ACO Passavant Installation guide ECOJET GREASE LEVEL SENSOR AUTHOR Kate Jennings DATE COMPLETED 8 August 2016 DATE COMPLETED V13 ACO Polycrete, 134-140 Old Bathurst Road, Emu Plains, NSW 2750 Tel: +61 2 4747 4000 Fax: +61 2 4747 4029 Email: sales@acoaus.com.au
Contents 1 GENERAL... 3 2 SAFETY CONSIDERATIONS... 3 3 INSTALLATION... 4 4 MAINTENANCE... 9 5 WATER AUTHORITY APPROVALS... 10 6 CONTACT INFORMATION... 10 2
1 GENERAL The ACO Passavant EcoJet grease separator is designed for above ground installation only. EcoJet 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 EcoJet 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. 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) EcoJet 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. 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 3
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 immediately repaired. Contact ACO in relation to repairs or replacement. 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, inlet and outlet parts, 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 EcoJet grease separator must be installed in compliance with local water authority regulations, Safework Australia and all other codes of practice. Prior to installation, ensure that the local water authority approves each installation. Queensland Urban Utilities Water requirement Queensland Urban Utilities require a raising piece on each maintenance opening cut to increase overall height of separator by 100mm. Ensure two are installed with each grease separator part number 3300.13.00. South Australia Water requirement South East Water, City West Water, Yarra Valley Water, Melbourne Water requirement ACTEW 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. Water Corporation requirement Require a cap on top of the outlet baffle only. To suit EcoJet NS 3-4: 142103 To suit EcoJet NS 5.5-10: 142104 4
Sydney Water requirement Sydney Water requires a certificate of compliance from a licensed plumber when a grease separator is being installed. 3.1 Sizing The correct sizing and regular emptying of a grease separator is vital to its correct and on-going function. 5
Each separator is supplied with a sticker on each side identifying the separator and size. 3.2 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). All above ground grease separators require steps and a platform for maintenance purposes, in accordance with AS 1657-1992. 3.3 Installation The grease separator should be installed on level concrete. Before using the grease separator for the first time, fill with clean water. 3.4 Connecting pipes Connecting pipes and pipe materials should be installed in accordance with AS 3500 and local plumbing codes. The grease separator has moulded 110mmØ (for NS 3-4 models) or 160mmØ (for NS 5.5-10), outlet and inlet points, marked respectively. A calming region of 10 metres of straight pipe is recommended upstream 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. 6
Vent IO IWSP *IO: Inspection Opening *IWSP: Industrial Waste Sampling Point 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 7
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 (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. 3.5 Sampling To test the quality of the influent and effluent, some water authorities have a requirement for an Inspection Opening/Industrial Waste Sampling Point (IWSP) to be installed at both the inlet and outlet of the grease separator. Pipe work must be a minimum DN100. Water Corporation requirement Refer to drawing HX33-11-30 for precise construction requirements of IWSP. 3.6 Flow distribution installation A flow distributor is available for ACO grease separators to evenly split flow into two correctly sized separators. To ensure the correct functioning of this, the Y branch flow distributor must be installed completely level within the pipework system. An access point for rodding must be installed directly upstream of the Y branch for maintenance purposes. This must be regularly maintained according to the maintenance plan to ensure the pipes run without blockage. 3.7 Disconnector Gully Disconnector gullies shall be installed where required in accordance to the local water authority. Refer to AS3500 part 2 for typical detail. Water Corporation requirement Refer to drawing HX33-11-30 for precise construction requirements of disconnector gully. 8
3.8 Ventilation A grease separator must be adequately ventilated at both the inlet and outlet pipe. 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 3500. To fit the vent, use a hole saw to drill open the cap marked vent or SA Water vent connection. Fasten the vent pipe (minimum DN100) using a flexible coupling. 4 MAINTENANCE 4.1 Disposal and cleaning The cleaning interval must be agreed with the local water authority. Once this has been reached, the contents of the grease separator must be emptied, cleaned and refilled with cold water to recommence kitchen activity. This must be carried out by qualified, approved personnel. 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 the residual FOG from the walls of the grease separator. Scraping may also be required to achieve this. The cleaning water must also be removed from the grease separator. Finally, the grease separator must be refilled at least 2/3 of the entire volume with a hosepipe from an on-site water supply and lids re-fitted with clamp ring in place. It is possible to install a fixed pump-out line for on-going servicing of grease separators. Consult the local water authority prior to installation. Water Corporation requirement Only camlock fittings are to be used for the pump out line and no fixed suction lines to be installed. 4.2 General inspection A general inspection should be carried out regularly by qualified personnel including: Visual check of the grease separator and its connections Determination of levels of sludge and grease 9
If any defects are found during the check, these must be remedied without delay (refer to 2.3). 5 WATER AUTHORITY APPROVALS Please refer to http://www.acoaus.com.au/pdf/aco-passavant-water-authorityapprovals.pdf for ACO Passavant water authority approvals. 6 CONTACT INFORMATION For queries, servicing assistance and spare parts, contact ACO. ACO Polycrete 134-140 Old Bathurst Road Emu Plains NSW 2750 Australia e: sales@acoaus.com.au p: +61 2 4747 4000 10