Biorock ECOROCK-5000 Installation And User Manual Download

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Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017

Summary of Contents for ECOROCK-5000

Page 1: ...PAGE 1 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 INSTALLATION AND USER GUIDE ECOROCK 5000 BIOROCK Multirock systems BIOROCK Multiple Installations ...

Page 2: ...PAGE 2 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 ...

Page 3: ...PAGE 3 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 TABLE OF CONTENTS A INSTALLATION GUIDE 4 B USER GUIDE 27 C APPENDICES 39 ...

Page 4: ...e to contact your BIOROCK distributor for any queries or further assistance Thank you for choosing BIOROCK The installation and commissioning of your BIOROCK system should be carried out by a BIOROCK trained and approved installer Your installer will be able to offer you a maintenance contract The BIOROCK Warranty is only valid if the required maintenance is carried out by a BIOROCK trained and ap...

Page 5: ...A INSTALLATION GUIDE PAGE 5 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 A INSTALLATION GUIDE ECOROCK 5000 BIOROCK Multirock systems BIOROCK Multiple Installations ...

Page 6: ...of the complete system 15 4 1 2 Installation of the Primary Tank 15 4 1 3 Installation of the ECOROCK treatment unit 16 4 2 Installation in dry ground conditions 16 4 2 1 Installation and digging in dry ground conditions 16 4 2 2 Installation of the Tanks in dry ground conditions 16 4 2 3 Backfilling in dry ground conditions 17 4 3 Installation in wet ground conditions 17 4 4 Installation in diffi...

Page 7: ...acity of the individual ECOROCK 5000 unit can be increased if the required final effluent quality is of a lower standard than the results achieved during the EN 12566 3 Performance test The ECOROCK 5000 units can be installed in parallel for larger capacities BIOROCK Multirock Systems When the ECOROCK 5000 units are installed in parallel we recommend the use of a Flow Management System between the...

Page 8: ... be installed The grease trap should be installed before the primary tank Do not dispose of the following items to the BIOROCK system Kitchen or motor oils fats wax resin paint solvents hydrocarbon based products petrol crude oil etc any pesticide or antibacterial product items of a toxic nature boiler or air conditioning condensate swimming pool backwash rainwater drainage water or ground water A...

Page 9: ... on the bottom of the tank enable a safe movement by fork lift Four lifting eyes are situated on the top corners of each tank enabling lifting by crane or JCB The tanks should be handled transported and stored with care after delivery to avoid being damaged When looking at the tank facing the BIOROCK logo the serial number is On an identification tag inside the tank and or Marked as on the drawing...

Page 10: ...y sludge This sludge breaks down in time by anaerobic digestion The primary tank should always be equipped with an efficient effluent filter This filter holds back remaining suspended solids fats and other floating matter which enables a higher quality of pre treatment In case of Multirock installation when a BIOROCK effluent filter is fitted into the Primary Tank and when the Primary Tank is of a...

Page 11: ...200 700 mg l KN 25 100 mg l NH4 N 22 80 mg l P Total 5 20 mg l 1 The ration between BOD5 and COD should always be 2 Minimum performance requirements of a Primary Tank 2 Effluent PT Average EN 12566 6 2008 BOD5 100 350 mg O2 l 200 50 mg O2 l COD 200 600 mg l S S 40 150 mg l 80 20 mg l KN 35 100 mg l NH4 N 30 80 mg l P Total 4 20 mg l 2 The sampling should be done with a minimum 24 hour sampling The...

Page 12: ...ng from the unit must flow by gravity to the next stage or a discharge point 2 3 ECOROCK 5000 TREATMENT UNIT TECHNICAL The tanks and covers are made of polyethylene Each tank has two lifting eyes that are situated at the middle of the tank The water inlet has a ø of 110 mm Air inlet and air outlet have a ø of 110 mm The water outlet has two possible diameters ø75 and ø 110 mm Each unit has a seria...

Page 13: ...on electric 3 2 INSTALLATION LAYOUT N 2 PUMPED DISCHARGE PUMP AFTER THE PRIMARY TANK In case of use of an intermediate pump well between the primary tank and the treatment unit an intermediate Flow Control Device may be required after the pump well for smooth water discharge to the Treatment Units 3 3 INSTALLATION LAYOUT N 3 PUMPED DISCHARGE PUMP AFTER THE TREATMENT UNIT S PRIMARY TANK OPTIONAL FL...

Page 14: ...connecting pipework DO NOT completely fill the tanks with water before unit is backfilled DO NOT use dirty or contaminated water DO NOT use a mechanical compactor only compact manually DO NOT reuse the excavated soil or spoil from the site DO NOT install the system too close to the house or other buildings DO NOT install the system too close to large trees 4 1 INSTALLATION PRINCIPLE Dimensions and...

Page 15: ...he distance between the side of the excavation and the tanks must be minimum of 300 mm Connections for the BIOROCK system are made with flexible seals with a diameter of 110 mm Local rules and legislation must be followed 4 1 2 Installation of the Primary Tank The Primary Tank must be installed as close as possible less than 10 m1 to the wastewater discharge point of the property this avoids fats ...

Page 16: ...he Treatment Units The gradient of the treated effluent pipe to the BIOROCK units should be a minimum of 1 4 2 INSTALLATION IN DRY GROUND CONDITIONS See Appendix Installation in dry ground conditions Conditions for installation Dry and stable ground conditions Absence of water at the bottom of the excavation 4 2 1 Installation and digging in dry ground conditions The maximum level of top soil abov...

Page 17: ...f the tanks again The lids or access covers of the system should be installed just above ground level to provide easy access for maintenance Close and secure all covers with screws Complete the backfilling once all pipework has been checked and connected 4 3 INSTALLATION IN HIGH GROUND WATER CONDITIONS Appendix Installation in high ground water conditions The ECOROCK 5000 units can be installed in...

Page 18: ...00 mm beyond the base of the tanks on all sides If you are unsure a qualified civil engineer should be consulted Anchoring the tanks to the base is achieved with a system using the anchoring points these are positioned on the lower corners of the tanks For installations in a high water table area ensure the adequate drainage of the excavation during installation and anchor the unit to the concrete...

Page 19: ...ventilation pipes ensure the units are perfectly installed and stable on the excavation base Ensuring that all levels are correct is crucial if the wastewater is to flow efficiently through the system Pay special attention to the rubber seals The seals ensure that the system is watertight 4 4 3 Backfilling in difficult ground conditions In all difficult ground conditions backfilling should be carr...

Page 20: ...tribution the access to the lids of the tanks the unit and sampling pipe the reinforcement and the structure of the slab etc will be specified by a qualified civil engineer based on expected traffic loads and the nature of the soil The high air outlet pipes should preferably be installed outside the concrete slab area if this is impossible then they should be anchored in the slab 4 6 OTHER SPECIFI...

Page 21: ... ventilation works properly Always check the efficiency of the ventilation through the system with a smoke test prior to backfilling If the site is not suitable for non electric ventilation electric ventilation should be installed Use as few bends as possible NEVER USE 90o bends Only use 45o bends 5 1 VENTILATION OF THE PRIMARY TANK A Primary Tank generates malodorous gases that must be removed by...

Page 22: ... use 45o bends never use 90o bends Always check the ventilation with a smoke test in representative conditions calm weather and storms are not representative conditions If the ventilation is not working properly Check the ventilation system again by following the diagram Check if the pipe work is obstructed or disconnected at any stage Check if the air outlet pipe is positioned high enough Check t...

Page 23: ...osition ensures unsurpassed and unique surface treatment with exceptional purification results In normal use the BIOROCK Media should not be removed or replaced The top layer of the BIOROCK Media may have to be rinsed after a period of time if contaminated with solids The BIOROCK Media is an ecological recyclable material For your safety always contact BIOROCK or your BIOROCK distributor for repla...

Page 24: ...d to check and clean it before the restart If a pump station is installed it is best to commission it and clean it before the shutdown period The BIOROCK system remains efficient after a shutdown period 7 CONFORMITY AND WORK COMPLETION In all cases the owner and the installer will jointly complete the installation checklist for BIOROCK Sewage Treatment Plants Appendix 5 and send it back to the man...

Page 25: ...ect to installation and operation as per the manufacturer s instructions and in accordance with good installation practices The warranty will not apply in the event of Failure to comply with the basic design data for the wastewater treatment plant failure to return the completed commissioning form or failure to issue a valid notice of conformity when commissioning is complete Failure to follow ins...

Page 26: ...ilable in the event of a complaint BIOROCK warranty 10 years on the BIOROCK Media biological part of the treatment plant 25 years on BIOROCK tanks 2 years on electrical options supplied by BIOROCK Condition of delivery In the case of incomplete delivery missing equipment or accessories or damage observed on delivery these remarks observations should be listed on the carrier delivery note or bill T...

Page 27: ...B USER GUIDE PAGE 27 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 B USER GUIDE ECOROCK 5000 BIOROCK Multirock systems BIOROCK Multiple Installations ...

Page 28: ... INSTRUCTIONS 29 2 SUSTAINABLE DEVELOPMENT 30 2 1 Useful information 30 2 1 1 Sustainability 30 2 1 2 Waste disposal 30 2 2 Polyethylene and PVC 31 2 2 1 Energy recovery 31 2 2 2 Material recycling 31 2 2 3 The BIOROCK Media 31 3 OPERATING AND MAINTENANCE RECOMMENDATIONS 32 3 1 Primary Tank and Effluent filter 34 3 2 The ECOROCK Treatment Unit 36 ...

Page 29: ...nt the clean water from the System is NOT drinkable NOTE Always keep the lid closed and open it only for inspections and maintenance work Never leave the lids and inspection points unsupervised while open Lids are for pedestrian use only NOTE Do not put your head directly into any septic tank or sewage treatment plant through the manhole even to have a look or in an effort to find the cause of a m...

Page 30: ...ATION 2 1 1 Sustainability Sustainable development is based on three factors Protection of the environment social progress and economic development Both production methods and consumption must respect both human beings and the natural environment to enable all inhabitants on Earth to meet their basic needs food clothing education work living in a healthy environment Education for sustainable devel...

Page 31: ...g plastics of this nature PVC PE into granules or powder which can be sold as an alternative to virgin material in manufacturing 2 2 3 The BIOROCK media The BIOROCK media is inert but if there is a need to replace some of the media the dirty bags once removed must be cleaned before recycling The used BIOROCK Media can be returned to BIOROCK for recycling Always ask a professional waste disposal co...

Page 32: ...nal is a condition for warranty However should you be unable to get this service locally BIOROCK can provide a maintenance planning schedule giving an overview of the maintenance procedures This planning schedule will allow a professional in the wastewater industry to provide the maintenance service Please check with local authorities how often the primary compartment should be emptied as this sho...

Page 33: ...water contains few suspended particles The colour may vary from neutral to dark yellow The odour of the water will normally be neutral to light ammonia Neutral Dark yellow FLOW MANAGEMENT SYSTEM For Multirock only Each quarter Clean the Flow Management System If BIOROCK Flow Control Chamber FCC and Splitterbox SB Rinse using a hose pipe Check and re adjust the float of the FCC if necessary Check e...

Page 34: ... find increased deposits in the pre treated waste water this may be caused by Water flowing too fast through the PT too short retention time hydraulic overload Check that no rainwater run off system passes through the installation The volume of the Primary Tank is too small to accommodate normal usage Incorrect disposal of harmful toxic anti bacterial or non biodegradable products into the install...

Page 35: ...mpany must be retained by the owner in and placed in the maintenance guide The septic tank emptier should pressure wash the sides of the tank and the Effluent Filter to remove the accumulated fats and other matter The tanker while emptying the Primary Tank must not be parked any nearer than 4 meters 14 from the installation to ensure and maintain stability Refill the Primary Tank with clean water ...

Page 36: ...t show at the bottom of the sampling glass after it has rested for twenty minutes The water shouldn t have a septic or nauseating odor It may have the characteristic smell of fresh humus If the visual check seems to show a malfunction turbid treated water presence of deposits or suspended matter nauseating or septic odor take the sample to a certified laboratory for testing If the laboratory confi...

Page 37: ...hat the aeration rings are put back to the same position and height BIOROCK can quote media replacement and recycling through its network of distributors and installers Contact us for your closest BIOROCK Certified Professional A well performing ECOROCK unit does not produce a bad smell it should have a smell of fresh humus Problems with bad smells are generally caused by a poor ventilation of the...

Page 38: ...e To be done annually Multirock Each quarter Visually check the water tightness of the water inlet pipe from the Primary Tank Check that the water distribution plate and tipping tray provide an equal distribution of water to the BIOROCK media To be done annually Clean the distribution plate with clean water using a hose pipe or high pressure cleaner 1 Adjust the height level of the water distribut...

Page 39: ...top layer may need to be cleaned more thoroughly see Ch Cleaning or replacement procedure for the BIOROCK Media Any long lasting water accumulation on the surface of the bags indicates that it is necessary to clean at least the first layer of BIOROCK media The frequency of cleaning and or replacement of the BIOROCK media bags depend on the quantity and quality of effluent leaving the Primary Tank ...

Page 40: ...Installation drawings of BIOROCK Multirock installations 2 1 Drawing Cross section of 1x ECOROCK 5000 plant in dry ground conditions 43 2 2 Drawing Cross section of 1x ECOROCK 5000 in high ground water conditions44 2 3 Drawing Top view of 1x ECOROCK 5000 treatment plant 45 2 4 Drawing of 2x ECOROCK 5000 systems 46 2 5 Drawing of 3x ECOROCK 5000 systems 47 Appendix 3 Technical drawings of the acces...

Page 41: ...C APPENDICES PAGE 41 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 1 1 1 ...

Page 42: ...C APPENDICES PAGE 42 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 Aeration and water distribution scheme without pumping well APPENDIX 1 1 2 ...

Page 43: ...C APPENDICES PAGE 43 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 Drawing Cross section showing the layers of BIOROCK Media in a ECOROCK 5000 unit APPENDIX 1 1 3 ...

Page 44: ...C APPENDICES PAGE 44 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 2 2 1 ...

Page 45: ...C APPENDICES PAGE 45 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 2 2 2 ...

Page 46: ...C APPENDICES PAGE 46 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 2 2 3 ...

Page 47: ...C APPENDICES PAGE 47 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 2 2 4 ...

Page 48: ...C APPENDICES PAGE 48 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 2 2 5 ...

Page 49: ...C APPENDICES PAGE 49 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 3 3 1 ...

Page 50: ...C APPENDICES PAGE 50 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 APPENDIX 3 3 2 ...

Page 51: ...T COMMISSIONING Product N of tank see page 9 in the user s guide Warning Please keep sludge emptying documents and proofs validated by the contractor DATE WORK COMPLETED CONTRACTOR S NAME COMMENTS If you have not subscribed to any maintenance agreement please ask a trained professional contractor to provide maintenance and any work required on your sewage treatment plant APPENDIX 4 ...

Page 52: ...C APPENDICES PAGE 52 52 Installation and User guide ECOROCK 5000 BIOROCK Multirock Systems 10 10 2017 ...

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