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BOSS OIL WATER SEPARATION

SYSTEM FOR PLATFORMS

OPERATIONS
&
MAINTENANCE
MANUAL

O&M Manual Page 1 12/08/21

 O&M MANUAL
VOLUME I
TABLE OF CONTENTS

1. SYSTEM DESCRIPTION:................................................................................................3
1.1. Components by System.................................................................................................3
a. Pre-filter system.............................................................................................................3
b. Oil water separator system...........................................................................................3
c. Filter/Polishing System..................................................................................................4
d. Filter Backwash System................................................................................................4
e. OCM/turbidity Monitoring...........................................................................................4
f. Electrical/Controls.........................................................................................................5
1.2 Process Description........................................................................................................5
1.2.1 Pre-Filtration System:............................................................................................5
1.2.2 Oil Water Separator System..................................................................................5
1.2.3 Filter/Polishing System:..........................................................................................6
1.2.4 Filter Backwash/Blowdown System......................................................................7
1.2.5 OCM and Turbidity Monitoring System..............................................................8
1.2.6 Ultraviolet Sanitizing..............................................................................................8
1.2.7 Area Classification (Class I, Div II).......................................................................9
1.3 System Specifications.....................................................................................................9
1.4 Fault Alarms and Remote Monitoring Capabilities...................................................9
2. STARTUP..........................................................................................................................11
2.1 Factory Testing/Delivery.............................................................................................11
2.2 Installation....................................................................................................................11
2.3 Power Test....................................................................................................................11
2.4 pH Probe Installation..................................................................................................12
2.5 UV bulb Installation....................................................................................................12
2.6 Initial Water Filling.....................................................................................................13
2.7 OCM and Turbidity Test............................................................................................13
3. OPERATION.....................................................................................................................15
3.1. Normal Operation........................................................................................................15
3.2. Alarm and Action Conditions.....................................................................................15
3.3. Backwash Mode...........................................................................................................16
4. CONTROL SYSTEM DESCRIPTION...........................................................................17
5 TROUBLE SHOOTING:.................................................................................................29
6 MAINTENANCE..............................................................................................................31
7. SPARE PARTS..................................................................................................................32
7.1 Pumps............................................................................................................................32
7.2 Valves............................................................................................................................32
7.3 Monitoring Equipment................................................................................................33
7.4 PLC...............................................................................................................................34
7.5 Miscellaneous...............................................................................................................35
ATTACHMENT 1 - P&ID DRAWING..............................................................................36
ATTACHMENT 1 – ELECTRICAL SCHEMATICS.......................................................37
ATTACHMENT 3 - CALIBRATION SHEETS.................................................................46
ATTACHMENT 4 - CALCULATIONS..............................................................................47

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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 system
MOV-102 Inlet shutoff valve
F-101 Inlet filter Y strainer
F-104 Hydrocyclone particulate filter
V-102 System isolation valve
G-103 Inlet pressure
V-105 Sample valve
V-104 Vent valve
CV-101 F-104 return check valve
V-103 F-104 effluent isolation valve

b. Oil water separator system

(see Arrangement Photo—Attachment 2a)

S-101 Coalescing separator

P-101 Process pump
P-102 Process pump
PRV-101 Pressure relief for P-101 and P-102
CV-102 Separator inlet check valve
CV-105 P-101 outlet check valve
CV-106 P-102 outlet check valve
V-130 P-101 isolation valve
V-131 P-102 isolation valve
G-101 Pump discharge pressure gauge
CV-107 Turbidity / OCM protection valve
V-143 Pre filter sample valve
V-101 Separator vent valve
V-106 S-101 center drain
LS-101 Separator oil level switch
MOV-101 Oil discharge control valve
V-107 P-104 suction valve
V-108 P-103 suction valve
P-103 Oil discharge pump

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 P-104 Oil discharge pump
CV-103 P-103 outlet check valve
CV-104 P-104 outlet check valve
G-104 Oil discharge pressure gauge
SOV-104 Makeup water control valve
SOV-102 Discharge control valve
SOV-101 Recycle control valve

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

F-102 Turbidity filter

F-103 Polishing filter
V-134 F-102 drain valve
V-135 F-102 vent valve
V-137 F-103 drain valve
V-136 F-103 vent valve
FCV-101 Flow control valve
FM-101 Flow meter
UV-101 Ultraviolet sterilizer
AI-102 pH meter
TG-101 Temperature gauge
V-142 UV drain valve / sample port

d. Filter Backwash System

(see Arrangement Photo—Attachment 2b)

P-105 Backwash pump

P-106 Backwash pump
CV-108 P-105 outlet check valve
CV-109 P-106 outlet check valve
V-138 P-105 isolation valve
V-139 P-106 isolation valve
G-102 Backwash pump pressure gauge
CV-110 F-102 inlet check valve
DPT-102 F-102 differential pressure transmitter
SOV-103 F-102 backwash control valve
MOV-103 F-101 blowdown control valve
DPT-101 F-101 differential pressure transmitter
T-101 Backwash water storage tank

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

AI-101 OCM monitor

V-125 OCM post filter sample valve
V-124 OCM pre filter sample valve
V-121 OCM sample return valve

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 AI-103 Turbidity monitor
V-123 Turbidity post filter sample valve
V-122 Turbidity pre filter sample valve

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

P1 Power disconnect
P2 Electrical panel
P3 PLC and Panel View display
AI-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 System

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

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 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

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 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

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 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

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 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. Dimensions
Length 157” –62.3 cm
Width 126” – 49.6 cm
Height 102” – 40.2 cm
Weight 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 barg
d. F-102 operating pressure— < 4.5 barg
e. F-103 operating pressure— < 4.5 barg
f. T-101 operating pressure— atmospheric vessel
g. System test pressure – 6.3 barg
h. Operating temperature range—5 to 60 C
i. Maximum oil concentration—35%
j. Maximum specific gravity of oil to achieve design separation—0.95
k. Oil in water discharge-- <15 ppm
l. Maximum turbidity for accurate OCM reading—35 NTU
m. 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 card
b. loss of communication between the display and the detector (loose cable)
c. internal board or power supply failure

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 (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 alarm
c. 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.

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2. STARTUP

2.1 Factory Testing/Delivery

Prior to delivery the system is tested in the manufacturers shop to verify that the
system is watertight and that all the pumps, 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

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 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

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 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.

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 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:

OCM Reading from

Válvula Before the Filter After the Filter (Normal))
V-122 Open (Abierta) Closed (Cerrada)
V-123 Closed (Cerrada) Open (Abierta)

Turbidity Reading From

Válvula Before the Filter After the Filter (Normal)
V-124 Open (Abierta) Closed (Cerrada)
V-125 Closed (Cerrada) Open (Abierta)

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

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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.

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 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.

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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.

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 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.

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(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.

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

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.

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O&M Manual Page 21 12/08/21
 4.5 Overview Screen
The 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

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

4.6 Valves Screen

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

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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.

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

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.

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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.

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

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.

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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.

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

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

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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.

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

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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.

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

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

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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.

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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.

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 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.

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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.

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 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-ring
CDU120REPKIT..............................................................(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:

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 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)

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

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 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)

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 O&M Manual
ATTACHMENT 1 - P&ID DRAWING

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 O&M Manual
ATTACHMENT 1 – ELECTRICAL SCHEMATICS

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O&M Manual Page 38 12/08/21
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 O&M Manual
ATTACHMENT 3 - CALIBRATION SHEETS

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 O&M Manual
ATTACHMENT 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

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