Uniclass L21725+L731
EPIC J325
CI/SfB (52.9)
ACO Grease Separators Gravity Grease Management Systems Handbook
X
ACO Building Drainage
Our built environment is becoming ever more complex. Applications are becoming more sophisticated and the increasing pressure of regulations and standards make achieving design, performance and financial goals ever tougher. ACO Building Drainage is a new concept within the ACO Group. Our mission: to eliminate design risk, to reduce installed and life cost and to deliver exceptional finish and performance in every product application.
ACO Building Drainage’s extensive portfolio includes:
Stainless steel Modular Channel system
Stainless steel EuroGully gully system
Stainless steel and polymer composite access covers
Biological Grease Management system
Gravity Grease Separator system
Anti-flood protection valves
We achieve this through three factors:
Stainless steel socketed pipe system
High performance materials
Rainwater outlets for flat roofs
Design experience and project support
Global manufacturing capacity
ACO Building Drainage is a division of ACO Technologies plc and part of the worldwide ACO Group. The Group has sales in excess of ÂŁ300 million worldwide with production facilities in the UK, Germany, France, Switzerland, Denmark, Spain, Poland, Czech Republic, Australia and the USA. In total more than 3000 people are employed in 30 countries throughout the world.
Our global resources and fabrication capacity make it possible for us to deliver best value, both with our standard products and with our bespoke designs. Confidence is further assured with quality systems that are in accordance with ISO 9001-2000.
Tel:
01462 816666 Fax:
01462 851490 e-mail Enquiries:
buildingdrainage@aco.co.uk website:
www.acobuildingdrainage.co.uk
ACO Gravity Grease Separators CONTENTS
The need for fat, oil and grease management Local effects of fats, oils and grease (FOGs)
4
Regional effects
4
Legislation and regulation
4
System and separation process Overview
5
Maintenance options
5
Choosing a grease management system Factors to consider
6
Further performance considerations
7
Selection process Stages 1-3
8-9
Sizing a gravity grease separator Overview
10
ACO below ground grease separators Features and benefits - ACO Liputec
12
Technical data - ACO Liputec
13
Features and benefits - ACO ECO-FPI
14
Technical data - ACO ECO-FPI Technical data - Accessories ACO ECO-FPI
15 16-17
ACO free-standing grease separators Concept overview and description
18
Features and benefits - ACO ECO-JET-O
19
Technical data - ACO ECO-JET-O
20
Features and benefits - ACO ECO-JET-G
21
Technical data - ACO ECO-JET-G Technical data - Accessories ACO ECO-JET-O and G
22 23-24
Features and benefits - ACO Hydrojet
25
Technical data - ACO Hydrojet
26
Technical data - Accessories ACO Hydrojet
27
Installation - below ground separators ACO Liputec
28
ACO ECO-FPI
29
Installation - free-standing separators General notes
30
Assembly guide - ACO ECO-JET-G
31
Operation, maintenance and accessories General Information
32
3
ACO Gravity Grease Separators THE NEED FOR FAT, OIL AND GREASE MANAGEMENT
Local effects of fats, oils and grease (FOGs) One of the greatest drainage problems faced in kitchens and food processing areas is the accumulation of fats, oils and grease within the drainage system.
Note: As FOGs cool in the drainage system they can solidify. If untreated, accumulation eventually leads to drainage system failure with potential health hazards within the food preparation area.
Regional effects
Legislation and Regulation The problem of FOG pollution is being addressed at a regional and national level. Recent incorporation into Building Regulations and the proactive stance from many Local Authorities require that the problem is, in part, managed at source.
4
ACO Gravity Grease Separators SYSTEMS AND SEPARATION PROCESS
Process overview
Maintenance options available
All ACO separators are designed to BS EN 1825 Part 1 Grease Separators Principles of Design, Performance and Testing, Marking and Quality Control.
(according to separator type).
Pumped outlet connection using Bauer couplings Advanced high pressure (170 bar) cleaning system manual or automatic
Integrated disposal pump to assist vacuum tanker Wastewater from kitchens and food processing plants contains a mixture of water, FOGs and food residue solids.
FOGs have a density less than water. Under the correct conditions, these contaminants will naturally float on the water surface.
FOG storage capacity minimum 40 litres x NS (Nominal Size of separator), FOG surface = 0.25m2 x NS.
Periodic maintenance is required to remove the entire contents of the separator for treatment at a sewage treatment plant and is normally carried out by a specialist waste contractor.
Separated FOGs and solids are retained in the separator body whilst “grey� wastewater passes through the separator via a submerged outlet.
Solids have a higher density than water and will fall to the bottom of the separator.
Sludge capacity 100 litres x NS (nominal size of separator) or 200 litres x NS for meat processing plants
Separation compartment capacity dependant on NS size.
5
ACO Gravity Grease Separators CHOOSING A GREASE MANAGEMENT SYSTEM
Factors to consider Compared with some European countries, the UK has only recently addressed the problems arising from fats, oils and grease through national mechanisms such as the Building Regulations which now enforce control in specific businesses. Differences also exist in the extent of assessment and policing of output quality.
ACO Building Drainage® offer a choice of grease management systems: a range of biological or enzyme based traps, or separators based on differential density, often referred to as gravity separators. There are a number of factors to be taken into account when deciding on a suitable system.
Without these key drivers, demand, and therefore supply of appropriate product has been limited, with subsequent variability in the performance of the alternate methodologies on offer.
Factors
Biological
Gravity
Mode of operation principal effect
Enzymes and bacteria break down long chain FOG molecules preventing drain blockage
Differential density causes FOGs to float and solids to sink. FOGs and solids retained in separator
Maintenance regime
• Linked to automated enzyme injection system
• Requires periodic FOG removal by licensed waste disposal contractor
• Requires routine periodic enzyme replenishment
• No user adjustable maintenance variables other than contractor visit frequency
• Requires periodic sludge removal • Allows large particle removal via sediment basket • Certain variables adjustable on site for example dosing frequency Physical size and location
• Consideration of accessibility for maintenance • Manual, semi-automated or automated integrated servicing facilities
• For equivalent ‘meals per day’ performance, biological traps are far smaller
• Physically large by comparison and unlikely to be to be sited in kitchen area
• Allows location in smaller premises or where space restrictions apply
• Access to free-standing systems located within the building
• Space saving ‘under sink’ units available
• Internal or external location
• Internal or external location Design guidance
No British or European Standard exists for biological traps. Manufacturers offer own sizing methodologies
BS EN 1825 Part 2 covering selection, installation, operation and maintenance
Size selection
Based on assessment of ‘meals per day’ production in kitchen or plant, making the method especially suitable where other data is not available
BS EN 1825 offers both ‘meals per day’ as well as alternative sizing methods, such as specific plant output flow rates. BS EN 1825 also considers: • Influent temperature • FOG density variations • Use of cleaning or rinsing agents This allows precise sizing where such variables are known, for example in food processing applications
6
Managing sludge, silt and other relatively dense particles
• Allowance made within unit design and is a fixed volume • Larger particles or debris can be removed by silt basket
Design criteria calls for a minimum sludge volume (litres) of 100 x nominal size (NS) with option for 200 x NS for meat processing plant and abattoirs
ACO Gravity Grease Separators CHOOSING A GREASE MANAGEMENT SYSTEM
Further performance considerations FOGs and specified output quality
Stable emulsions
Vegetable and animal fats are separated through the differential density mechanism in the separator. However some residual fats always remain in the output effluent.
Certain FOGs may form a stable emulsion, negating the differential density mechanism of a gravity separator. Such emulsions may be present in dairy production processes for example.
Regulatory authorities may require specific output quality and may test the installation for performance.
Stable emulsions are not suitable for treatment in gravity separators.
Increasing levels of sophistication are available and can be discussed with the designer on a bespoke basis. ACO Building Drainage has over 35 years experience in water treatment technologies.
Starch Certain foods such as potatoes and rice produce high levels of starch. Excessive amounts of starch form an adhesive like gel, especially in turbulent water, potentially blocking or reducing flow in associated pipework. ACO Building Drainage has a range of starch separators.
7
ACO Gravity Grease Separators SELECTION PROCESS
Stage 1 Consider wastewater contents Although all separators accommodate silt, it is often necessary to remove course particles which might otherwise cause problems, for example fish waste, which will putrefy if allowed to enter the separator. It is important to realise that gravity separators are not designed to accommodate output from macerators.
Such waste can be removed by use of pre-strainer (see pages 23 and 27 for details)
Stage 2 Establish separator size Separator size can be established through the methodologies given in BS EN 1825 part 2. This Standard considers either type of kitchen equipment in use or assesses throughput per day in terms of meals produced or in the case of abattoirs, the volume of meat produced.
8
ACO Gravity Grease Separators SELECTION PROCESS
Stage 3 Select separator type. Below ground separators for external applications. ACO Building Drainage offer BS EN 124 Load Class D400 covers on two separator bodies. Our Liputec separator provides an economical product where the structure is non load bearing, the cover load is borne by surrounding structural detail. The ECO-FPI unit is a fully load bearing structure, minimising installation time and cost. For further information see pages 14-15.
ECO-FPI Load bearing separator
Free standing internal installations. With ECO-JET-O, ECO-JET-G and HYDROJET models, all aspects of access for installation and considerations for maintenance are accommodated. With ECO-JET-G, the separator splits into smaller components for hard to access sites. HYDROJET models present sophisticated integrated self cleaning functions.
ECO-JET-G Free-standing separator
9
ACO Gravity Grease Separators SIZING A GRAVITY GREASE SEPARATOR
Overview BS EN 1825 describes 3 methods of calculating the nominal size (NS) of a grease separator. Sizing methods contained in this Design Guide cover the more common applications only. For other sizing methods, refer to BS EN 1825 part 2 or contact ACO Building Drainage. Step 1 - Select FOG density Common FOG densities are: Fat/Oil
Density (g/cm3)
Fat/oil
Density (g/cm3)
Fat/Oil
Density (g/cm3)
Animal fat
0.85-0.94
Sesame oil
0.92
Corn oil
0.92
Butter fat
0.91
Sunflower oil
0.92-0.93
Fish oil
0.89-0.94
Coconut oil
0.92-0.93
Vegetable oil
0.95-0.97
Olive oil
0.91
Step 2 - Select kitchen type The table below details various types of kitchen, as listed in BS EN 1825. Kitchen Type
Description
Typical kitchen characteristics
Hotel
A
• High variety of meals available • à la carte menu
• Market fresh produce
Restaurant
B
• Average variety of meals available • Individual preparation of food with prepared cooking processes
• Market fresh, partly prepared produce
Hospital, clinics, care homes
C D E
10
• Few main menus (2 – 4) • Prepared in large food containers • Many forms of special foods in small food containers Large catering establishment (24h operation)
Factory and office, canteens, student refectory
• Prepared, partly market fresh produce
• Market fresh produce, large proportion of canned food • Few menus per day (1 – 2) • Prepared in few, large food containers • Kitchen ready, if applicable portioned out and pre-cooked/deep frozen food • Few menus • Prepared in large kitchens and/or microwave ovens • Large proportion of disposable crockery
ACO Gravity Grease Separators SIZING A GRAVITY GREASE SEPARATOR
Stage 1
Select kitchen type
2
Meals per day where 1 meal = 1 restaurant cover
3
Multiply by:
x 100
x 50
x 20
x 10
x5
x50
Water volume per meal in litres as stated in BS EN 1825
=
=
=
=
=
= 8500
Multiply by:
x5
x 8.5
x 13
x 22
x 20
x8.5
Peak flow coefficient as stated in BS EN 1825
=
=
=
=
=
= 72250
Multiply by:
1.3 ONLY if temperature is > 60째C otherwise go to stage 6
x1.3
=
= 93925
4
5
A
B
C
D
E
Worked Example (Type B selected)
170
Temperature at inlet in 째C
6
Multiply by: Factor for detergents, dishwasher powders and rinsing agents
7
Multiply by:
=
=
=
=
- Never used? Go to stage 7. - Occasionally used? x 1.3, - Special circumstances? (e.g hospital) x1.5 =
=
=
=
x1.3
=
x 1.5 only if density > 0.94g/cm3, otherwise go to stage 8
Olive oil is mainly used therefore go to stage 8
=
=
Factor for fat/oil density in g/cm3
8
10
=
=
=
=
Establish average daily kitchen operation in seconds (3600 seconds per hour)
11 hours
=
9
Take answer from stage 5 (or if used, stage 6 and 7) and divide answer by answer from stage 8
Round up to available NS size Sizes available 1, 2, 3, 4, 7, 10
= 122102.5
=
=
=
=
= 39600
122102.5 39600 =
=
=
=
=
= 3.08
3.08 to NS 4
11
ACO Gravity Grease Separators ACO LIPUTEC BELOW GROUND GREASE SEPARATORS
Features and benefits 1 Load Class D400 cast iron access cover with single seal. 1 2
2 600mm clear opening access cover for easy servicing access. 3 Raising tube easily cut on site to suit specific inlet/outlet pipe invert requirements. 4 Ă˜110mm or Ă˜160mm inlet/outlet spigots.
3
5 Highly corrosion resistant high density polyethylene construction. 6 Lightweight construction for easy of handling. 7 Tough, fully welded construction withstands site handling, concrete pour and groundwater pressures. 8 Concrete anchor flanges to arrest buoyancy in high water table applications. 9 Flat base ensures high stability during site movement, storage and installation.
4 5 6
7 8 9
1
ACO Liputec grease separators offer the most cost effective component system solutions. The separator body is not a load bearing structure therefore any wheel or traffic loadings must be supported via a suitable slab (designed by others) to support the applied loadings.
8
4
NBS Specification Clause Reference
12
For relevant NBS specification, refer to NBS section R12 Below Ground Drainage, Clause 630 Grease Traps/Converters and insert the appropriate model reference.
ACO Gravity Grease Separators ACO LIPUTEC BELOW GROUND GREASE SEPARATORS
Technical data
780mm
c
ød
b (range)
ACO Liputec grease separator
e
f
Flow
øa
Nominal Size NS
Part No D400 System Assembly
Flow Rate l/s
Grease Volume Sludge Volume* HDPE Body Only Litres Litres Weight kg
D400 Cover Weight kg
1
403660
1.0
180
100
96
165
2
403661
2.0
180
200
111
165
4
403662
4.0
210
400
119
165
7
403663
7.0
290
700
176
165
10
403665
10.0
400
1000
235
165
* All ACO below ground grease separators are available with optional double sludge volume (200 x NS litres, the standard item is 100 x NS litres) capacities for abattoir and other high volume sludge applications as per BS EN 1825. Contact the ACO Building Drainage Helpline on 01462 816666 for further details.
Nominal Size NS
a
b
Dimensions mm c
d
e
f
1
1100
738-1000
345
110
705
70
2
1100
743-1000
350
110
830
70
4
1100
798-1000
405
160
1145
70
7
1300
858-1000
465
160
1385
70
10
1600
740-1000
348
160
1367
100
Accessories
Part no. 90495
Description
Weight kg
Lifting key
0.8
13
ACO Gravity Grease Separators ACO ECO-FPI BELOW GROUND GREASE SEPARATORS
Features and benefits 1 Load Class D400 airtight cast iron access cover with 600mm clear opening for easy servicing access with concrete cover plate.
1
2 Lifting hooks cast in to assist site manoeuvre. 10
2
3 Separator assembly is a structural element in its own right accommodating D400 Load Class without additional concrete support or reinforcement. Maximum installation speed with minimal installation cost. 4 Ă˜110mm Ă˜160mm inlet/outlet spigots. Integrated sampling station in outlet. 5 Highly corrosion resistant spiral-wound twin-walled high-density polyethylene (HDPE) construction for the ultimate in strength.
10
6 Lightweight body construction for easy handling. 7 Robust construction withstands site handling, concrete pour and groundwater pressures. 8 Concrete anchor flanges to arrest buoyancy in high water table applications.
3
5
4
9 Flat base ensures high stability during site movement, storage and installation.
6 12
7
10 Fine and course adjustment raising rings accommodate most site requirements 11 Optional baseplate reinforcement
9
8
12 Optional built-in suction pipe for contents removal
Note. All ACO ECO-FPI systems are load bearing units and therefore offer the minimum installation requirements in the fastest time saving the installing contractor both time and money.
Base plate reinforcement
2
3
4
11
NBS Specification Clause Reference
14
For relevant NBS specification, refer to NBS section R12 Below Ground Drainage, Clause 630 Grease Traps/Converters and insert the appropriate model reference.
ACO Gravity Grease Separators ACO ECO-FPI BELOW GROUND GREASE SEPARATORS
Technical data ACO ECO-FPI below ground separator 125mm
e
100mm
Flow
ød
b
600mm
c
200mm
øf
øa
Nominal Size NS
Part No D400 System Assembly
Flow Rate l/s
Grease Volume Sludge Volume* HDPE Body Only Concrete Cover Litres Litres Weight kg Weight kg
Access Cover Weight kg
1
704901
1.0
120
100
170
450
150
2
704909
2.0
120
200
170
450
150
3
704917
3.0
120
300
185
450
150
4
704925
4.0
160
400
185
450
150
7
704933
7.0
400
700
380
1070
150
10
704941
10.0
400
1000
415
1070
150
* All ACO below ground grease separators are available with double sludge volume (200 x NS litres) capacities for abattoir and other high volume sludge applications as per BS EN 1825. Contact the ACO Building Drainage Helpline on 01462 816666 for further details.
Nominal Size NS
a
b
c
Dimensions mm d
e
f
1
1250
695
590
110
885
1300
2
1250
570
465
110
1010
1300
3
1250
685
580
110
1140
1300
4
1250
560
455
110
1265
1300
7
1800
650
545
160
1205
1800
10
1800
683
578
160
1372
1800
For NS sizes greater than NS10, contact the ACO Building Drainage Helpline on 01462 816666 for further details.
15
ACO Gravity Grease Separators ACCESSORIES - ACO ECO-FPI
Technical data
H
The inlet invert position for all ACO ECO-FPI gravity separators can be extended to suit specific site requirements by the addition of raising rings for fine adjustment or coarse adjustment, or combinations of the two.
Inlet invert
h
Adjustment rings
Flow
Simply mix and match the heights ‘h’ and ‘H’ to suit the installation.
h
Fine adjustment raising rings (all ACO ECO-FPI separators)
Ø625mm Ø865mm
Part No
Description
h mm
Weight kg
700821
Fine adjustment raising ring
60
50
700822
Fine adjustment raising ring
80
60
700823
Fine adjustment raising ring
100
70
Course adjustment raising rings Course adjustment raising rings are supplied complete with interconnecting seals
H
ØD
Description
Separator size NS
H mm
ØD mm
Weight kg
700904
Course adjustment raising ring
1, 2, 3, 4
250
1000
240
700906
Course adjustment raising ring
1, 2, 3, 4
500
1000
500
700913
Course adjustment raising ring
7, 10
250
1500
480
Part No.
16
ACO Gravity Grease Separators ACCESSORIES - ACO ECO-FPI
Technical data Slab
High Water Table Baseplate Reinforcement
>1m
Water table
Base plate reinforcement
Part No
Description
04391
High Water Table Baseplate Reinforcement
ECO-FPI Built-in Suction Pipe
Optional pumped outlet connection
Part No 04392
Description ECO-FPI Built-in Suction Pipe
ACO ECO-FPI gravity grease separators are optionally available with a factory fitted suction pipe for built-in FOG removal management installations. Outlet orientation to suit site requirement.
17
ACO Gravity Grease Separators ACO FREE-STANDING GREASE SEPARATORS
Concept overview and description ACO ECO-JET and HYDROJET free-standing grease separators are each available in Standard and Level 1 formats providing choice and full flexibility of operation with matched degrees of sophistication and automation to suit the application and budget.
ECO-JET Standard
Std
• Lowest cost option free-standing separator • Basic separator design • Access lids removed for service access
ECO-JET Level 1
1
• Standard ECO-JET format plus integrated direct disposal connection with 3” Bauer male coupling for direct disposal avoiding odours during service access
HYDROJET Standard
Std
• Integrated direct disposal connection with 3” Bauer coupling for direct disposal avoiding odours • Advanced high pressure (170 bar) cleaning system with manual control
HYDROJET Level 1
1
18
• Standard HYDROJET format plus advanced high pressure (170 bar) integrated cleaning system with automatic control
ACO Gravity Grease Separators ACO ECO-JET-O FREE-STANDING GREASE SEPARATORS
Features and benefits
1 Oval body contour for easy door accessibility. 2 One-piece lightweight monocoque construction for easy handling and transport.
1 2
4
3 Corrosion resistant rotationally moulded polyethylene body (316 stainless steel available to special order).
5
4 Two air-tight easy screw access lids for servicing and cleaning.
6
5 Ă˜110mm inlet/outlet spigots. Integrated sampling station in outlet on NS 7 and 10 models. 6 Tough site-friendly body with integrated strengthening ribs to withstand internal water pressure.
3
7 Flat base ensures high stability during installation and service.
7
8 Available in Standard format and Level 1 format with direct suction 3� Bauer service connection coupling to prevent odours during servicing. 9 NS 1-4: maximum width 800mm NS7 and 10: maximum width 930mm 10 Sampling station, horizontal or vertical outlet options available. 11 Pre-filter/sampling station supplied with air tight cover
11 12
10
12 Course pre-filter to remove particles of 10mm or greater. Removable stainless steel filter basket with 10mm x 10mm screen size and 3.3 litre sludge capacity. 13 The viewing window provides a quick and convenient method of assessing FOG level. Comes with rotating wiper blade. This item is a factory fitted accessory. 14 The clean water filling station allows re-filling of the separator with water following a service. The open tundish design prevents back-siphoning, the 75mm foul air trap and manual flow control tap add convenience and safety. This item is a factory fitted accessory.
8
9
13
NBS specification Clause reference For relevant NBS specification, refer to NBS Section R11 Above Ground Drainage, Clause 380 Grease Traps/Converters and insert the appropriate model reference.
14
19
ACO Gravity Grease Separators ACO ECO-JET-O FREE-STANDING GREASE SEPARATORS
Technical data ECO-JET-O and ECO-JET-G
Std
f
e
d
øg
flow
1
a x b (a shown) c
Direct suction 3" Bauer male connector for odour prevention
Nominal Size NS
ECO-JET-O Part No. Standard
ECO-JET-O Part No. Level 1
Flow Rate l/s
Grease Volume Litres
Sludge Volume Litres
Dry Weight kg
Filled Weight kg
1
04332
04333
1.0
125
111
45
497
2
04334
04335
2.0
121
200
65
685
3
04336
04337
3.0
121
300
65
785
4
04338
04339
4.0
166
400
75
1050
7
04340
04341
7.0
400
700
170
2042
10
04342
04343
10.0
400
1000
170
2342
a
b
c
Dimensions mm d
e
f
g
1
1135
750
1235
1215
930
860
110
2
1540
750
1640
1215
880
810
110
3
1540
750
1640
1215
1010
940
110
4
1850
780
1950
1300
1010
940
110
7
2370
920
2615
1825
1210
1110
160
10
2370
920
2615
1825
1392
1292
160
Nominal Size NS
20
Accessories for ECO-JET-O can be found on pages 23 and 24. Note. The above separators are available in 316 grade stainless steel. Contact the ACO Building Drainage Helpline on 01462 816666 for further details.
ACO Gravity Grease Separators ACO ECO-JET-G FREE-STANDING GREASE SEPARATORS
1 3-piece construction for easy installation in the most inaccessible of areas, particularly suitable for refurbishment or retro-fit installations. Maximum segment dimensions (lxwxh): NS 2: 620 x 700 x 1360 NS 4: 1050 x 700 x 1360
Features and Benefits 4
2 Oval body contour for easy door accessibility.
6
3 Lightweight construction for easy handling and transport. 2
4 Two air-tight easy screw access lids for servicing and cleaning.
3
5 Corrosion resistant rotationally moulded polyethylene body.
5
6 Connector friendly inlet/outlet spigots.
7
7 Tough site-friendly body with integrated strengthening ribs to withstand water pressure. 8 Flat base ensures high stability during installation and service.
8
9 Available in Standard format and Level 1 format with direct suction 3� Bauer service connection coupling to prevent odours during servicing. 10 Sampling station, horizontal or vertical outlet options available. 11 12
11 Pre-filter/sampling station supplied with air tight cover. 10
12 Course pre-filter to remove particles of 10mm or greater. Removable stainless steel filter basket with 10mm x 10mm screen size and 3.3 litre sludge capacity. 13 The clean water filling station allows re-filling of the separator with water following a service. The open tundish design prevents back-siphoning, the 75mm foul air trap and manual flow control tap add convenience and safety. This item is a factory fitted accessory.
9
1
13
NBS specification Clause reference For relevant NBS specification, refer to NBS Section R11 Above Ground Drainage, Clause 380 Grease Traps/Converters and insert the appropriate model reference.
21
ACO Gravity Grease Separators ACO ECO-JET-G FREE-STANDING GREASE SEPARATORS
Technical data
flow
f
e
d
øg
Std
a x b (a shown)
1
c
Direct suction 3" Bauer male connector for odour prevention
Nominal Size NS
ECO-JET-G Part No. Standard
ECO-JET-G Part No. Level 1
Flow Rate l/s
Grease Volume Litres
Sludge Volume Litres
Dry Weight kg
Filled Weight kg
2
04344
04345
2.0
80
210
75
555
4
04346
04347
4.0
161
420
115
995
a
b
c
Dimensions mm d
e
f
g
2
1200
700
1360
1360
1000
930
110
4
2000
700
2160
1360
1000
930
110
Nominal Size NS
22
ACO Gravity Grease Separators ACCESSORIES - ACO ECO-JET-O AND G SERIES
Technical data Ø385
150
øa
485
Sampling Station – horizontal outlet pipe connection
385x385 b
Part No
Description
Inlet/Outlet Pipe OD
b
Weight
a mm
mm
kg
04376
Downstream sampling station for output quality assessment
110
560
7
04377
Downstream sampling station for output quality assessment
160
490
7
Ø385
øa
b
485
Sampling Station – vertical outlet pipe connection
øa 385x385 560
Part No
Description
Inlet/Outlet Pipe OD
b
Weight
a mm
mm
kg
04378
Downstream sampling station for output quality assessment
110
100
7
04379
Downstream sampling station for output quality assessment
160
140
7
Ø385
150
øa
485
Coarse Filter
385x385 b
Part No
Description
Capacity
Inlet/Outlet Pipe OD
b
Weight
L
a mm
mm
kg
04380
Coarse pre-filter station 10mm x 10mm screen
3.3
110
560
16
04381
Coarse pre-filter station 10mm x 10mm screen
3.3
160
490
12
23
ACO Gravity Grease Separators ACCESSORIES - ACO ECO-JET-O AND G SERIES
Technical data Viewing Window (ECO-JET-O only)
Ø245mm
Left Hand
Right Hand
Plan view
Part No
Ø175mm
Description
Weight kg
04348
Viewing window assembly, right hand
5
04349
Viewing window assembly, left hand
5
Clean Water Filling Station (ECO-JET-O and G) Ball valve G 3/4”
Open
335 60
600
Closed Inlet funnel
265
205
Description
Water pipe connection
Max flow rate
Max supply pressure
Water seal depth
Weight kg
04350
ECO-JET-O clean water filling device
3/4”BSP
5l/s
4 bar
75
4
04351
ECO-JET-G clean water filling device
3/4”BSP
5l/s
4 bar
75
4
Part No
24
145
Odour seal
Note. The above separators are available in 316 grade stainless steel. Contact the ACO Building Drainage Helpline on 01462 816666 for further details.
ACO Gravity Grease Separators ACO HYDROJET FREE-STANDING GREASE SEPARATORS
1 Direct suction 3� Bauer male connector supplied to prevent odours during servicing.
Features and benefits
2 Oval body contour for convenient door accessibility.
2
3 One-piece lightweight impact and corrosion resistant polyethylene construction for easy handling and transport (316 stainless steel available to special order).
1
9
4 5
4 Connector friendly inlet/outlet spigots. Integrated sampling station in outlet on NS 7 and 10 models. 5 FOG level viewing window as standard, available right or left hand reference to inlet. 6 Flat base ensures high stability during installation and service. 7 Built-in high pressure (170 bar) rotating head grease cutting and cleaning facility with choice of manual or automatic control.
3 6
12
10
11
8 Available in Standard format as described above under manual control and Level 1 format with full automatic control. 9 Disposal pump to aid servicing where head height exceeds 6 metres, or total horizontal run of connecting pipework is greater than 30m, under manual or automatic control to suit Standard or Level 1 formats. 10 Sampling station, horizontal or vertical outlet options available. 11 Pre-filter/sampling station supplied with air tight cover. 12 Course pre-filter to remove particles of 10mm or greater. Removable stainless steel filter basket with 10mm x 10mm screen size and 3.3 litre sludge capacity.
Service requirements:
6m Max
3.9kW 415V 3-phase 50Hz supply. (6.9kW 415V 3-phase 50Hz with disposal pump fitted). Clean water supply, 4 bar maximum pressure.
30m Max
7
8
5
NBS specification Clause reference For relevant NBS specification, refer to NBS Section R11 Above Ground Drainage, Clause 380 Grease Traps/Converters and insert the appropriate model reference.
9
25
ACO Gravity Grease Separators ACO HYDROJET FREE-STANDING GREASE SEPARATORS
Technical data
Std
d
øg
flow
f
e
Manual Control
a x b (a shown)
1
c
*Note Viewing Window on right hand side when observing from inlet end (shown) Viewing Window on left hand side when observing inlet end
Automatic control
Viewing window position*
HYDROJET Part No. Standard
HYDROJET Part No. Level 1
Flow Rate l/s
Grease Volume Litres
Sludge Volume Litres
Dry Weight kg
Filled Weight kg
1
Right hand Left hand
04352 04353
04354 04355
1.0
125
111
146
598
2
Right hand Left hand
04356 04357
04358 04359
2.0
121
200
172
792
3
Right hand Left hand
04360 04361
04362 04363
3.0
121
300
176
896
4
Right hand Left hand
04364 04365
04366 04367
4.0
166
400
221
1196
7
Right hand Left hand
04368 04369
04370 04371
7.0
400
700
355
2227
10
Right hand Left hand
04372 04373
04374 04375
10.0
400
1000
377
2549
Nominal Size NS
Nominal Size NS
Dimensions mm a
b
c
d
e
f
g
1
1140
700
1565
1485
1090
1020
110
2
1496
700
1922
1431
1040
970
110
3
1496
700
1922
1561
1170
1100
110
4
1860
760
2274
1581
1190
1120
110
7
2340
910
2829
1885
1390
1290
160
10
2240
910
2829
2065
1570
1470
160
Note. The above separators are available in 316 grade stainless steel. Contact the ACO Building Drainage Helpline on 01462 816666 for further details.
ACO Gravity Grease Separators ACCESSORIES - ACO HYDROJET
Technical data Ø385
150
øa
485
Sampling Station – horizontal outlet pipe connection
385x385 b
Inlet/Outlet Pipe OD
b
Weight
Description
a mm
mm
kg
04376
Downstream sampling station for output quality assessment
110
560
7
04377
Downstream sampling station for output quality assessment
160
490
7
Part No
Ø385
øa
b
485
Sampling Station – vertical outlet pipe connection
øa 385x385 560
Inlet/Outlet Pipe OD
b
Weight
Description
a mm
mm
kg
04378
Downstream sampling station for output quality assessment
110
100
7
04379
Downstream sampling station for output quality assessment
160
140
7
Part No
Ø385
150
øa
485
Coarse Filter
385x385 b
Capacity
Inlet/Outlet Pipe OD
b
Weight
Description
L
a mm
mm
kg
04380
Coarse pre-filter station 10mm x 10mm screen
3.3
110
560
16
04381
Coarse pre-filter station 10mm x 10mm screen
3.3
160
490
12
Part No
Disposal pump Part No 04376
Additional length
Additional weight
Description
(see column c on page 26)
(see weight on page 26)
Factory fitted disposal pump
+50mm
+40kg
27
ACO Gravity Grease Separators INSTALLATION - BELOW GROUND SEPARATORS
ACO Liputec Concrete slab (design by others)
Flow
200mm min Strength Class C20/ 25 concrete
20mm levelling bed
150mm min Strength Class C20/ 25 concrete
1. Ensure ground conditions are suitable. Engineering advice may be required. 2. Determine falls and ventilation requirements as per BS EN 1825 Part 2 if appropriate to the separator. Assess pipe levels and lay a concrete bed (Strength Class C20/25 min) minimum 150mm thick to level. Allow for a mortar levelling bed 15 to 20mm thick. 3. Lower the separator body on the mortar bed and make inlet and outlet pipe connections according to flow direction of separator. 4. Fill the separator with water to help resist floatation during concrete pour and test pipe joints. 5. Pour a minimum of 200mm thick (Strength Class C20/25 min) concrete around body of separator. Ensure the body cannot float during the concrete pour. A two-stage concrete pour sequence may help control buoyancy.
28
6. The top of the access cover must be positioned level with the finished slab or a maximum of 3mm below it. Trim the HDPE raising piece so that the access cover does not bear directly on the raising piece as the separator body is not a load bearing element. 7. A reinforced concrete slab (designed by others) must be provided to suit ground and loading conditions. Pour slab to engineers’ detail. 8. Clean the rubber seal and fix the access cover with the screws provided.
ACO Gravity Grease Separators INSTALLATION - BELOW GROUND SEPARATORS
ACO ECO-FPI Concrete Slab
Access Cover Raising Ring (Option) Concrete Cover Plate Chamber Raising Ring (Option)
Flow
Separator Body
Pea Shingle Backfill
20mm Levelling Bed
High Water Table Baseplate Reinforcement For installations where the water table is at least one metre above the base of the separator, optional integrated baseplate reinforcement may be required to withstand the hydrostatic pressure.
3. Lower the separator body on the mortar bed and make inlet and outlet pipe connections according to flow direction of separator. 4. Fill the separator body with water to test pipe joints and to assist stabilisation.
Baseplate reinforcement is only available as a factory fitted option. See page 17 for part number.
5. Lower chamber raising ring(s) on to separator body if required, ensuring seals are free from detritus.
Use of fine and course adjustment rings.
6. Lower concrete cover plate in position ensuring seal is free from detritus.
Access cover raising rings are not supplied with seals. Interconnecting joints require bed of mortar during assembly for airtight operation. For stability during installation, a maximum of three access cover raising rings should be used. Additional invert depths can be achieved with combinations of course raising rings.
7. Fit access cover raising rings if required using a suitable mortar grout between joints.
Installation 1. Ensure ground conditions are suitable. Engineering advice may be required. 2. Determine falls and ventilation requirements as per BS EN 1825 Part 2 if appropriate to the separator. Assess pipe levels and lay a lean mix mortar levelling bed 15 to 20mm thick.
8. Lower access cover into position ensuring the top is level with the finished slab or a maximum of 3mm below it and grout. 9. Backfill with 10mm pea shingle or to engineers detail to slab level. 10. Pour slab to engineers’ detail. 11. Clean the rubber seal and fix the access cover with the screws provided.
29
ACO Gravity Grease Separators INSTALLATION - FREE-STANDING SEPARATORS
General notes for all freestanding separators
Typical installation schematic
In the absence of prevailing Local Authority regulations, refer to BS EN 1825 Part 2: Grease Separators Selection of Nominal Size, Installation, Operation and 14 Maintenance for detailed description of installation requirements.
HYDROJET system installed in the basement of a catering establishment. Schematic depicts ancillary equipment and fittings supplied by others 15
9
21 7
Place of installation Separators should be located as close to the FOG source as possible, but should not be located in unventilated rooms, car parks, or storage areas. To prevent odour nuisance, separators should not be located close to habitable buildings, especially to opening windows and air intakes. Protect the separator and inlet/outlet pipes from frost and ensure adequate space for maintenance and service access.
12
5 15 10
6
16
23 13
4
11 2
22
Drainage to and from the separator Grease separators are designed to operate with a freerunning outlet without backflow. Separators operating below the backflow/flood level (usually the street level) should be fitted with an appropriate lifting station. To prevent the build up of fats and grease in pipes upstream of the separator, the inlet pipe should be laid at a minimum gradient of 2% to the separator. Additional measures such as thermal insulation and trace heating may also be required. Transition from vertical to horizontal inlet pipes may be achieved using two 45° bends between which a length of pipe, at least 250mm long, is placed. This is followed by a stilling section that has a length (in mm) equal to at least 10 times the nominal size of the inlet supply pipe. For example, an inlet pipe size of 110mm, the stilling section should be at least 1100mm long before connection to the separator inlet. Ventilation Upstream and downstream pipe connections to the separator must be adequately ventilated. Provide the discharge pipe with a stack vent and provide a branch vent to all upstream branch pipes greater than 5 metres long.
30
19
17 8
1
20
3
18
1. Grease separator with direct suction device 2. Sampling station 3. Lifting station 4. Separator inlet 5. Direct suction pipe/connections 6. Bauer 3” connector 7. Bauer 3” connector for external servicing 8. Clean water fill supply pipe 9. Clean water shut-off valve 10. Separator outlet/lifting station inlet 11. Lifting plant outlet 12. Backflow loop 13. Lifting plant controller 14. Inlet ventilation 15. Separator ventilation (if required) 16. Lifting plant ventilation 17. Basement drainage pump 18. Basement sump 19. Foul sewer 20. Manual diaphragm pump connection 21. In-situ wall box for external suction connection 22. Flexible hose for cleaning purposes 23.Wall seal/bushing
Note. In the event of the basement flooding, precautions needed to prevent floatation of the separator and lifting station as appropriate together with the electrical power supplies.
ACO Gravity Grease Separators ECO-JET-G ASSEMBLY
1. Locate base section and lay flat on the ground.
4. Secure sludge and separating chambers together using the metal straps and screws supplied.
2. If applicable, insert the suction pipe (Level 1 system only) into the sludge/separating chamber connecting pipe. Assemble into the sludge chamber, ensuring all seals and mating faces are clean.
5. Locate the assembled chambers on to the base section and make the two screwed connections as shown.
Suction pipe (Level 1 system only) Sludge chamber
Connecting pipe
3. Fit the separator chamber to the sludge chamber assembly ensuring the connecting pipe and overflow spigot connection seals and mating faces are clean.
Separating chamber
31
ACO Gravity Grease Separators OPERATION, MAINTENANCE AND ACCESSORIES
All gravity grease separators require periodic maintenance to remove the fats, oils and grease (FOGs) together with sludge deposits that have been separated from the wastewater. Such maintenance is usually undertaken by a specialist waste contractor.
Thick encrustations of FOG residues can form within the separator body and may therefore require vigorous cleaning methodologies to remove them during the cleaning process. FOG Thickness Measurement FOG thickness accumulation in below ground separators can be easily assessed using this hand held measurement tool. The open ended sampling tube is simply inserted into the separator to penetrate the FOG layer, withdraw the operating rod to close off the tube and remove. FOG thickness can then be assessed by viewing the translucent tube.
Note. Only wastewater containing organic FOGs shall be discharged to a grease separator. Effluent from the following should NOT be connected to the separator:
Toilets
Macerators
Rainwater
Light liquids e.g. grease or oil of mineral origin
Macerators have the effect of artificially consuming the sludge capacity of the separator and thereby shortening the service interval to the separator. Additionally, under certain conditions, the process of maceration can emulsify waste products and prevent them from separating via the natural gravity process, thereby reducing the separation efficiency of the unit. Start Up and System Characterisation Before using the separator for the first time, fill with clean water. When first commissioned, it is recommended that the separator is emptied and cleaned refilled ideally every 2 weeks, or on a monthly basis in order to characterise the system to assess volumes of separated matter for that installation.
32
2000mm
The frequency of maintenance will depend on the volume of FOGs and the volume of sludge that is generated in the food production process. Sludge volume can be significantly reduced by effective use of strainers on sink outlets.
2450mm
General Information
Ă˜50mm
Part No 04382
Description
Weight kg
FOG thickness tool
4
The table below indicates maximum FOG thickness for each model of separator. HYDROJET models are not included as a viewing window is supplied as standard. Model Liputec
ECO-FPI
ECO-JET-O
As soon as the separator is emptied, fill with clean water to allow the separation process to continue immediately. The waste disposal contractor should be able to recommend the optimum servicing frequency. ECO-JET-G
NS
Max FOG Volume litres
Max FOG Thickness mm
1
180
250
2
180
250
4
210
290
7
290
300
10
400
400
1
125
160
2
121
160
3
121
160
4
166
160
7
400
160
10
400
160
1
125
160
2
121
160
3
121
160
4
166
160
7
400
160
10
400
160
2
80
240
4
161
240
ACO Gravity Grease Separators NOTES
33
ACO Gravity Grease Separators NOTES
34
ACO Gravity Grease Separators NOTES
35
ACO Technologies plc ACO Building Drainage ACO Business Park, Hitchin Road, Shefford, Bedfordshire SG17 5TE Tel: 01462 816666 Fax: 01462 851490 e-mail: buildingdrainage@aco.co.uk website: www.acobuildingdrainage.co.uk
Š June 2006 ACO Technologies plc. 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. This brochure and any advice is provided by ACO Technologies plc (the Company) free of charge and accordingly on terms that no liability including liability for negligence will attach to the Company or its servants or agents arising out of or in connection with or in relation to this brochure or any such advice. Any goods supplied by the Company will be supplied solely upon its standard conditions of sale, copies of which are available on request. The Company's policy of continuous product development and improvement renders specifications liable to modification. Information provided in this brochure is therefore subject to change without prior notification.