Installation guide ACO PASSAVANT – ECO-JET GREASE SEPARATORS Maintenance openings (includes clamp ring and seal) Ventilation connection Inlet Ventilation connection Outlet Inspection window (optional) Buoyancy safeguard provision 1.0 General p. 2 2.0 Safety considerations 2.1 Site handling 2.2 Foreseeable misuse 2.3 Owners responsibilities 2.4 Workplace Health and Safety (WH&S) p. 2 p. 2 p. 2 p. 2 p. 3 3.0 Installation 3.1 Sizing 3.2 Location 3.3 Installation 3.4 Connecting pipes 3.5 Sampling 3.6 Disconnector gully 3.7 Ventilation p. 3 p. 4 p. 5 p. 5 p. 5 p. 6 p. 6 p. 6 4.0 Maintenance 4.1 Disposal and cleaning 4.2 General inspection p. 6 p. 6 p. 7 5.0 Water authority approvals p. 7 Bulletin No.: Date: Issued By: TB201404 – revision 3 November 2014 KJ Page 1 of 7 U:\Technical Services\Kate\Product Management\ACO Passavant\Operations manual\Internal document\EcoJet\v3 - TB201404.doc ACO Polycrete Pty Ltd 134-140 Old Bathurst Road Emu Plains NSW 2750 Telephone (02) 4747 4000 Facsimile (02) 4747 4040 Email: [email protected] © 2014 COPYRIGHT ACO POLYCRETE PTY LTD. All reasonable care has been taken in compiling the information in this technical bulletin. 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 the product is fit for its intended purpose and that the actual conditions of use are suitable. ACO Polycrete pursues a policy of continuous product development and reserves the right to amend specifications without notice. 1.0 General The ACO Passavant Eco-Jet grease separator is designed for above ground installation. Eco-Jet 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. 2.0 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 Eco-Jet upon delivery and before installation to 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) Eco-Jet is not designed for waste oil to be tipped into it and garbage disposal units (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 • 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 ACO Polycrete Pty Ltd Technical Bulletin No.: TB201404 Date: 12 November 2014 Page 2 of 7 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 3.0 Installation The Eco-Jet 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 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. To suit EcoJet NS 3-4: 418834 To suit EcoJet NS 5.5-10: 418836 Sydney Water requirement Sydney Water requires a certificate of compliance from a licensed plumber when a grease separator is being installed. ACO Polycrete Pty Ltd Technical Bulletin No.: TB201404 Date: 12 November 2014 Page 3 of 7 3.1 Sizing The correct sizing and regular emptying of a grease separator is vital to its correct and on-going functioning. Dimensions in mm Contents in litres NS 3 4 5.5 7 8.5 10 Sludgetrap Grease storage volume 300 400 725 800 1000 1000 150 200 360 400 475 520 Total 1055 1055 1430 1600 1900 2000 All types H1 1055 1055 1250 1250 1250 1250 H2 985 985 1180 1180 1180 1180 H4 1500 1500 1700 1700 1700 1700 L1 1450 1760 1760 1960 2450 2450 L2 1650 2000 2000 2200 2690 2690 B1 700 700 950 950 950 950 B2 770 770 1020 1020 1020 1020 D 110 110 160 160 160 160 Part No. 3553.34.00 3554.34.00 3555.34.00 3557.34.00 3558.34.00 3560.34.00 Each separator is supplied with a sticker on each side identifying the separator and size. ACO Polycrete Pty Ltd Technical Bulletin No.: TB201404 Date: 12 November 2014 Page 4 of 7 3.2 Location Ensure the intended 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. However, due to hygiene, grease separators should not be installed directly in the kitchen. A hose tap fitted with a backflow prevention device (as per AS/NZS 3500) must be located within 5 metres of the grease separator for cleaning purposes. All above ground grease separators require steps and a platform for maintenance purposes (as per AS 16571992). 3.3 Installation The grease separator should be installed on level concrete. The grease separator does not require a stand, but slots at the bottom of the grease separator can be used as an anchor to resist buoyancy. 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. Vent IO IWSP *IO: Inspection Opening *IWSP: Industrial Waste Sampling Point ACO Polycrete Pty Ltd Technical Bulletin No.: TB201404 Date: 12 November 2014 Page 5 of 7 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 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. 3.7 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 Once the agreed cleaning interval with the local water authority 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. ACO Polycrete Pty Ltd Technical Bulletin No.: TB201404 Date: 12 November 2014 Page 6 of 7 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 If any defects are found during the check, these must be remedied without delay (refer to 2.3). 5.0 Water authority approvals Please refer to http://www.acoaus.com.au/pdf/ACO-Passavant-water-authority-approvals.pdf for ACO Passavant water authority approvals. ACO Polycrete Pty Ltd Technical Bulletin No.: TB201404 Date: 12 November 2014 Page 7 of 7
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