LIPUMAX-G GREASE SEPARATOR

Transcription

1 ACO Passavant Installation guide LIPUMAX-G GREASE SEPARATOR VERSION NO. IMPLEMENTED BY REVISION DATE REASON 1 Kate Jennings 29 September 2017 Amendments Water Corp 2 Kate Jennings 31 October 2017 Amendments Water Corp 3 Kate Jennings 19 March 2018 Product table update 4 Kate Jennings 12 th April 2018 Ventilation requirement (Water Corp) V4 PA0016 ACO, Old Bathurst Road, Emu Plains, NSW 2750 Tel: Fax: sales@acoaus.com.au

2 Contents 1 GENERAL SAFETY CONSIDERATIONS INSTALLATION MAINTENANCE WATER AUTHORITY APPROVALS CONTACT INFORMATION

3 1 GENERAL The ACO Passavant Lipumax-G grease separator is designed for below ground installation only. Lipumax-G grease separators are designed to remove waste Fats, Oils and Grease (FOG) from commercial tradewaste from applications such as commercial kitchens and food processing factories. They are not anticipated for use in residential applications. When discharging tradewaste into the public sewer system, local water authority requirements must be adhered to. 2 SAFETY CONSIDERATIONS All work in installing and maintaining this grease separator shall comply with requirements of the relevant authorities. 2.1 Site handling Inspect the Lipumax-G upon delivery and prior to installation, check for damage that may have occurred during transportation or at the job site prior to installation. Grease separators can be extremely large. To avoid damage to the grease separator, ensure that correct equipment (e.g. forklift, crane or sling ropes) is available for proper unloading and manoeuvring on site. Use lifting provisions (shown below). Note: separators may require a 3 tonne excavator to dig the required depth. 2.2 Foreseeable misuse No substances that pollute the water or limit the functionality of the grease separator should be introduced into the grease separator. This is particularly important in regard to: Wastewater containing faeces Wastewater containing light liquid oil (e.g. petrol) Wastewater in which a considerable amount of stable emulsions is present (e.g. dairy) 3

4 Lipumax-G is not designed for waste oil to be tipped into it and macerators must not be discharged into it. Note that only wastewater from specific fixtures from commercial kitchen and food processing facilities should be connected to the grease separator. Good work practices are vital to ensure the correct functioning of the grease separator. Before plates and dishes are washed, they should be scraped of food scraps into a bin. Waste oil must never be poured down the sink and it should be set aside and removed by an appropriate disposal company. 2.3 Owners responsibilities All work performed on the grease separator equipment is to be carried out by trained and approved personnel, in accordance with local water authority regulations. The owner is responsible for complying with the following points and must ensure that: The grease separator is in proper condition. Personnel are qualified and authorised to operate and maintain the grease separator. Adequate personal safety equipment is used. The grease separator is operated according to relevant regulations. There is adherence to a scheduled maintenance program (as per individual tradewaste agreement with the local water authority) and faults are repaired immediately. Contact ACO for information on replacement parts. Complete and legible operating instructions are displayed at the grease separator s site of installation and training is provided for relevant personnel. 2.4 Workplace Health and Safety (WHS) Safety instructions are intended to prevent damage to equipment or injury to personnel and must be read before any maintenance is performed. All safety instruction labels must be replaced if they become detached or illegible Installed devices (e.g. baffles, inlets, outlets etc.) are not load bearing. They must not be used as steps, footholds or resting places for cleaning equipment etc. Grease separators should be not be installed where a danger to health is possible from the grease separator leaking, blocking or surcharging 3 INSTALLATION The Lipumax-G grease separator must be installed in compliance with local water authority regulations, Safe Work Australia and all other codes of practice. Prior to installation, ensure that the local water authority approves each installation. Sydney Water requirement Sydney Water requires a certificate of compliance from a licensed plumber when a grease separator is being installed. 4

5 Icon Water and Water Corporation requirement A cap is required on top of each baffle (inlet and outlet) to prevent surcharge. Ensure each grease separator is installed with a baffle cap on the inlet and outlet baffle. Part no: Sizing The correct sizing and regular emptying of a grease separator is vital to its correct and on-going functioning. Refer to local water authority and council guidelines for sizing. 5

6 *To suit engineered slab details ACO Passavant can be used in conjunction with a number of different pipe materials. The most commonly used pipe materials are HDPE (High Density Polyethylene) and PVC (Poly Vinyl Chloride). These pipe materials have various connection methods. The most commonly used methods are detailed below. a) HDPE pipe HDPE pipe is commonly used in applications where the temperature of discharging water is high. There are three options available for connecting the ACO Passavant inlet and outlet with HDPE pipe: HDPE connector (left) Flexible coupling (middle) Flex seal shielded coupling (right) The HDPE connector (pictured left) allows the ACO Passavant inlet or outlet to be buttwelded to the connector, and the other end of the connector is a push-fit connection to the connecting HDPE pipe. Flexible couplings are designed to fit two pipes of a similar outside diameter together. The flexible connector (pictured middle) is placed over the inlet or outlet and over the connecting HDPE pipe. The stainless steel hose clamps are tightened to achieve the seal. Note: some authorities do not permit the use of flexible couplings in ground slabs. Alternatively, a flex seal shielded coupling (pictured right) can be used. This coupling is also a flexible coupling, but has a layer of stainless steel and is designed for below ground applications. Check manufacturers approvals for use in ground slab applications prior to use. b) PVC pipe PVC pipe is used in projects where cost requirements exceed the importance of hygiene, heat and corrosion resistance. To connect the ACO Passavant inlet or outlet to PVC pipe, a flexible coupling can be used 6

7 (pictured left). The flexible connector is placed over the inlet/outlet and over the connecting PVC pipe. The stainless steel hose clamps are tightened to achieve the seal. Note: some authorities do not permit the use of flexible couplings in ground slabs. Another option is a flex seal shielded coupling (pictured middle). This is also a flexible coupling, but has a layer of stainless steel and is designed for below ground applications. Ensure to check manufacturers approvals for use in ground slab applications prior to use. A slip coupling (pictured right) is another option for connecting PVC pipe below ground. The inlet/outlet push-fits into one end of the slip coupling and the connecting PVC pipe the other. This method can also be used in ground slabs. Please note, couplings are not supplied by ACO. 3.2 Identification The grease separator model and size can be identified on the inside lip of the separator. 3.3 Location Ensure the location of the grease separator is positioned where a maintenance contractor can easily access for pump out. If in doubt, contact a grease removal contractor and obtain a written agreement that the grease separator is able to be serviced. To minimise sedimentation in long runs, grease separators should be installed as close to the source of the grease as possible. Due to hygiene, grease separators should not be installed directly in the kitchen. A hose tap fitted with a backflow prevention device must be located within 5 metres of the grease separator for cleaning purposes (as per AS/NZS 3500). 3.3 Connecting pipes Connecting pipes and pipe materials should be installed in accordance with AS/NZS 3500 and local plumbing codes. The grease separator has moulded outlet and inlet points, marked respectively. A calming region of 10 metres of straight pipe upstream is recommended of the inlet to reduce turbulent wastewater from entering the grease separator and disrupting separation. Any angled pipes to the inlet should not exceed 45. Adequate backflow prevention must be in place. 7

8 Water Corporation requirement Refer to Information Sheet 23B. 3.4 Sampling To test the quality of the influent and effluent, some water authorities have a requirement for a Trade Waste Sampling Point (TWSP) to be installed at the outlet of the grease separator to test the quality of effluent. Pipework must be a minimum DN100. Water Corporation requirement Refer to drawing HX for precise construction requirements for Trade Waste Sampling Point (TWSP). 3.5 Disconnector Gully Disconnector gullies shall be installed where required in accordance to the local water authority. Refer to AS/NZS 3500 part 2 for typical detail. Water Corporation requirement Refer to section Ventilation Grease separators should be adequately ventilated using the marked vent connection in accordance with Australian Standards and local building and plumbing codes. To fit the vent, remove the cap. Fasten the vent pipe (minimum DN100). 8

9 The high level vent on the inlet line must terminate above the roofline and the vent from the outlet shall be installed to AS/NZS Site works Excavation should comply with Work Health and Safety (WHS) regulations and Safe Work Australia. Excavate to the required depth, allowing for the separator depth and an additional 300mm. Concrete is to be used to bed the separator. The separator bed must be applied on to a well compacted foundation. The width of excavation should be sufficient for the compactor to access. Ensure the angle of excavation is suitable for the soil type. Backfill with compacted sand and gravel or non-binding soil in 300mm layers. 3.8 Load class, cover and collar/load distribution plate installation Each Lipumax-G separator requires a gas and water tight access cover (complaint to AS 3996) to close the system and offer access for maintenance purposes. A range of Class B and Class D covers are available. Class B covers are supplied with a reinforced concrete collar. For Class D applications, there is a fully engineered solution including: Class D cover and reinforced collar, load distribution plate and raising tube. An alternative, for use in a structural slab where the load is distributed through the slab, is to purchase a Class D cover and reinforced collar only. Refer to engineers detail for design preference. 9

10 Note: Lipumax-P pictured When installed, the tops of the cover and collar assembly should be flush with the finished surface level. A load distribution plate is available separately and with Class D assembled solutions, where a structural slab is not present, to distribute load. A load distribution plate can also be used for Class B applications where buoyancy is a concern in high water tables. If in doubt, seek specific engineering advice. An optional riser tube can be ordered (part no ) to achieve a greater depth in installation and comes with Class D assembled solutions. For Class B installations, the minimum height the riser tube adds is 367mm and maximum height 607mm. For Class D installations, the minimum height the riser tube adds is 170mm and maximum height 411mm. 10

11 When the raising tube is used in conjunction with a load distribuion plate, the rebate must be cut to off the top of the raising tube (prior to installation) using the groove provided and a saw, as per the diagrams below. L1 L2 Ø 836 Ø 836 To achieve a variable height, the riser tube can be cut.the riser tube uses two o-rings: a retaining ring to prevent the raising tube sliding into the separator and a sealing ring to seal between the separator and riser to stop odours escaping. Retaining ring Sealing ring Prepare shaft by cutting it to the required height and fitting the sealing ring (supplied) and position the retaining ring one notch above to bring the riser to the desired height. To ensure water tightness, apply acid free grease to the seal and collar seating. Before installing the concrete collar and cover, ensure the riser tube has been backfilled. For downloadable installation details, visit Start-up Before using the grease separator for the first time, fill with clean water. 11

12 4 MAINTENANCE 4.1 Disposal and cleaning The cleaning interval must be agreed with the local water authority and in compliance with AS A proper disposal and cleaning procedure is critical to the ongoing efficient function of the grease separator. Before disposal and cleaning, kitchen operation must stop. The entire contents of the grease separator should be removed by a disposal truck with a suction hose through the maintenance openings. Once emptied, the tank must be cleaned manually using a hose/high pressure hose to completely remove residual FOG from the walls of the grease separator. Scraping may also be required to achieve this. The cleaning water must be completely removed from the grease separator. Finally, the grease separator must be refilled at least two thirds of the entire volume with hosepipe from an on-site water supply. Water Corp requirement Only camlock fittings are to be used for pump out line and no fixed suction is to be installed. 4.2 General inspection 4.2 General inspection A general inspection should be carried out regularly by qualified personnel, including a visual check of the grease separator and its connections. If any defects are found, they must be remedied without delay (refer to 2.3). 5 WATER AUTHORITY APPROVALS Please refer to for a list of the approved ACO grease separator water authority approvals. 6 CONTACT INFORMATION For queries, servicing assistance and spare parts, contact ACO. ACO Pty Ltd Old Bathurst Road Emu Plains NSW 2750 Australia e: sales@acoaus.com.au p: Original manufacturer document ACO Haustechnik HT 869 subject number