Biorock ECOROCK-700 Installation & User Manual Download

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Installation and User guide – ECOROCK 700 to 900 Units – 05-12-2016

INSTALLATION & USER GUIDE

BIOROCK TREATMENT UNITS:

ECOROCK-700
ECOROCK-800
ECOROCK-900

Summary of Contents for ECOROCK-700

Page 1: ...PAGE 1 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 INSTALLATION USER GUIDE BIOROCK TREATMENT UNITS ECOROCK 700 ECOROCK 800 ECOROCK 900 ...

Page 2: ...PAGE 2 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 TABLE OF CONTENTS A INSTALLATION GUIDE 5 B USER GUIDE 27 C APPENDICES 39 ...

Page 3: ...ntact 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 approved ...

Page 4: ...A INSTALLATION GUIDE PAGE 4 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 A INSTALLATION GUIDE ECOROCK 700 to 900 UNITS ...

Page 5: ... 1 2 Installation of the Primary Tank 14 4 1 3 Installation of the ECOROCK treatment unit 15 4 2 Installation in dry ground conditions 15 4 2 1 Installation and digging in dry ground conditions 15 4 2 2 Installation of the Tanks in dry ground conditions 15 4 2 3 Backfilling in dry ground conditions 16 4 3 Installation in wet ground conditions 16 4 4 Installation in specific sites 18 4 4 1 Installa...

Page 6: ... Person Equivalent The capacity of the individual ECOROCK 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 Based 150 l p e day UNITS PARAMETERS ECOROCK 700 ECOROCK 800 ECOROCK 900 MAX PEOPLE EQUIVALENT 4 P E 5 P E 6 P E RECOMMENDED VOLUME PRIMARY TANK 2000 L 3000 L 3000 L WASTE WATER TREATED 150 L d...

Page 7: ...n with the aeration of the system The aeration should be checked by the installer using a smoke test once pipework and ventilation ducts have been connected and before backfilling the system The smoke test should be performed under normal representative conditions Each system should be vented independently and equipped with its own ventilator wind driven or electrical The number of elbows used in ...

Page 8: ...SPORT OF THE TANKS Lifting eyes are situated on the top 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 below Engraved on the area to your right at the bottom o...

Page 9: ...ter holds back remaining suspended solids fats and other floating matter which enables a higher quality of pre treatment 2 1 1 Ventilation of the Primary Tank Any Primary tank should have a proper unencumbered low level and high level vent The low level vent should be connected directly on the outlet side of the tank and the high level on the inlet side and should not be positioned more than 10 m1...

Page 10: ...uent 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 effluent is easy biodegradable if the ratio of BOD5 and COD is less than 2 Between 2 and 3 it is partially biodegradable and greater than 3 the effluent is not biodegradabl...

Page 11: ...ction of the tank contains a third media bed providing final treatment See Ch B 3 2 for weight details of each BIOROCK media layer The treated water discharging from the unit must flow by gravity to the next stage or a discharge point Avoid stagnant treated effluent at the discharge point Make sure the discharge pipe is equipped to avoid small animals entering the system Each ECOROCK Treatment Uni...

Page 12: ...mpling shaft should be installed The pump shaft may be used as a sampling shaft 3 1 INSTALLATION LAYOUT N 1 GRAVITY DISCHARGE non electric 3 2 INSTALLATION LAYOUT N 2 PUMPED DISCHARGE PUMP AFTER THE PRIMARY TANK 3 3 INSTALLATION LAYOUT N 3 PUMPED DISCHARGE PUMP AFTER THE ECOROCK TREATMENT UNIT PRIMARY TANK ECOROCK TREATMENT UNIT OPTIONAL SAMPLING PIPE DISCHARGE PRIMARY TANK INTERMEDIATE PUMPING WE...

Page 13: ...turers of non BIOROCK products integrated into the system by the user Please take photographs of each stage of the installation with particular attention to all of the 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 t...

Page 14: ...s should not be buried and should always remain accessible for maintenance The minimum distance between the primary tank and the treatment unit is 300 mm The 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 should be respected 4 1 2 Installation o...

Page 15: ...N 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 above the backfill is 200 mm The units must stand on a clean and stable base such as concrete In dry ground conditions pea gravel...

Page 16: ... connected 4 3 INSTALLATION IN HIGH GROUND WATER CONDITIONS Appendix Installation in high ground water conditions The ECOROCK units can be installed in high ground water conditions with special precautions If you don t use a BIOROCK Primary Tank please confirm with the other manufacturer that this Primary tank is suitable for high ground water conditions If the Primary Tank is not a BIOROCK tank p...

Page 17: ... adequate drainage of the excavation during installation and anchor the unit to the concrete slab Important The tanks should be secured and anchored to the concrete base In all high ground water conditions the backfilling should be carried out to a level of 20 cm below the tank covers We recommend that the tanks are backfilled with lean mix concrete instead of a regular backfill ...

Page 18: ...ion 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 carried out ...

Page 19: ...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 Ventilation should be checked before leaving the site in any ca...

Page 20: ... 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 effective ventila...

Page 21: ...air outlet pipe should always be equipped with a wind driven or electrical ventilator The ventilation pipes must have a minimum diameter of 100 mm Only 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...

Page 22: ...a is clearly visible in the treatment unit Under the water distribution system the BIOROCK Media will have a grey colour The BIOROCK Media is highly resistant to degradation and remains extremely stable over the long term It is an inorganic material which does not break down over time It requires little maintenance Scraping and scarification is not necessary Its structure and composition ensures u...

Page 23: ...main accessible for maintenance Always close and secure the lids after use Always close and secure the lids Always keep the lids accessible Make sure the lids are air tight The lids are for pedestrian use only After any maintenance visit on the ECOROCK 700 900 systems and if the lids were open Make sure the seals of lids are correctly positioned ensuring air tightness once manholes are closed ...

Page 24: ...e absence period and 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...

Page 25: ...y is subject 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 f...

Page 26: ...e made available 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...

Page 27: ...B USER GUIDE PAGE 27 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 B USER GUIDE BIOROCK TREATMENT UNITS ECOROCK 700 ECOROCK 800 ECOROCK 900 ...

Page 28: ...TRUCTIONS 29 2 SUSTAINABLE DEVELOPMENT 29 2 1 Useful information 29 2 1 1 Sustainability 29 2 1 2 Waste disposal 29 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 INSTRUCTIONS 32 3 1 Primary Tank and Effluent filter 33 3 2 ECOROCK Treatment Unit 35 ...

Page 29: ...OTE 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 malfunction Noxious gases may accumulate in the system...

Page 30: ...NFORMATION 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 ...

Page 31: ...ling 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 the BIOROCK for recycling Always use a professional waste disp...

Page 32: ...be emptied as this should be in line with local regulations The summary below indicates the commissioning of your sewage treatment plant Your sewage treatment plant can be free from any failures as the BIOROCK system does not require electricity In normal operation and following the maintenance recommendations GENERALLY Every year Visually check the water tightness of the complete system Check the...

Page 33: ... purified water may have a slight septic odor If the water looks different or you 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 dispos...

Page 34: ...rtified septic tank cleaning company must be retained by the owner in and kept 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 The Primary ...

Page 35: ... deposit might 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 lab...

Page 36: ...ly covers the surface of the Treatment Compartment ensure that there is no free space between the bags The bags of BIOROCK Media should always overlap each other BIOROCK can quote media replacement and recycling through its network of distributors and installers Contact us for your closest BIOROCK Certified Professional Top layer top basket Middle layer second basket Bottom layer 4 PE 9 5 kg 9 5 k...

Page 37: ...water flows through it This generally occurs after some years of usage Should this occur just shake the BIOROCK media bags manually and placed them back in the baskets Make sure that each layer of bags completely covers the surface of the Treatment Compartment with no free space between the bags which should always overlap each other If the inspection shows an accumulation of suspended solids at t...

Page 38: ... PE 20 holes are closed water is dispersed through 48 holes Top view Bottom view Water dispersion plate 6 PE No holes are closed water is dispersed through 68 holes Top view Bottom view Check water dispersion on top of the BIOROCK media and clean the water distribution system using a hosepipe if necessary a Open the lid and remove the 50mm water inlet pipe b Remove water distribution system and wa...

Page 39: ... 6PE 42 1 5 Aeration Water distribution schematic of an ECOROCK Treatment unit 44 1 6 Cross section of the layers of BIOROCK Media in an ECOROCK Treatment unit 45 Appendix 2 Installation drawings of the BIOROCK installations with ECOROCK units 2 1 Drawing Cross section of 1x ECOROCK Treatment unit Plant in dry ground conditions 46 2 2 Drawing Cross section of 1x ECOROCK Treatment unit Plant in hig...

Page 40: ...C APPENDICES PAGE 40 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 APPENDIX 1 1 1 Drawing of an ECOROCK 700 treatment unit ...

Page 41: ...C APPENDICES PAGE 41 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 APPENDIX 1 1 2 Drawing of an ECOROCK 800 treatment unit ...

Page 42: ...C APPENDICES PAGE 42 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 APPENDIX 1 1 3 Drawing of an ECOROCK 900 treatment unit ...

Page 43: ...C APPENDICES PAGE 43 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 APPENDIX 1 1 5 Aeration and water distribution scheme without pumping well ...

Page 44: ...C APPENDICES PAGE 44 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 APPENDIX 1 1 6 Drawing Cross section showing the layers of BIOROCK Media in an ECOROCK unit 1 2 3 ...

Page 45: ...C APPENDICES PAGE 45 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 APPENDIX 2 2 1 APPENDIX 2 2 2 ...

Page 46: ...F FIRST 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 CARRIED OUT CONTRACTOR 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 ...

Page 47: ...C APPENDICES PAGE 47 47 Installation and User guide ECOROCK 700 to 900 Units 05 12 2016 ...

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