B91002_OM_Manual[1]

BOSS OIL WATER SEPARATIONSYSTEM FOR PLATFORMS

OPERATIONS&

MAINTENANCEMANUAL

O&M Manual Page 1 04/08/23

Website: www.recoveredenergy.comEmail: [email protected]

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O&M MANUALVOLUME I

TABLE OF CONTENTS

1. SYSTEM DESCRIPTION:................................................................................................31.1. Components by System.................................................................................................3

a. Pre-filter system.............................................................................................................3b. Oil water separator system...........................................................................................3c. Filter/Polishing System..................................................................................................4d. Filter Backwash System................................................................................................4e. OCM/turbidity Monitoring...........................................................................................4f. Electrical/Controls.........................................................................................................5

1.2 Process Description........................................................................................................51.2.1 Pre-Filtration System:............................................................................................51.2.2 Oil Water Separator System..................................................................................51.2.3 Filter/Polishing System:..........................................................................................61.2.4 Filter Backwash/Blowdown System......................................................................71.2.5 OCM and Turbidity Monitoring System..............................................................81.2.6 Ultraviolet Sanitizing..............................................................................................81.2.7 Area Classification (Class I, Div II).......................................................................9

1.3 System Specifications.....................................................................................................91.4 Fault Alarms and Remote Monitoring Capabilities...................................................9

2. STARTUP..........................................................................................................................112.1 Factory Testing/Delivery.............................................................................................112.2 Installation....................................................................................................................112.3 Power Test....................................................................................................................112.4 pH Probe Installation..................................................................................................122.5 UV bulb Installation....................................................................................................122.6 Initial Water Filling.....................................................................................................132.7 OCM and Turbidity Test............................................................................................13

3. OPERATION.....................................................................................................................153.1. Normal Operation........................................................................................................153.2. Alarm and Action Conditions.....................................................................................153.3. Backwash Mode...........................................................................................................16

4. CONTROL SYSTEM DESCRIPTION...........................................................................175 TROUBLE SHOOTING:.................................................................................................296 MAINTENANCE..............................................................................................................317. SPARE PARTS..................................................................................................................32

7.1 Pumps............................................................................................................................327.2 Valves............................................................................................................................327.3 Monitoring Equipment................................................................................................337.4 PLC...............................................................................................................................347.5 Miscellaneous...............................................................................................................35ATTACHMENT 1 - P&ID DRAWING..............................................................................36ATTACHMENT 1 – ELECTRICAL SCHEMATICS.......................................................37ATTACHMENT 3 - CALIBRATION SHEETS.................................................................46ATTACHMENT 4 - CALCULATIONS..............................................................................47


1. SYSTEM DESCRIPTION:

The BOSS Platform oil water separation system includes the following basic components:

Pre filter system Oil Water Separator Filter/Polishing System Filter Backwash System OCM/turbidity monitoring Electrical/controls

1.1. Components by System

a. Pre-filter systemMOV-102 Inlet shutoff valveF-101 Inlet filter Y strainerF-104 Hydrocyclone particulate filterV-102 System isolation valveG-103 Inlet pressureV-105 Sample valveV-104 Vent valveCV-101 F-104 return check valveV-103 F-104 effluent isolation valve

b. Oil water separator system (see Arrangement Photo—Attachment 2a)

S-101 Coalescing separatorP-101 Process pumpP-102 Process pump PRV-101 Pressure relief for P-101 and P-102CV-102 Separator inlet check valveCV-105 P-101 outlet check valveCV-106 P-102 outlet check valve V-130 P-101 isolation valveV-131 P-102 isolation valveG-101 Pump discharge pressure gaugeCV-107 Turbidity / OCM protection valveV-143 Pre filter sample valveV-101 Separator vent valveV-106 S-101 center drainLS-101 Separator oil level switchMOV-101 Oil discharge control valveV-107 P-104 suction valveV-108 P-103 suction valveP-103 Oil discharge pump


P-104 Oil discharge pumpCV-103 P-103 outlet check valve CV-104 P-104 outlet check valveG-104 Oil discharge pressure gaugeSOV-104 Makeup water control valveSOV-102 Discharge control valveSOV-101 Recycle control valve

c. Filter/Polishing System (See Arrangement Photo—Attachment 2d)

F-102 Turbidity filterF-103 Polishing filterV-134 F-102 drain valveV-135 F-102 vent valveV-137 F-103 drain valveV-136 F-103 vent valveFCV-101 Flow control valveFM-101 Flow meterUV-101 Ultraviolet sterilizerAI-102 pH meterTG-101 Temperature gaugeV-142 UV drain valve / sample port

d. Filter Backwash System (see Arrangement Photo—Attachment 2b)

P-105 Backwash pumpP-106 Backwash pumpCV-108 P-105 outlet check valve CV-109 P-106 outlet check valveV-138 P-105 isolation valveV-139 P-106 isolation valveG-102 Backwash pump pressure gaugeCV-110 F-102 inlet check valveDPT-102 F-102 differential pressure transmitterSOV-103 F-102 backwash control valveMOV-103 F-101 blowdown control valveDPT-101 F-101 differential pressure transmitterT-101 Backwash water storage tank

e. OCM/turbidity Monitoring (see Arrangement Photo—Attachment 2g)

AI-101 OCM monitorV-125 OCM post filter sample valveV-124 OCM pre filter sample valveV-121 OCM sample return valve


AI-103 Turbidity monitorV-123 Turbidity post filter sample valveV-122 Turbidity pre filter sample valve

f. Electrical/Controls (see Arrangement Photo—Attachment 2h)

P1 Power disconnectP2 Electrical panelP3 PLC and Panel View displayAI-103 Turbidity meter and display AI-101 OCM monitor

1.2 Process Description

1.2.1 Pre-Filtration System:

Process water is pumped to the system from the sump at a pressure of at least 2.3 bars. A shutoff valve (V102) is provided for system isolation. A Y strainer (F-101) removes particulates larger than 1/20th of an inch in any dimension. The pre-filter system also includes a differential pressure transmitter to determine when F-101 needs cleaning and a blow down valve (MOV-101) to blow down the Y strainer when it is full. The process water goes through a control valve MOV-102 to prevent water from back flowing from the system when the unit is off or in the fill/oil discharge mode. The customer is responsible to determine what to do with the blow down.

The pressure drop across F-101 starts out at 0 and will go up to whatever it is set at before it causes the blowdown function to trigger. The pressure drop allowed will depend on the inlet pressure available. F-104 needs at least 2 bar so the amount of pressure drop available for F-101 is the difference between the inlet pressure and the pressure drop required for F-104. The blowdown can be controlled either by the pressure drop or time. A more complete description of how the blowdown works is included in the discussion of the control system.

The water goes through a hydrocyclone (F-104) to remove smaller sediment down to about 30 micron particle size. The sediment slurry comes out the bottom of the hydrocyclone through an isolation valve (V-103) and must be handled in some way by the customer. Any water going through the hydrocyclone that is more than the capacity of the system will go back to the oily water storage tank or sump. The pressure drop across F-104 is about 2 bar. The hydrocyclone will work better if there is excess flow going through it.

1.2.2 Oil Water Separator SystemThe oil water separator (S-101) is a coalescing type gravity separator that relies on the difference in specific gravity of oil and water. The separator will not remove aqueous fluids or fluids that have a specific gravity of near 1.0 or higher. The oily water flows from F-104 into the bottom of the separator. P-101 / P-102 will pull a


vacuum if the inlet pressure has been used by F-101 and F-104. If the inlet pressure is more than what is required by F-101 and F-104 and the water comes to the separator under pressure, the separator is designed for up to 2.8 bar pressure.

The separator has an inner and outer section. The water comes up through the center section of the separator through an oleophilic media (polyethylene or polypropylene). The media facilitates the separation of the oil from the water by providing a surface area that attracts droplets of oil and holds them until they coalesce into larger droplets which rise rapidly to the surface of the water in the separator. As oil collects in the top of the separator it displaces the water and forces The water level in the separator downward. Any gas vapor or air that enters the separator will rise rapidly to the top of the separator where it collects with the oil. Air or vapor that collects in the separator will be discharged with the oil. A level sensor (LS-101) in the top of the separator detects the water level in the separator. When the oil in the top of the separator reaches the full level set point the process pump (P-101 or P-102) shuts off, the discharge valves (SOV 101 or SOV 102) close and Pump 103 or P-104 turns on until the oil level reaches the empty level set point at which time the level switch automatically switches all the valves and pumps back into the process mode. While the oil is being discharged the separator is not operating. As the oil is evacuated the water level rises in the separator until the oil reservoir is empty and the oil discharge valve shuts.

During normal operation oily water entering the system flows up through the center section of the separator and over the top of the inner section weir where most of the oil is separated from the water. The water then flows down through the outer section of the separator, which contains additional media. The pass through the second stage of coalescing media helps remove any residual oil and provides discharge water from the primary separator in most cases with less than 15-PPM oil content. Separated water exiting the separator comes out the bottom of the outer section and is pumped to the sand filter (F-102) by P-101 or P-102. The suction of the pump is continuously flooded with a positive head so there is no need to prime the pump. The duplex pumps are progressive cavity pumps and share a common safety relief valve. The process pumps are capable of pumping the design flow at 3 bar. The system is not designed for much turn down. As the flow is restricted the pumps will go up in pressure to compensate. The system will operate best at design flow. Depending on suction and head requirements for a given installation, the process pump will be capable of pumping slightly more than the design flow rate through the system. The flow rate is controlled by the flow meter (FM-102) and control valve (FCV-101).

1.2.3 Filter/Polishing System:

The water leaving the separator goes to a sand filter (F-102) to remove turbidity from the water. The sand filter has a differential pressure transmitter (DPT-102) and backwash feature that is discussed below.

The water then goes to a polishing filter (F-103) that can contain several different types of bulk media. The initial charge of media is organoclay. The primary types


of media options are activated carbon and organoclay. Each type has advantages and disadvantages depending on your specific needs. Carbon generally works better than organoclay for most emulsions. Organoclay works better than carbon for any free oil, BTEX or heavy metals. The mix of media can be adapted to fit any specific requirement.

The filter has an inlet distributor at the top and an outlet distributor at the bottom. The filter vessels are rated for 4.5 barg pressure. The pumps are sized to give no more than 3.4 barg under normal operating conditions. A relief valve on the process pumps is set at 3.4 barg.

The organoclay media will need to be replaced when the system will no longer keep the oil content within acceptable limits. Before deciding that the media is spent, clean the OCM cell and make sure the oil content reading is accurate. The media can either be vacuumed out or dumped out through the side manway. Each filter has an inlet nozzle on top that can be used to loan new media and an outlet nozzle at the bottom that can be used to remove spent media. The used media can generally be thrown away in the same manner a spent oil filter is discarded or with the other municipal waste from the vessel or facility. It is generally best to add coarse sand (40 mesh or coarser--#20) in the bottom of F-103 to a level a few inches above the top of the bottom distributor. This helps keep the distributor from plugging up with fines. Fill the rest of the filter with media up to a few inches below the top distributor.

You can expect the following results from the system:

1. With no emulsions present and using organoclay in a down flow configuration, the system will generally remove any free oil and the monitor will generally read close to 0 ppm.

2. The higher the volume of oil in the oily water the more oil the primary separator will discharge. For example, in most situations the primary separator will remove free oil to < 15 ppm. However, with high concentrations of oil the primary separator will pass more than 15 ppm oil. The more oil in the separator discharge the faster the post filter media will be consumed but the system will generally accommodate such conditions.

3. Organoclay does not remove emulsions as well as carbon. Sometimes the best option is a combination of both carbon and organoclay. Some adjusting over time may be necessary to achieve the best results.

New organoclay will generally remove free oil to a non-detect level. If emulsions are present it will require a combination of carbon and organoclay to achieve non-detect levels. This can sometimes be done by combining carbon and organoclay in the same filter. To do this load sand in the filter first, then carbon and then organoclay on top.

1.2.4 Filter Backwash/Blowdown System


The Y strainer (F-101) and sand filter (F-102) have automatic backwash/blowdown features. Each has a differential pressure transmitter to determine when the filter needs to be cleaned. The clean water from the discharge of the UV goes into the backwash tank (T-101). During backwash mode water is pulled from this tank for the backwash/blowdown. During normal operation the clean discharge water goes into the backwash tank and overflows from the top of the tank. The overflow goes back into the ocean. . This tank is designed to be full at all times so that there is always adequate water for backwash.

When the Y strainer (F-101) needs to be cleaned MOV-102 closes, P-101 or P-102 shuts off, MOV-101 opens and P-105 or P-106 turns on. This forces the sediment out of the Y strainer to wherever the customer sends the blowdown. It will only take a few seconds to blow down the Y strainer. The blowdown can be set to come on either based on the differential pressure or based on a timer. When the control system calls for a blowdown of F-101 it will wait to blow down until the system goes into the fill mode. This way the system will not be shutting down for the blowdown. For more explanation of how the settings are adjusted for the blowdown process see the discussion on the control system.

When the sand filter needs to be backwashed, the process pump (P-101 or P-102) shuts off, the discharge valve (SOV-102) or recycle valve (SOV-101) shut off, the backwash control valve (SOV-103) opens, MOV 102 closes and the backwash pump (P-105 or P-106) turns on and runs for a pre set time that is adjustable by the customer. The backwash can be set to come on either based on the differential pressure or based on a timer or based on loss of flow. For more explanation of how the settings are adjusted for the backwash process see the discussion on the control system.

1.2.5 OCM and Turbidity Monitoring System

This system includes a NE Controls Oil Content Monitor (OCM), also referred to as a The Oil Content Monitor (“OCM”) also called the Total Petroleum Hydrocarbon meter (“TPH”) that has been certified to meet MEPC 60(33) regulations. The OCM monitor has the ability to automatically return non-conforming discharge water back to the sump or oily water storage tank. The recycle and discharge solenoid valves (SOV-101 and SOV-102) are controlled by the oil content monitor (OCM). The OCM unit, which has been tested and approved in accordance with IMO Resolution MEPC 60(33), is set from the factory to alarm at 15 PPM. Through the PLC, the monitor can be set to alarm down to 1 ppm.

Turbidity to the monitor should not be an issue if the sand filter is used because the sand filter will remove the turbidity from the water.

1.2.6 Ultraviolet Sanitizing

The water goes from the organoclay filter to an ultraviolet disinfecting system (UV-101) as it enters into the water storage tank (T-101). The UV unit disinfects


water by sterilizing bacteria in the water and rendering them incapable of reproduction.

1.2.7 Area Classification (Class I, Div II)

The system has been designed to meet a hazard area classification for Class I, Div II, groups B,C and D. The pump motors are explosion proof. The solenoid valves, motorized ball valves and level controller are rated for Class I, Div II. The electrical panels are aluminum NEMA 7/4X enclosures. The PLC panel is NEMA 4X with a type Z purge control. The external wiring is armored cable with the appropriate connectors. The Oil Content Monitor is enclosed in a NEMA 7/4X enclosure. The PLC system included a PanelView Plus touch screen. All other instruments or controls are properly protected and rated.

1.3 System Specifications

a. DimensionsLength 157” –62.3 cmWidth 126” – 49.6 cmHeight 102” – 40.2 cmWeight approx. 15,000 lbs. (6800 kg) dry

b. Flow rate—32 gpm (7.2 m³/hr.)c. S-101 operating pressure— vacuum to 2.8 bargd. F-102 operating pressure— < 4.5 barge. F-103 operating pressure— < 4.5 bargf. T-101 operating pressure— atmospheric vesselg. System test pressure – 6.3 bargh. Operating temperature range—5 to 60 Ci. Maximum oil concentration—35% j. Maximum specific gravity of oil to achieve design separation—0.95 k. Oil in water discharge-- <15 ppml. Maximum turbidity for accurate OCM reading—35 NTUm. IMO MEPC Compliance—60(33)n. Voltage—440 V 3 phase, 60 Hz.o. Hazardous area classification—Class I, Div II group B,C,D

1.4 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 PLC display. Any OCM alarm or fault condition will automatically put the system into the recycle mode. Potential causes of the OCM system fault include:

a. loose or improperly inserted data cardb. loss of communication between the display and the detector (loose cable)c. internal board or power supply failure


(See separate OCM O&M manual for a more detailed explanation of the OCM monitor.)

The customer can connect directly to the control system and obtain the following information at a remote location:

a. 4-20 mA signal showing the ppm oil content in the water (0-20 ppm)b. Voltage free contact for the OCM alarmc. Voltage free contact for the OCM system fault

The customer can connect to the main control panel and obtain the following:a. 120 V signal showing whether the system is in normal operation mode

(pump is running and either discharging water or recycling water)b. 120 V signal showing whether the system is in fill mode (pump is not

running, the system is filling and oil is being discharged)c. The customer can remotely start or stop the system with an external voltage

free contact.


2. STARTUP

2.1 Factory Testing/Delivery

Prior to delivery the system is tested in the manufacturers shop to verify that the system is watertight and that all the pumps, instrumentation and controls are operational. A FAT report is completed and included in the information provided with the system. When the system arrives at it final destination it should be carefully checked for damage that may have been sustained during shipping. All damage should be noted and reported to the shipping company and to the manufacturer. If replacement parts or components are needed the manufacturer should be informed immediately.

2.2 Installation

The system is a self-contained package system that has been tested and operated under test conditions at the factory. Within the system battery limits no installation will be necessary except to mount the system, make the necessary connections, bring power to the main disconnect, install the UV tubes and install the pH probes.

After the system is placed in the location where it will operate, it will be necessary to connect power and piping connections. The power connections to the main power disconnect are shown on the electrical schematics attached as Attachment 3. All piping connections to the system are listed in Attachment 4. We would advise the customer to install an isolation valve on any line where there is not one from the factory EXCEPT the water discharge from T-101. It is important that there not be any restrictions in this line. T-101 is designed to gravity flow to the ocean. This is clean water that has been tested and the system will not allow water into this tank that does not meet the ppm requirement. Any restrictions in this line will plug up the whole system.

2.3 Power Test

After the installation of power and before any water is put in the system the pumps should be checked for proper direction of rotation. They will come from the factory all tested so if you test the rotation of 1 pump (either P-101 or P-102) you will know that the rotation is correct for all pumps.

Check that power has been connected and verified to the Main Disconnect. Turn on the main disconnect. The PLC panel should power up. Go to either the PID or Main Console screens. The system can be started from either of these screens. Turn the system switch to Manual and bump any one of the pumps. Have someone watch the blower end of the pump motors to verify the direction of pump rotation. P-101, P-102, P-105 and P-106 rotate clockwise. P-103 and P-104 rotate counter clockwise when looking at the blower end. If necessary correct the wiring for the proper pump rotation. Switch the main system switch to off. Do not make any


changes to the internal wiring. The only requirement is to connect the main feed. You only need to check one pump since the whole system has already been verified at the factory.

2.4 pH Probe Installation

Remove the pH probe port plug. Remove the protective wrapping from the probe. Remove the cap on the end of the pH probe. This cap has liquid in it to protect it from drying out. Install the fitting in the pipe and tighten. Tighten the compression fitting on the probe.

2.5 UV bulb Installation

The UV consists of a glass tube, which separates the water in the system from the UV bulb. Remove the enclosure cover on the UV assembly. Install the O-ring and then the flat gasket onto the open end of the glass tubes. Carefully insert the glass tubes into the holes where the plugs were removed. There are internal supports at the end of the housing that the tubes must fit in. Carefully move the end of the tube around until it fits into the support. When this is accomplished screw on the seal nut. If the tube is not seated the seal nut will not go


on. Tighten the seal nut hand tight and snug. Do not tighten with a wrench. After the quartz tubes are properly installed, carefully insert the UV bulb. Before sliding the UV lamp all the way into the tube, connect the electrical plug to the bulb and finish inserting the bulb all the way into the tube. The metal housing of the plug should fit over the gland nut that holds the tube in place.

2.6 Initial Water Filling

The water tank (T-101) needs to be filled with clean water before the system can start up. This will provide the water to fill up the rest of the system and to test the system before introducing oily water. To fill up the tank connect a hose to the T-101 drain and fill until water comes out the overflow. Once the water tank is filled the system will be filled automatically from the water tank. The control system includes an INITIAL FILL sequence. The instructions for this sequence are built into the control system. It will take you through the process step by step. The INITIAL FILL is only used when the system is empty at the initial startup or when the system is emptied for maintenance. It should not be used in normal operation.

2.7 OCM and Turbidity Test

Zero the OCM meter by doing the following. Open the top of the OCM cell and fill with clean water. Open the plug on the bottom fitting to drain the OCM cell if necessary. Replace the top plug. Set the display switch to the OCM position. Adjust the potentiometer on the right side of the OCM electrical enclosure until the display meter reads 0.00. This sets the zero for the OCM. All other adjustments are factory adjustments and cannot be done in the field.

The following needs to be performed while the system is running with clean water. Open V-122, V-123, V-124, and V-125. This should establish flow through the OCM and Turbidity meters. The Turbidity meter should read less than 10 NTU. If not there may be red rust in the water system. This rust may have developed during shipping and having the system wet from testing and emptied before shipping. If this is the case, the system will need to be run with clean water until the turbidity is below 10 NTU or let it run in recycle mode until it clears up.


Using valves V-122, V-123, V-124 and V-125, the OCM and Turbidity can be set up to sample from prior to the sand filter or after. The corresponding valve positions are as follows:

The OCM meter will likely read 15 ppm when the turbidity is greater the 35 NTU.


OCM Reading fromVálvula Before the Filter After the Filter (Normal))V-122 Open (Abierta) Closed (Cerrada)V-123 Closed (Cerrada) Open (Abierta)

Turbidity Reading FromVálvula Before the Filter After the Filter (Normal)V-124 Open (Abierta) Closed (Cerrada)V-125 Closed (Cerrada) Open (Abierta)

3. OPERATION

3.1. Normal Operation

After all of the specified testing has been completed and the system has run satisfactorily with clean water then the system can be put in operation with oily water. Turn the system switch to automatic. This can be done either at the PID screen or the Main Console screen. From this point everything should be automatic. After the system has been put into operation care should be taken to not allow the separator tank to be emptied. The system is designed to operate without operator interface except in certain conditions as described below. :

3.2. Alarm and Action Conditions

There is 1 alarm condition and 4 action conditions that require operator response.

a. High Oil in Discharge Water Alarm—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. The alarm light on the control panel indicates that the system is in recycle and that oil greater then 15 ppm has been detected in the water. There is a delay before the recycle valve is actuated. This time delay can be changed by adjusting the value on the setpoint screen. In the case of a OCM alarm the operator does not need to do anything to the system—it will recycle automatically. However, the operator should check other plant conditions to determine what is causing the alarm.

b. High Turbidity Condition—If there is high turbidity in the water this can effect the oil in water reading and cause a false positive OCM monitor alarm. The system allows the turbidity sample to come either from the discharge from the oil separator (S-101) or the discharge from the polishing filter (F-103). Normally the system should be operated with the turbidity sampled from the polishing filter discharge to prevent false OCM alarms caused by turbidity. If the system is in alarm and the turbidity is above 35 NTU verify that the valves are set to sample from the polishing filter discharge.

c. Plugged filter—F-101 and F-102 are installed with a differential pressure transmitter (DPT 101 for the Y strainer (F-101) and DPT-102 for the sand filter (F-102) to indicate when the filter is plugged and needs to be cleaned. The exact differential pressure at which the filters should be cleaned will be established over time from experience. A routine maintenance schedule should be established for back washing the system. If the system will not process 7.2 m³/hr., one or both of the filters are likely plugged. If the turbidity is greater than 35 NTU under normal operations the sand filter is likely plugged.


The system has been programmed to automatically go into backwash mode under 3 conditions—when the differential pressure reaches a designated level OR based on a timer that can be set for a specified period OR when the system flow goes below a normal operating range. The customer can select which option fits the operating conditions best. The unit will not come preset from the factory. The customer will need to input the set points they wish to use.

d. Short-cycle condition—If the inlet pump is pulling air into the system, gas will collect in the top of the separator and force the oil down. This will cause the level sensor to read high oil level and will short cycle the oil discharge pump. This is a possible indicator that the external sump low-level switch is faulty or the system is pulling more water than the platform is generating. Check the sump level switch or adjust the system flow rate. If the inlet line is plugged, or the pre-filter is plugged, the separator will likely short cycle. Remove the restriction.

e. Excess flow condition—The system is designed to process 7.2 m³/hr (32 gpm). The pumps are capable of pumping the design capacity at 3 barg backpressure. If the back pressure is less (clean filters) the flow could be more than design. The system has an automatic flow control valve that will adjust the flow to the design rate. If the flow is set at lower than design rate the pump will compensate and increase the pump pressure. The pumps are not designed to operate properly except at design rates. Processing more than 7.2 m³/hr will reduce the effectiveness of the separator.

3.3. Backwash Mode

Backwash operation is automatic with 4 modes of operation. Option 1 is to have the backwashed controlled manually. Option 2 is to have the backwash controlled by a timer. Option 3 is to have the backwash controlled by the differential pressure across the filter. Option 4 is to have the backwash controlled based on the flow through the filter. When there is a loss of flow the backwash mode is initiated. Any of the options will work fine, although we do not recommend using the manual option in normal conditions. You can select which option you want to use from the Sand Filter Backwash Options Screen on the Display Panel. The backwash functions on the display panel are explained in greater detail in the next section.


4. CONTROL SYSTEM DESCRIPTION

The control system is a redundant Allen Bradley ControlLogics PLC system that has been pre programmed for easy operator interface. For questions regarding the programming or control system itself refer to the Allen Bradley manual and instructions. The following section will explain how the screens have been set up for operator interface. The screen shots that are shown below do not necessarily represent an actual state of the machine.

4.1 Main Screen

The system will automatically boot up to the main screen when powered. The PanelView screen is a touch screen. If it goes blank just touch the screen anywhere to bring it back up.

The following screen will come up whenever the system is turned on. The buttons give the operator various screen options for controlling and setting the system parameters. The system can be controlled either from the P&ID screen or the Console screen. The remaining screens are used to set the operating parameters or to display the status of key operating parameters. The button in the bottom right hand corner is exit out of this screen. If this screen is exited it will shut off the PanelView. You will find this same button on all of the screens. In the case of all other screens, pushing this button will exit to the previous screen or the main screen.


If you exit out of the main screen the following prompt will come up to make sure you really want to exit the system.

4.2 P&ID Screen

The P&ID Screen shows a picture of the system components and their status at any given time. You cannot change the settings for the pumps, valves, blowdowns, TPH or UV from this screen. However, it will show the status of all of these components during normal operations and during the Initial Fill procedure.

The system can be operated from this screen either in a manual or automatic mode. The manual mode would generally be used only for maintenance purposes to test individual components or sequences. The AUTO mode will turn on the system’s normal operating sequences.

The E-STOP is an emergency stop button that will shut the system down regardless of what is happening. This should only be used in emergency situations.

The INITIAL FILL button is used to initially fill up the system with water. Do not operate the system in AUTO mode without filling the system up with water first.

Manual valves are shown smaller than solenoid (SOV) or motorized (MOV) valves and they do not change color. They are shown for training purposes only. The indicators for LS102 and LS103 turn green when the PLC is receiving a signal from them. The actual state of the liquid inside the tank is shown by the light blue indicators inside the tank. Same with the separator tank level LS101.


(Note: This screen shot does not represent an actual state of the machine.)

4.3 Console Screen

The CONSOLE SCREEN, shown below, provides the ability to start the entire system, either in manual or automatic mode. The system can be started or stopped either from the P&ID SCREEN or the CONSOLE SCREEN. This screen also includes an emergency stop button.

The primary purpose of this screen is to enable or disable various backwash and pump options.

This screen will also display a log of various alarm conditions and messages and allows you to silence the alarms.



4.4 Initial Fill Screen

The INITIAL FILL screen is used ONLY during initial startup or after a major maintenance process to fill the system with water prior to operating the system. This screen has a series of instructions that will walk the operator through the initial fill procedure. After each instruction is completed push the NEXT button to go to the next step or push the PREV button to go back to an earlier step. This is a function that is done only when the system does not have water, such as initial startup or after a major maintenance function. The INITIAL FILL is not used in normal operations to fill the system up after an oil discharge.

The INITIAL FILL procedure can only be started from the P&ID screen. Once the INITIAL FILL button is pushed on the P&ID screen the INITIAL FILL SEQUENCE screen will come up and provide the instructions for how to proceed. The P&ID screen will show orange rectangles around the tanks, valves or pumps that are affected in each step.



4.5 Overview ScreenThe OVERVIEW Screen below shows the status of the key variables that are being controlled. It shows the outlet flow, the differential pressure of F-101 and F-102, the pH, the turbidity and the oil content. It also shows the status of each of the pumps


4.6 Valves Screen

This screen shows the status of the valves. You cannot control the valves from this screen.


4.7 Pumps Screen

The pump screen shows the status of the pumps and is also used to select the pump that will be running. The system will not switch back and forth between pumps. If you want to switch pumps it has to be done from this screen.


4.8 Y Strainer (F-101) Blowdown Screen

This screen is used to set the parameters for the Y strainer (F-101) blowdown. The first line shows the amount of time that the blowdown will be running. Normally the blowdown should not be more than 1 minute. There is a counter on this clock showing the number of seconds remaining for the blowdown.


The blowdown can be controlled either based on a fixed amount of time between each blowdown or it can be based on the pressure drop across the filter. The blowdown is programmed to take place during the fill mode, so the system does not need to shut down to blow down the Y Strainer. When the clock or the dPT says it is time for a blowdown the system will hold the blowdown in a waiting mode until the system goes into fill and then it will blow down the Y Strainer while the system is filling.

The “Time Based” method allows the operator to set the number of days or hours between each blowdown. This time should be set based on the experience of the operator about the normal operating conditions.

The “Pressure drop Based” method allows the operator to set the differential pressure that should be allowed. It also allows for the operator to set a delay so that the pressure has to reach the set point for a fixed amount of time. This prevents the blowdown from happening based on normal fluctuations in the differential pressure.


4.9 Sand Filter (F-102) Backwash Screen

This screen is used to set the parameters for the sand filter (F-102) backwash. The first line shows the amount of time that the backwash will be running. Normally the backwash should not be more than 10 minutes. There is a counter on this clock showing the number of seconds remaining for the backwash.


The backwash can be controlled either based on a fixed amount of time between each blowdown or it can be based on the pressure drop across the filter or it can be based on the overall flow through the system.

The “Time Based” method allows the operator to set the number of days or hours between each backwash. This time should be set based on the experience of the operator about the normal operating conditions.

The “Pressure drop Based” method allows the operator to set the differential pressure that should be allowed. It also allows for the operator to set a delay so that the pressure has to reach the set point for a fixed amount of time. This prevents the blowdown from happening based on normal fluctuations in the differential pressure.

The “Flow loss Based” method allows the operator to set the allowed flow loss before the system goes into backwash.

The operator can choose from any of these methods. Experience will determine which option is better.


4.10 Flow Control Screen

The FLOW CONTROL screen is used to control the flow control valve. The setpoint will generally be the design flow of 7.2 m³/hr. The system is not designed to deviate much from


setpoint. The PV shows the current flow rate. The CV shows the % the valve is open. These 3 factors are charted on the screen. Control is accomplished by an independent PID (Proportional – Integral - Derivative) algorithm in the PLC program. The PID controller compares the actual value of the flow (PV) with the desired set-point (SP) and by subtracting SP-PV calculates the error. This error, multiplied by the Gain, constitutes the proportional component of the control action CV. The integral factor keeps adding to the CV while the error is still present. At a reset value of 60 repeast/minute it will add 60 times the proportional response for every minute the error persists.

The gain and reset allow the operator to adjust the reaction time and speed for how the valve opens and closes. The flow control loop is extremely fast by nature. In the BOSS 32 TPX oil separator system, the distances between the pressurized tank, the control valve and the volumetric flow transmitter are small. Therefore, the dead band (the time between the moment the valve changes position and the transmitter sees a change in flow) and the lag (the capacity of the pipe and flow transmitter internals) are very small. We estimate them at 1 second each.

With those values in mind, good start values for the PID controller are:

Gain = 0.6

Reset = 60 repeats/minute

Those values should provide a quick reaction time and a 1/4 amplitude response (the second overshoot after a set-point change should less than 1/4 of the first one).

If the process is slower than 1 second you will see oscillations. In that case, reduce the reset value to 30 repeats/minute and try again. If the process is faster than 1 second the original values should work as well. When the system is in MANUAL mode (selected from the P&ID or Overview screens, you can enter a desired control valve opening by touching the “Manual CV” button.



4.11 OCM / UV Screen

This screen allows the operator to set the alarm level for the OCM. It shows the set point limit and the actual measured oil content. The delay allows for minor fluctuations without alarming the system. The maximum delay is programmed into the computer and is set by IMO.

The UV Light screen allows the operator to set the number of hours of runtime before the UV light needs to be changed. The maximum runtime is 3000 hours. This is a maintenance feature to inform the operator when the UV light should be changed.

The oil pump delay allows the operator to set a delay before the oil pump comes on so that the oil pump will never be pumping dry.


4.12 Redundant System Architecture

The Allen-Bradley ControLogix system supplied includes two identical chassis that host a processor card, a redundant module, an Ethernet card and a ControlNet card each. A separate chassis includes two ControlNet cards and the I/O modules. There is a single ControlNet network that links all four ControlNet cards.

The two Ethernet cards share the same IP address and the two ControlNet cards (in the processor chassis) share the same ControlNet node number. When the Primary processor


goes down, the redundant modules sense the loss and switch the operation to the secondary processor. The second ControlNet card in the I/O chassis is required so the other ControlNet card in the I/O chassis will not go into the “alone” state while the processor chassis ControlNet cards are switching.

At the time of commissioning of this system (December 2009), Allen-Bradley does not offer firmware revision 17 for the redundant modules. For that reason, the processors and ControlLogix program are set at revision 16.xx. please do not upgrade the firmware or the ControlLogix program to revision 17.


5 TROUBLE SHOOTING:

The following suggestions are provided for situations that have been encountered in the past:

5.1 Solenoid Valve

If a solenoid valve does not work the most likely cause is a failure of the coil or a loose wire. You can verify the electrical continuity from the control panel. To replace the coil, turn off the power to the system, disconnect the wiring, remove the cover and replace the coil.

NEVER remove the coil with the power still connected. You will destroy the coil instantly if the coil is separated from the valve and the power somehow is either left on or gets turned on.

If the valve needs a new gasket or O ring turn off the power and make sure there is no power to the coil. Then loosen the nut just above the valve and remove the coil section. Replace the gasket/Oring and reassemble the valve. Do not turn the power back on until the valve is fully reassembled.

5.2 MOV

If an MOV is not functioning properly the first thing to check is the internal limit switch. Most of the problems with the MOV are with the internal limit switch. The normal symptom is that the MOV opens but fails to make full contract. The MOV opens but the other related valve(s) do not perform their normal function. If this happens you likely have a bad switch on the MOV and need to replace the switch.

5.3 Filters

There are a number of situations that can occur with the filters:

a. If there is turbidity in the water the OCM monitor can give a false oil content reading. The sand filter should prevent this from happening.

b. If you have high levels of emulsions and the organoclay is not removing the oil adequately, you may need to use carbon instead of organoclay or you can use a combination of carbon and organoclay. Carbon will work better for emulsions and organoclay will work better for free oil. If you use the combination you should load a bed of sand first, then carbon and then organoclay. The water goes down through the media. It is best to go through the organoclay first and then the carbon.

c. If you are running high concentrations of oil the primary separator may pass more than 15 ppm oil. The system will handle up to 100% slugs of oil and will handle 25% or more on a continuous basis. However, the water coming out of the separator will also go up in oil content. This is generally not a problem because the organoclay filter will remove the oil. However, the organoclay media will fill up faster and the media will need to be changed more often.

d. The organoclay works best in a downflow configuration, where the water goes down through the media. The oil content will be at least 5 ppm lower in a downflow configuration.


e. In most situations the organoclay will remove 100% of the free oil that goes through the filter. As the organoclay or carbon fill 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.

f. There are 2 ways to remove the filter media. Option 1 is to vacuum out the media with a shop vac or a vac truck. Option 2 is to blow the media out. Each filter has an inlet and an outlet nozzle at the bottom of the filter. Connect a water hose to the inlet pipe and a discharge hose to the outlet and turn on the water. The water will slurry the media and wash it out of the filter. 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. You will need to keep the media wet in order to vacuum it out. To replace the media, dump sand in the bottom up to about 6” above the bottom distributor, then add organoclay to about 8” from the top distributor. Any combination of sand, carbon and organoclay is possible depending on your situation. If you have a lot of turbidity add more sand (up to half). If you have more emulsions add more carbon. If you have high concentrations of oil use more organoclay. You can purchase pre-measured buckets of sand/carbon/organoclay from the factory or your distributor.

You can also hire a local filter company (such as US Filter) to change the media. They will come out and vacuum out the filter and replace the media.

h. Sometimes a high OCM reading has nothing to do with the filter 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.


6 MAINTENANCE

The separator system may require periodic maintenance on or replacement of the components shown in the spare parts list below. The following items may require periodic maintenance at specific intervals.

A. Pump—The centrifugal pumps installed on the system do not require lubrication. The mechanical seal should be replaced periodically or when it fails. The progressive cavity and gear pumps should have a routine maintenance schedule to replace the rotors and stators.

B. Valves—The solenoid valves installed on the system are high quality marine grade valves and do not require lubrication. If sand particles get into the solenoid valves it can cause them to leak and they will need to be cleaned. The coils and gasket may need to be replaced periodically. NEVER remove the solenoid from the valve with the power on. This will IMMEDIATELY destroy the coil and will void any warranty on the valve.

The most common maintenance on the motorized ball valves is the replacement of the switch. On rare occasions the switch will open or close but not make full contact.

C. OCM Monitor—The OCM will need a periodic check of zero against clean water, and frequent cleaning of the glass sample cell. Any maintenance on the OCM will require the unit to be sent back to the factory for repair.

D. Coalescing Media—The coalescing media in the separator should last for several years. It does not require specific maintenance or replacement under normal operating conditions. If the media is damaged by adding chemicals to the water or for some unusual reason you should do the following in order to change out the media:

1. Remove the old media. This is easier if you make a hook using a small diameter rod. Shove the rod down the side of the media. Turn 90 degrees so the hook part is under the media and use the hooked rod to pull the media up.

2. The replacement media should come packaged with an inner section and an outer section. The inner section should come partially shoved inside the outer section. Remove the inner section.

3. It 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 but not too tight. If the section is too large you may need to trim a small amount off the roll. To do this just cut off the excess with a utility knife.

4. It is easier to push the media into the vessel with 2 people. Both people can help get the media started about 1/3 of the way. Then use the round piece of wood to put on top of the media and push down uniformly.

5. Repeat the same process for the other section of media. The inner section should be pushed down about 1-2 inches below the weir. The outer section should be pushed down just below the weir.


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

F. Controls 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.

7. SPARE PARTS

The following list shows the available spare parts that could be needed for routine maintenance and repair of the Recovered Energy platform oil/water separation system. In the case of valves, OCM, turbidity, UV and pH, we recommend that the customer spare a complete assembly plus rebuild components. That way if a component breaks down the spare assembly can be installed and the rebuild kit can be used to repair the component that failed and the customer will always have a functioning spare.

7.1 Pumps

a. Complete pump assembly including motor for each type of pump:

Separator pump P101,P102 CPML-67 SCQM 2 HP EX...................(1)Backwash pump P105,P106 CDU 120/315X3C 1.5 HP EX..............(1)Oil pump P103, P104 VP G475MIRVX ¾ HP EX..................(1)

b. Pump repair/rebuild kits:

Hydrocyclone pumps. Rotor, stator, flex coupling, shaft seal, CPML67REPKIT.............................................................(1)

Separator and backwash pumps. Impeller, shaft seal, cover O-ringCDU120REPKIT..............................................................(1)

Oil pumps gear head assembly 6475MIRV ...................................(1)

7.2 Valves

a. Complete valve assembly for each type of valve

SOV-102 F35A46B 1.5”...........................(1)SOV-101, 103 F18A44B 1”..............................(2)SOV-104 F18A43B ¾”.............................(1)MOV-101, 102 ABV1U1103-EX 3/4" ......................................(2)MOV-103 ABV1U1206-EX 1.5”...........................................(1)FCV-101 ABV1U1203-EX ¾” w/positioner.....................(1)

b. Valve repair/rebuild kits:


coil for SOV-102 A3-120vac.................................................(1)coil for SOV-101, 103, 104 A2-120vac.................................................(3)Bonnet O-ring and valve seal: SOV-102 35A46-1.5-S .......(1)Bonnet O-ring and valve seal: SOV-101, 103 18A44-1-S.............(2)Bonnet O-ring and valve seal: SOV-104 18A43-3/4-S..........(1)Switch for MOVs ...............................(3)

7.3 Monitoring Equipment

a. Complete units:

OCM monitor complete unit OPM2-2 .....................................(1)Turbidity readout and sample chamber T53A4A15 / AC4A1A0N.........(1)PH transmitter PHTX-212....................................(1)PH electrode PHE 5460 ....................................(1)Level relay 16M..............................................(1)Endress & Hauser flow meter 50P25 ELOA1RAOB 1”.............(1)Sailsors DPT V6DP 5E-CO-E-B1-V1-W2........(1)

b. Spare consumables and repair parts:

Main panel four position switch GOL54H8....................(1)Main panel three position switch G0L53C3.....................(1)Main panel amber light lens guard assembly GOL3A........................(1)Main panel green light lens guard assembly GOL3G........................(1)Main panel clear light lens guard assembly … GOL3C........................(1)Bulbs for light 800T-N320A...............(2)Bulbs for light 800T-N320G...............(2)Bulbs for light 800T-N320C................(2)Motor starter MS25-1000..................(1)Connector 153...............................(1)Connector 753...............................(1)15A fuses ATDR15......................(2)2.25A fuses ATQR2 ¼ ...................(2)6A fuses ATQR6........................(2)Contactor GH15BN-3-10A..........(1)Control transformer CO150E2A..................(1)PLC base unit 1764-24BWA..............(1)PLC processor 1764-LSP.....................(1)OCM Sample chamber quartz tube 101597-1......................(1)OCM sample tube o-ring D0127..........................(4)OCM detector assembly 200070-1......................(1)OCM silica gel pack 107717-1 .....................(3)OCM main circuit board 107803-2 ....................(1)OCM relay module 911341 ........................(1)OCM .5 amp breaker S272-K0.5 ..................(1)


OCM 4 – 20 mA safety barrier 728+ ............................(1)OCM Detector safety barrier 760AC ........................(1)Turbidity flow chamber cover 8220C2F1076..............(1)Turbidity flow cover O-ring 5H1288 .....................(1) Turbidity light source retainer clip 8220F1078 ..................(2)Turbidity 3 way sensor valve and hoses 8320A1074-001 ..........(2)Turbidity complete flow chamber assembly 8220G1090-004 ..........(1)Turbidity baffle assembly 8220G1060 .................(1)Turbidity LED source assembly 8220G1320-104 ..........(1)Turbidity Detector assembly 8220G1330-104 ..........(1)Turbidity LED or detector assembly O-rings 5H1251 ..............(6)PH calibration solution packs--PH4 20 packs PHA-20-4....................(1)PH calibration solution packs--PH7-20packs PHA-20-7....................(1)PH calibration solution packs--PH10 20 packs PHA-20-10 .................(1)PH electrode mounting gland PHEH-54-10 ...............(1)Ultraviolet (UV) quarts sleeve 15-1274A.....................(2)UV lamps 05-1382R.....................(3)UV master static gland 25-1027A.....................(3)UV nylon static gland nut 25-1492D.....................(3)UV Teflon sealing washer 25-1235A.....................(3)UV gland O-ring 00-1108B.....................(3)UV lamp socket 05-0164A.....................(3)UV quartz sleeve o-ring 00-1238A.....................(3)UV end cap 25-1499A1...................(3)UV rubber ball 00-0031........................(3)UV transformer -- single SM1E40-S-TP.............(1)UV transformer -- double SM2E40-S-TP.............(1)

7.4 PLC

7 Slot Chassis 1756-A7.......................(2)10 Slot Chassis 1756-A10....................(1)Cnet Bridge Gen 2 1756-CN2 .................(2)ControlNet Bridge Module 1756-CNB...................(2)Ethernet / IP Module 1756-EN2T..................(2)30 VDC 20 Pin 16 Pt Input 1756-IB16....................(1)Analog Input 1756-IF8......................(1)Processor 1756-L61.....................(2)20 Pin Analog Output 1756-OF4....................(1)16 Pt Relay Output 1756-OW16I................(1)Redundant Power Supply 1756-PAR2..................(1)265V Power Supply 1756-PA72..................(2)Redundancy Module 1756-RM.....................(2)36 PN Screw Clamp Bloc 1756-TBCH.................(2)20 PN Screw Clamp Bloc 1756-TBNH.................(2)Terminator Plug` 1786-XT......................(2)


Straight T Tap 1786-TPS.....................(4)Touch Screen Monitor 2711P-T15C4D2.........(1)Unmanaged Switch 1783-US05T................(1)

7.5 Miscellaneous

Organoclay charge BOSS 25--OC .............(1)Top flange gasket for 45 GPM separator BOSS 45 gasket ..........(1)Top flange gasket for sand filter BOSS filter gasket-8 ...(1)


O&M ManualATTACHMENT 1 - P&ID DRAWING


O&M ManualATTACHMENT 1 – ELECTRICAL SCHEMATICS










O&M ManualATTACHMENT 3 - CALIBRATION SHEETS


O&M ManualATTACHMENT 4 – CALCULATIONS

Calculation Data

1. Separator Vessel S-101

The separator vessel is designed for a 7.8 minute retention time. The normal design is a 5 minute retention time but the system design does not fit a standard certified size so the system is sized for the next size up standard certified size. The time is divided between the inside and outside compartments.

Inner compartment 24” x 42” = 82.60 gal.Outer compartment 42” x 42” = 251.9 – 82.60 = 169.30 gal.

251.90 gal.

Divided by 32 gpm = retention time 7.8 minutes

2. Organoclay Filter F-103

The organoclay has a 4.84 minute retention time.

30” diameter x 48” between distributors = 154.88 gal.

Divided by 32 gpm = retention time of 4.84 minutes

3. Sand Filter F-102

The sand filter is designed for no more than 12 gpm per square feet of surface area.

24” diameter = 3.14 sq. ft.32 gpm / 3.14 = 10.2 gpm / sq. ft.

The backwash pump for the sand filter is designed for at least 15 gpm per sq. ft surface area.

24” diameter = 3.14 sq. ft.15 x 3.14 = 47.1 gpm required. The pump curve shows that the pump will produce 60 gpm at 3 barg pressure


Documents

B91002_OM_Manual[1]