5_PEWE_Operation_Manual-_OWS-200.pdf

Process Engineered Water Equipment, LLC

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

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OPERATIONS MANUAL

FOR

Oil/Water Separator System

Model: OWS-200

VERSION: 1.1

June 7, 2013

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

TABLE OF CONTENTS

1. Safety ………………………………………………………………………………………………………. 1

1.1 Safety Instructions

2. System Information-...............................................………..……………………….. 2

2.1 Design Parameters

2.2 Utility Consumption

2.3 WWT Site Conditions

3. Process Description ....……………………………………………………………………………… 3

3.1 Influent Feed

3.2 Oil Recovery

4. Unit Operation .........……………………………………………………………………………….. 4

4.1 OWS Precautionary Measures

4.2 Manual System Control

5. OWS Unit Adjustment ........……………………………………………………………………. 5

5.1 Flow and Levels

System Flow Control Water Level in OWS Unit

5.2 Oil Removal

6. OWS Unit Service ……………………………………………………………………………………….. 6

6.1 Daily Check Points

6.2 Periodic Check Points

6.3 Cleaning and Housekeeping

OWS Vessel Oil Basin High Pressure Water General Housekeeping

7. Equipment Checklist ……………………………………………………………………………… 7

7.1 Feed Pump

7.2 Level in OWS

7.3 Oil Removal

8. Trouble Shooting …………………………………………………………………………….. 8

APPENDIX- at the back of this manual

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

1.0 Safety

1.1 Safety Instructions

The design and construction of PEWE equipment is based on the applicable standards with respect to safe use and avoidance of personal injury.

The following standards and directives apply for PEWE, with reference to quality and safety requirements for mechanical engineering.

These standards are based on fundamental requirements issued by the United States OSHA and implied in the directives to which the standards are connected.

Each product will be checked by PEWE on meeting the quality requirements constituted in the standards and directives.

PEWE does not take any responsibility if the warnings and instructions described in this manual are not accurately followed, or for removal of protective measures by others.

General safety measures are as follows;

Stop the whole process and lockout the electrical connection s before starting with any maintenance and repairs.

Don’t touch moving parts.

Be careful with wastewater in contact with skin injuries due to the bacteriological effect (or other pollutants) of the dirty water, use gloves to protect your skin. Also wear gloves during operation, maintenance or other activities on the equipment.

During hoisting or lifting work of the equipment, proper fastenings and supports of the installation must be ensured.

Take care of splashing, always wear safety glasses during installation and operation of the equipment.

The system starts automatically. Keep hands and clothing away. Solids and water may splash from the system during operation. Keep sufficient distance and wear safety equipment.

WARNING!

Before carrying out any maintenance or repairs ensure that the machine is electrically isolated and locked off to prevent unauthorized operation. Take all precautions to prevent injury.

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

2.0 System Information

2.1 Design Parameters

2.1.1 Type of water treated Oily Wastewater

2.1.2 Plant design capacity 200 gpm

2.1.3 FOG up to 500 ppm

2.1.4 pH 6.0 to 8.0

2.1.5 Temperature 60F to 100F

2.2 Utility Consumption

2.2.1 WWT System

Electricity

Low load none Installed power none Compressed air none

2.3 WWT Site Conditions

The equipment, process and electrical control panel are designed for installation and operation in a frost free area or indoors. Electrical panels should be protected from excessive exposure to water and heat.

3.0 Process Description

3.1 Wastewater Influent Feed

The raw water is collected prior to treatment. From this point it will be pumped or gravity fed into the OWS unit inlet flange. If a pipe flocculator(optional) is used then the water introduced at that point. The water then flows into the OWS unit. Fast oil rising particles will float to the liquid surface of the OWS. Heavy solids settle to the bottom of the separation chamber of the OWS and may be drained as necessary. Oils filter to the surface of the OWS where they are periodically drained from the compartment via an adjustable weir into the oil collection basin.

3.2 Oil Recovery

The oil collection basin is in turn left open to drain into a container or valved for periodic removal. The treated water flows through to the clear well effluent compartment for final discharge.

The chemical system starts automatically. Keep hands and clothing away. Chemicals and water may splash from the unit. Keep sufficient distance and wear safety equipment.

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

4.0 Operation

4.1 Precautionary Measures

Before the OWS system can be put in operation a number of conditions must be fulfilled, which are:

Read all safety instructions very carefully and follow the safety measures described therein. Ensure that valves in the following piping lines are open:

Feed lines Oil recovery container Discharge lines

If the OWS unit has been empty, fill it up with clean water to the edge of the adjustable clear well weir. The optional adjustable outlet weir may be in a low to mid position.

Remove any big floating material such as wood, plastic, etc. before starting the system.

4.2 Manual Control

The OWS can be started manually by the operator by opening the influent valve.

4.3 Automatic Control

The OWS can be started in AUTO by the operator by the following procedure:

4.3.1 Start Procedure

Provided that sufficient influent water is present, the unit can be put in service.

Gravity Feed- Open the OWS influent valve.

Pumped Feed- Check if power is provided for any pump.

Check that OWS inlet valves are open if using a pump.

Turn the pump switch to “ON” position if necessary.

Note the OWS will start in the sequence as described hereafter, once level of the water has reached the ON position if using automated pump system.

4.3.2 Start/Run Sequence

The OWS feed pump is turned ON when sufficient water is present.

4.3.3 Stop Sequence

The OWS feed pump stops automatically when insufficient water is present. All equipment is shut down.

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

5.0 OWS Adjustment

5.1 Flow and Levels

5.1.1 System Flow Proportional Control

The OWS system is designed for variable flow conditions. The OWS unit is best controlled with a magnetic flow-meter to measure the volume of water passing through the system. This meter supplies the various proportionally controlled sub-systems with input data. This data may also be used for record keeping purposes as well.

5.1.3 OWS Water Level

The water surface level in the OWS may be adjusted (optional) with the clear well adjustable effluent weir. Raising and/or lowering the weir directly affects the water height in the OWS. More detail is provided below.

5.2 Oil Removal

The quantity of oil in the collection basin must be checked regularly. This oil must be drained into a receiving container by opening the drain valve. Clogging of this drain indicates the need for more frequent operation.

The draining of oil is manually controlled by the operator.

5.2.1 Water Level and Oil

The optimal oil layer thickness depends on two factors-

• The water surface level in the OWS unit.

• The weir control adjustments.

The level in the OWS unit is important for balancing between oil dewatering, i.e. the thickness, and oil removal by the weir. In a properly adjusted system, variations in oil load from the influent feed water can be handled as the oil layer will float, thicken and be subsequently flow off the liquid surface. If the quantity of solids becomes greater than that which is removed by the then current weir height there are several means provided to correct this. These means are that 1) the flow to the OWS can be reduced, 2) the oil basin drainage cycle time may be increased, 3) the water level may be adjusted in the OWS unit.

A rise in the liquid surface level will mean the weir potentially removes more oil. If the water level is too high wetter solids may result and/or excess water may be let into the oil collection basin.

Lowering the water level results in a smaller portion of oil being removed. Too low a water level may result in an excessive build up of the oil layer with the result being excessive oil carry-over in the effluent.

Optional- The water surface level in the OWS is adjusted with the optional clearwell adjustable effluent weir. Raising and/or lowering the weir directly affect the water height in the OWS.

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

Keep hands and clothing away. Solids and water may splash from the equipment during operation. Keep sufficient distance and wear safety equipment.

6.0 OWS Service

The OWS requires minimal service. However periodic checks will assure continued performance. The quantity of sand or other sediment which fall to the bottom of the unit should be checked regularly. This sediment must be drained with the OWS drain port. Clogging of this drain indicates the need for more frequent operation.

6.1 Daily OWS Check Points

Once the OWS and wwt system are in regular service, it should be examined several times a day to monitor that it’s working properly. This examination will be mainly visual in nature by the operator. The daily checks are:

Alarm conditions.

Leaks from piping, pumps, OWS, etc.

Quality of effluent.

Quality of floating oil layer.

Oil drain cycle Sediment buildup.

Chemical feed system, if needed.

6.2 OWS Periodic Check Points

The periodic check should be done at short regular intervals (weekly) once the system is brought on line.

Later these checks may be further apart (monthly) as the new wwt system and crew settles into a regular routine. The periodic checks are:

Accumulation of solids in the bottom of the OWS.

Excess oil in the OWS collection basin.

Control adjustments on pumps, etc.

Lubrication of moving parts as required.

Oil piping lines.

Water leaks in piping.

6.3 Cleaning and Housekeeping

The wwt system, and particularly the OWS, is designed so that servicing is reduced to a minimum. It is advisable to clean the whole system including any screen filter, pumps and other accessories regularly.

When cleaning the system the following measures should be taken.

FIRST FOLLOW SHUT DOWN PROCEDURES BEFORE ATTEMPTING ANY CLEANING.

IMPORTANT!

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

6.3.1 Cleaning the OWS Unit

Weekly (at a minimum monthly) rinsing of the OWS unit interior components is suggested to keep the system operating at peak efficiency. Over time, depending upon water and solids being treated, soils including adherent residues, fats, oils and some chemical products may build gooey plague like substances on the surfaces. These can impede the design hydraulics of the system.

They can facilitate the growth of undesirable bacteria to the detriment of downstream systems.

They will slough off and catch in piping. They can also affect test results, yielding false readings, should they occur during sampling.

6.3.2 Cleaning OWS Vessel

Remove the oil coalescing media blocks. Rinse down of the interior assembly with a warm soapy solution is recommended. While the soapy water removes the majority of the oil sludge solids, bits cling to the sides, drying and build up. Left unchecked these solids can be bothersome to remove as well as interfere with hydraulics. This build up also can create objectionable odors and attract insects and vermin. Remove it periodically.

6.3.3 Cleaning with High Pressure Water

While cleaning the equipment with high pressure water some water may enter cavities and tight spaces. Be sure and lubricate the equipment after such cleaning.

6.3.4 General Housekeeping

A clean and well maintained OWS system and area will be an optimally operating and safe system. It is a good practice to routinely:

Rinse down walking surfaces.

Clean up spilled chemistry, oils and lubricants.

Re-stock supplies, such as gloves, hand soap and cleaning items.

Check and clean safety equipment, such as chemical safety showers and eye wash stations.

Coil and store hoses and electrical cords when not in use.

Report any equipment issues or unusual system noises.

Dispose of all oil and oil contaminated products in an appropriate legal manner.

Check to be sure the electrical systems are thoroughly dry before restoring power to the systems.

IMPORTANT!

Keep hands and clothing away. Solids and water may splash from the equipment during operation. Keep sufficient distance and wear safety equipment.

Before carrying out any maintenance or repairs ensure that the machine is electrically isolated and locked off to prevent unauthorized operation. Take all precautions to prevent injury.

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

7.0 Equipment Checklist

7.1 OWS Feed Pump

7.1.1 Start Level ____________% ______measure

7.1.2 Stop level ____________% ______measure

7.1.3 High level alarm ____________% ______measure

7.2 Level of Oil in OWS

7.2.1 Top to weir ____________measure

7.2.2 Oil basin ____________measure

7.3 Oil Removal

7.3.1 Manual valve ____________/day,week,mnth ______min open

7.3.2 Manual valve- bottom ____________ /day,week,mnth______min open

7.4 Maintenance

7.4.1 Cleaning ____________/day,week,mnth

SIGNED BY DATE

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

8.0 Trouble Shooting

Introduction This chapter will deal with process and control problems. In many cases of difficulty with equipment or in case of maintenance or servicing, please refer to the chapter on maintenance or the individual component manuals in the appendix of this manual.

Turbid Effluent

Probable Cause Check Solution

Flow Rate too high Check all feed valve positions Adjust valves, rechecking flow

Flow rate too low Check pump, sump pit, lines for Remove blockages.

blockages

Excessive Carry-Over

Floating oil layer Check for too thick oil layer Raise water level. Increase drainage timing sequence.

Excess oil in influent Check on high solids loading Find cause in upstream plant operations.

Chemical Feed Check chemical feed system Adjust chemical feed to optimal dosage level.

Excessive Turbulence in OWS

Influent Flow Check pump feed Adjust pump control, valves.

No Oil recovered

Oil Basin Weir Check weir height Adjust weir height.

19215 SE 34th St, Suite 106-202 Camas WA, 98607 USA P: 360-798-9268 F: 360-735-9437

Wet Oil Layer

Short retention time Check retention time Lower the level in the OWS, reduce rake flow speed.

Chemical Feed Check chemical feed system Adjust chemical feed to optimal dosage level.

APPENDIX

The Appendix contains documentation for the various PEWE subsystems as well as those supplied by their respective manufacturers.