ACO Oleopator P NS6/660 1, Oleopator P NS10/1080, Oleopator P N 3/950, Oleopator P NS3/670, Oleopator P NS3/450 Operating Manual

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Light oil and sediment

separator system

ACO Construction & Building Products

ACO Environment

Oleopator P Oil Water Separator Operating Guide

1. Installation

2. Initial set-up/commissioning

3. Operation

4. Maintenance

System Components

Load

distribution

plate***

Extension

shaft

Cover

Adapter

plate *

Float

Bypass

inlet**

Inlet

connections

Inlet pipe

Bafe plate

Tank

Identication

plate

Coalescence

insert

Bypass

outlet**

Outlet

connections

Sampler

connections

Outlet pipe

*only with load class D **not used

***Cast on site by others; only class D (40 ton)

The ACO Oleopator P is a range of oil separators that allow sediments and oils to be separated out simultaneously in one tank. Separator systems are available with a range of different sludge and oil capacities to suit specific site requirements.

Class I light-oil separators

Alarm sensor systems are available to notify personnel when maintenance is required. Oil level sensors are required for compliance with UL 2215.

Include a coalescence unit which traps the

smallest oil drops that are too small to oat

to the surface naturally and coalesces them to form larger oil drops capable of being separated out.

Capable of achieving efuent quality of 5 parts per million (ppm). Certied to EN 858.

Bypass separators

A bypass version is available for when full

treatment of large ows is not required; ‘rst-ush effect’ theory. The unit will fully treat ows until it reaches maximum inow volume (GPM) at which point additional inow

bypasses the separator and diverts directly to the outlet pipe. Typically most pollutants are washed into the separator during the

initial ow so efuent quality is not drastically

affected.

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Contents

1. Safety Considerations

1.1 Designated use __________________________________________________________________________________________4

1.2 Qualifications of personnel ______________________________________________________________________________4

1.3 Personal safety equipment ______________________________________________________________________________4

1.4 Responsibility of the owner _____________________________________________________________________________4

2. Installation

2.1 On-site handling _________________________________________________________________________________________5

2.2 Ground conditions _______________________________________________________________________________________5

2.3 Separator positioning ____________________________________________________________________________________6

2.4 Installation ______________________________________________________________________________________________7

3. Initial Set-up

3.1 Prior to filling the system _______________________________________________________________________________8

3.2 Filling separator system _________________________________________________________________________________8

4. Operation

4.1 Entering the separator __________________________________________________________________________________9

4.2 Oil/Sludge level sensors _________________________________________________________________________________9

5. Maintenance

5.1 Maintenance schedule _________________________________________________________________________________ 10

5.2 Cleaning coalescing units ______________________________________________________________________________ 11

5.3 Oil/Sludge disposal ____________________________________________________________________________________ 11

5.4 General inspection ____________________________________________________________________________________ 11

Product Information

Detailed product information available in product catalog, spec info sheets or

on-line.

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1. Safety considerations

The safety guidelines in this chapter are to be read before using the separator. Serious injuries or death could occur as a result of misuse.

1.1 Designated use

1.1.1 Areas of Application

Oleopator separators are designed to remove mineral light liquids from wastewater.

Applications where mineral oils or mineral light liquids are able to enter the sewer system should have separator systems connected downstream from drainage collection points. Such applications include petrol stations, parking lots, roadways, car washes, engine washes, garages, vehicle recycling, scrap yards, fueling stations, tank pits and transformer stations.

Stormwater from areas where no light liquids accumulate, such as roofs and courtyards, should not be fed into separator.

Separators should be installed such that no light liquids can escape in the event

of backow from the sewer or automatic closure of the oat. An automatic alarm

may be required. Regulations may vary by state.

1.1.2 Limitations

The separators are not to be installed for residential wastewater.

When delivering waste water into the public sewer system, the local hydrocarbon limits should be observed. Further treatment may be required.

1.1.3 Foreseeable misuse

No substances that pollute the water or limit

the functionality of the separator should be introduced into the separator.

This is particularly important in regard to:

• wastewater containing feces,

• wastewater containing animal or

vegetable greases,

• wastewater in which a considerable

amount of stable emulsions is present.

1.2 Qualifications of personnel

All work performed on the separator equipment is to be carried out by trained personnel.

1.3 Personal safety equipment

Personal safety equipment is necessary for a variety of works on the separator.

1.4 Responsibility of owner

The owner is responsible for complying with the following points:

• Only operate the separator according to

regulations and in proper condition

• Ensure that function of protection

devices is not impaired

• Adhere to a scheduled maintenance

program and immediately repair faults. Only repair faults yourself if the measures are described in these operating instructions. Contact ACO for all other measures

• Inspect data plate on the separator for

completeness and legibility

• Adequate personal safety equipment

must be available and used

• Provide complete and legible operating

instructions at the separator’s site of

installation and training based on this

• Only employ qualified and authorized

personnel.

Health & Safety

Safety instructions are intended to prevent damage to equipment or injury to personnel and must be read before any maintenance is performed.

The separated oils and any vapors are

ammable and/or combustible so care

must be taken whenever the system is opened.

• All safety instruction labels must be

replaced if they become detached or illegible.

• Gas concentrations MUST be tested

before entering the separator;

breathing apparatus is recommended for all personnel entering separator.

• Safety lines, harness and radios/

whistles are advised if entering separator.

• Smoking and naked lights are

strictly forbidden anywhere in area surrounding the system.

• Installed devices (e.g. bafes,

inlet and outlet parts, coalescence element, etc.) are intended for operation of separator system and

are not load bearing - they must

not be used as steps, footholds or resting places for cleaning equipment etc.

• The separator system is dened

as a zone 0 explosion hazard area.

Only authorized, properly trained, personnel are permitted to perform work on the electrical components of the separator (where used).

• Contact with wastewater containing

light liquids, e.g. during maintenance, can lead to dry, irritated skin, skin infections, headaches, dizziness, nausea, vision problems, loss of consciousness, and, in serious cases,

death. Ensure proper protective

clothing is used and immediately

wash any exposed skin.

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2. Installation

Oleopator separators are intended for

in-ground installation. Care must be taken

to determine correct installation to take into

account site loadings and trafc patterns.

Details are provided for light duty and heavy duty applications.

Inspect Oleopator upon delivery and before installation to check for damage that may have occurred during shipping or at the job site prior to installation.

Light oil separators can be extremely large (depending upon ow and holding capacity)

ensure correct equipment is available for proper unloading, moving around site and

lowering into required nal position.

Remove oats and lters during installation

and protect separator openings from site

run-off as stones and debris may cause

surface damage inside the separator.

2.1 On-site handling

2.1.1 People

Carry separator with 2 people using circular ring as a grip and pipe connections for additional stability. NOT suitable for single person lift.

2.1.2 Crane

Sling attachment points are provided for proper handling of the tank.

DO NOT transport separator with extension shaft sections and/or covers assembled.

2.2 Ground conditions

Where groundwater is present, certain additional measures may need to be taken to prevent lifting.

Pedestrian applications - if groundwater level is less than 20” (0.5meters) below

grade no additional measures are required.

Where groundwater level is higher than 20” (0.5meters) below grade, an on-site 63” (1600mm) dia x 6” (150mm) thick concrete ring is cast in-situ over the large, lower

tank ridge (see diagram) to avoid

‘oating’.

Heavy duty applications - no additional

measures are required.

max 19.7”

(500mm)

min 6”

(150mm)

min Ø 63” (1600mm)

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2.3 Separator positioning

The purpose of a separator is to collect light oils for proper disposal. Timely emptying and maintenance is critical for effective operation. Alarm systems can help

Super elevated positioning is where the cover of the separator is higher by a minimum height (V) than the collection

xture.

ensure light oils and sludge are removed in a timely fashion and can alert potential maintenance issues.

Alarm failure (or failure to action alarm

alerts) and back ow from sewer are

potential causes of operation error and pollution.

These can be overcome in certain applications by adjusting height of separator

relative to collection vessel/drain.

Installation situation

Super elevated

No No Yes

positioning

Alarm system No Yes No

Ready for

use

V - Super elevated positioning

Cover

Cover &

only

Size Pedestrian

NS3/450 1.78 (45) 2.75 (70) 5.90 (150)

NS3/670 1.78 (45) 2.75 (70) 5.90 (150)

N 3/950 1.78 (45) 2.75 (70) 5.90 (150)

NS6/660 1.57 (40) 2.56 (65) 5.71 (145)

NS6/1210 1.57 (40) 2.56 (65) 5.71 (145)

NS10/1080 1.97 (50) 2.95 (75) 6.10 (155)

Shaft

in (mm)

Cover &

Shaft

Heavy duty

in (mm)

Yes

Normal operation Normal operation Normal operation Normal operation

Max. oil =

float closure

= blockage

Oil will leak from cover Alarm will alert and

Backflow

Operating situations

from sewer

Oil will leak from cover -

unless a backflow prevention

pump is used downstream

from separator

oil will leak from cover

Alarm will alert and oil will

leak from cover - unless a

backflow prevention pump

is used downstream from

separator

Oil will stay in separator,

wastewater will flood from

collection fixture

Oil will stay in separator,

wastewater will flood from

collection fixture

Alarm will alert and oil will stay

in separator, wastewater will

flood from collection fixture

Alarm will alert and oil will stay

in separator, wastewater will

flood from collection fixture

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2.4 Installation

Load distribution plate Ø 61.0”/33.5”x8.0” (1550/850x200mm)

Concrete: 5,000psi (35MPa) Concrete Steel: #4 rebar (10M) Concrete Cover: 1.2” (30mm)

(150mm)

(115mm)

Cross section

2.4.1 Light Duty Installations

1. Excavate area 60” wider and 12”

deeper than the separator; this allows for a 12” aggregate base compacted

to Proctor density 97%.

2. Check level of unit and inverts of inlet/

outlet pipes

3. Backll around unit to the level of

inlet/outlet pipes (backll should be 2-16mm sand/gravel); take care when compacting ll not to damage separator

4. Connect inlet/outlet pipes - pipes

should be resistant to hydrocarbons.

Flexible couplings will be required as inlet/outlet pipes are metric dimensions

5. Inlet pipes should be installed with

as few bends and slopes as possible to prevent blockages and reduce turbulence of incoming wastewater

6. Install extension shaft (if used) - cut to

required height, place seal in lowest notch of remaining section. Grease seal

and tank collar with acid-free grease to

ensure watertight seal.

7. Install wiring conduit for alarm system

(if used)

8. Recheck levels

9. Continue to backll and compact

10. Install cover with 4” deep concrete

collar to ensure it is held securely in place

11. Install alarm sensors (if used)

2.4.2 Heavy Duty Installations

1. Excavate area 60” wider and 12”

deeper than separator; this allows for a full 12” concrete encasement

2. Check level of unit and inverts of inlet/

outlet pipes

3. Pour concrete to level of inlet/outlet pipes

4. Connect inlet/outlet pipes - pipes

should be resistant to hydrocarbons.

Flexible couplings will be required as inlet/outlet pipes are metric dimensions

5. Inlet pipes should be installed with

as few bends and slopes as possible to prevent blockages and reduce turbulence of incoming wastewater

6. Install extension shaft - cut to required

height, place seal in lowest notch of remaining section. Grease seal and

tank collar with acid-free grease to

ensure watertight seal.

7. Install wiring conduit for alarm system

(if used)

8. Continue backfilling up to 8” (200mm)

below top of access shaft

9. Install reinforcement, form and pour

concrete load distribution plate - 8” thick and extending 14” around shaft in

all directions (see below for details)

10. Install cover, frame and concrete

adaptor plate to ensure it is held securely in place

11. Install alarm sensors (if used)

35 x #4 rebar @ 3.15” (10M @ 80mm) stirrups

8.0” (200mm)

6.0”

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13.75”

(350mm)

Typical reinforcement plan

61.0” (1,550mm)

Ø 33.5” (850mm)

4.5”

13.75”

(350mm)

3. Initial Set-up/Commissioning

3.1 Prior to filling the system

• Ensure all required air and water tests

are completed before finished installation of unit.

• All system components; baffles,

coalescing units and internal piping must be inspected to ensure that nothing is missing, loose or damaged.

• Installation of identification plate in

maintenance shaft as shown in diagram below. (This will assist in future maintenance and ordering of consumables etc.)

3.2 Filling separator system

• System MUST not be filled until

installation is complete and all mortared and sealed joints have been allowed to cure properly.

• System should be cleaned before use.

• Float MUST be removed before the

separator is filled. Failure to do so may cause outlet pipe to be blocked by float and improper functioning of separator may occur.

3.2.1 Removing float & coalescent

filter

1. Lift coalescence insert out of

separator via extension system .

2. Remove float , located in the

supporting cage .

3. Remove sheeting from coalescence

insert .

4. Store coalescence insert and float in

water, in safe place until separator is filled and they are required for reinstallation.

3.2.2 Filling procedure

1. Ensure inlet and outlet valves are open.

2. Fill separator with clean water, either

via manhole cover or inlet/trench drain.

3. When separator is full, water will

start to ow out of outlet; this can be identied from outlet sampling chamber/hose (if used), or when water

Identification plate provides:

• Separator type identification

• Nominal size

• Class

• Number of the LGA Test report.

• Volume of separator and sludge trap

• Maximum storage volume and maximum

thickness of light oil layer

• Maximum permissible sludge thickness

reaches outlet invert using a depth gauge stick.

4. Allow water to continue to run to

check for blockages in outlet pipe - if

water depth remains constant then no

blockage exists. If water starts to back-

up, then an investigation into the cause of blockage is required.

5. Ret oat and coalescent lter.

6. Fit and check alarm sensors if used.

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4. Operation

The ACO Oleopator is designed to be easy to operate with minimal intervention required.

4.1 Entering the Separator

All relevant local accident prevention regulations must be strictly observed when entering a separator.

Size NS 3 to NS 10 Separators

Separators can be entered via maintenance shaft located above the float cage. The following steps ensure easy accessibility:

1. Clean out separator sludge/oils

2. Remove coalescence unit (if installed -

Class I separators only)

3. Remove float

4. Pull float cage from the holder and

remove it. (if possible)

The separator can now be entered.

Once all work has been carried out, ensure original condition of separator is reinstated:

1. Place float cage back in holder (taking

care to properly align pins in the cage)

2. Replace float after separator has been

filled

3. Install coalescence unit (if installed -

Class I separators only)

4.2 Oil/Sludge Level Sensors

Optional alarm system makes operation easier and ensures compliance with UL2215. It does not replace visual maintenance but ensures timely disposal of

oil and/or sludge to guarantee continued

operation of system.

Sensors will alert when;

• Oil has reached 80% maximum

capacity (once oil reaches 100% capacity oat will sink and close outlet

pipe)

• Sludge has reached 50% maximum

capacity (once sludge reaches 100%

capacity inlet pipe will become blocked)

• When liquids in the separator reach

a specic level, alarm indicates that

outlet pipe is blocked

• The oil sensor is also able to identify if

tank has failed and liquids are leaking into surrounding ground

When any of these events occur a signal is sent to the building management system which can send out audio, visual and SMS alerts to ensure maintenance can be carried out before the separator system fails.

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5. Maintenance

5.1 Maintenance Schedule

Table below provides a recommended schedule of maintenance and inspection to ensure trouble free operation of separator.

Note: Refer to 4.1 (Pg 9) Entering the

Separator before maintenance is undertaken

Measures What must be done? Who should do it? Interval

Visual

Inspection and

Maintenance

Disposal

(Service)

General

Inspection

• Check proper functioning of self-actuating closure

and coalescence unit in the separator

• Measuring thickness and volume of oil layer

separated out at top of separator

• Measuring height of sludge layer in sludge trap

• Empty and clean separator as required (see disposal

requirements).

• Remove any coarse floating material

• Inspect all components of alarm system (if used)

• Immediately rectify any faults identified

• Report findings and any work carried out in operating

The separator must be emptied when:

• 80% of the maximum oil storage volume has been

reached, and/or

• 50% of the max sludge trap volume has been

reached

• Separator must be emptied and contents properly

disposed of

• Inside of separator must be cleaned

• Check proper functioning of self-actuating closure

• Check water-tightness of the system

• Check condition of installed devices and interior

surface condition

Properly qualified operative

Properly authorized disposal company

Properly qualified technician

Maximum every 6

months and immediately after any large oil spill

incident and/or excessive rain storm

As required, but at least every year

Prior to initial use and then every five years.

ACO Control Kit

ACO offer a control kit to assist with

maintenance and inspection; the kit

contains: a dipstick, dipstick plate, water verification paste, pH indicator rods, operations log.

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5.2 Cleaning Coalescing Units

Coalescing unit must be removed periodically for cleaning, the separator is not functional during this process.

1. Ensure inlet / outlet valves are closed

2. Pull coalescence unit up above water

level in the separator, using a hoist where necessary

3. Allow water to drip into separator

before removing coalescing unit

4. Clean unit in bucket, or appropriate

area, to contain wastewater for proper disposal (contaminated water can be poured back into separator)

5. Completely remove all dirt by spraying

with clean water from either:

- a min. ¾ inch hose, under mains

pressure (min. 58psi), or

- a high pressure device at max

870psi and using cold water

6. Only use cleaning products when

absolutely necessary (ensure cleaning

agent will not damage separator;

consult cleaning product MSDS details for suitability), rinse thoroughly with a

high pressure device with max 870psi and 140 °F (60 °C)

Removing coalescence mats

Mats need only be removed from basket if soiling is particularly bad. Coalescence mats are attached to a supporting basket at top and bottom with tensioners and

Velcro strips (uffy side outwards). Once

these are removed, mat can be unwound from basket.

Replacing coalescence mats

To replace, wrap mat around supporting basket and replace tensioners and Velcro

straps (uffy side outwards). When

wrapping mat around basket ensure no openings are left that could allow

wastewater to ow through untreated.

Avoid wrapping coalescence mats too tightly to prevent damage.

Tip – Lengthy operational hold-ups can be prevented by swapping dirty coalescence units for clean back-up/spare coalescence unit. The dirty coalescence unit can be

stored in a water-lled container until, to prevent dirt drying hard onto unit, until it

can be cleaned.

5.3 Oil / Sludge Disposal

Maximum levels for emptying separator are

when:

• 80% of maximum oil storage has been

reached, and/or

• 50% of maximum sludge trap volume

has been reached.

Identication plate shows maximum thicknesses of each layer (identication

plate is located inside separator).

Even if levels remain below these limits,

separator should be emptied at least every year.

• Contents of separator must be

disposed of by authorized disposal company

• Care must be taken not to damage

inside walls and internal equipment of separator

• Rinse down walls and base of

separator using hot water to loosen hardened solids and suction out left over slurry

• Rell separator with clean water,

following initial set-up procedure (See

3.2 Filling separator system - Pg 8)

5.4 General Inspection

Prior to initial use, and thereafter at regular

ve yearly intervals, a “properly qualied technician”* must inspect the separator to

ensure it is in good condition and operating properly – separator must be completely emptied and cleaned before general inspection can be carried out.

An integral part of every general inspection

is a water-tightness test carried out in accordance with EN 858-2.

1. Close inlet & outlet pipes

2. Fill separator with water until full

3. Check for changes in water level

indicating possible leaks - investigate/ repair/replace as required

* “Properly qualied technician” is

dened as staff of independent companies, independent experts, or other institutions with certied special

technical knowledge on the operation, maintenance and testing of the separators described here, and have the necessary equipment.

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ACO Polymer Products, Inc.

West Sales Office

P.O. Box 12067 Casa Grande, AZ 85130 Tel: (520) 421-9988 Toll Free: (888) 490-9552 Fax: (520) 421-9899

Northeast Sales Office

P.O. Box 245 Chardon, OH 44024 Tel: (440) 285-7000 Toll free: (800) 543-4764 Fax: (440) 285-7005

Southeast Sales Office

4211 Pleasant Road Fort Mill, SC 29708 Toll free: (800) 543-4764 Fax: (803) 802-1063

Electronic Contact:

info@acousa.com www.acousa.com

All reasonable care has been taken in compiling the information in this document. All recommendations and suggestions on the use of ACO products are made without

guarantee since the conditions of use are beyond the control of the Company. It is the customer’s responsibility to ensure that each product is fit for its intended purpose

and that the actual conditions of use are suitable. ACO Polymer Products, Inc. reserves the right to change products and specifications without notice.

Re-order Part # EL014

ACO Oleopator P NS6/660 1, Oleopator P NS10/1080, Oleopator P N 3/950, Oleopator P NS3/670, Oleopator P NS3/450 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual