KESSEL – Oil / Fuel separator KESSEL – Coalescence separator
Contents
1. page 13 page 16 1 Safety Precautions 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 separator please follow the instructions listed in the Guarantee section of this user s manual AN By installation use maintenance and repair of this unit please follow all appropriate DIN VDE DVGW safety precautions and accident prevention guidelines Also please follow any local safety precautions and accident prevention guidelines established in your area Also please observe the following 6 BGV C22 formerly VBG 37 DIN 4124 Safety precautions for excavations trenches DIN EN 1610 Standard procedures for the installation of drainage piping BGR 117 formerly ZH1 77 Standard procedures for working in confined spaces Do not allow any type of wastewater into the separator which could hinder the proper separation between oils fuels and water 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 when2. prevention of oil fuel ladened wastewater runoff from entering sewage treatment plants lakes rivers and public drinking water supplies Handling of the oil fuel wastewater at the source is the most efficient and most economical method of handling this polluted wastewater Installation of a KESSEL oil fuel or coalescence separator guarantees the proper treatment of the wastewater according to German and European regulations 2 2 Separator description The KESSEL oil fuel and coalescence separators are designed for underground installation and include a separation chamber as well as an integrated sludge sedimentation separation area The body of the separator is manufactured from virgin Polyethylene whose wax like smooth finish requires that no other additional coatings are necessary The upper sections of the separators are manufactured from Duroplast or Polypropylene The separators are designed for underground installation at various pre specified depths and are available with Class B 12 5 ton or Class D 40 0 ton load manhole covers Additional technical information concerning the separators can be found on the nameplate attached to all units as well as the technical specification sheet included in this manual 3 1 Transport 3 Transport and Storage cK Transportation of the KESSEL separator should be handled only by a transporter who has the proper knowledge equipment and employees to handle such a
3. s manual Information concerning each disposal should also be kept on record Please take care that e This Installation Service and Maintenance Guide is kept in a safe location where it is always available e The disposal of the separator is only carried out by a certified company e Safety precautions listed in this manual and all other relevant safety precautions are followed at all times 10 8 Accessories and Replacement Parts DN 100 001110 KESSEL polyethylene sampling chamber diameter 400 mm For underground installation DN 100 750 inlets and outlets cut on site to required size connects to plastic pipe based on DIN 19534 400 mm interior diameter sampling chamber vertically adjustable upper section with clamp ring covers available in Class A 1 5 ton Class B 12 5 ton and Class D 40 0 toni load classes covers are lockable and odor tight inlet to outlet elevation drop 120 mm Manufacturer KESSEL Inlet depth Inlet amp Outlet sizes Load La T mm DN 00 Class Article z 900 1300 100 150 110 160 A 1 5 toni 9158804 200 1300 109 150 110 160 B 12 5ton 915880B 900 1300 100 150 110 160 D 40 0 ton 915880D For shallower installation depth the necessary length of the upper section of the sampling chamber is simply sawed off gasket is replaced and upper section inserted into gasket sampling chamber body KESSEL polyethylene sampling chamber diameter 300 mm Fo
4. standing walking near the separator During disposal cleaning and maintenance the surrounding area can become extremely slippery due to spilled oil fuel SEPARATOR AREA REGULATIONS x No access of the separator for unauthorized personnel x The location of the separator should be chosen carefully as to allow sufficient access for maintenance inspection repair and disposal of the separator x The wastewater in the separator can contain skin irritants After Coming in contact with wastewater or the separator itself it is important to wash clean and disinfect all skin and clothing which has been contaminated x All personnel having anything to do with the separator should have a sound knowledge of the above safety precautions Helpful Hints 1 Manhole covers on top of fuel separators must not be screwed or locked on 2 Manhole covers on top of fuel separators must not have ventilation ports 3 All drains connected to the separator must not have any type of odour trap 4 All drains connected to the separator should be equipped with sludge traps 5 Wastewater must not be pumped into the separator it must be gravity fed 6 Detergents and cleaners used to clean the separator must not be emulsifiable they should be cleaners which separate quickly with water contact detergent cleaner manufacturer for additional details 2 1 Application The KESSEL oil fuel and coalescence separators are of special design to aid in the
5. use of the vertically adjustable upper sections The manhole covers for the upper sections are available in load classes B 12 5 ton and D 40 0 ton and meet EN 124 standards Note before installation make sure that no dirt grit debris exits between any of the sealing areas gaskets Also check the entire separator to make sure that no cracks holes or dents have occurred during transportation or storage Before installation be sure to determine the maximum groundwater level at the site of installation to make sure that groundwater will never rise higher than the bottom of the outlet 1 The excavation in which the separator is to be installed must be level and capable of handling the appropriate loads The base of the excavation should be comprised of a 25 cm layer of frost free gravel covered by a 3 to 10 cm layer of sand or fine gravel 2 Before installation remove the float switch chamber coalescence amp float switch chamber if a coalescence separator is being installed and store in a safe place Place the separator in the prepared excavation hole Make sure the separator is level and rests at the appropriate elevation Fill the separator with fresh cold water to the outlet level 3 The excavation should now be backfilled with non binding material such as sand or fine gravel Backfill only the main body of the separator do not backfill around the upper sections The backfill should be firmly compacted at incremental levels appro
6. 1 4501 170 4800 99406 30D sw iar som amor TT or or ion Se eet 3 10 1500 650mm 3000 150 1200 1280 1070 1170 3001 130 2500 99410 15 D es oor nem lar awl 8 8 sor aor Fro ast aS 6 15 3000 1100 mm 3000 200 1760 1330 1600 1350 4501 170 4800 99415 30D zo com oor nl E GE TS an eos io Sst se 10 20 4000 1100 mm 8000 200 1760 1330 1600 1900 I 170 5700 99420 40D 4 Installation 4 3 Installation example KESSEL Coalescence separator Illustration shows coalescence separator with class B cover 4 4 Dimensioned drawing Class A B Class D 2080 950 1100 331 kg 99503 10B S 650 mm 2000 150 1200 1280 1030 300 1800 99503 10D tam nn ol 88 Re aor om a Pr 1100 mm 6000 I 150 1760 1330 1560 13501 4501 4800 I 99506 30D SI O A E av aor io a 3 10 15001 650 mm 3000 I 150 1200 1280 1030 11701 3001 130 2500 I 99510 15 D ao sor somm aso ool 1o HS Trosor esn mo et ea 3 10 30001 1100 mm 3000 I 200 1760 1330 1560 13501 4501 170 4800 I 99510 30D as Lo Loron Loomi nl 80 88 88 ns wr Loa e E 3 15 40001 1100 mm 8000 I 200 1760 1330 1560 1900 I 170 5700 I 99515 40D 4 Installation 4 5 Installation area When the shipment arrives please inspect it immediately for damage which may have been caused during transport shipping The inlet of the KESSEL separator must be installed below the frost level This can be achieved by the
7. EL Oil fuel direct disposal device see pages 10 and 11 Article 917 803 KESSEL Sludge sediment direct disposal device see pages 10 and 11 Article 917 804 KESSEL Coalescence filter insert Article 917805 12 1 In the case that a KESSEL product is defective KESSEL has the option of repairing or replacing the product If the product remains defective after the second attempt to repair or replace the product or it is economically unfeasible to repair or replace the product the customer the has the right to cancel the order contract or reduce payment accordingly KESSEL must be notified immediately in writing of defects in a product In the case that the defect is not visible or difficult to detect KESSEL must be notified immediately in writing of the defect as soon as it is discovered 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 defective 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 months This warranty period begins on the day the product is shipped from KESSEL to its customer The warranty only applies to newly manufactured products Additional information can be found in section 377 and 378 of the HGB 2 Wear and tear on a product will not be
8. INSTALLATION AND OPERATING INSTRUCTIONS KESSEL Oil Fuel separator KESSEL Coalescence separator PE Separators according to Euro norm EN 858 NG 3 20 KESSEL Oil Fuel separator 99403 99420 KESSEL Coalescence separator 10 15 30 40 B D Accordino to EN 858 99503 99515 NG 3 20 for underground installation 10 15 30 40 B D Product advantages Easy on site mobility without the need for heavy machinery Simple and quick installation and hook up Recycable material Seamless body due to monolith construction 100 watertight The installation and service of this unit should be carried out by a licensed professional servicer Company Telephone No Edition 07 02 HG ID number 010 615 Subject to technical amendment 1 Safety Precautions and Helpful Hints 2 1 Application 2 2 Separator description 3 Transport and Storage 3 1 Transportation 3 2 Temporary Storage 4 Installation 4 1 Oil Fuel separator 4 2 Dimensioned Drawing 4 3 Coalescence Separator 4 4 Dimensioned Drawing 4 5 Installation Area 5 Commissioning 5 1 Separator Commissioning 5 2 Commissioning Participants 6 Separator Contents Disposal 7 Maintenance 8 Accessories and Replacement parts Important Contacts Info Table of Contents page 3 page 4 page 4 page 5 page 5 page 6 page 6 page 7 page 7 page 8 page 9 page 9 page10 page10 page 11
9. considered a defect Problems with products resulting from improper installation handling or maintenance will also not be considered a defect 01 01 2002 13 10 Separator Characteristics E KESSEL Type Production number production year Weight kg length x width X height EN Approval Sludge trap volume Oil 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 Important Contacts Info Separator Type Day Hour Project description Building services supervisor Address Telephone Fax Builder Address Telephone Fax Planner Address Telephone Fax Contracted plumbing company Address Telephone Fax Commissioning no KESSEL System operator owner Address Telephone Fax Other remarks The system operator and those responsible were present during the commissioning of this system Place and Date 15 Everything for drainage _ F ie gt Backwater valves and cleanouts gt Grease separators gt Polymer and cast iron drains gt Oil fuel and coalescence separators gt Volatile liquid traps gt Inspection chambers gt Lifting stations pumps warning and gt Custom projects for industrial control units applications gt Rainwater management systems IK KESSEL
10. e sure that e The separator is completely clean including inlet and outlet and that the interior of the chamber is free of dirt and debris e The cleaned separator is completely filled with clean cold water up to the outlet this step should already have taken place in the Installation phase of this user s manual e Re insert the float switch chamber coalescence amp float switch chamber if a coalescence separator is being installed e Replace manhole covers manhole covers MUST NOT be screwed or fastened to the separator Manhole cover should simply rest on the upper sections of the separator 5 2 Commissioning participants The commissioning of the separator is usually handled by a tradesman although this can be handled by a KESSEL contractor or KESSEL employee if desired 1 The following people should be on hand during the commissioning e Building contractor representative e Plumber tradesman who will be maintaining the separator e Building maintenance personnel e Disposal company who will be handling the disposal account 2 Commissioning preparation e Separator is completely filled with clean water 3 Commissioning e Separator to be checked for water tightness and for proper functionality e Contents of this user s manuals to be discussed with those present 4 Transfer of this manual to the appropriate personnel 6 Separator Contents Disposal The separator should be emptied disposal when the oil fuel
11. product During transport the separator must be firmly fixed into position and must not be allowed to move or shift in place It also must be protected from other objects coming in contact with the separator during transport lf and when the separator is lifted it is important to follow the following 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 between the two manholes covers as illustrated on this page In instances where a forklift is used secure the separator to the forklift with appropriate cloth hemp securing straps In cases where the separator needs to be temporarily stored before installation it is important that the separator is placed on firm level ground and in an area where it is protected from coming in contact with other objects Storing the separator outdoors will not cause any problems 4 Installation 4 1 Installation example KESSEL Oil Fuel Separator KAE N Class A B Class D 2080 950 1100 331 kg 99403 10B 3 1000 650mm 2000 150 1200 1280 1070 300 130 1800 99403 10D ea oor nm oooi il 83 88 sor aor foro ast sh 3 6 3000 1100 mm 6000 150 1760 1330 1560 1350
12. r underground installation Connects to SML pipe based on DIN 19522 860 mm interior diameter sampling chamber vertically adjustable and titable upper section with clamp ring manhole entry clearance 610mm covers available in Class A 1 5 ton Class B 12 5 ton and Class D 40 0 ton load classes covers are odor tight manhole cover removal tool included Inlet depth Inlet amp Outlet sizes Inlet depth Inlet amp Outlet sizes Atile _ ClassA B ClassD T mm 450 950 150 160 915 760 80B 915 760 80 D 620 1120 150 160 915762 80B 915 762 480 D 620 1120 200 200 upon request upon request For shallower installation depths the necessary length of the upper section is simply sawed off 400 mm Extension height KESSEL polyethylene extension section 400 mm extension section complete with sealing gasket Article 917 402 11 8 Accessories and Replacement Parts KESSEL Cast iron manhole cover for Euro Norm 124 underground grease separator Includes gasket and screws Load Class Article class B 916802 class D 916803 KESSEL Replacement gasket for manhole cover Article 917101 KESSEL alarm unit For monitoring oil fuel level inside the separator see pages 10 and 11 Article 917 801 KESSEL alarm unit Alerts when outlet of separator is blocked or if inlet flows are exceeding the separators capacities see pages 10 and 11 Article 917 802 KESS
13. storage capacity has reached approximately 4 5 s 80 of its capacity or every 6 months whichever is sooner In order for a separator to function as designed it is very important that the separator is emptied at regular intervals as described above It is recommended that a licensed disposal company is contracted to handle the entire disposal procedure Disposal procedure e Remove manhole covers e Remove the float switch chamber coalescence amp float switch chamber if disposing a coalescence separator Rinse clean the filter with fresh water and inspect for damage e Place disposal truck s suction hose inside separator and remove entire contents of the chamber sludge and fuel oil e Rinse and clean interior walls of chamber Remove any solids or particulates e Remove remaining contents inside separator e Re insert the float switch chamber coalescence amp float switch chamber if disposing a coalescence separator e Refill entire separator with cold clean water e Clean and grease all accessible seals Replace seals if necessary e Replace manhole covers 7 Maintenance Before the separator is placed into service and at regular intervals thereafter minimum two times per year it is important that 1 The interior and exterior walls of the separator are thoroughly cleaned and checked for damage Inlet and outlet equipment should also be checked 2 All inspection and maintenance work should be logged into this user
14. x 30 cm For load class D 40 0 ton situations the upper section and manhole cover of the underground separator must be poured into a steel reinforced concrete apron for proper load support Additional information regarding this load class D support is available from KESSEL 4 Connect the inlet and outlet of the separator to the drainage piping 5 Install and adjust the upper section s of the separator to the desired level and secure with the included clamp ring clamp ring will rest on the chamber itself Final upper section level adjustments can be made by using the elevation adjustment screws located on the clamp ring Back fill the remaining area around the upper sections with sand or fine gravel leave space for a 15 cm concrete load supporting apron steel reinforced if installed Load Class D 40 0 ton covers NOTICE Take care not to place any loads on top of the manhole covers and upper sections of the separator until the separator is completely backfilled and if required the load supporting concrete apron around the manhole covers has completely cured INUIT Ke aS SST eae is Som eb Eee se Merad LZ L A Bnr S x a rs q z 300M fae T mA L T ee 4 l BAERE C0 MS MS K Ad SS fez gt 300m Se oe pried gt 50cm a Eger eran NA A vee Ls S 300m le e 9 P i T Lane E A S S PUCTB 5 1 Separator commissioning Before the separator is put into service please mak
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