KESSEL – Oil / Fuel separator KESSEL – Coalescence separator
Contents
1. e oe 8 Se 8 oe Qe S e Ce Eu EM 8 Se 6 mom leleem S Le lt a o tege To Done 0 o S gt Tose 9 7o T oye 7 0 T oxe C o T Tasya Son 0 9 S gt o5s C Lo 0 9 7 6 o 270cm Subbase round grain gravel max graining 8 16 according to DIN 4226 1 compacted with Dpr 95 Tank bed compacted sand 270cm DIN 4226 1 compacted with Dpr 95 5 Area outside tank encasing materi al of suitable Tank consistence Top layer topsoil road surface concrete or similar Tank encasing round grain gravel max graining 8 16 according to 5 5 Installation The float and coalescence insert if fitted remain in the tank du ring installation Insertion The tanks must be placed carefully in the construction pit with the aid of suitable lifting equipment and positioned on the sub strate bedding see also the Chapter Transport Filling of the tank and the backfilling construction pit In order to avoid deformation of the tank the filling of the tank with water and the construction pit should take place in paral lel The tank jacketing should be applied to a width of at least 50 cm The backfilling around the tank should take place in 30 cm incremental layers Each2. 3 Installation In cases a to d the discharged water from the separators is intended to be fed back into the public drainage system If the discharged water is to be returned into waters this is only possible in individual cases following clarification with the local water authority Separators used in case d are used in systems for the re striction of hydrocarbons in waste water containing mineral oil in the sense of Part E Paragraph 2 of Appendix 49 of the waste water regulations The level of hydrocarbons required by regulations in cases c and d of 20 mg l is considered to have been observed 2 2 System description The illustration shows a fuel separator cistern installed in the ground of Class A B D Outlet point without stench trap Light fluid separator Inlet with stench trap Outlet with self actuating closure Guide tube Float Attachment piece Cover 9 Sample removal shaft Backwater valve 2 3 Functional description The separators separate light fluids and sludge out of the waste water by means of gravity Light fluids refers to fluids of mineral origin with a density of lt 0 95 g cm3 which are in soluble or only slightly soluble in water and which are non saponifiable These do not include stable emulsions fats and oils of vegetable or animal origin Light fluids float up in the separation chamber and collect at the surface Sludges which are heavier than water sink to the b
3. Connection of the warning system empty pipe if applicable The connecting section between the separator and control unit must be kept as short as possible Unnecessary changes of direction in particular those with angles above 45 should be avoided The empty pipe for the cable should have a continual slope down to the separator The formation of condensation within the empty pipe can be minimised by an airtight closure of the empty pipe on the side of the control unit A cable pull through wire can also be laid for subsequent cable laying KESSEL light fluid separator Layer thickness sensor 1 6 Watertight cable connection 2 8 Reverse flow sensor 4 S 7 Attachment set 8 Empty pipe closure Control unit Housing for wall installation a KESSEL Insert the lip seal DN 600 in the groove in the dome Telescopic attachment Minimum insertion depth 100 mm L Tank dome and apply grease Insert the telescopic KESSEL upper section into the opening of the separator and adjust to the required po sition With the aid of the clamping ring the upper sec tion can now be fixed in the required position aligned with the upper ground level The fine adjustment to the final height is then made with the aid of the setscrews Slopes can easily be compensated for by the fully height adjustable and inclining upper section The upper section must be adequately
4. When actuated in an emergency the separa tor must be taken out of service and maintained a KESSEL 3 2 Dimensioned drawing 7 in dh lu de d k 1000 1000 2500 2500 5000 5000 1500 1500 2500 2500 5000 5000 5000 5000 pe trap na 150 150 200 200 200 200 150 150 200 2004 200 200 200 200 A Tue eu UU meus 1200 1200 1760 1760 1760 1760 1200 1200 1760 1760 1760 1760 1760 1760 830 840 850 850 870 870 830 840 850 850 870 870 870 870 1240 1100 1230 1090 1250 1090 1240 1100 1230 1090 1250 1090 1250 1090 3 1 Installation example KESSEL Oil Fuel Separator gt B L in Tinmm mm min max 1100 1100 1630 1630 1630 1630 1100 1100 1630 1630 1630 1630 1630 1630 1 Comparable total sludge trap volume according to dimensioning of DIN EN 858 2 Eccentric reduction of inlet outlet to DN 150 possible on site fitted through DN 150 sample removal shaft Do oa 187 187 265 265 380 380 262 262 265 265 380 380 380 380 Illustration shows KESSEL oil fuel separator class Il with cover class B and sampling chamber 3 Installation DN 150 T Tg 155 mm DN 200 T Tev 180 mm T Tev Height above ground Class D 700 mm x Tet lt 1 500 mm rstand m 50 50 70 70 100 100 70 70 70 70 100 100 100 100 379 635 519 775 594 850 42
5. 19 1 A specialist in this sense refers to personnel of the opera tor or other company who by means of their training skills and experience obtained from practical work ensure that they carry out assessments or checks in the relevant specialised field to the required standard A specialist can acquire the specialist knowledge required for the operation and maintenance of separator systems in a trai ning course with the following on site instruction which is of fered for example by the corresponding manufacturers pro fessional trade associations chambers of commerce and ex pert organisations in the field of separator technology 2 A specialist in this sense refers to personnel of business other than the operator experts or other institutions which de monstrably have the specialist skills required for the operati on maintenance and checking of separator systems In indi vidual cases such as larger operating units for example these checks can also be carried out by internally independent spe cialists of the operator not bound by instructions with regard to their area of responsibility who have equivalent qualificati ons and technical equipment Qualified bodies are specialist businesses independent of the operator or similar institutions whose employees demonstra bly have the specialist skills required for the operation main tenance and checking of separator systems to the extent spe cified here together
6. 99703 04B 99703 04D 99703 10B 99703 10D 99403 10BEX 99403 10DEX 99610 15BEX 99610 15DEX 99606 30BEX 99606 30DEX 99610 30BEX 99610 30DEX 99606 80BEX 99606 80DEX 99610 80BEX 99610 80DEX 99615 80BEX 99615 80DEX 99503 10B 99503 10D 99710 15B 99710 15D 99706 30B 99706 30D 99710 30B 99710 30D 99706 80B 99706 80D 99710 80B 99710 80D 99715 80B 99715 80D 15 99503 10BEX 99503 10DEX 99710 15BEX 99710 15DEX 99706 30BEX 99706 30DEX 99710 30BEX 99710 30DEX 99706 80BEX 99706 80DEX 99710 80BEX 99710 80DEX 99715 80BEX 99715 80DEX 1450 mm a KESSEL 6 Commissioning The chapter Safety instructions must be heeded 6 1 Setting up for operation Before the separator is put into operation please make sure that p gt the separator is clean and the interior is free from any ob jects which may have been placed inside during shipping or installation p gt the separator is completely filled with clean cold water Completely filling the separator is complete when water begins to drain from the outlet 6 2 Initial Instructions Placing the separator into full operation is normally handled by alicensed tradesman although upon request can be hand led by a KESSEL representative The following personnel should be on hand when the initial instructions for placing the separator into operation are given B Building facilities manager p gt Building maintenance workers p gt Contracted plumber trade
7. erc r3 f HE DEN trap T in mm hin Total Oil NUR dcs Weight Cover Art No min max mm volume l mm Kg class TT 150 1100 560 1010 1090 1020 1580 B 110 305 99706 10B 1000 150 11000 560 1010 1090 1020 1580 200 110 338 99706 10D an KESSEL 4 Transport and Storage Transportation of the KESSEL separator should be handled only by a transporter who has the proper knowledge equipment and employees to handle such a product During transport the separator must be firmly fixed into position and must not be al lowed to move or shift in place It also must be protected from other objects coming in contact with the separator during trans port If and when the separator is lifted it is important to follow the fol lowing correct procedures The separator is not to be lifted with the use of steel cables or chains Proper equipment are heavy duty cloth or hemp straps designed to handle the corresponding loads The separator should be lifted by placing the proper straps beneath the inlet and outlet of the separator as seen in the illustration Do not lift the separator by the small holes bet ween the two manholes covers as illustrated on this page In in stances where a forklift is used secure the separator to the for klift with appropriate cloth hemp securing straps In cases where the separator needs to be temporarily stored be fore installation it is important that the separator is placed on firm level ground and
8. sensor self monitoring and alarm repetition KESSEL alarm system for limit value display detection of backing up in the light fluid separator Limit value probe suitable for Ex Zone 0 with 5 m connection cable extendible up to max 200 m attachment set for easy installation and maintenance the probe is accessible from above watertight cable connector for extension of the connec tion cable through pipe with screw closure and two screw type cable connectors housing for wall mounting IP 65 control unit with visual and acoustic alarm with potential free contact with sensor self monitoring and alarm repetition The sensors of the warning system must be fitted at different height levels depending on the size of the separator The in stallation dimensions are shown in the table The specified values must be checked during the course of re gular maintenance and corrected if necessary A ee fluid separator Art No Art No The installation and maintenance of the warning system is de scribed in the enclosed original operating instructions Illustration of the cistern E Illustration of the oil layer probe Old i Drobe KVF 103 PF Oiflsyer New probe Alarm lev level 1 KVF 104 PF Distance B of the oil layer probe from the tank bottom Distance A of the limit value A ee from the tank bottom 99403 10B 99403 10D 99
9. 4 680 519 1715 594 850 594 850 A B D A B D A B D A B D A B D A B D Class A B 700 mm x Te lt 1 800 mm Oil storage Ove Weight C Art No Art No Kg over lass A B D 99403 10B 99403 10D 99606 30B 99606 30D 99606 80B 99606 80D 99610 15B 99610 15D 99610 30B 99610 30D 99610 80B 99610 80D 99615 80B 99615 80D 3 Installation 3 3 Installation example KESSEL Coalescence separator Ed Illustration shows KESSEL coalescence separator class with cover class B and sampling chamber 3 4 Dimensioned drawing DN 150 T Tev 155 mm DN 200 T Tev 180 mm T Te Height above ground LA 22Cc 222 Klasse D 700 mm lt TEU lt 1 500 mm Klasse A B 700 mm x Te x 1 800 mm L D Bi LE ETE EE mm votre RR rt No 1 mm min max volume l l mm Kg class 1000 150 2080 1200 830 1240 1100 1040 1800 187 50 395 A B 99503 10B 1000 150 2080 1200 840 1100 1100 1040 1800 187 50 651 D 99503 10D 2500 200 2300 1760 850 1230 1630 1560 4300 265 70 535 A B 99706 30B 2500 200 2300 1760 850 1090 1630 1560 4300 265 70 791 D 99706 30D 5000 200 3060 1760 870 1250 1630 1560 5800 380 100 610 A B 99706 80B 5000 200 3060 1760 870 1090 1630 1560 5800 380 100 866 D 99706 80D 1500 150 2860 1200 830 1240 1100 1040 2600 262 70 440 A B 99710 15B 1500 150 2860 1200 840 1100 1100 1040 2600 262 70 696 D 99710 15D 2500 200 2300 1760 850 1230 1630 1560 4300 265 70 535 A B 99710 30
10. 610 15B 99610 15D 99606 30B 99606 30D 99610 30B 99610 30D 99606 80B 99606 80D 99610 80B 99610 80D 99615 80B 99615 80D 99703 04B 99703 04D 99703 10B 99703 10D 99403 10BEX 99403 10DEX 99610 15BEX 99610 15DEX 99606 30BEX 99606 30DEX 99610 30BEX 99610 30DEX 99606 80BEX 99606 80DEX 99610 80BEX 99610 80DEX 99615 80BEX 99615 80DEX 99503 10B 99503 10D 99710 15B 99710 15D 99706 30B 99706 30D 99710 30B 99710 30D 99706 80B 99706 80D 99710 80B 99710 80D 99715 80B 99715 80D 13 99503 10BEX 99503 10DEX 99710 15BEX 99710 15DEX 99706 30BEX 99706 30DEX 99710 30BEX 99710 30DEX 99706 80BEX 99706 80DEX 99710 80BEX 99710 80DEX 99715 80BEX 99715 80DEX 1820 mm 1335 mm 1230 mm 1230 mm 1730 mm 1730 mm 764 mm 764 mm 1264 mm 1264 mm a KESSEL 5 Installation and assembly Note The holes for the attachment set must be drilled only at the specified positions The holes must be made using a 3 5 mm diameter drill The original attachment screws must be used in the attachment without plugs The positions of the holes should be adjusted accordingly if the seal might be damaged by the drill Under no circum stances must the cone of the rotation tank be damaged or drilled through The extension of the cable to max 200 m is only possible using original parts cable and cable connectors Information can be obtained from the KESSEL Customer Service Department under telephone no 0 18 05 27 82 82 Th
11. B 2500 200 2300 1760 850 1090 1630 1560 4300 265 70 791 D 99710 30D 5000 200 3060 1760 870 1250 1630 1560 5800 380 610 A B 99710 80B 5000 2002 3060 1760 870 1090 1630 1560 5800 380 866 D 99710 80D 5000 200 3060 1760 870 1250 1630 1560 5800 380 100 610 A B 99715 80B 5000 200 3060 1760 870 1090 1630 1560 5800 380 866 D 99715 80D 1 Comparable total sludge trap volume according to dimensioning of DIN EN 858 2 Eccentric reduction of inlet outlet to DN 150 possible on site fitted through DN 150 sample removal shaft 3 Installation 3 5 Illustration KESSEL coalescence separator shaft 3 6 Dimension drawing of KESSEL coalescence LW 1000 NS 3 separator shaft LW 1000 NS 3 1 min max A oa T am Lg Ed Em are n pa E HEJ O BE HB m BEA Jy FE HR n2 T I ef Hr mT E trap T in mm hin Total Oil Pd m Weight Cover NANA min max mm volume l mm e class 800 100 11000 545 995 1105 1055 790 200 110 175 99703 04B 3 800 100 11000 545 995 1105 1055 790 200 110 205 D 99703 04D 3 1600 100 11000 545 995 1605 1555 1390 200 110 190 B 99703 10B 3 1600 100 11000 545 995 1605 1555 1390 200 110 220 D 99703 10D 3 7 Dimensioned Drawing KESSEL coalescence separator LW 1000 NS 6 with upstream sludge trap min max hr N DI vami al le Pp h h2 l a k ETENEE Fami EN i LJ ian orco
12. INSTALLATION AND OPERATING INSTRUCTIONS KESSEL Oil Fuel separator KESSEL Coalescence separator PE Separators according to Euro norm EN 858 NS 3 15 99 403 99615 KESSEL Oil Fuel separator 10 15 30 80 B D KESSEL Coalescence separator 99 503 99715 99703 04 10 B D NG 3 15 for underground installation 9970610 B D obs Product advantages E Easy on site mobility without the need for heavy machinery E Simple and quick installation and hook up B Recyclable material m Seamless body due to monolith construction 100 watertight Installation Commissioning J Instruction The installation and service of this unit should be carried out by a licensed professional servicer Subject to technical amendment Company Telephone No Edition 2009 11 ar K FSS E i ID number 010 619 1 Safety Instructions Personnel used for installation assembly operation maintenance and repair must have the cor responding qualifications for such work Areas of responsibility and the supervision of personnel must be clearly specified by the operator The operating safety of the system supplied is only ensured in the event of proper use The limit values specified in the technical data must not be exceeded under any circumstances Accident prevention regulations and the applicable standards and directives must be observed at all times during installation assembly operation maintenance and repair of th
13. ater level x I i rarum IE md 80 full rx rur T separator should be emptied 2 I 1 10096 full E un a float switch closes o Cc o O x lt E i KESSEL 17 D Q p P lt Q O lt G O Q lt lt Q ajas 4 co Jsi eroeds e q no peuueo eq snu eoueuojureuu 3y saee G UU s eAJejui 19140Us ye nO pales si uoroedsur e1eue eu JJ uone 1odaoJ eoueueiure N isijeioods Aq u uu yooqBo Gunejedo 1odai Ss L xXooq5o Bunejedo uodajJ eoueueiure N xXooq60 Gunejedo tioneoumieo uone eisu nooq Tni Sr Jequieuo uonoejoo ebDpnis uun oA poaurejaJ oui MOJ9Q SI A BU JO peJuinbaJ sy sJeo S n u u Buluoissiuuuuo2 9JOoJeg payors si 08 piny 106r u1uouJ 9 u1uOUJ ueuM Sulejs s 10 eJedoes y Jo eoueuuopged pue AjiqelIns Buiuoisueuilq suois nuJe e qeis Jo q epioAe speuejeuu Burejedo sjueDe Duiueej o s u uoo Ajuenb uiBuo 1878M JSEM JO euJnjoA enjoy pexoeuo eqos e 1snuJ sjuiod BuiwoJ eui se oruaA Jo Buliue 5 y UJOJJ JBJEM JSEM JO JOJEM JSEM 6I9JOUJUJOO JO Ju u e 1 BU 104 pesn osje si Wa sAs Joje1edes U JI uonejueuunoop pue s eAo4dde pouinbed y jo sseuejejduioo pue jj iqejreAy peAouJai sjenayew eu JO suomneuunuoo esodsiq yooqBol yooqBo Bunejedo Duie1edo eui jo YOOUD y ui Sp10991 y Jo y iqisnejd pue ss u duuoo OSIA D EAOUJOJ IA p eJnso o Dunenjoe j e
14. begins on the day the product is shipped form KESSEL to its customer The warranty only applies to newly ma nufactured products Additional information can be found in sec tion 377 and 378 of the HGB 2 In addition to the standard warranty KESSEL AG offers an ad ditional 20 year warranty on the polymer bodies of class Il fuel separators grease separators inspection chambers wastewa ter treatment systems and rainwater storage tanks This additional warranty applies to the watertightness usabili ty and structural soundness of the product A requirement of this additional warranty is that the product is properly installed and operated in accordance with the valid in stallation and user s manual as well as the corresponding norms regulations 2 Wear and tear on a product will not be considered a defect Problems with products resulting from improper installation handling or maintenance will also be considered a defect a KESSEL Separator Characteristics Bahnhofstr 31 D 85101 Lenting Type Production number production year Weight kg length x width X height EN Approval Sludge trap volume Oil fuel storage volume Control stamp Material Accessories This unit has been checked for watertightness to be sure that it is fully operational before leaving the factory Date Name of examiner iki KESSEL 22 Important contacts Info Separator Type Day Hour Project de
15. bserved 2 1 2 Oil fuel separators to Separator Class iki KESSEL Separators for light fluids with coalescence device can be used a for the treatment of rainwater contaminated with light fluids from surfaced areas e g filling stations oil storage and handling areas parking areas and streets in water pro tection areas b as a retaining system for light fluids for the safety of sy stems and areas where light fluids are handled e g filling stations oil storage and handling areas c for the treatment of dirty water contaminated with light fluids commercial waste water produced taking into ac count the operating conditions of industrial processes the cleaning of parts contaminated with oil and the clea ning of floor areas contaminated with oil except workshop floors d for the treatment of waste water produced taking into ac count the operating conditions of automatic vehicle clea ning partial flow outlet from the closed circuit into the drainage system manual cleaning vehicle washing en gine washing underbody washing chassis cleaning in washing bays self service or commercial washing bays except for the cleaning of workshop floors contaminated with oil and for the drainage of areas used for the receipt storage drying dismantling and crushing of old vehicles e for preliminary separation of light fluids from waste water before further treatment in subsequent internal waste water treatment plants
16. d to DIN 4124 The depth of the construction pit should be such that the limits of the earth covering are not ex ceeded MIN lt TEU lt MAX see dimension drawing in the Chapter on Technical Data Root penetration In case of installation in the vicinity of trees or shrubbery pe netration by roots must be reliably prevented Installation on a sloping site In case of installation of the separator on a sloping site care must be taken to ensure that the laterally acting soil pressure of unsecured soil is absorbed by a suitably dimensioned sup porting wall Frost free depth for all year round use Always take care to observe the locally established frost free depth when installing the separator In order to ensure the smooth operation even in winter the inlet and outlet pipes must also be laid at a frost free depth during installation 5 4 Tests before installation Immediately before installation of the tank in the construction pit the responsible specialist of the company carrying out the installation must test and certify the following the integrity of the tank wall the proper condition of the construction pit in particular with regard to the dimensions and substrate bedding the particle size of the filling material 11
17. disposal company should be contracted to hand le disposal of the separator Disposal should take place when little or no wastewater is entering the separator Emptying intervals The light fluid retained in the separator must be removed at the latest when the quantity of separated light fluid reaches 80 of the maximum storage quantity or the level is below the retai ned volume For separators simultaneously or exclusively used for the drainage of systems or areas where light fluids are hand led e g fuelling areas the retained volume required under state regulations must also be provided The separated light fluid must also be removed at levels below this retained volu me if the quantity of separated light fluids has not yet reached a KESSEL 80 of the maximum storage quantity The disposal of the sludge contained in the sludge trap must be removed at the latest when the separated sludge quantity reaches half of the sludge trap volume Note Light fluids and sludge must be removed as specified above in order to ensure the correct operation of the sy stem For this reason a disposal contract should be concluded with a specialist disposal company The disposal work should be carried out if possible when the system is not in operation Expected disposal volumes in accordance with the filling level can be estimated by means of the following table The figures contained in the table are approximate figures only for the purpos
18. e system These include Accident prevention regulations Construction work BGV C22 Waste water systems GUV V C5 e Safety regulations for work in enclosed areas of waste water systems GUV R 126 e Handling of biological materials in waste water systems GUV R 145 Directives for work in tanks and restricted areas BGR 117 Standards Construction pits and ditches Embankments shoring working area widths DIN 4124 Laying and testing of waste water pipes and channels DIN EN 1610 Work aids for safety and health protection in waste water systems ACCESS NO SMOKING Smoking is strictly prohibited near or around the separator at all times All sources of ignition or sparks are prohibited near or around the separator at all times SLIPPERY WHEN WET Take caution when standing walking near the separator During dis posal cleaning and maintenance the surrounding area can become extremely slippery due to spilled oil fuel e Dangers from gases and vapours such as the danger of suffocation poisoning or explosion e Danger of falling e Danger of drowning Fecal pollution in waste water containing faeces High physical and psychic stresses of work in deep restricted or dark areas and others Failure to observe these operating instructions may result in substantial material damage phy sical injuries or fatal accidents The system constitutes one component of an overall system The operating instructions of the overa
19. e use of any parts other than KESSEL original parts will invalidate the ATEX approval the construction type appro val and any guarantee claims against KESSEL When drawing in the cable into the empty pipe to the con trol unit the cable screw connections on the empty pipe clo sure must be tightened firmly The union nut must then be fixed to the end of the pipe Inner side 1 Outer side Cables to the probes Cable screw fittings Union nut Through seal 5 Empty pipe closure 6 Through pipe 7 Empty pipe 5 7 Oil and sludge extraction for shaft LW 1000 on request only For normal disposal the hose from the suction vehicle is held in the light fluid separator and the complete contents pumped out The volume of light fluid is however significantly less than the total volume of the separator Assistance is provided in this case by the oil extraction device For disposal of the light fluid the suction hose is connected to the oil extraction device The suction vehicle can then remove only the volume corresponding to the maximum light fluid quan tity This means a significant reduction of the disposal quantity which together saves both time and disposal costs and cau ses less wear to the separator components In the same way as the oil extraction device the disposal quantity can also be significantly reduced by the sludge extraction device a KESSEL This is beneficial particularly for businesses with a high le
20. es of estimating quantities when contracting a specialist disposal company 16 7 Disposal Oil fuel Separator Oil Fuel Art Nr 1 Measured Disposal 2 Measured Disposal Filling level layer thickness volume Filling level layer thickness volume in 96 in mm in litres in 96 in mm in litres 99403 10B 99403 10BEX 99503 10B 99503 10BEX 99403 10D 99403 10DEX 99503 10D 99503 10DEX c1 N N c1 Co N co N Oo 99610 15B 99610 15BEX 99710 15B 99710 15BEX 99610 15D 99610 15DEX 99710 15D 99710 15DEX Q ho co NO Oo c1 no 99606 30B 99606 30BEX 99706 30B 99606 30D 99606 30DEX 99706 30D 99610 30B 99610 30BEX 99710 30B 99610 30D 99610 30DEX 99710 30D N O1 OO Oo O1 G5 O1 Co G 99606 80B 99606 80BEX 99706 80B 99606 80D 99606 80DEX 99706 80D 99610 80B 99610 80BEX 99710 80B 99610 80D 99610 80DEX 99710 80D 99615 80B 99615 80BEX 99715 80B 99615 80D 99615 80DEX 99715 80D C1 co O1 NO Co N O 99703 04B 99703 04D coo gt 99703 10B 99703 10D c1 gt gt N N RB RB e e co 99706 10B 99706 10D C1 cO N O 1 The sludge retained in the separator must be disposed of at the latest at a filling level of 50 2 The light fluid retained in the separator must be disposed of at the latest at a filling level of 80 or when the retained volume is exceeded o o o c x S i ey h E Z 4 o W
21. ical Data If this excess height cannot be maintained a warning device for light fluids must be installed Drainage area Surface level covers Illustration 1 Separator system ready for use Light fluid separators must be protected against reverse flow from the drainage system KESSEL recommend the following protective precautions Inside a building Projection available Inside a building No projection Reverse flow closure Outside a building Projection available Outside a building No projection Lifting system Reverse flow closure 10 5 Installation and assembly 5 2 Filling material The separator must only be installed in non cohesive or low co hesive soils Group G1 to G2 to ATV DVWU A127 Substrate Round particle gravel max particle size 8 16 to DIN 4226 1 Tank bed Sand Tank jacketing Round particle gravel max particle size 8 16 to DIN 4226 1 Area outside tank jacketing Material with suitable properties Covering layer Humus or similar 5 3 Construction pit The foundation must be horizontal and level in order to be able to set up the system over the full surface and must also afford adequate load bearing capability The substrate consists of compacted round particle gravel max particle size 8 16 mini mum depth 30 cm Dpr 95 covered by 3 10 cm of com pacted sand The spacing between the construction pit wall and the tank must be at least 70 cm The embankments must be constructe
22. in an area where it is protected from co ming in contact with other objects Storing the separator outdo ors will not cause any problems a KESSEL 5 Installation and assembly During interim storage of the separator and up to the end of the installation work suitable safety measures must be taken on the construction site to avoid accidents and da mage to the light fluid separator The Chapter Safety Instructions must be observed 5 1 Installation requirements The installation must be carried only by companies who have the necessary specialist experience suitable equipment and adequately trained personnel for the task The soil characteristics must be investigated for technical con struction suitability Soil classification for technical construction purposes DIN 18196 The maximum ground water level likely to occur must also be established The ground water level must not exceed the level of the outlet Adequate drainage of see page water is also essential in the case of soils impermeable to water The types of stresses occurring such as maximum traf fic loads and installation depth must also be clarified The separators for ground installation should be installed out side the building as near as possible to the outlets If neces sary the connection pipes of the inlets to the separator should be laid with heat insulation or heated The required frost free installation depth is achieved by the use of telesc
23. l Page 1 1 5 3 F K Viola Page 1 1 5 4 Tryouts before assembly Page 11 5 5 Assembly a Page 1 1 5 6 Ai Ti u uu unus s gt Page 13 5 7 Oil and Sludge extraction Page 14 6 Operation 6 1 Making the plant ready for operation Page 16 6 2 Commissioning Instruction Page 16 6 3 Iggjoro grin a e ERE Page 16 FDP uennecdudietiumditelece imeem dle eee cca asma iue ie senes Page 16 S Mamntenahce suiqiuemniipiiis ER ae tp etidm Penc M S EAD LA Ede Page 18 9 Accessories Replacement parts a r nnn nennen nnne nnns Page 20 10 UL oli S E E Page 21 11 Separator characteristics sse memini nnns Page 22 12 Important contacts 7 info n Page 23 a KESSEL Dear Customer Before the KESSEL Oil Fuel or Coalescence separator is installed and placed in operation please carefully read and follow all of the instructions contained in this Installation Maintenance and User s Manual Upon delivery of the KESSEL separator please thoroughly inspect the separator to make sure that it has not been damaged during shipping In case damage has occurred to the se
24. layer should be compacted with light compaction devices min Dpr 95 Damage to the tank wall and displacement of the tank during and after installation must be avoided The self actuating closure keeps the system clo sed during the complete filling process Connection of the tank Any transport safety devices fitted must be removed Note the pipe connection fittings must be protected against damage in order to ensure the permanent integrity of the system To make connection easier the pipe connection fittings should be ade quately greased The transition from downpipes to horizontal pipes must be made using two 45 elbows separated by an intermediate pipe at least 250 mm long A calming section must be installed in front of the separator system which must be at least 10x as long as the nominal width of the feed pipe a KESSEL 5 Installation and assembly When the construction pit has been filled and compacted to the lower edge of the feed and outlet connections the feed and outlet pipes are laid frost free and connected Instructions for the warning system Lay the connection cable or empty pipe during the earthworks Connection of the sample removal shaft Sample removal devices must be installed in the direction of flow immediately after the separator The sample removal device of the separator system must be freely accessible and positioned so that only waste water is removed which has passed through the separator
25. let AtN DN 200 917 808 KESSEL Sludge Extraction System Suction pipe B 50 with sludge suction funnel 0 5m re enforced suction hose Bi 50 for on site connection to interior of upper section with Storz 52 C connection cou pling mlt ARNO DN 200 917 809 20 9 Accessories Replacement parts 917 816 917 805 KESSEL Coalescence filter insert KESSEL Coalescence filter replacement part for KESSEL Coalescence separator LW 1000 1 In the case that a KESSEL product is defective KESSEL has the option of repairing or replacing the product If the product re mains defective after the second attempt to repair or replace the product or it is economically unfeasible to repair or replace the product the customer has the right to cancel the order contract or reduce payment accordingly KESSEL must be notified im mediately in writing of defects in a product In the case that the defect is not visible or difficult to detect KESSEL must be noti fied immediately in writing of the defect as soon as it is disco vered If the product is repaired or replaced the newly repaired or replaced product shall receive a new warranty identical to that which the original defective product was granted The term de fective product refers only to the product or part needing repair or replacement and not necessarily to the entire product or unit KESSEL products are warranted for a period of 24 month This warranty period
26. ll system and the individual components must therefore also be observed During all as sembly maintenance inspection and repair to any of the components the overall system must be shut down and secured against restarting Conversion or modifications to the system must only be made after consultation with the manu facturer Original spare parts and accessories approved by the manufacturer must be used in order to ensure safety The use of other parts may invalidate liability for the resulting conse quences a KESSEL Table of Contents 1 Safety Instructions 2525s Page 2 2 General 2 1 PA UIC 00 u uuu uuu u u ua Page 4 2 2 Separator description Page 4 3 Technical Data 3 1 Installation example Oil Fuel Separator Page 6 3 2 Dimensioned drawings Oil Fuel Separator Page 6 3 3 Installation example Coalescence Separator Page 7 3 4 Dimensioned drawings Coalescence Separator Page 7 3 5 Drawing Coalescence Separator Inspection Chamber LW 1000 Page 8 3 6 Dimensioned drawings Coalescence Separator Inspection Chamber LW 1000 Page 8 4 Transport Storage 4 1 TIAS DONT ee 222 ua Page 9 4 3 wilelfzio u uni nu Page 9 5 Installation and assembly 5 1 Assembly requirements Page 10 5 2 Filing Materia
27. llations if fitted The findings and work carried out must be recorded in the operating logbook and evaluated If fitted electro mechanical assemblies such as pumps val ves shut off devices etc must be maintained twice yearly in accordance with the manufacturers instructions 8 2 Checking general inspection Before commissioning and then at regular intervals of no more than 5 years the separator system must be completely emptied and cleaned and then checked by a specialist 2 for proper condition and operation The following points at least must be checked and recorded Assessment of the separator system Structural condition and integrity of the separator system Condition of the inner wall surfaces of the installed parts and the electrical equipment if fitted laying of the feed pipe of the separator system as a ventila tion pipe over the roof Completeness and plausibility of the records in the operating logbook Confirmation of the proper disposal of the materials remo ved from the separator system Availability and completeness of the required approvals and documentation approvals drainage plans operating and maintenance instructions A checking report must be compiled on the checks perfor med noting any existing faults If faults are discovered these must be rectified immediately Article General inspection of oil coalescence separator Operating logbook of oil coalescence separator
28. opic attach ment pieces which also allows easy adjustment to feed and ou tlet pipes drainage system The covers for the load classes A B and D are not bolted and comply with EN 124 Separator systems must be installed close to the point of ori gin of the light fluids They must be easily accessible for clea ning and maintenance purposes The use of locked or ventilated covers is prohibited Pump or lifting systems must not be installed in the supply line in front of the separator If these are necessary they must be in stalled after the separator For the reliable operation of the system KESSEL recommends the installation of a projection and also a warning system The necessary fitting requirements must be provided before filling of the construction pit Separator systems must be installed so that the upper edge of the covers is sufficiently high in comparison to the made level of the surfaces to be drained see Figure 1 The fluid level in the separator is always higher than the water level in the drainage system due to the difference in density bet ween light fluid and water The definitive level is the highest possible standing rainwater height when dirty water and rainwater are channelled together If only dirty water is being fed in the definitive level is the upper a KESSEL edge of the lowest connected outlet The necessary projection depends on the nominal size of the separator see Chapter on Techn
29. ottom and form a sludge layer Coalescence separators like oil fuel separators work on the principle of gravity To increase the separation performance the tank also contains a coalescence insert This cylindrical insert has two functions Firstly it affects the flow in the se parator and secondly it filters all the waste water through the coalescence material When waste water containing oil flows through this filter fa bric very fine oil droplets that can no longer be separated out by gravity collect on the coalescence material and combine to form large oil droplets When these reach a sufficient size to create buoyancy they detach themselves from the filter material and rise to the surface Light fluid separators are equipped as standard with a self actuating closure When the maximum oil storage volume is exceeded this de vice closes the outlet into the drainage system This prevents the escape of light fluids into the drainage system This sa fety device consists of a guide tube full of water which hou ses a float The float is carefully designed with regard to its weight so that it floats in water and sinks in light fluid up to a density of 0 95 g cm3 When the maximum oil storage quantity is re ached oil flows through the lateral openings into the float guide tube The float then sinks reliably shutting off the ou tlet of the separator The self actuating closure of a separator is an emergency closure valve
30. parator please follow the instructions listed in the Guarantee section of this user s manual 2 General 2 1 Area of application The separators are intended for use under specified conditi ons see the Chapter Installation and assembly for instal lation underground or below the foundation slab in well ven tilated areas 2 1 1 Oil fuel separators to Separator Class Il The separators can be used a for the treatment of rainwater contaminated with light fluids from surfaced areas e g filling stations oil storage and handling areas parking areas and streets in water pro tection areas b as a retaining system for light fluids from systems and areas where light fluids are handled e g filling stations oil storage and handling areas c for preliminary separation of light fluids from waste water before further treatment in subsequent internal waste water treatment plants In cases a and b the discharged water from the separators is intended to be fed back into the public drainage system If the discharged water is to be returned into waters this is only possible in individual cases following clarification with the local water authority In the treatment of dirty water contaminated with light fluids commercial waste water or waste water from the applicati on areas of Appendix 49 of the waste water regulations the observation of a limit value for hydrocarbons of 20 mg l can not be considered to have been o
31. s eui JO uoneJqi e ej duues y jo Buiueo 2 jueuudinbe Aresseoeu Jl IP911199 9 y pue sued pej eisui y JO uonipuo Guiueojo pue Buiaduia u s s Joyesedas eui JO AjuBeiul pue uomipuoo eunonuig 55 1 iuBi u ss ox sliun yeus eui Jo Walshs soresed 1snuJ suome n69J eoi vep BuiujeM pue aJnso o eolMep BulusemM pue inso 5 S eui WO4 spiny 1uBii Jo edeose eui 1sureBe Haes Jesodsip e jsew eu Dugenjoe jjes y jo oeu Dumnenioe jjes eui jo Y90940 9A9MOU 1S 9 ye JoKe eDpn s eui Jo JoKe eDpn s eui Jo pue uonejedo Jedoud pue uonipuoo 1edoud 10 499u2 pini WUBI pins 1uDi Buliue o lt oDpn s pue Jo sseuxpotu JABAL Jo sseuxpotu JABAL Bui iduu ejejduio2 lt pini 13uDi jo PAouu t J y Jo jueujeJnseoeJ u y Jo jueujeJnseoe u JeuM O9IAJ8S JOLUO SND SXyJOM ueduuoo sijgio ds Apog peueno Auedwioos jesodsiq Jo Auedwood jsije109ds isiyeinads Auedwod js eroodS ouM NOILOAdSNI TVd3N39S TVSOdSIG 3ONVN3 LNIVIAI AO3HO 7A4143S NOILVTIVLSNI 7 diVd3d KESSEL IK 18 8 Maintenance and Controls The Chapter Safety instructions must be observed 8 1 Maintenance The separator system must be maintained annually by a specialist 1 In addition to the removal of materials the following work must also be carried out Check of the inner wall surfaces of the sludge trap and the grease separator Functional check of the electrical devices and insta
32. scription Building services supervisor Address Telephone Fax Builder Address Telephone Fax Planner Address Telephone Fax Contracted plumbing company Address Telephone Fax KESSEL Commissions no oystem operator owner Address Telephone Fax User Address Telephone Fax Person of delivery Other remarks The system operator and those responsible were present during the commissioning of this system Place and date Signature owner oignature user a KESSEL 23 Everything for drainage 1 Backwater valves and cleanouts Grease separators 6G Polymer and Ecocast drains 99 Oil fuel and coalescence separators 9 Volatile liquid traps 9 Inspection chambers Lifting stations pumps warning and control units 9 Custom projects for industrial applications G Rainwater management systems ac KESSEL
33. sman p gt Contracted disposal company What to do B Check to make sure the separator is completely wa tertight Check to make sure that during transport and installation that no damage to the separator was caused Check to make sure all connections to the separator inlet outlet refill rinse pipes etc are in perfect working order B Representative should discuss all necessary infor mation regarding the disposal Representative should take the customer step by step through all stages of a separator disposal p X After the separator has been emptied disposed all necessary paperwork and documentation should be handed over to the customer B The separator should be returned to service by filling the separator with fresh cold water Y 6 4 Hand over of installation and user s manual 6 5 Completion of the commissioning report After commissioning has been completed the separator should be placed into normal operation mode 6 3 Commissioning report see attachment 7 Disposal Disposal intervals The fuel oil collected in the separator should be collected disposed when the level has reached 80 of the maximum storage capacity Disposal of collected sludge in the base of the separator should be collected disposed when the level has reached 50 of the maximum sludge storage capacity Important Timely disposal of the separator is mandatory to insure proper function and operation of the separator A licensed
34. supported from underneath and vi brated in using a flat bed vibrator and a steel plate laid on the upper section For greater installation depths the special KESSEL in termediate piece Art no 917402 height 400 mm in tended for this purpose should be used Lip seal DN 600 0 remaining filling For installation in areas of heavy vehicle traffic cover class D a reinforced concrete slab must be provided as the upper layer A corresponding formwork and reinfor cement plan is available from KESSEL 12 5 Installation and assembly 5 6 Warning system As specified by DIN EN 858 separator systems must be equip ped with self actuating warning devices The KESSEL warning systems Art no 917801 917802 and 917806 are alarm devices for light fluid separators fuel coale scence and oil separators They are approved for operation in areas subject to the risk of explosion Zone 0 KESSEL alarm system for oil layer monitoring detection of the layer thickness in oil and light fluid sepa rators Oil layer probe suitable for Ex Zone 0 with 5 m connection cable extendible up to max 200 m attachment set for easy instal lation and maintenance the probe is accessible from above watertight cable connector for extension of the connection cable through pipe with screw closure and two screw type cable connectors housing for wall mounting IP 65 control unit with visual and acoustic alarm with potential free contact with
35. vel of sludge The complete separator can of course also be emptied by the sludge extraction device If both devices are used for disposal it must be ensured that the oil is disposed of first followed by the sludge The retaining device is attached at the inlet using the pipe clamp as shown in the drawing Fit the oil extraction to the retaining device set to the required height x see Table and fix in position Stub connection Sludge extraction f Oil extraction Retaining device I j Fitthe sludge extraction to the retaining device feed to the bot tom and then fix in position Fitthe stub connections to the attachment as shown in the dra wing using the stainless steel screws provided 5 Installation and assembly The holes must be made using a 3 5 mm diameter drill Use the stub connection as a drilling template Fit the knuckle coupling to the end of the hose and fix with a hose clamp Hook the hose with the knuckle coupling upwards in the stub connection lead to the extraction device and adjust to the re quired length Connect the hose and extraction device and fix using a hose clamp When the cover is closed it must not be in contact with the knuckle coupling Light fluid separator Art No Distance X of the oil extraction from the tank bottom 99403 10B 99403 10D 99610 15B 99610 15D 99606 30B 99606 30D 99610 30B 99610 30D 99606 80B 99606 80D 99610 80B 99610 80D 99615 80B 99615 80D
36. with the technical equipment for the checking of separator systems In individual cases such as larger operating units for exam ple these checks can also be carried out by internally inde pendent specialists of the operator not bound by instructions with regard to their area of responsibility who have equivalent qualifications and technical equipment Order No 917 411 L 917 812 a KESSEL 9 Accessories Replacement parts a KESSEL KESSEL alarm system set Oil fuel level monitoring device see Art no 917801 and back up over flow monitoring device see Art no 917802 917 806 KESSEL Oil fuel level monitoring device 5 meter connection cable extendable up to 200 meter installation set watertight cable connection conduit access insert IP 54 control unit housing plug in ready with LED and audible alarm and potential free contact 917 801 KESSEL back up overflow monitoring device 5 meter connection cable extendable up to 200 meters installation set watertight cable connection conduit access insert IP 54 control unit housing plug in ready with LED and audible alarm and potential free contact 917 802 KESSEL alarm system cable for extension of the KESSEL oil layer probe and KESSEL limit value probe 917 810 KESSEL Oil Suction System Suction pipe B 50 with Bi 50 suction hose for on site connection to interior of upper section with Storz 52 C connection coupling in
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