INSTALLATION AND OPERATING INSTRUCTIONS

KESSEL – Oil/fuel separatorPE Separators NS 1,5

Edition 2011/05

Name Date Town

ID number 308-100_EN

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mend

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Easy on-site mobility with-out the need for heavymachinery

Simple and quick installationand hook up

Recycable material

Seamless body due tomonolith construction –100% watertight

Company - Telephone No.

KESSEL - Oil/fuel separatorNS 1,5 for underground installation

99601.002B99601.016 B/D99601.041.B/D

Installation

The installation and service of this unit should be carried out bya licensed professional servicer

Commissioning Instruction

Product advantages

2

1. Safety Precautions

By installation, use, maintenance and repair of this unit please follow all appropriate DIN/ VDE / DVGW safety precautions and accident prevention guidelines. Also please followany local safety precautions and accident prevention guidelines established in your area.Also please observe the following:• BGV C22 (formerly VBG 37)• DIN 4124 - Safety precautions for excavations / trenches• DIN EN 1610 - Standard procedures for the installation of drainage pipingBGR 117 (formerly ZH1/77) - Standard procedures for working in confined spacesDo not allow any type of wastewater into the separator which could hinder the proper se-paration 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 when standing / walking near the separator. Du-ring disposal, cleaning and maintenance the surrounding area can become extremelyslippery due to spilled oil / fuel.

SEPARATOR AREA REGULATIONS:� No access of the separator for unauthorized personnel� The location of the separator should be chosen carefully as to allow sufficient access

for maintenance, inspection, repair and disposal of the separator.� 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 allskin and clothing which has been contaminated.

� All personnel having anything to do with the separator should have a sound knowled-ge 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 / cleanermanufacturer for additional details).

1. Safety instructions ......................................................................................... Page 2

2. General ......................................................................................... Page 5

3. Technical specifications Dimensioned drawing ...................................................... Page 6

4. Transport and storage 4.1 Transport........................................................................... Page 64.2 Storage............................................................................. Page 6

5. Installation and assembly 5.1 Installation requirements .................................................. Page 75.2 On-site earthwork ............................................................. Page 75.3 Excavation pit ................................................................... Page 75.4 Inspection prior to installation........................................... Page 75.5 Installation ........................................................................ Page 8

6. Commissioning 6.1 Making the plant ready for operation ................................ Page 96.2 Operator's duties .............................................................. Page 96.3 Hand-over Certificate ....................................................... Page 9

7. Operation and disposal ........................................................................................................ Page 9

8. Maintenance ........................................................................................................ Page 10

9. Accesories/Replacement Parts ........................................................................................................ Page 11

10. Warranty ........................................................................................................ Page 13

11. Important contacts/info ........................................................................................................ Page 14

Plant passport and factory approval ........................................................................................................ Page 15

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Table of Contents

4

Dear Customer,

Before the KESSEL Oil / Fuel separator is installed and placed in operation please carefully read and follow all of the in-structions 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 beendamaged during shipping. In case damage has occurred to the separator, please follow the instructions listed in the“Guarantee” section of this user's manual.

�� KESSEL oil/fuel separator� for underground installation. � For fuels / oils of mineral origin with densities up to 0.95

g/cm3. � With self actuating emergency closure float switch.

This separator is not for use for treatment of stabile emulsi-fied fuels / oils. It is also not for use with fats / oils from plantor animal origin.

�� Oil / Fuel Separator

This separator can be used for the following:1. Treatment of oil / fuel contaminated surface run-off of ga-

soline stations, oil storage facilities, fuel transfer facilities,parking areas and streets.

2. For the treatment of wastewater run-off from private fuelpumps, private cleaning / washing areas and private ve-hicle repair facilities.

3. For pre-treatment of wastewater before entry into primarytreatment systems

In cases 1 and 2 above, the treated wastewater is allowed tobe drained into the main public drainage network. In the casethat the treated wastewater is to be drained into a nearbywater resource (lake / river), permission must first be gran-ted by the governing local authority.

�� Oil / Fuel Separator

Oil / Fuel separators main purpose is to remove mineral oilcontaminants before the wastewater is drained into local se-wage systems or public watershed areas. The separatorsoperate with the gravity principle in that the oil / fuel conta-minants (being of a lower specific weight than water) float tothe surface of the separator before reaching the separatorʼsoutlet. The inlet of the separator, connected to nearby drainswithout odor traps, is hydraulically designed to distribute theincoming wastewater in an evenly manner which optimizesthe separation efficiency. Sludge and sediment, with a spe-cific gravity higher than water, settle to the base of the cham-ber while fuel and oil particles float to the surface. The inte-grated emergency closure switch (float switch) prevents oil /fuel from flowing out of the separator.

�� Self closing float switch

Oil and oil/fuel separators are equipped with a self closing float switch which prevents oil / fuel from flowing outof the separatorʼs outlet. In KESSEL oil / fuel separator systems, this consists of a float switch which is installed in aguide pipe which during operation is full of water. The floatswitch is calibrated to float in water and to sink in fluids witha density at or below 0.95 g/cm3. In the case that the fuelstorage capacity of a separator has been reached but the separator is not emptied / disposed, then the float switch willsink in the guide pipe and completely close off the separa-torʼs outlet. This float switch closure valve is an emergencyprotective device which should never close if the separatoris properly operated

22.. Application

5

Oil / Fuel Storage

InletOutlet

Float SwitchWater

Sludge Chamber

6

3. Technical specifications

Dimensioned Drawing

NS

1,51,51,5

Sludge chamber(l)17130360

LW(mm)

4008001000

Qmax.(l/s)1,51,51,5

DN

100100100

L(mm)

58210911425

B(mm)

52010121300

Tmin max231 324518 942570 995

h2(mm)

389508630

h1(mm)

342461583

Oil/fuel (l)

17,670,5110

Overhang (mm)

505070

Weight(kg)1274110

total volume(l)43230580

Art.No.

99601.002B99601.016B/D99601.041B/D

The chapter "Safety instructions" must be heeded!

4.1 TransportTransportation of the KESSEL separator should be handledonly by a transporter who has the proper knowledge, equipmentand employees to handle such a product. During transport theseparator must be firmly fixed into position and must not be al-lowed to move or shift in place. It also must be protected fromother objects coming in contact with the separatorduring transport.If and when the separator is lifted it is important to follow the fol-lowing correct procedures: The separator is not to be lifted withthe use of steel cables or chains. Proper equipment are heavyduty cloth or hemp straps designed to handle the correspondingloads. In instances where a forklift is used, secure the separa-tor to the forklift with appropriate cloth / hemp securing straps.4.2 Storage

In cases where the separator needs to be temporarily stored be-fore installation, it is important that the separator is placed onfirm level ground and 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.

4. Packaging, transport and storage

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During the intermediate storage of the separator anduntil completion of the installation work, suitable safe-guarding measures must be taken at the building site toprevent accidents and damage to the separator

The chapter "Safety instructions" must be heeded.

5.1 Installation RequirementsInstallation of a oil / fuel separator should be handled only aprofessional installation company with experience in thisfield. The soil / earth in the area of installation must be testedto determine if is appropriate or not for the installation of apolymer separator (soil classification according to DIN18196). The maximum groundwater height in the area of in-stallation must be determined. Max load class of vehicles dri-ving over the separator as well as the final installation depthof the separator must be determined before specifying / or-dering the separator.

The underground installed separator should be installed asclose as possible to the drains connected to it. In certain circumstances, the drainage pipe leading to the separatorshould be thermally insulated or heated. The vertically adju-stable upper sections allow easy connection of the inlet andoutlet of the separators. The load class B and D cast ironmanhole covers are not equipped with screws and are in ac-cordance with EN 124.

5.2 On-site earthwork

The separator should only be installed in areas with soil classification Group G1 to G2 according to ATV-DVWU-A127.

Sub-base Gravel / process (max 8/16) according to DIN 4226-1.

Base Sand Side backfill material Gravel / process

(max 8/16) according to DIN 4226-1Cover Asphalt, paving stores, concrete

5.3 Trench preparation / Backfilling

The sub-base of the installation trench should be a 30cmthick flat compacted layer of 8/16 gravel / process, Dpr =95%). On top of the sub-base should be a 3-10cm thick flatcompacted layer of sand. Lateral space between separatorsides and trench walls should be a minimum of 70 cm.Trench walls should conform to DIN 4124. The depth of installation should take into consideration theminimum and maximum allowable soil coverage (MIN≤ TEÜ≤ MAX – see dimensioned drawing).

� Installation in sloped areas:In the case that the separator is to be installed in a sloped location, a proper retaining wall should be designed andconstructed.

� Frost level:In the case that the separator will be in operation throughthe winter, it is important that the inlet and outlet to the separator is installed below the local frost level to assure pro-per wastewater flow and operation throughout the season

5.4 Inspection prior to installationShortly before the separator is to be installed in the excava-tion it is important that the following is checked.- separator walls are in pristine condition- Sub-base and base have been properly constructed and

compacted- Base material is according to specification

4. Installation and assembly

8

5.5 Installation

� InstallationThe separator is to be carefully lowered into the excavationand placed on the compacted sand base (see ‚Transportʼchapter).Please note:Weather influences or cooling of the chamber during installati-on (due to filling with cold water) could result in slight dimen-sional changes of separators, wastewater treatment systemsand rainwater storage tanks in comparison with dimensions li-sted in catalogs or drawings. Before installation of the cham-ber it is recommended that the exact dimensions of the cham-ber being installed (especially the chamber height) is checked.

� Separator FillingPrior to backfilling the excavation, the separator should becompletely filled with water.

� Backfilling ExcavationLateral space between separator walls and excavation wallsshould be a minimum of 70cm. The excavation should bebackfilled in 30cm increments / layers with each layer beingproperly compacted (min- Dpr=95%).Be sure to prevent movement of the separator or damage tothe walls during backfilling. If the separator is to be installedin a load class D (40.0 ton) area, a steel re-enforced concreteload support platform needs to be installed on the surface ofthe separator (drawings for this platform are available fromKESSEL if required).

� ConnectionsAfter the excavation has been incrementally filled and com-pacted up to the inlet / outlet level, connection pipes belowthe local frost level should be laid and connected to the inlet/ outlet.

� Before installing the KESSEL upper sections be sureto insert the gasket into the recessed opening of the accessshaft. Lubricated the gasket and insert the polymer uppersection to the desired height / position. Tightening the sup-plied clamping ring will firmly set the upper section in positi-on – final height / slope adjustments can be make with thethree adjustment bolts (bolts should be in the up-side-downposition). Final backfilling and compacting can now takeplace. If a deeper installation depth is required, use a KES-SEL extension section.

� Please see the following table for information regarding themaximum oil / fuel storage capacity of the available separa-tors. This information is based on a oil / fuel with a densityof 0,85 g/cm3

In the case of an outlet blockage or the closure of the emer-gency float switch, special installation instructions should befollowed in order to prevent oil / fuel from overflowing out ofthe manhole covers. This requires the manhole covers to bea higher than the lowest drain connected to the separator.This height is the following:- Base of manhole cover should be higher than the cover of

the lowest connected rain in cases that no rainwater canenter the separator.

- In the case that rainwater can enter the separator, the baseof the separator cover must be higher than the highest pos-sible back up level of rainwater.

5.6 Installation heights for alarm systems

5. Installation and assembly

NS Sludge Chamber(l)

Oil-Chamber(l)

Overstand(mm)

1,51,51,5

LW(mm)

400800100

17130360

17,670,5110

505070

Chamber body

Measured from interiorbase of separator

Measured from interiorbase of separator

Height HeightOil / fuel level sensor

(mm)Overflow sensor

Disposal intervals:The fuel / oil collected in the separator should be collected /disposed when the level has reached 80% of the maximumstorage capacity. Disposal of collected sludge in the base ofthe separator should be collected / disposed when the levelhas reached 50% of the maximum sludge storage capacity.

Important: Timely disposal of the separator is mandatory toinsure proper function and operation of the separator.

A licensed disposal company should be contracted to hand-le disposal of the separator. Disposal should take place whenlittle or no wastewater is entering the separator.

7. Disposal

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6. OperationThe chapter "Safety instructions" must be heeded.

6.1 Setting up for operationBefore the separator is put into operation, please make surethat:� the separator is clean and the interior is free from any ob-

jects which may have been placed inside during shippingor installation.

� the separator is completely filled with clean cold water.Completely filling the separator is complete when waterbegins to drain from the outlet.

6.2 Initial Instructions

Placing the separator into full operation is normally handledby a licensed tradesman although upon request can be hand-led by a KESSEL representative.The following personnel should be on hand when the initialinstructions for placing the separator into operation are given:

� Building facilities manager� Building maintenance workers� Contracted plumber / tradesman� Contracted disposal company

What to do:� Check to make sure the separator is completely wa-

tertight. Check to make sure that during transport andinstallation that no damage to the separator was

caused. Check to make sure all connections to theseparator (inlet, outlet, refill, rinse pipes etc.) are inperfect working order.

� Representative should discuss all necessary infor-mation regarding the disposal.

� Representative should take the customer step by stepthrough all stages of a separator disposal

� After the separator has been emptied (disposed) allnecessary paperwork and documentation should behanded over to the customer.

� The separator should be returned to service by fillingthe separator with fresh, cold water

6.4 Hand-over of installation and userʼs manual.

6.5 Completion of the commissioning report.

After commissioning has been completed the separatorshould be placed into normal operation mode.

6.3 Commissioning report (see attachment)

Chamber body

LW 400LW 800

LW 1000

Art.No.

99601.002

99601.016

99601.041

Measured layer thickness

65 mm

125 mm

180 mm

Sludge (50% full)

Disposal Voume

8,5 l65 l180 l

Measured layer thickness

95 mm95 mm95 mm

Oil/Fuel (80 % full)

Disposal Voume

12 l48 l75 l

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1. Do it yourself inspection- Technically trained staff- Measurement of:- Oil / fuel level- Sludge levelInspection of self activating emergency closure float switch and alarm system

- monthly (at least every 6 months)

2 Maintenance- Technically trained staff- Measurement of:- Oil / fuel level- Sludge level- Inspection of self activating emergency closure float

switch and alarm system- Disposal and cleaning, if necessary- Cleaning of sampling chamber- Data entry in log book- Every six months (at least every year)

3. General inspection- By licensed service professional- Technically trained staff- Complete separator disposal- Cleaning- Check of proper condition and operation including:

- Insure system is secure against overflowing of fuel / oil.- Condition of tank and walls- Check condition of internal parts and electrical systems.- Calibration of self activating float switch- Data entry in log book- Availability of separator certification and documents

- In the case that separator treats commercial wastewateror wastewater from the cleaning of vehicles, the followingis required:- Actual amount of entered wastewater (source, amount,

contaminants, cleaning agents, type of oil / fuel, pre-vention of entrance of emulsified agents)

- Sizing calculation and proof of proper operation of theseparator

- Prior to commissioning and then every 5 years.

Pleaser insure that:- Installation and Userʼs Manual and all relevant docu-

mentation is placed in an accessible area near the se-parator.

- The disposal procedure is handle as documented- The disposal is handled only by a licensed professional

service company.Rights reserved for technical amendments

- Please follow all local and national safety regulations- Smoking or open sources of fire is STRICTLY prohibited

when separator covers are open.

Technically trained staff:Definition – technically trained staff are individuals with theappropriate background, training and practical experience inthe use and maintenance of oil / fuel separators.

Licensed service professional:Definition – third party individuals fully trained and licensedin the field of oil / fuel separator installation, operation, dis-posal and maintenance.

8. Maintenance

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9. Accessories / Replacement partsKESSEL-Sampling Chamber B=400 for connectionto separator systemsFor underground installation, free flowing sample availability.For installation depths T=….DN 100 / 150 inlet / outlet (required size cut off on-site),connection to SML pipe according to DIN 19522.Sampling chamber internal diameter 400mm, vertically ad-justable upper section with Load Class A, B or D covers,odour tight, locked, inlet / outlet height difference – 120mm.Manufacturer: KESSEL.

* Neck portion of chamber can be sawed of on-site to reduce installationheight (do not cut at recessed gasket area).

Article Number 915402 for deeper installations

Installation Inlet Outlet Art.No.height T (mm) DN OD Class A Class B Class D

*400-1300 100/150 110/160 915 880 A 915 880 B 915 880 D1330-1660 100 110 915 813 A 915 813 B 915 813 D1330-1660 150 160 915 823 A 915 823 B 915 823 D

KESSEL-Extension section for sampling chambers

for deeper installationMax. extension height. 600 mm Manufacturer: KESSEL

Art.No.

- 915 402

Extension height Art.No.

512 mm 917 4061012 mm 917 407

KESSEL-Extension section for underground

KESSEL separator systems, polyethylene material, includes gasket

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Art.No.

917 801

Art.No.

917 802

Art.No.

917 803

Art.No.

917 804

KESSELKESSEL Oil / fuel level monitoring device.

5 meter connection cable (extendable up to 200 meter), installation set, watertight cableconnection, conduit access insert, IP 54 control unit housing, plug in ready, with LED andaudible alarm and potential free contact.

KESSEL-KESSEL back up / overflow monitoring device.

5 meter connection cable (extendable up to 200 meters) installation set, watertightcable connection, conduit access insert, IP 54 control unit housing, plug in ready,with LED and audible alarm and potential free contact.

KESSEL Oil Suction System

Suction pipe B 50 with Bi 50 suction hose for on-site connection to interior of uppersection, with Storz 52 C connection coupling

KESSEL Sludge Extraction System

Suction pipe B 50 with sludge suction funnel, 0.5m re-enforced suction hose Bi 50for on-site connection to interior of upper section, with Storz 52 C connection cou-pling.

9. Accessories / Replacement parts

13

10. Guarantee

1. In the case that a KESSEL product is defective, KESSEL hasthe option of repairing or replacing the product. If the productremains defective after the second attempt to repair or repla-ce the product or it is economically unfeasible to repair or re-place the product, the customer has the right to cancel theorder / contract or reduce payment accordingly. KESSELmust 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 defectas soon as it is discovered. If the product is repaired or re-placed, the newly repaired or replaced product shall receivea new warranty identical to that which the original (defective)product was granted. The term defective product refers onlyto the product or part needing repair or replacement and notnecessarily to the entire product or unit. KESSEL products arewarranted for a period of 24 month. This warranty period be-gins on the day the product is shipped form KESSEL to its cu-stomer. The warranty only applies to newly manufacturedproducts. Additional information can be found in section 377of the HGB.

In addition to the standard warranty, KESSEL offers an addi-tional 20 year warranty on the polymer bodies of class I / IIfuel separators, grease separators, inspection chambers, wa-stewater treatment systems and rainwater storage tanks. Thisadditional warranty applies to the watertightness, usabilityand structural soundness of the product.A requirement of this additional warranty is that the product isproperly installed and operated in accordance with the validinstallation and user's manual as well as the correspondingnorms / 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.

Note: Only the manufacturer may open sealed components orscrew connections. Otherwise, the warranty may become nulland void

01.06.2010

Separator Characteristics

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Separator characteristics

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Important contacts / Info

Separator Type: __________________________________________________________

Day / Hour __________________________________________________________

Project description / Building servicessupervisor __________________________________________________________Address __________________________________________________________Telephone / Fax __________________________________________________________

Builder __________________________________________________________Address __________________________________________________________Telephone / Fax __________________________________________________________

Planner __________________________________________________________Address __________________________________________________________Telephone / Fax __________________________________________________________

Contracted plumbing company __________________________________________________________Address __________________________________________________________Telephone / Fax __________________________________________________________

Commissioning no. KESSELSystem operator / owner __________________________________________________________Address __________________________________________________________Telephone / Fax __________________________________________________________

Other remarks ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

The system operator, and those responsible, were present during the commissioning of this system.

____________________________ ____________________________ ____________________________Place and Date Signature Builder Unterschrift Anlagenbetreiber

��

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