Operating and maintenance instructions for ACO light-oil separators

Oleotop Oleomax Oleopator Oleopator-CCB Akkumat Oleopator-CRB Oleopator-PR Oleopass

Inhaltverzeichnis

Introduction 1.1 1.2 1.3

................................................................. 5

General .................................................................................................... 5 Technical changes ................................................................................... 5 General symbols ...................................................................................... 6 ................................................................. 7

Safety 2.1 2.2 2.3 2.4 2.5 2.6

Area of application ................................................................................... 7 Improper usage violating the regulations ................................................. 7 Climbing into the separator ...................................................................... 7 General safety instructions....................................................................... 8 Instructions on the installed devices......................................................... 9 Authorised operatives .............................................................................. 9

System description of the separator types............................................... 11 3.1 3.2 3.3 3.4 3.5 Oleomax and Oleopator ......................................................................... 11 Oleopator-CRB ...................................................................................... 13 Oleopator-CCB Akkumat........................................................................ 15 Oleopator-PR NS 80 and NS 100 .......................................................... 17 Oleopass................................................................................................ 19 ............................................................... 23

Commissioning 4.1 4.2

General .................................................................................................. 23 Filling the separator................................................................................ 24

Self-checking, maintenance, disposal and inspection ............................ 27 5.1 Self-checking and maintenance work..................................................... 27 Self-checking by the operator ......................................................... 28

5.1.1 5.2

Maintenance .......................................................................................... 29

5.3

Checking the coalescence unit............................................................... 30

5.3.1 Type Oleomax, Oleopator-CRB NS 3 to 20, Oleopator NS 30, Oleopass, Oleopator-CCB Akkumat.............................................................. 30 5.3.2 5.3.3 5.3.4 5.3.5 5.4 6 7 Type Oleopator CRB NS 30 to 50 and Oleopator NS 40 to 50........ 31 Type Oleopator CRB NS 65 to 100 ................................................. 32 Oleopator-PR .................................................................................. 33 General hints for cleaning ............................................................... 34

Disposal ................................................................................................. 36 ............................................................... 37

Entering the separator

ACO Civil Engineering service network and ordering wear and tear parts ............................................................... 39

Introduction

1.1 General
These operating and maintenance instructions provide detailed directions for the safe and proper operation of a separator system. The instructions are an integral part of the separator and must be available at all times.

Important Please read these operating and maintenance instructions carefully before commissioning the separator. The directions specified in these operating and maintenance instructions must be strictly complied with. This is for your benefit because it will enable you to: ensure that the system will operate safely ensure that the efficiency and cost-effectiveness of the system will be enhanced to your satisfaction ensure that faulty operation and problems are avoided avoid costs for repairs and shut-downs make a valuable contribution to environmental protection maintain the warranty

1.2 Technical changes

ACO Beton GmbH reserves the right to make technical changes to the separators as described and shown in the details and pictures in these operating and maintenance instructions.

1.3 General symbols

Special directions are included throughout the operating and maintenance instructions wherever special aspects have to be taken into consideration. These special directions consist of a symbol, a signal word, and the accompanying text. The general symbols used are as follows:

WARNING This symbol accompanies all the operational safety instructions in this manual which could be associated with a risk to human life and health. It is very important in these cases to observe the instructions and to act cautiously. All of the operational safety instructions must be passed on to other persons operating the system. The instructions in this manual must be observed in addition to the general safety and accident prevention regulations.

CAUTION This symbol highlights those positions in the instruction manual where special care has to be taken to ensure compliance with the regulations, standards, stipulations, instructions and the proper sequence of the work carried out, as well as where there is a risk of damaging the system, the components and the surroundings, and to ensure smooth operations.

ENVIRONMENTAL PROTECTION This symbol highlights environmental protection measures.

Safety

2.1 Area of application

These instructions apply to separators for mineral light liquids. The separators are classified as separator Class I or II pursuant to EN 858. The separator tank consists of reinforced concrete. It is designed for ground installation.

2.2 Improper usage violating the regulations

The regulations governing the use of the separator are considered to have been violated when the plant is not used or connected in accordance with the descriptions defined in EN 858. The manufacturer is not liable for any damage arising from improper use which violates the regulations. It is forbidden to make unauthorised changes or modifications to the plant, and such actions lead to the immediate termination of the warranty rights!

Caution

ENVIRONMENTAL PROTECTION

Problem-free operation and compliance with the safety regulations can only be guaranteed by the installation when it complies one hundred per cent with the model as produced by the manufacturer.

2.3 Climbing into the separator

WARNING Climbing into the separator is only permitted when observing all of the relevant accident protection regulations in your country at the time planned for entry.

2.4 General safety instructions

WARNING The safety instructions must be strictly implemented. Failure to follow the instructions properly can lead to material damage or injury.

WARNING The separator system is defined as a zone 0 explosion hazard area. Only authorised properly trained staff are therefore allowed to carry out work on the electrical components of the separator (where present).

WARNING No one must be allowed to enter the separator without breathing apparatus or before previously testing the gas concentrations, and nobody must be allowed to enter the separator without safety equipment (see the relevant accident prevention regulations in your country).

WARNING Smoking and naked lights are strictly forbidden anywhere in the area surrounding the system.

CAUTION Adhesive safety instruction labels must be replaced if they become detached or illegible.

2.5 Instructions on the installed devices

CAUTION The installed devices (e.g. inlet structure, outlet structure, coalescence element, etc.) are designed for operation within a separator system. They must not be misused as steps for operatives or as resting places for heavy cleaning equipment etc. They are not designed to carry loads of this kind!

WARNING Stepping onto any of the installed devices carries with it a risk of falling, especially by the breakage of the installation device, because the strength of the installation devices is not designed to carry the weight of operatives.

2.6 Authorised operatives

The system must only be operated and maintained by properly qualified operatives or properly qualified technicians. The operator is obliged: to make an operating manual available to the operator (supplied separately or available upon request from your ACO service partner), as well as these operating and maintenance instructions. The handing over of these instructions and manual must be recorded pursuant to the mandatory stipulations. The operator must satisfy himself that the operatives have read and understood these instructions to ensure that the plant operatives have been properly instructed and can operate the plant safely

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System description of the separator types

The following provides a short system description and important instructions for each of the different separator types.

3.1 Oleomax and Oleopator

Fig. 1. Light-oil separator Oleomax and Oleopator Class I, and light-oil separator Oleomax and Oleopator Class II (identical to Oleomax and Oleopator Class I, but without the coalescence element (2)) 1 2 3 4 5 Inlet pipe to the separator Coalescence unit (knitted wire mesh or perforated metal sheet or polyurethane material) Outlet pipe with float cage Reinforced concrete tank Integrated sludge trap

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General description of the Oleomax and Oleopator light-oil separators Oleomax and Oleopator Class I and Class II light-oil separators have an integrated sludge trap (5). This allows sediments and light oils to be separated out simultaneously in one tank. This means that an additional sludge trap positioned upstream of the light-oil separator is no longer required. The Oleomax light-oil separator has an optimised sludge trap according to the German DIN 1999-100 compared to the Oleopator light-oil separator. The Oleomax light-oil separator is therefore particularly compact. Oleomax and Oleopator light-oil separators are identical in all other respects. Function of Class I light-oil separators Light oils in the Oleomax and Oleopator Class I light-oil separators are separated out by a coalescence unit which helps trap the finest oil drops and coalesce them together to form larger oil drops capable of being separated out. This coalescence unit (2) consists of a cylindrical coalescence element centrically positioned around the float cage. It consists of a PE-HD supporting basket and usually a single or double-layered coalescence mat made out of a mixture of knitted materials (stainless steel and polypropylene or polyurethane material (only from Oleopator NS 40 upwards), which is wrapped around the supporting basket and held in position by tensioners with Velcro strips. In the NS 6 version (only Oleomax) with a 5000 litre sludge trap, the coalescence element consists of a cylindrical perforated sheet of PE-HD positioned centrically around the float cage. Function of the Class II light-oil separators No coalescence unit is required in the Oleomax and Oleopator Class II light-oil separators. Light oils are exclusively separated out statically via the flow path and the dwell time within separator.

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3.2 Oleopator-CRB

3 4 4 Oleopator-CRB

Fig. 2. Light-oil separator Oleopator-CRB Class I (Oleopator-CRB Class II not shown: identical configuration to the Oleopator-CRB Class I, but without the coalescence element (2)) 1 2 3 4 5 Inlet pipe Coalescence element (knitted wire mesh or polyurethane material) Outlet pipe with float cage Reinforced concrete tank Upstream sludge trap (optional accessory)

General The Oleopator-CRB Class I and Class II light-oil separators do not have an integrated sludge trap. A sludge trap (5) can be installed upstream of the light-oil separator to trap sediments before they enter the separator. The latest ACO Civil Engineering catalogue for separators and pumping stations designed for ground installation contain all of the necessary dimensions and layouts of sludge traps pursuant to EN 858, as well as the appropriate ACO sludge traps.

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General function Class I light-oil separator Light oils in the Oleopator-CRB Class I light-oil separators are separated out by a coalescence unit (2) which helps trap the finest oil drops and coalesce them together to form larger oil drops capable of being separated out. This coalescence unit (2) consists of a cylindrical coalescence element centrically positioned around the float cage. It consists of a PE-HD supporting basket and usually a single or double-layered coalescence mat made out of a mixture of knitted materials (stainless steel or polypropylene) or from nominal size 30 made of porous polyurethane material seated on a round supporting basket made of PE-HD. From nominal size 65, the porous polyurethane material lines the inside of a rectangular supporting basket. The separators from size 65 have coalescence elements consisting of two of these rectangular supporting baskets. General function of Class II light-oil separator No coalescence unit is required in the Oleopator-CRB Class II light-oil separators. Light oils are exclusively separated out statically via the flow path and the dwell time within the separator.

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3.3 Oleopator-CCB Akkumat

3 2 4 5 6

8 7

Fig. 3. Light-oil separator Oleopator-CCB Akkumat Class II and Class I in a reinforced concrete tank 1 2 3 4 5 6 7 8 Inlet pipe Light-oil separator Class II Outlet pipe separator Class II and inlet pipe separator Class I Light-oil separator Class I in the form of a PE-HD or stainless steel internal tank Coalescence element (with knitted wire mesh) Outlet pipe with float cage Reinforced concrete tank Integrated sludge trap

General The Oleopator-CCB Akkumat light-oil separator is an integrated Class II and Class I light-oil separator. Pursuant to EN 858 Part 2 Selection of nominal size, installation, operation and maintenance the use of a Class II (2) light-oil separator upstream of a Class I (4) light-oil separator is specified for handling certain qualities of wastewater and special applications. The Oleopator-CCB Akkumat was developed as a mono-tank solution for these special applications.

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Function The wastewater flowing into the Oleopator-CCB Akkumat first flows through the Class II (2) light-oil separator where the wastewater is pre-treated before flowing into the Class I light-oil separator the ACO CCB Akkumat internal tank (4) which is made of PE-HD and is integrated within the surrounding reinforced concrete tank. Class II light-oil separators require no coalescence units (5). The light oils are separated out in a purely static method via the flow path and the dwell time. In the ACO CCB Akkumat Class I light-oil separator which is installed in the form of a PE-HD internal tank within the reinforced concrete tank light oil is separated out by a coalescence unit (5) which helps trap the finest oil drops and coalesce them together to form larger oil drops capable of being separated out. This coalescence unit (5) consists of a cylindrical coalescence element centrically positioned around the float cage. It consists of a PE-HD supporting basket and usually a single or double-layered coalescence mat made out of a mixture of knitted materials (stainless steel and polypropylene), which is wrapped around the supporting basket and held in position by tensioners with Velcro strips.

CAUTION Pay attention when filling the Oleopator-CCB Akkumat that the Class I ACO CCB Akkumat internal tank (4) is filled first before filling the Class II separator (2) in the light-oil separator system. Failure to follow this instruction may cause the ACO CCB Akkumat internal tank to float upwards! This could destroy the ACO CCB Akkumat internal tank!

WARNING Failure to fill the separator in the proper way as described above can cause the ACO CCB Akkumat internal tank (4) to float upwards. This generates very large forces with a great risk of injury or death if the instructions are not carried out properly!

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3.4 Oleopator-PR NS 80 and NS 100

5 4

Fig. 4. Light-oil separator Oleopator-PR Class I and light-oil separator OleopatorPR Class II (identical construction to Oleopator-PR Class I, but without the coalescence element (2)) 1 2 3 4 5 Inlet pipe Coalescence element (with knitted wire mesh) Outlet pipe with float cage Reinforced concrete tank Integrated sludge trap (only for Oleopator-PR NS 80)

General The Oleopator-PR NS 80 Class I and II light-oil separators have a 3000 litre sludge trap. The Oleopator-PR NS 100 Class I and Class II light-oil separators, however, have no integrated sludge trap. A sludge trap can be installed upstream of the light-oil separator to trap sediments before they enter the separator. The latest ACO Civil Engineering catalogue for separators and pumping stations contain all of the necessary dimensions and layouts of sludge traps pursuant to EN 858, as well as the appropriate ACO sludge traps for the Oleopator-PR NS 80.

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General function Class I light-oil separators Light oils in the Oleopator-PR Class I light-oil separators are separated out by a coalescence unit (2) which helps trap the finest oil drops and coalesce them together to form larger oil drops capable of being separated out. This coalescence unit (2) consists of two cylindrical coalescence elements centrically positioned around the float cage. It consists of a PE-HD supporting basket and usually a multi -layered coalescence mat made out of a mixture of knitted materials (stainless steel or polypropylene) wrapped around the supporting basket and held in position by tensioners and Velcro strips. General function of Class II light-oil separators No coalescence unit is required in the Oleopator-PR Class II light-oil separators. Light oils are exclusively separated out statically via the flow path and the dwell time within the separator.

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3.5 Oleopass

9 7 1 6 2

Fig. 5. Light-oil separator Oleopass Class I and light-oil separator Oleopass Class II (same construction as Oleopass Class I, but without a coalescence element (2)) 1 2 3 4 5 6 7 8 9 Inlet pipe Coalescence element (made of knitted wire mesh or perforated sheet) Outlet pipe with float cage Reinforced concrete tank Bypass channel Outlet pipe sludge trap and inlet pipe to light-oil separator Light-oil separator consisting of a PE-HD internal tank Sludge trap Weir sill in the bypass channel

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General The Oleopass light-oil separator has an internal bypass channel (5) within the separator and a weir sill (9) integrated within this bypass channel. The light-oil separator has the form of a PE-HD internal tank (7) and this is the element which separates out the light oils. No light-oil separation takes place outside of this PEHD internal tank. Solids mainly sediment out outside of the PE-HD internal tank in the sludge trap zone (8).

CAUTION Pay attention when filling the Oleopass that the round PE-HD internal tank (7) is always filled first. Only then fill the reinforced concrete tank (sludge trap (8) of the Oleopass) of this light-oil separator. Failure to fill the light-oil separator in this order may cause the internal tank to float upwards! This could destroy the internal tank!

WARNING Failure to fill the separator in the proper way as described above can cause the PE-HD internal tank (7) to float upwards. This generates very large forces with a great risk of injury or death if the instructions are not carried out properly!

Function of the bypass separator Wastewater flowing into the Oleopass exclusively flows through the sludge trap (8) and the light-oil separator (7) where it is treated as long as the wastewater does not overflow the weir sill in the bypass channel (9). Wastewater only overflows the weir sill (9) when a certain inflow volume is exceeded (more than the nominal size in l/s: e.g. NS 6 = inflow of 6 l/s). Wastewater flowing over the weir sill moves along the bypass channel (5) and is discharged untreated. The special design of the Oleopass bypass separator was developed to clean as completely as possible the usually heavily contaminated first pulse of wastewater flowing into the separator during very heavy downfalls or normal rainfall. The subsequent pulses of wastewater flowing into the separator after a heavy downpour especially during peak flow usually consists of pure rainwater without much contamination and can therefore be discharged untreated into the sewers or rivers. 20

Function light-oil separator Class I In the Oleopass Class I light-oil separator which takes the form of a PE-HD internal tank (7) installed within the reinforced concrete tank (4), light oils are separated out by a coalescence unit (2) which helps trap the finest oil drops and coalesce them together to form larger oil drops capable of being separated out. This coalescence unit (2) consists of a cylindrical coalescence element centrically positioned around the float cage. It consists of a PE-HD supporting basket and usually a single or double-layered coalescence mat made out of a mixture of knitted materials (stainless steel and polypropylene), which is wrapped around the supporting basket and held in position by tensioners with Velcro strips.

General function of Class II light-oil separators No coalescence unit is required in the Oleopator-PR Class II light-oil separators. Light oils are exclusively separated out statically via the flow path and the dwell time within the separator.

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Commissioning

4.1 General
All of the components of the system must be inspected to ensure that nothing is missing (inspection should take place using the delivery documents). A very important aspect is the proper fastening of the type plate in the maintenance shaft as shown in Figure 7.

Equalising ring Eye screw Rope Manhole ring

Seil

Manhole cone

Type plate

Fig. 6. Fixing the type plate in the maintenance shaft The front of the type plate contains information on the following: Type identification Nominal size Class Volume of the separator and the sludge trap Maximum storage volume of light oil and the maximum thickness of the light-oil layer Maximum permissible sludge thickness

Instructions on installing the float are given on the reverse of the type plate.

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4.2 Filling the separator

WARNING The excavation should be filled in before filling and commissioning the separator. There is otherwise the risk that the cover plate and the shaft top section could float upwards!

ENVIRONMENTAL PROTECTION Clean the system thoroughly before filling. Any mortar residues which may have been left behind after previous construction work should be removed and disposed of appropriately.

CAUTION The mortared joints must be allowed to harden properly before filling the tank with water.

CAUTION The float must be removed before the separator is filled. Do not install the float in the float cage until the separator has been completely filled (this is indicated by the continuous flow of water into the sewers via the sampling shaft). Failure to follow this instruction may cause the outlet pipe to be blocked by the float, causing excess water to accumulate in the separator and backflow into the sewers. The separator cannot function properly if this occurs.

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Special instructions for filling the Oleopass and Oleopator CCB Akkumat light-oil separators

CAUTION Pay attention when filling the Oleopass and Oleopator-CCB Akkumat that the round PE-HD or stainless steel internal tank is filled first before filling the reinforced concrete tank of the light-oil separator system. Failure to follow this instruction may cause the internal tank to float upwards! This could destroy the internal tank!

WARNING Failure to fill the separator in the proper way as described above can cause the PE-HD internal tank to float upwards. This generates very large forces with a great risk of injury or death if the instructions are not carried out properly!

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Self-checking, maintenance, disposal and inspection

Because proper maintenance of the separator is restricted when the separator is full, it is recommended that the dates for disposal and maintenance are coordinated. Instructions on entering the separator are given in chapter 6.

5.1 Self-checking and maintenance work

Measures for self-checking, maintenance and inspection must be carried out in compliance with the stipulations laid down EN 858.
Measures What must be done? Who should do it? Recommended Interval

Self-checking Checking the proper functioning of the by the opera- system. In particular, the selftor actuating closure and the coalescence unit. The checks should be documented in the operations log. Maintenance Measures as under self-checking by the operator, and the following additional measures when required: cleaning or replacing the coalescence unit; emptying and cleaning the separator; cleaning the discharge channel in the sampling shaft. The separators must be emptied at the latest when: 80 % of the maximum oil storage volume has been reached or 50 % of the max sludge trap volume has been reached.

Properly quali- Monthly fied operative

Properly quali- Every 6 or 12 fied operative months depending on the application for which the separator is used Always only by a properly authorised disposal company As required, but at the latest for the general inspection

Disposal

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5.1.1 Self-checking by the operator The scope of the monthly inspection of the separator by a properly qualified operativen2) includes:

Measuring the thickness and volume of the layer of light oil separated out at the top of the separator Measuring the height of the sludge layer in the sludge trap Checking the proper functioning of the self-actuating closure in the separator Inspecting any of the alarm systems which may be present (not until 6 months after the general inspection) The cyclone (type Oleotop) is usually kept clean by the flow.

ENVIRONMENTAL PROTECTION Immediately rectify any faults which are identified, and remove any coarse floating material. Equipment to help self-checking by the operator:

Fig. 7. ACO control kit Order our specially developed control kit for your monthly inspection. The control kit consists of: a case with a dipstick, dipstick plate, water verification paste, pH indicator rods, operations log, etc. . Please order from your local ACO service partner. More informations: www.aco-online.de

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5.2 Maintenance
The separator must be maintained every six months in accordance with the stipulations in EN 858. In addition to the inspection measures carried out by the operator, it may also be necessary to carry out the disposal operations if necessary.

Emptying and cleaning the separator as required (e.g. if there is a large accumulation of sludge or if the sludge has reached its maximum height, or when 80 % of the maximum oil storage volume has been reached).

If the separator has been exclusively used for

Treating rainwater contaminated with light oils, As a safety measure connected to installations and areas where light oils are handled

It may be possible to extend the maintenance intervals to a maximum of 12 months depending on the amount of sludge and light oils which accumulate the decision is up to the operator.

CAUTION The findings and the work carried out must be recorded and commented on in the operating log (supplied as standard in the control kit).

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5.3 Checking the coalescence unit

5.3.1 Type Oleomax, Oleopator-CRB NS 3 to 20, Oleopator NS 30, Oleopass, Oleopator-CCB Akkumat Cleaning the coalescence unit The coalescence unit must be pulled up above the water level in the separator using a hoist where necessary. The coalescence unit should be held above the water for a while to allow water to drip off before removing it completely using the hoist. Separator nominal size NS 3 6 / 8 / 10 15 20 30 Weight in kg dirty coalescence unit 6 9 12 15 20

The coalescence unit can be cleaned as it is when it is removed from the separator. All of the dirt in the knitted wire mesh must be removed completely. The coalescence unit should be cleaned in a basin to ensure that any oil contaminating the cleaning water is not discharged into rivers or sewers. When the coalescence unit has been cleaned and replaced in the separator, the contents of the basin can be disposed of by simply pouring it into the separator. Cleaning can be carried out as follows:

Spraying with a jet of water, min inch pipe, under mains pressure (min 4 bar) or Spraying with a high pressure device at max 60 bar and using cold water.

And only when absolutely necessary: With cleaning products (it is important here to only use separator-friendly cleaning products see the manufacturers details describing the cleaning product or contact your local ACO service partner), and using a high pressure device with max 60 bar and 60 C.

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5.3.2 Type Oleopator CRB NS 30 to 50 and Oleopator NS 40 to 50 Structure of the coalescence element The coalescence material consists of a porous polyurethane material with a thickness of 75 or 100 mm. It is fastened onto the supporting basket with a special clamp. Additional tensioners with Velcro strips ensure that it is held in place in the proper position. The dimensions are listed in Table 1. Table 1. Dimensions of the coalescence material Separator nominal size NS 30 40 50 Material thickness in mm 75 75 100 Dimensions of the coalescence material in mm Diameter 600 600 650 Height 600 1200 1200

Depending on the type, the weight of the contaminated coalescence element is around 160 kg. Preparations for cleaning It is easier to clean the coalescence mat by first removing it from the supporting basket so that it can be thoroughly cleaned from both sides. First remove the tensioners and then the clamp. The coalescence mat is then free to be removed from the supporting basket. Cleaning Lay the coalescence mat onto a wire mesh to allow the cleaning water to pass through the mat and flow out on the lower side.

CAUTION

ENVIRONMENTAL PROTECTION

The water used to wash the coalescence mat must be treated in a light-oil separator afterwards and must not be discharged untreated into the sewers or rivers! Assembling the coalescence mat The coalescence mat is assembled in the reverse order described above.

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5.3.3 Type Oleopator CRB NS 65 to 100 Structure of the coalescence element The coalescence material is 100 mm thick and consists of a porous polyurethane material fixed in special cassettes which can be removed from the separator for cleaning. There are 4 cassettes in each separator. Table 2 lists the dimensions of the coalescence elements. Table 2. Dimensions of the coalescence elements in type Oleopator CRB NS 65 to 100 light-oil separators (the weights in the table refer to contaminated elements) Separator nominal size NS 65 80 100 Dimensions in mm 1360 x 540 x 100 1755 x 540 x 100 2050 X 540 x 100 Weight kg 70 90 110

Depending on the type, the weight of the contaminated coalescence element is around 160 kg. Preparing for cleaning Cleaning is made easier by first removing the coalescence mat from the cassette so that the mat can be cleaned on both sides properly. Bend the upper part of the cassette upwards slightly to remove the coalescence mat. This makes removing the mats easier. Cleaning Lay the coalescence mat onto a wire mesh to allow the cleaning water to pass through the mat and flow out on the lower side.

CAUTION

Environmental protection

The water used to wash the coalescence mat must be treated in a light-oil separator afterwards and must not be discharged untreated into the sewers or rivers! Assembling the coalescence mat The coalescence mat is assembled in the reverse order described above.

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5.3.4 Oleopator-PR Structure of the coalescence element The coalescence material is fixed to the supporting basket at 2 or 3 levels each with 4 or 6 layers. Each separate layer is held in place by tensioners. Table 3. Dimensions of the coalescence elements in type Oleopator-PR Separator nominal size NS 80 100 Number of levels 2 3 Number of mats per level 4 6

The weight of a dirty coalescence element is approx. 260 kg. Type Oleopator-PR separators have 2 coalescence elements. Preparations for cleaning Because the coalescence elements have 4 to 6 layers, it makes cleaning easier if the outer layers are wound off the supporting basket for cleaning. The two inner layers can be left on the supporting basket for cleaning. The three tensioners are first removed by opening the Velcro fastener. The coalescence mat can then be removed from the supporting basket. Make sure that the sequence in which the mats are removed is noted because each layer has a different length. Cleaning Lay the coalescence mat onto a wire mesh to allow the cleaning water to pass through the mat and flow out on the lower side.

CAUTION

Environmental protection

The water used to wash the coalescence mat must be treated in a light-oil separator afterwards and must not be discharged untreated into the sewers or rivers! Assembling the coalescence mat The coalescence mat is assembled in the reverse order described above.

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5.3.5 General hints for cleaning These general hints for cleaning are guilty for every ACO separator. Cleaning can be carried out much more easily and quickly if a redundant coalescence unit is used. Simply swap the clean coalescence unit for the dirty coalescence unit to avoid long operational hold-ups. The dirty coalescence unit can be cleaned when time allows. The dirty unit should be stored in a water-filled container or in a plastic sack before it is cleaned, to prevent any dirt on the unit from drying hard.

CAUTION The water used to wash the coalescence unit must be treated in a light-oil separator and must not be discharged untreated into sewers or rivers!

ENVIRONMENTAL PROTECTION The water used to wash the coalescence unit is generally disposed of by pouring it into one of the separator inlet pipes or having it disposed of by an authorised disposal company! Coalescence mats Multiple use: The coalescence material consists of a high quality knitted mesh of two materials (polymer/stainless steel) which is very resistant to ageing and physiologically neutral. It can therefore generally be repeatedly cleaned and reused. However the coalescence mats and the tensioners are regular wear parts. New mats and tensioners can be bought at your local ACO dealer or ACO service partner. Used only once: If there are no suitable cleaning options (in exceptional cases) or for other reasons, it is also possible to use the coalescence mats only once. The contaminated coalescence mats are removed from the supporting basket, placed in a rugged and tight plastic sack, and then disposed of as oily toxic waste. Removing the coalescence mats:

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Every coalescence mat is fixed to the supporting basket at the top and the bottom with tensioners and Velcro strips (the fluffy side outwards). These have to be removed. The mat can then be wound off. Reversing this procedure is used to fix the coalescence mats in place again. Pay attention when doing this to make sure that the coalescence mats are properly wrapped around the supporting basket leaving no unwanted openings which could allow the wastewater to flow through untreated. It is important that the water can flow through the mat itself though. The tensioner is extremely tear resistant and should have no problems in holding the coalescence mat in place. However, the tensioners should be replaced every five years. Pay attention here to make sure that the coalescence mats are not pulled in place so tightly that the mats themselves are damaged. The coalescence mat, the supporting basket and the tensioners are subject to wear and tear. Inexpensive replacements can be ordered from your local ACO service partner. The article numbers for these items are listed on the delivery document. If the delivery document is no longer at hand, the parts can be ordered by stipulating the type identification and the year of manufacture.

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5.4 Disposal
The latest time for emptying a separator is when: 1. 2. 80 % of the maximum oil storage has been reached and/or 50 % of the maximum sludge trap volume have been reached.

The type plate shows the relevant thicknesses of each layer (the type plate is located inside the separator). If the levels always remain below these limits, it is still useful to empty the separator at least every five years starting with the time start of operating took place. The contents of the separator must be disposed of by an authorised disposal company.

CAUTION If biodiesel enters the separator, the light oil separated out should be removed from the surface of the water after one year. The light oil separated out must be removed immediately after accidental spills.

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Entering the separator

WARNING All of the relevant accident prevention regulations must be strictly observed when entering a separator! The separator can be entered via the maintenance shaft which is usually located above the float cage. Entering the following models (Oleomax, Oleopator) is possible via openings above the float cage. In these cases, carry out the following steps to ensure optimal accessibility: 1. 2. 3. Remove the coalescence unit (if installed) Remove the float Pull the float cage from the holder and remove it.

The separator can now be entered. Once all of the work has been carried out, the next steps ensure that the original condition of the separator is reinstated: 1. Place the float cage back in the holder (taking care to properly align the pins in the cage) Replace the float after the separator has been filled Install the coalescence unit (if fitted)

2. 3.

The float cage does not need to be removed in any of the other models because the separator can be entered by a third maintenance shaft.

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ACO Civil Engineering service network and ordering wear and tear parts

ACO has its own service and customer care organisation in your country. You will find your local ACO dealer on this website: www.aco-online.de

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Space for your notes

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Space for your notes

Producing factory of the separator: ACO Beton GmbH Mittelriedstrae 25 68642 Brstadt Tel.: 0049-6206-9816-0 Fax: 0049-6206-9816-80

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