applicant to issue the Declaration of Conformity and to affix the mark of conformity
(wheelmark) to the products corresponding to this type. To this end, the production-control phase module D "Production Quality
Assurance" or E "Product Quality Assurance" or F "Product Verification" of Annex B of the Directive is to be complied with
and controlled by a written inspection agreement with a notified body.
5.2 The manufacturer shall institute quality control procedure in order to ensure that the oil filtering equipment is produced to
the same standard as the prototype approved one, and to keep records of any production tests carried out in accordance with
Requirements stated on the front page of this certificate.
5.3 Each oil filtering equipment (15 ppm equipment) shall be delivered with a declaration of conformity to type issued by the
manufacturer.
Place of Production
11455 N. Rio Vista Rd.
83202 Pocatello, ID
UNITED STATES OF AMERICA
6. MARKING OF PRODUCT
The equipment shall be marked as follows:
- Manufacturer's name or logo
- Serial number
- Type designation
- IEC Ex marking when required
- Markings as per MED 96/98/EC when authorized by a Notified Body: ¤ YYYY/XX where YYYY is the number of the Notified
Body undertaking surveillance module (when BV, 0062) and where XX are the last two digits of year mark affixed.
7. OTHERS
This approval is given on the understanding that the manufacturer will accept full responsibility for informing shipbuilders or
their sub-contractors of the proper methods of use and general maintenance of the Marpol equipment and of the conditions of
this approval.

Page 5 / 6
Appendix to the EC Type Examination Certificate No. 43963/A0 EC
Test data and results conducted on a 15 ppm bilge separator in accordance with Part 1 of the annex to the guidelines and
specifications contained in IMO Resolution MEPC.107(49)
15 ppm Bilge Separators submitted by : Recovered Energy, Inc. (USA)

Sample Models : BOSS 5T/107 and BOSS 25T/107 representing all BOSS XXT/107 Series
Test location : TEi-Testing Services (USA)
Method of sample analysis : ISO 9377-2:2000 "Water quality - Determination of hydrocarbon oil index
Part 2: Method using solvent extraction and gas chromatography
Samples analysed by : TEi-Testing Services (USA)
Test reports : No. TS-A-02866 dated 31/12/2006 (BOSS 5T/107) & TS-A04186 dated 15/06/2010 (BOSS 25T/107)
Environmental testing of the electrical and electronic sections of the 15 ppm Bilge Separator has been carried out in accordance
with part 3 of the annex to the guidelines and specifications contained in IMO resolution MEPC.107(49). The equipment
functioned satisfactorily on completion of each test specified on the environmental test.
Environmental tests carried out by : TEi-Testing Services (USA)
EUT : New Control Panel with the replacement of the Analog Level Sensor Relay to an Integrated Circuit Digital Level
Sensor Controller
Test reports : No. TS-P00944 dated 02/11/2015 & TS-M00695 dated 30/10/2015
Properties of test fluids A and B Test fluid “A” Test fluid “B”
Density at 15ºC 989 kg/m3 845 kg/m3
Viscosity 35 Centistokes @ 100ºC 5.50 Centistokes @ 40ºC
Flashpoint 60°C 62°C
Ash content 0,12 % <0.01 %
Water content at start of test % 0,5 % 0,2 %
Test fluid “C”

Surfactant : Sodium salt of dodecylbenzene sulfonic acide in dry form
Iron oxides : Fe3O4
Test water
Density at 20ºC : 1.012 gr/cm3
Solid matter present : 0.05 % solids by weight
Test temperatures
BOSS 5T/107 BOSS 25T/107
Ambient 18°C °C
Test fluid “A” 14.1°C °C
Test fluid “B” 15.9°C °C
Test fluid “C” 24.2°C °C
Test water 8.6°C °C
Diagram of test rig

according to
Diagram of sampling arrangement

according to

Page 6 / 6
TEST RESULTS (IN PPM) AND TEST PROCEDURES
Test Fluid A - Sample Model BOSS 5T/107

1 2 3 4 5 6 7 8 9
Influent 0.5 -1 % 0.5 -1 % 0.5 -1 % 25 % 25 % 25 % 100 % 0% 25 %
Effluent 2.2 ppm 1.9 ppm 1.3 ppm 1.7 ppm 1.9 ppm 1.6 ppm 1.5 ppm 2.1 ppm 1.7 ppm
Refer to Figure "Test Fluid A" in IMO resolution MEPC.107(49), Appendix 1, p. 28.
Test Fluid B - Sample Model BOSS 5T/107

10 11 12 13 14 15
Influent 0.5 -1 % 0.5 -1 % 0.5 -1 % 25 % 25 % 25 %
Effluent 2.4 ppm 2.2 ppm 2.3 ppm 2.5 ppm 2.1 ppm 1.8 ppm
Refer to Figure "Test Fluid B" in IMO resolution MEPC.107(49), Appendix 1, p. 28.
Test Fluid C - Sample Model BOSS 5T/107

16 17 18
Influent 6% 6% 6%
Effluent 3.1 ppm 2.8 ppm 3.2 ppm
Refer to Figure "Test Fluid C" in IMO resolution MEPC.107(49), Appendix 1, p. 28.
----------------------------------------------------------------------------------------------------------------------------------------------------------------
Test Fluid A - Sample Model BOSS 25T/107

1 2 3 4 5 6 7 8 9
Influent 0.5 -1 % 0.5 -1 % 0.5 -1 % 25 % 25 % 25 % 100 % 0% 25 %
Effluent 1.2 ppm 1.1 ppm 3.3 ppm 4.1 ppm 1.3 ppm 4.1 ppm 4.3 ppm 3.8 ppm 4.0 ppm
Refer to Figure "Test Fluid A" in IMO resolution MEPC.107(49), Appendix 1, p. 28.
Test Fluid B - Sample Model BOSS 25T/107

10 11 12 13 14 15
Influent 0.5 -1 % 0.5 -1 % 0.5 -1 % 25 % 25 % 25 %
Effluent 1.3 ppm 0.7 ppm 1.1 ppm 0.5 ppm 0.8 ppm 0.8 ppm
Refer to Figure "Test Fluid B" in IMO resolution MEPC.107(49), Appendix 1, p. 28.
Test Fluid C - Sample Model BOSS 25T/107

16 17 18
Influent 6% 6% 6%
Effluent 3.6 ppm 3.8 ppm 4.3 ppm
Refer to Figure "Test Fluid C" in IMO resolution MEPC.107(49), Appendix 1, p. 28.
*** END OF CERTIFICATE ***

Page 1 / 2
Certificate number: SMS.MED.D/65484/A.0
Notified Body N° 0062 www.veristar.com
MED 96/98/EC QUALITY SYSTEM MODULE D CERTIFICATE

This certificate is issued under the French Maritime Authority, in compliance with the Council Directive 96/98/EC amended by Commission
Directive (EU) 2015/559 as transposed in the French Regulations, to

Pocatello - UNITED STATES OF AMERICA
Summary of the range of the recognition which is detailed in the subsequent page(s):
OIL-FILTERING EQUIPMENT (for an oil content of the effluent not exceeding 15 p.p.m.)
This certificate is issued to attest that BUREAU VERITAS, notified body number 0062, did undertake, at the above company's request, an
assessment of the quality system for production quality assurance related to the equipment of the type described in EC type-examination (Module
B) certificate(s) listed in the subsequent page(s). BUREAU VERITAS, notified body number 0062, has considered that the quality system
operated was satisfying the applicable requirements of the Marine Equipment Directive 96/98/EC as amended.
This certificate will expire on: 15 Oct 2019
For BUREAU VERITAS,

At BV PORT EVERGLADES CENTRE, on 23 Jun 2016,
Flavio Rosas
This certificate remains valid until the date stated above, unless cancelled or revoked, provided the conditions indicated in the subsequent page(s) are complied
with. This certificate is issued within the scope of the General Conditions of BUREAU VERITAS Marine & Offshore Division available on the internet site
www.veristar.com. Any Person not a party to the contract pursuant to which this document is delivered may not assert a claim against BUREAU VERITAS for any
liability arising out of errors or omissions which may be contained in said document, or for errors of judgement, fault or negligence committed by personnel of the
Society or of its Agents in establishment or issuance of this document, and in connection with any activities for which it may provide.
The electronic version is available at: http://www.veristarpm.com/veristarnb/jsp/viewPublicPdfRecognition.jsp?id=bphomua8kk

BV Mod. Ad.E 618-D May 2009 This certificate consists of 2 page(s)
Page 2 / 2
Certificate number: SMS.MED.D/65484/A.0
ANNEX
1. SCOPE
Products
App. number Date of issue Validity date Item designation Trade name Comment
43963/A0 EC 18 May 2016 12 May 2021 OIL-FILTERING EQUIP- BOSS Oil Water Separa-
MENT (for an oil content tion System Models
of the effluent not exceed- BOSS 2.2T/107, BOSS
ing 15 p.p.m.) - A.1/2.1 5T/107, BOSS 11T/107,
BOSS 25T/107 & BO
2. LIMITATIONS
The EC type-examination certificates listed in the scope are to be valid.
Bureau Veritas is to be informed immediately of any modification to the quality system in order to agree on appropriate
actions.
Recovered Energy, Inc. has to apply for the periodical audits as agreed with Bureau Veritas.
Recovered Energy, Inc. must draw up a written EC declaration of conformity to type in compliance with the article 10 of
the MED 96/98/EC.
Recovered Energy, Inc. must affix the mark of conformity in compliance with the article 11 of the MED 96/98/EC taking
into consideration the following example:
0062/xx Where xx are the last two digits of the year in which the mark is affixed.
3. REMARKS
Nil.
*** END OF CERTIFICATE ***
The electronic version is available at: http://www.veristarpm.com/veristarnb/jsp/viewPublicPdfRecognition.jsp?id=bphomua8kk

BV Mod. Ad.E 618-D May 2009 This certificate consists of 2 page(s)
Coast Guard Approval Number: 162.050/9033/0 Expires: 06 September 2018
OIL POLLUTION PREVENTION EQUIPMENT

The following device has been tested in accordance
with IMO Resolution MEPC.107(49)
RECOVERED ENERGY INCORPORATED

11455 N. Rio Vista Rd.
Pocatello ID 83202
BOSS 25T/107; 15 ppm Separator
Equipment manufactured by Recovered Energy Incorporated to specification/assembly drawing

no. BOSS 2 107C dated 5/26/2005. Coalescer manufactured by Recovered Energy Incorporated to
specification/assembly drawing no. BOSS 107 Separator System, Rev. A dated 7/7/2005.
Filters manufactured by Recovered Energy Incorporated to specification/assembly drawing no.
BOSS 107 Separator System, Rev. A dated 7/7/2005. Control equipment manufactured by
Recovered Energy Incorporated to specification/assembly drawing no. IMO 107 dated 5/23/2005.
Maximum throughput of the system is 5.7 cu. m/hr (25.0 gpm).
An integral pump is fitted with this equipment. A copy of this certificate should be
carried aboard a vessel fitted with this equipment at all times. IMO Certificates of Type
Approval do not expire and are valid for equipment manufactured at any time during the
period of validity of this certificate. Test data and results attached in the appendix.
This certificate documents compliance with 46 CFR 162.050.
*** END ***
THIS IS TO CERTIFY THAT the above named manufacturer has submitted to the undersigned satisfactory evidence that the item specified herein complies
with the applicable laws and regulations as outlined on the reverse side of this Certificate, and approval is hereby given. This approval shall be in effect until the
expiration date hereon unless sooner canceled or suspended by proper authority.
GIVEN UNDER MY HAND THIS 6th DAY OF

SEPTEMBER 2013, AT WASHINGTON D.C.
P. W. GOODING
Chief, Engineering Division
U.S. Coast Guard Marine Safety Center
TERMS: The approval of the item described on the face of the Certificate has been based upon the submittal of satisfactory
evidence that the item complies with the applicable provisions of the navigation and shipping laws and the applicable regulations in
Title 33 and/or Title 46 of the Code of Federal Regulations. The approval is subject to any conditions noted on this Certificate and
in the applicable laws and regulations governing the use of the item on vessels subject to Coast Guard inspection or on other
vessels and boats.
Consideration will be given to an extension of this approval provided application is made 3 months prior to the
expiration date of this Certificate.
The approval holder is responsible for making sure that the required inspections or tests of materials or devices covered
by this approval are carried out during production as prescribed in the applicable regulations.
The approval of the item covered by this certificate is valid only so long as the item is manufactured in conformance
with the details of the approved drawings, specifications, or other data referred to. No modification in the approved design,
construction, or materials is to be adopted until the modification has been presented for consideration by the Commandant and
confirmation received that the proposed alteration is acceptable.
NOTICE: Where a manufacturer of safety-at-sea equipment is offering for sale to the maritime industry, directly or indirectly,
equipment represented to be approved, which fails to conform with either the design details or material specifications, or both, as
approved by the Coast Guard, immediate action may be taken to invoke the various penalties and sanctions provided by law
including prosecution under 46 U.S.C. 3318, which provides:
"A person that knowingly manufactures, sells, offers for sale, or possesses with intent to sell, any equipment subject to
this part (Part B. of Subtitle II of Title 46 U.S.C.). and the equipment is so defective as to be insufficient to accomplish the purpose
for which it is intended, shall be fined not more than $10,000, imprisoned for not more than 5 years or both."

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Final Document

Oily Water Separator

Model: BOSS 25T/107

SHANHAIGUAN SHIPBUILDING INDUSTRY Co.,Ltd.(SHGSIC)

Hull No.: CT370-01

4.2.2 Control Valves............................................................................................................ - 14 -

Chapter 1 System Description

1.2 Process Description

1.2.1 General Description of the Process

1.3 System Specifications

IMO MEPC 107(49) Certified Monitor with Data

DN15,PN1.0 DN15,PN1.0 DN20,PN1.0 DN20,PN1.0 DN20,PN1.0

Separator Outer Drain ¾” / na 1” / na 1” / na 1 ½” / na 1 ½” / na

3.2 Before Applying Power

3.3 Power Test

Watch the direction of the fan on the rear of

3.4 Power ON & Initial Water Filling

3.5 OCM Test

3.6 Introduce Process Water & Set Flow Rate

3.7 Verify Suction

3.8 Simulate Alarm Conditions for Inspector or Verification of Valve

3.9 Normal Operation

3.10 Backwash system

3.11 Maintaining and Servicing the Oil Content Monitor (OCM)

3.12 Calibration of the Oil Content Monitor (OCM)

3.13 Shutdown Procedures

4.2 Component Maintenance

Here is a photo of a ½”A42 solenoid valve

CAUTION! NEVER POWER THE COIL TO “TEST” IT UNLESS IT IS

Begin by removing the bonnet, spring washer,

The core stem can then be removed from here.

Generally a good cleaning here will

COIL BASE COIL SPRING WASHER BONNET

1. Remove the head on the separator vessel.

(The black section is only colored for contrast)

4.3 Draining the Separator

4.4 Annualized Recommended Maintenance Schedule

4.4.2 OWS Condition-Based Maintenance

5.1 Short Cycle Condition

5.2 Reduced Flow Through the System

5.2.2 Plugged Polisher

5.3 Fault Alarms and Remote Monitoring Capabilities

5.4 High Oil Content Reading Causing Water to Recycle

5.5 No Flow Through the OCM

5.6 Common Fault Alarm

6.3 29 CFR, Part 1910

6.4 Dangers, Warnings, Cautions

6.5 Federal Protection Standards

Chapter 7 Spare part list

Item Photo Part name Description Quantity Part No.

2 Fuse 750mA 1 1H5360026

Item Drawing No. Description Total Pages

1 32825-00LC P&ID Drawing 1

2 32825-00XS Assembly Drawing 1

3 32825-00MX Parts Identification Drawing 1

4 32825-00BZ Installation Diagram 1

5 32825-00WH Maintenance Access Drawing 1

6 30028-00ADL Electrical Schematics 2

7 20028-35-0 Overboard 3-way L-port Ball Valve 1

Appendix B – OCM Instruction Manual

10.1 While separator is active. ........................................................................................... - 26 -

Chapter 1 Table of validity