OWS Oil Water Separator
OWS Oil Water Separator
OWS Oil Water Separator
Oil/Water Separators
Proudly made
in America
Oil/Water Separators
814.893.5701 | highlandtank.com
®
®
Chemthane 4200 PW
Polyurethane Corrosion Control
Coating for Steel Structures
Features Description
UL Certified Chemthane 4200 is a 1:1, fast-set, spray applied two-component
Certified to meet UL Subject polyurethane coating. It is 100% solids and contains zero VOCs.
2215 – Oil Water Separators for
Chemthane 4200 has been approved by Underwriter’s Laboratories to
Interior Corrosion Protection
comply with the NSF/ANSI 61 standard for potable water.
Coatings
Chemthane 4200 is applied directly to the surface of prepared steel
UL Certified without the use of primers. It is very resistant to abrasion, chemical attack
Certified to meet ANSI / NSF
and cathodic disbondment.
Standard 61 – Drinking Water
System Components.
Technical Data
ANSI/AWWA Certified to meet
“Coating Steel Water Storage Property Value
Tanks” – Inside Coating System Hardness, Shore D 77
No. 4.
Tensile Strength, psi >5,000
Green Seal Standard
Chemthane 4200 meets the Elongation, % 6%
Green Seal Standard GS-11 for Impact Strength (Direct), in lbs. >30
VOC and chemical content.
Adhesion to Steel, psi (CS10, 3.0 mil) >2,000
Zero VOCs Flexibility, 180° bend over 1/8 in. mandrel Pass at 15 mils
Chemthane 4200 is a 100% solids
coating and is formulated with Cathodic Disbondment, mm radius <8
zero VOCs. Abrasion Resistance, mg loss
60
CS17 wheels, 1000g, 1000 cycles
Unlimited Color Availability
Standard Color is light blue, but
Chemthane 4200 is available in Application Temperature
any custom color. Consult your Substrate, °F 40 to 120
Chemline representative for
more information. Ambient, °F 40 to 120
Chemline, Inc. • 5151 Natural Bridge Rd. • St. Louis, MO 63115 • Phone : (314) 664 - 2230
While the descriptions, designs, data and information contained herein are presented in good faith and believed to be accurate, it is provided for your guidance only. Because many factors may affect
processing or application/use, we recommend that you make tests to determine the suitability of a product for your particular purpose prior to use. NO WARRANTIES OF ANY KIND, EITHER EXPRESS OR IMPLIED,
INCLUDING WARRANTIES OF MERCHANTABILITY OF FITNESS FOR A PARTICULAR PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED OR DESIGNS, DATA OR INFORMATION SET FORTH, OR THAT THE PRODUCTS,
DESIGNS, DATA, OR INFORMATION MAY BE USED WITHOUT INFRINGING THE INTELLECTUAL PROPERTY RIGHTS OF OTHERS. IN NO CASE SHALL THE DESCRIPTIONS, INFORMATION, DATA OR DESIGNS PROVI DED BE
CONSIDERED A PART OF OUR TERMS AND CONDITIONS OF SALE. Further, you expressly understand and agree that the descriptions, designs, data, and information furnished by Chemline, Inc. hereunder are
provided gratis and Chemline assumes no obligation or liability for the descriptions, designs, data and information given or results obtained, all such being given and accepted at your risk.
Technical Specification
885872_4.0
Flygt 3069
50 Hz
4 N-pump
4 N-pump
4.1 Product description
WS009070A
Usage
A submersible pump for efficient pumping of clean water, surface water, and wastewater
containing solids or long-fibered material. The pump is designed for sustained high
efficiency. For abrasive media, Hard-Iron™ is required. Stainless steel N-impeller is
available as an option.
Denomination
Type Non-explosion proof Explosion proof Pressure class Installation types
version version
Gray iron 3069.160 3069.190 MT — Medium head F, H, P, S, X
SH — Super head
Hard-Iron™ 3069.060 3069.070 MT — Medium head F, H, P, S, X
SH — Super head
Stainless steel 3069.760 3069.770 MT — Medium head F, H, P, S, X
SH — Super head
Application limits
Feature Description
Liquid temperature Maximum 40°C (104°F)
Liquid temperature, warm water version Maximum 70°C (158°F)
Depth of immersion Maximum 20 m (65 ft)
pH of the pumped liquid 5.5 – 14
Liquid density Maximum 1100 kg/m3
Motor data
Feature Description
Motor type Squirrel-cage induction motor
Frequency 50 Hz
Power supply 1-phase or 3-phase
Starting method • Direct on-line
• Star-delta
• Soft starter
Number of starts per hour Maximum 15
Code compliance IEC 60034-1
Voltage variation • Continuously running: Maximum ±5%
• Intermittent running: Maximum ±10%
Voltage imbalance between Maximum 2%
phases
Stator insulation class F (+155°C)
Cables
Application Type
Direct-on-line start or Y/D start with two cables Flygt SUBCAB® - a heavy duty 4 cores motor power cable
with two twisted pair screened control cores. Conductor
insulation rating of 90°C, which allows for increased
current. Superior mechanical strength and high abrasion
and tear resistant. Chemical resistant within pH 3-10 and
ozone, oil, and flame resistant. Used up to 70°C water
temperature. Cables < 10 mm2 with unscreened control
cores.
Y/D start Flygt SUBCAB® - a heavy duty 7 cores motor power cable
with two twisted pair screened control cores. Conductor
insulation rating of 90°C, which allows for increased
current. Superior mechanical strength and high abrasion
and tear resistant. Chemical resistant within pH 3-10 and
ozone, oil, and flame resistant. Used up to 70°C water
temperature. Cables < 7G6 mm2 with unscreened
control cores.
Monitoring equipment
Motor Thermal contacts opening temperature
13-08-4, 13-08-2, 13-10-2 125°C (257°F)
13-10-4 140°C (284°F)
Materials
Surface treatment
Priming Finish
Painted with a primer, see internal standard Navy gray color NCS 5804-B07G. Two-component high-
M0700.00.0002 solid top coating, see internal standard M0700.00.0004
for standard painting and M0700.00.0008 for special
painting.
Options
• Warm liquid version (non-explosion proof versions)
• Leakage sensor in the stator housing (FLS)
• Surface treatment (Epoxy)
• Zinc anodes
• Other cables
Accessories
Discharge connections, adapters, hose connections, and other mechanical accessories
Electrical accessories such as pump controller, control panels, starters, monitoring relays,
cables
Installation Procedures
The faultless functioning of a Flygt Pumping Station will D. Top Slab with Access Cover:
depend upon the correct selection of the pump to suit Diameter of Top Slab shall be at least two feet larger
system requirements and proper installation. A great than O.D. of ring sections. The Access Cover must be
majority of Flygt Electric Submersible Wastewater Pumps installed and properly oriented in the Top Slab.
are installed in underground wet pits with Automatic
Discharge Connections, Guide Bars and Access Covers 1. See Station Drawings for Pump Model and
as shown in the station drawings. Access Cover location in relation to the
Wet Pits constructed of precast concrete rings offer centerline of the station.
significant savings in labor costs over poured-in-place
concrete, masonry or brick and are universally accepted 2. Positioning of the Hinge Side of the Cover
for use in sanitary or storm sewer systems. Precast (See Accessories Section).
concrete sections are available up to 120 inch inside
diameter (sometimes up to 144 inch inside diameter) 3. The Top Slab and Access Cover must be
throughout the U.S. and are generally manufactured in level.
accordance with the provisions of ASTM Specification
C478. E. Automatic Discharge Connection:
The Automatic Discharge Connection must be attached
Because of this, Flygt official engineering documentation to the Bottom Slab at the exact location required relative
is based on stations designed in precast concrete to the Access Cover.
circular man-holes. Each individual station drawing
shows a suggested Simplex and a suggested Duplex SUGGESTED PROCEDURES:
Pumping Station built of precast concrete sections
installed between a Bottom Slab and a Top Slab (the 1. Attach the Upper Guide Bar Bracket(s) to the
Top Slab, usually at ground level, contains the cast-in Access Frame (See Accessories Section). Also,
Access Cover). the centerline of the Bracket(s) will determine the
The configurations and dimensions shown on these centerline of the installed pump(s).
Proposed Layouts are suggested minimum requirements
only, all details, including sizing of pit, type, size, location 2. Place the pump Discharge Connection(s) on
and arrangement of valves and piping, etc. are to be the Bottom Slab and line up as shown in the
specified by the Consulting Engineer and are subject Accessories Section.
to his approval.
3. Cut to length and install the Guide Bars between
The following is a partial list of useful suggestions for the Upper Guide Bar Bracket(s) and Discharge
construction and installation. Please always observe Connection(s).
local regulations applicable.
4. Before securing anchor bolt nuts, check across
A. Excavation: the Discharge Connection(s) Outlet Flange(s)
Excavate a large enough hole to provide sufficient face with level and shim if necessary. Guide Bars
working room around the station. The outside diameter should be Parallel and Vertical.
of the Bottom Slab should be at least one foot larger
than that of the concrete sections used. F. Internal Piping and Manifold:
Use proper gaskets, tighten bolts gradually and evenly.
B. Connecting Pipes: In deep stations, install Discharge pipe Brackets to
Provide connecting holes for the Influent Pipe, Effluent relieve Discharge Connections from overload and in-
Pipe(s) and Cable Thrulets in accordance with the termediate Guide Bar Brackets to prevent Guide Bars
Engineer’s specification. Flexible joints outside of from bending.
concrete wall will reduce the danger of dislocation due
to settlement. G. Installation of Pump Units:
Lower Pump Units into place along guide bars. Check
C. Backfill: visually metal-to-metal contact between Volute Flange
Backfill gradually and evenly around station after and Discharge Connection.If necessary, re-check and
concrete and joints have hardened. Compact backfill re-align Discharge Connection(s) and Guide Bars with
to minimize post-installation settlement. pumps in place.
Issued: 4/08 Supersedes: 6/90
Installation Procedures
Storage
Storage 12 to 24 months:
In addition to the above, apply a protective spray coating
of silicone or rust inhibiting oil to the impeller and inside
of the volute by spraying in through the volute outlet
and up through the volute inlet. Also coat the volute
outlet flange face.
USED pumps:
Installation
Operation
Maintenance
www.highlandtank.com • 1
Warning and Disclaimer
This manual is intended for use only by persons knowledgeable
and experienced in underground oil/water separator installation,
operation and maintenance. This manual provides general guidance,
and conditions at your site may render inapplicable some or all of
the guidance. If you are uncertain, or require clarification or further
instruction, please contact Highland Tank prior to commencing any
installation, operation or maintenance procedure. You are solely
responsible for compliance with all federal, state and local laws,
regulations and ordinances applicable to your installation and
operation. Highland Tank disclaims all liability related to any misuse
of the oil/water separator or failure to follow all guidance and
instruction provided by Highland Tank.
2 • www.highlandtank.com
Contents
Installation 6
Start-up 21
Operation 23
Maintenance 31
Troubleshooting Guide 39
Abbreviations used:
OWS – Oil/Water Separator
AHJ – Authority Having Jurisdiction
PSIG – Pounds per square inch gauge
OSHA – Occupational Safety and Health Administration
www.highlandtank.com • 3
Important points to consider prior to installation, operation and maintenance
of the OWS:
Carefully read and follow instructions in this manual. Local codes and ordinances may apply.
Check with local AHJ prior to installation of OWS.
• Ensure adequate site space - almost all products are delivered on a 75 foot long tractor-trailer.
Allow space for unloading, positioning and temporary storage if applicable.
• Ensure the crane has adequate lifting capacity and clearance - have operator check site for
clearances (overhead, turning, etc.). Spreader bars may be required for 10 foot diameter
and larger OWSs.
• OWSs that are 10 foot diameter and larger are typically shipped rotated to minimize over-the-
road height. They must be lifted from the hauling trailer by the supplied lifting lugs on the heads
of the OWS. They must then be rotated before final lifting into the excavation. Spreader bars
and/or adequate lifting straps/chains must be available to maintain recommended safe lifting
capacity. Please check approval drawing for overall length of the OWS and location of the
head lifting lugs.
• DO NOT rotate the OWSs while they are still on the trailer - damage may result. OWSs must
be lifted from the trailer, using the lifting lugs supplied on the heads, and lowered onto a flat
area, free from anything that may cause damage to the exterior coating. Once the OWS is
stable, the lifting device may need to be repositioned and then reattached to the lifting lugs
on the top centerline of OWS. At this point, slowly roll the OWS to upright position on the
ground before lifting to place in final resting position.
• Special permits may be required for weight, size, etc. by local code or ordinance.
• Confirm inlet and outlet piping elevations - check/recheck approval drawing and site plan
when OWS arrives.
• The amount of debris, such as sand, gravel, dirt, leaves, wood, rags, etc., permitted to enter
the OWS must be minimized for maximum effectiveness. Installation of an appropriately sized
Collection Catch Basin or other similar device upstream of the OWS is recommended.
• Detergents and solvents must not enter the OWS. The OWS will not remove chemical
emulsions or dissolved hydrocarbons, and their presence retards the recovery of oils that
would otherwise be separated.
• Never enter the OWS or any of its enclosed spaces without proper confined space entry training
and approved equipment. See OSHA, Regulations for Permit-Required Confined Spaces
29 C.F.R. § 1910.146.
4 • www.highlandtank.com
Important points to consider continued:
• The OWS will not remove chemical or physical emulsions, dissolved hydrocarbons, solvents
or Volatile Organic Compounds. Installation of an appropriately sized Advanced Hydrocarbon
Filtration System (brochure HT-2502) is recommended for treatment of wastewater contaminated
with these pollutants.
• Waste oils, such as automobile and truck crank case oil, should not be intentionally
drained into the OWS. Filling the OWS with waste oils adversely affects OWS performance.
Waste oil should be dumped into a waste holding tank for proper disposal.
• The OWS needs to be maintained to remain as free of accumulated oil and sediment as
possible. Suction removal of waste, as needed, is the best and recommended method
of maintenance.
• The location of your OWS should be in an area with sufficient truck access (top-side
clearance) for waste removal.
• An absence of gravity flow to the OWS will necessitate wastewater pumping. Pumping
should be restricted to the clean water, effluent end of the OWS. If pumping occurs at the
influent end, it will mix the oil and water, increasing the emulsified and dissolved
oil content and may cause separation failure. If a pump is installed upstream of
the OWS, it must be a positive displacement pump (e.g. progressive cavity, diaphragm,
sliding shoe), set at minimum flow rate/RPM and installed as far upstream as possible
to minimize oil/water mixing.
• The OWS must be kept from freezing at all times. The OWS and piping should be installed
below local frost levels. If necessary, a thermostatically controlled steam or electric
heating device may be installed.
• Complete the OWS Installation Checklist and Start-up Report (Form # HT-9039). A copy of
the completed form should be retained by the OWS owner and/or installation contractor.
• Complete the HighGuard, ACT-100-U® or sti-P3® Installer Information Card that was
included with the delivery documents. This information is required to activate and maintain
the Limited Warranty.
• OWS must be filled with clean water before introducing any wastewater. Filling should only
be done after OWS has been leveled and anchored in final installation location.
www.highlandtank.com • 5
Installation
Care in Handling OWSs OWSs must not be dropped, dragged or handled with sharp objects
and, except as minimally necessary for inspection and testing,
should not be rolled. Lifting equipment must be of adequate size
to lift and lower the OWS without dragging, dropping or
damaging the OWS or its coating.
OWS Unloading The OWS must be mechanically unloaded. Use extreme care when
unloading as weight distribution of OWS may be uneven.
Lifting and Moving Lifting and moving the OWS must only to be done using the lifting
lugs welded to the OWS. OWSs should be carefully lifted, moved
and lowered using cables, chains or straps of adequate size. When
two lifting lugs are used, the angle between the lifting cable and
vertical shall be no more than 30 degrees. See Fig.1. Use a spreader
bar where necessary. Maneuver OWSs with guidelines attached
to each end of the OWS. If OWSs must be relocated on a job site
during installation, they must be lifted and not rolled.
Fig. 1
WARNING:
Under no circumstance
should chains or slings Max. 30º
be used around
the OWS shell.
Highland Tank
®
www.highlandtank.com
HTM-0001
6 • www.highlandtank.com
Pre-Installation Upon delivery, visually inspect the OWS for exterior damage that
Inspection & Testing may have occurred during shipping or job site handling. Any
damage that could result in leakage or corrosion must be repaired in
a manner approved by Highland Tank. Please refer to coating repair
instructions below. If an OWS is not buried within 90 days, the OWS
should be covered to protect the exterior coating from the effects
of ultraviolet light damage.
Coating Repair Before placing the OWS in the excavation, all dirt clods and foreign
matter shall be cleaned from the surface of the OWS. Damage to
surface must be repaired using the supplied coating touch-up kit.
Internal Piping Carefully remove manway covers so as not to damage the gaskets.
Inspection Inspect the interior of the OWS from above (without entry) to ensure
that internal piping is secure and has not been damaged during
transport. Do not allow anyone to enter the OWS unless it has been
properly prepared for entry and the person entering the OWS has
been properly trained for confined-space entry per OSHA,
Regulations for Permit-Required Confined Spaces
29 C.F.R. § 1910.146.
www.highlandtank.com • 7
Coating Repair Fig. 2
continued
Anode Integrity DO NOT perform a 15,000 volt holiday test on sti-P3® protected
(sti-P3® only) OWSs. Refer to Steel Tank Institute sti-P3® Installation Instructions,
R821 for more information.
8 • www.highlandtank.com
Pre-installation Tightness The appropriate air or hydrostatic test must be performed prior to
Testing Procedures placing OWS into service, as outlined below. Factory-applied
vacuum test may be substituted for on-site testing. Check with AHJ
for approval. Take all necessary safety precautions during air tests.
Single-Wall OWS Remove factory installed temporary plugs & thread protectors.
Air Test Apply compatible, non-hardening pipe sealant to threads and install/
reinstall liquid-tight steel or cast-iron plugs at all unused openings
taking care not to cross-thread or over-tighten plugs. Manway
gaskets, lids and blind-flanges must be in place prior to
performing air test. (Refer to Steel Tank Institute ACT-100-U®
Installation Instructions, R971 or sti-P3® Installation Instructions,
R821 if nylon dielectric bushings are present.)
Fig. 3
Gauge
Overpressure Relief Device - Set at 5 PSIG
Valve A
Air Supply
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Pre-installation Tightness
Testing Procedures
continued
Double-Wall OWS Double-wall OWSs require different air pressure testing procedures.
Air Test
DO NOT connect a high-pressure air supply line directly to the
interstitial monitoring port.
While air tests are generally inconclusive without soaping and the
careful inspection for bubbles, this step is recommended to detect
a very large leak in the inner tank and prepare for the next step.
Fig. 4
Flexible Valve B
Connection Gauge 1
Valve C
Overpressure Relief Device - Set at 5 PSIG
Valve A
Air Supply
Outer Wall
Gauge 2
Inner Wall
Leak Detection
Monitoring Pipe
10 • www.highlandtank.com
Pressurize the interstice with air from the inner tank by closing
valve C, then opening valve B. Allow pressure to equalize.
Soap the exterior of the OWS and inspect for bubbles while
continuing to monitor the gauges to detect any pressure drop.
Release the pressure from the interstice first by opening valve C,
then open valves A and B to release all test pressure and vent
both spaces.
Optional Hydrostatic Test An on-site hydrostatic test of the single-wall OWS may be required
for Single-Wall OWS by the AHJ before installation to ensure no damage has occurred
if Required by AHJ during shipping and handling.
After the separator has been leveled, secured to foundation, and the
OWS is fully supported with backfill around the bottom quadrant, fill
the OWS with clean, fresh water (See Filling the OWS on page 21.)
until water is discharged from the outlet. Allow the OWS to stabilize
to a no-flow, static condition. If required by AHJ, attach blind flanges
to inlet/outlet and fill completely.
Accurately measure and record the fluid level from the top of the
manway to the static fluid level. After one hour, verify that the
fluid level has not dropped. A fluid level change would indicate that
there may be a leak in the primary tank. If a leak is detected, contact
Highland Tank before proceeding.
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Excavation and Bedding The excavation should provide adequate space for the OWS(s)
piping and associated equipment. It must also be free of any
hard or sharp material that could cause damage to OWS coating.
Fig. 5
Slope of excavation
determined by soil
type and/or code.
Consult AHJ. 24" Minimum
12 • www.highlandtank.com
Excavation and Bedding The bottom of the excavation must be covered with bedding
continued material to a minimum depth of one foot, suitably graded and
leveled and extend at least two feet around the perimeter of the
OWS for backfill operations. Place at least 24 inches of backfill
between any adjacent OWSs, tanks and excavation walls.
See Fig. 6.
Fig. 6
Highland Tank
®
www.highlandtank.com
HTM-0001
Installation & Maintenance Instructions are available at www.highlandtank.com
Placement of the OWS The OWS must be installed in a level and plumb position.
Check elevations at each end of the OWS with a transit and adjust
as necessary to 1/2 inch in 20 feet. Check elevations across the
diameter of the separator tank and adjust to 1/4 inch in 10 feet.
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Anchoring High water tables or partially flooded excavation sites exert
significant buoyant forces on OWS. Buoyant forces are partially
resisted by the weight of the OWS, the backfill and any pavement
atop the OWS. Additional buoyant restraint, when required, is
obtained by using properly designed hold-down straps in
conjunction with concrete hold-down pads or deadman anchors.
The use of steel cable and/or round bar as buoyant restraints
is prohibited.
Fig. 7
Concrete Deadman
Anchors Polyester Hold
Down Strap
Turnbuckle Galvanized
with Hook Wire Rope
or Jaw Ends
Cable
Clamps
14 • www.highlandtank.com
Anchoring When anchoring by means of a concrete pad is required, the OWS
continued must not be placed directly on the pad. See Fig. 8.
Fig. 8
Strap
Hold-down Strap
(with neoprene liner)
Turnbuckle
Hole in
angle for
anchor bolt
Anchor Bolt*
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Backfilling Approved backfill similar to bedding material must be placed around
the entire OWS to create a uniform homogeneous environment. Be
certain that foreign matter is not introduced into the excavation or
backfill. Special care shall be taken when backfilling to ensure that
the OWS is fully and evenly supported around the bottom quadrant
and that no damage to the coating occurs. See Fig. 9 and 10.
Fig. 9
Remove all large and sharp rocks/debris that may Special placement and compaction
have fallen into the excavation before backfilling. of backfill may be required
Fig. 10
Remove all large and sharp rocks/debris that may have Special placement and compaction
fallen into the excavation before backfilling. of backfill may be required
Highland Tank
®
www.highlandtank.com
HTM-0001
The backfill should be placed carefully around the OWS to the top of
the OWS.
16 • www.highlandtank.com
Piping & Venting
Piping Inlet piping installation should be straight and true with as few turns
as possible to limit turbulence. (When dielectric isolation is required,
consult Steel Tank Institute ACT-100-U® Installation Instructions,
R971 or sti-P3® Installation Instructions, R821 and Petroleum
Equipment Institute PEI/RP100 for further instructions.)
The OWS inlet and outlet piping must be sloped from 1/8 inch to 1/4
inch per foot to maintain gravity flow. A greater slope, or a free fall of
wastewater in the OWS will cause turbulence, which adversely
affects OWS performance. Piping must also be designed to limit
flow into the OWS to the flow rate specified. Use of a flow control
device may be required.
IMPORTANT: The OWS should be fitted with properly sized inlet and outlet
shut-off valves (contractor supplied) for emergency shut-down
and service purposes.
Attach manway extensions, riser and sensor pipes and any other
contractor supplied piping to the OWS. Take special care to prevent
damage to any gaskets or pipe threads.
OWS Venting Guidelines OWS is designed for operation at atmospheric pressure ONLY.
OWS inlet, outlet and manways MUST be vented to atmosphere
to assure proper operation. See Fig. 11.
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Fig. 11
Terminate vent piping
as required by AHJ
Manways
Inlet
Outlet
Oil/Water Separator
OWS with Gravity Oil If an oil skimmer is to be installed, piping between the OWS and the
Skimmers and/or waste oil tank must be sloped between 1/8 inch to 1/4 inch per foot
Monitoring Equipment to maintain gravity flow.
For OWS with oil level sensors, pump-out pipes and leak detection
sensors, install riser pipes using compatible non-hardening sealant,
taking care not to cross thread or damage the nonmetallic bushings.
Torque of 400 to 1,000 foot-pounds may be required to fully insert
pipe. For electrical wiring details, please refer to the sensor and
control panel installation instructions.
18 • www.highlandtank.com
Final Air Test An additional air test may be required after OWS is secured and
backfilled to the top of the OWS. Air pressure for air testing after
installation must not exceed 5 PSIG and must be measured at
the top of the OWS. Refer to appropriate air tests procedure on
pages 9 and 10.
Sealing of Lifting Lugs During the installation process, steel can become exposed at the
and Pipe Connections lifting lug due to the handling of the OWS. These areas, along with
all other exposed steel surfaces, must be covered using the coating
kit supplied by the manufacturer.
After an air test has established tightness, apply coating to the OWS
fittings and allow to cure prior to backfill. Coating must include the
entire plug on unused fittings.
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Final Backfilling Deposit homogeneous backfill carefully around OWS to a depth of
at least one foot over OWS to avoid damage to coating especially
where tamping is required. Refer to the National Fire Protection
Association’s Regulation NFPA 30 and state or local codes for
minimum depth of cover required.
Use grade level covers and street boxes to access the manways,
sensors, or pump-out pipes. The grade level covers above the
access manways must be of a greater diameter (i.e. 36 inch grade
level cover over a 24 inch access manway).
Fig. 12
Minimum Depth of Cover Minimum Depth of Cover
in Areas Subject to Traffic in Areas Not Subject to Traffic
Top of OWS
20 • www.highlandtank.com
OWS Start-Up
IMPORTANT:
The OWS must be full of water to operate.
CAUTION:
Separated liquid oil and vapors are flammable
and/or combustible.
The final state of all wiring must comply with all applicable
electrical and fire code standards.
If the OWS has not yet been filled with water, as may have been
required for ballasting, (see page 16) fill with clean, fresh water at
this time. The OWS must be full of water before any wastewater
can be treated. The OWS can be filled through the facility’s drain
leading to the OWS inlet or through a manway.
The OWS is full when water drains out of the Outlet. Check the water
level using a gauge stick. The level on the gauge stick must equal
the invert of the Outlet Pipe as measured from the OWS bottom.
www.highlandtank.com • 21
OWS Start-Up continued
And/Or
Move the bottom float up and down on the probe stem. As the
bottom float approaches the lower grip ring, the High-High Oil Level
Warning Alarm (light and audible alarm) should activate.
Move the top float up and down on the probe stem. As the top float
approaches the lower grip ring, the High Oil Level warning alarm
(light and audible alarm) should activate.
Note: If one or both alarms do not activate properly, check the panel
and sensor wiring for proper connections and continuity.
After Oil Level Sensor As installed OWS fills with water, both floats will be in low position
Installation (dry condition) and both alarms will be activated.
While the OWS is filling with water, the High-High Oil Level Warning
Alarm should deactivate, and soon thereafter the High Oil Level
Warning Alarm should deactivate.
Note: If the alarms do not deactivate upon filling, remove the sensor
and check for float binding or poor electrical connections.
22 • www.highlandtank.com
Standard OWS Highland Tank’s OWS is a wastewater treatment tank used to
Description & Operation intercept and collect free-oil, raw petroleum hydrocarbons, grease
and oily-coated solids from a wastewater stream.
During operation, the wastewater flows into the OWS through the
inlet pipe and is directed over the Velocity Head Diffusion Baffle,
a reinforced steel plate inclined at a 45 degree angle.
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Operation continued In the sediment chamber, heavy solids settle out and are collected
behind the Sludge Baffle. Concentrated oil slugs rise immediately
to the surface.
When wastewater enters the OWS, the cleanest water from the
bottom of the OWS is discharged via gravity flow. Treated water is
only discharged from the bottom of the OWS via the downcomer
pipe during periods when wastewater flows into the OWS.
Free-floating oil and greasy solids accumulate in the OWS until they
are pumped out. Any and all oil recovered and removed from the
OWS must be recycled or disposed of in accordance with federal,
state and local regulations.
Optional Petro-Screen Most OWS models are equipped with an optional Petro-Screen
Coalescer coalescer. The Petro-Screen coalescer intercepts oil droplets too
minute to be removed by the Corella Coalescer. This bundle of
oil-attracting polypropylene fibers traps oil particles down to 20
microns in size. These small particles coalesce into larger globules
that eventually break free and rise to the surface.
24 • www.highlandtank.com
Model HTC Oil/Water Separator
with EZ Access option shown.
Flanged
Manways Monitoring Pipe
& Covers
Flanged Outlet Piping
OUTLET
Underflow Baffle
Water
Outflow
Inlet Vent Piping**
Sludge
Baffle
Petro-Screen
Coalescer
www.highlandtank.com • 25
Oil Level /Leak Alarms For easy, efficient operation and maintenance, the OWS may be
(Optional) equipped with an Oil/Water Interface and Level Sensor and/or Leak
Detection Sensor to activate warning alarms at high oil levels or
in the event of a leak.
26 • www.highlandtank.com
Oil Level If your OWS has a control panel and sensors installed, locate the
Controls diagram for your panel from the five selections and then refer to
(Optional) the button/light function listing for operation and required action.
continued Please consult the job specific project information should you need
detailed information regarding a specific alarm/control panel.
Contact Highland Tank if you still need assistance.
TEST TEST
ALARM TEST ALARM SILENCE LEAK TEST ALARM TEST ALARM SILENCE
www.highlandtank.com • 27
Oil Level HT-A2-LDFW - 4-Channel
HTA2LDFW High-Oil, High-High-Oil
Controls and discriminating
(Optional) Fuel/WaterLeak Detection
continued
NORMAL ALARM HORN HIGH-HIGH OIL
ALARM HORN Works in conjunction with yellow alarm lights. Emits audible
(90-95 decibel) sound alerting operator that system has entered
an alarm mode.
28 • www.highlandtank.com
Oil Level ALARM #2 Alerts operator of High-High-Oil level. Oil has reached a critical
Controls predetermined level and must be pumped out immediately.
(Optional) RESPONSE: Stop OWS operation. Pump out oil. Refill OWS with
continued water to reset sensors. Resume OWS operation.
OR
Leak Detection – See Leak Detection System procedure, page 30.
ALARM SILENCE Silences the audible alarm temporarily for operator to perform
service. (Does not cancel alarm mode.)
LEAK TEST Temporarily closes the control panel’s leak detection circuit to
provide a system test.
FUEL LEAK Alerts operator of a leak from primary wall of OWS into interstice.
RESPONSE: Contact Highland Tank for procedure. Fuel leak will
cause only fuel leak alarm.
WATER LEAK Alerts operator of a water leak from primary or secondary wall
of OWS into interstice.
RESPONSE: Contact Highland Tank for procedure. Water leak
will cause both fuel and water leak alarm.
FUEL LEAK TEST Temporarily closes the control panel’s fuel leak detection circuit to
provide a system test.
WATER LEAK TEST Temporarily closes the control panel’s water leak detection circuit
to provide a system test.
www.highlandtank.com • 29
Leak Detection Leak Detection Procedure for fuel or water in the OWS interstice.
System Procedure
(Optional) For easy and efficient monitoring of the interstitial space, the OWS
may be equipped with a Liquid Leak Detection Sensor to activate
warning alarms if the interstitial space becomes filled with
hydrocarbons or water during operation.
Use a gauge stick to inspect the monitoring pipe for the presence
of oil or water.
After water has been removed from OWS interstice, reinstall sensor
and wiring making sure to seal all threaded connections with
approved sealant. Restart OWS operation as described earlier.
30 • www.highlandtank.com
Maintenance
CAUTION: Separated liquid oil and vapors are flammable
and/or combustible.
Inlet and effluent pipe valves should be closed and locked for
safety prior to OWS entry.
All liquid must be removed from the OWS prior to entry. Any and
all oil recovered and removed from the OWS should be recycled
or disposed of in accordance with federal, state and local codes
and regulations.
CAUTION: Interior surfaces of the OWS will be slippery.
www.highlandtank.com • 31
Maintenance OWSs with oil level sensors require oil removal when the alarm is
continued activated. Stop OWS operation, remove the oil and then refill OWS
with clean water (see Start-Up Instructions, page 21).
Use a gauge stick and water finding paste to check the oil/water
interface level.
Step 1 - Measure and record the distance from the fluid surface
to the bottom of the OWS.
Step 2 - Measure and record the thicknesses of the oil (top) and
solids (bottom) layers.
Step 3 - Add thickness measurements of the oil and solids layers
then divide this number by the distance from fluid surface to
bottom of OWS, from Step 1, to obtain the accumulated wastes
volume percentage.
If the combined oil and solids layers are equal to or greater than
20%, the separator is considered full. Stop OWS operation, remove
accumulated oils and solids. Refill the OWS with clean fresh water
and resume operation (see Start-Up Instructions, page 21).
WARNING: If the oil is not pumped out, the oil concentration in effluent
may exceed the desired levels.
32 • www.highlandtank.com
Maintenance If the OWS has been cleaned within the year and only bottom sludge
continued has built up while the effluent water is contaminant free, it may be
sufficient to vacuum the sludge from the sediment chamber and
refill OWS with clean water. (See Start-Up Instructions, page 21.)
Oil Removal Procedures Confirm that the High-Oil Level Warning Alarm is due to an actual
(with optional oil level high-oil level in the OWS, otherwise a mixture of oil and water will
controls) be removed. Oil levels can be verified using a sampling device or
a gauge stick with water finding paste.
Using suction, remove the oil. Refill OWS with clean water to
deactivate the High Oil Level Alarm (see Start-Up Instructions,
page 21).
Oil Removal Procedures Determine where the oil/water interface by using a sampling device
(without optional oil or a gauge stick with water finding paste.
level controls)
If oil/water interface level is beyond the maximum allowable level,
oil needs to be removed and the OWS refilled with clean water.
Mixed Oil and Water Place a 3 inch or smaller suction hose inside the OWS through
Removal Procedures either the 4 inch diameter Gauge Port in the Sediment Chamber
Manway or through the Sediment Chamber Manway.
Using suction, remove all contents from the OWS. Refill with clean
water (see Start-up Instructions).
www.highlandtank.com • 33
Major Oil Spill
Response Procedures
IMPORTANT: A major oil spill is a spill that exceeds the normal oil storage
capacity of the OWS. In the event of a major spill, notify proper
authorities as required by federal, state and local laws.
After a major oil spill, the OWS should always be emptied, cleaned
and refilled with clean water.
Oil Spill Removal If OWS has optional oil level controls, confirm that the High and
Procedures (with or High-High Oil Level Alarms are activated due to an actual
without optional oil High-High oil condition.
level controls)
Determine exactly where the oil/water interface is located using
a sampling device or a gauge stick with water finding paste.
Place sampling device or gauge stick into the OWS through the
4 inch diameter Gauge Port or Manway to determine the oil/water
interface location.
If oil is still visible on the surface of the OWS or the alarms remain
on, suction out the oil and refill with clean water.
34 • www.highlandtank.com
Sludge Removal Determine exactly where the sludge/water interface is located using
Procedures a sampling device or a gauge stick.
If used, insert gauge stick into the OWS through the 4 inch diameter
Gauge Port or Manway. Alternately, a sampling device enables
taking accurate readings on settled solids to any depth in the OWS.
Slowly lower the gauge stick until it comes into contact with the
sludge blanket. Mark the stick.
Push the stick downward until it comes into contact with the Striker
Plate on the OWS bottom. Mark the stick.
Sludge Removal Place a 3 inch diameter or smaller suction hose inside the OWS
Procedures through either the 4 inch diameter Gauge Port or through
(for full OWS) the Manway.
Using suction, remove the sludge while slowly lowering the suction
hose nozzle until it comes into contact with the Striker Plate on the
OWS bottom.
Sludge Removal
Procedures (for
completely empty OWS)
WARNING: Never enter an OWS or enclosed space, under any
condition without proper training and OSHA approved
equipment. Consult OSHA, Regulations for Permit-Required
Confined Spaces 29 C.F.R. § 1910.146.
Using suction, remove the sludge and debris. Use caution to avoid
internal coating damage.
www.highlandtank.com • 35
General OWS If not properly maintained, the OWS may malfunction.
Cleaning Procedures
NOTE: Over a period of time sediment, oil and grease will build up
on the walls and floors of the OWS. Dirt and heavy oil may also
build up on the Corella® coalescer, reducing the unit’s efficiency. In
addition, the petro-screen removes some suspended solids along
with the small oil droplets in the wastewater. Periodic cleaning of the
petro-screen is also required.
Sediment Chamber Remove manway covers to expose the sediment chamber, being
careful not to damage the gasket.
Direct the spray to the OWS wall sides, top and bottom.
36 • www.highlandtank.com
Cleaning OWS Coalscers Disconnect all Oil Level Sensor wiring. Carefully remove the
Oil Level Sensor.
Carefully check the Oil Level Sensor floats. If the floats do not
slide easily on the stem or have sludge on them, clean the Oil
Level Sensor. Use a parts washer and mineral spirits to remove
accumulated oil, grease or sludge.
Corella® Coalescer Attach spray nozzle wand extension to the high-pressure hose.
Direct spray downward and toward the Corella® coalescer to loosen
caked oily solids that may have accumulated on the plates. Flush
the Corella® coalescer from the outlet side to direct debris into
sediment chamber. The coalescer packs must be cleared of all
sludge to operate properly.
Direct the spray to the OWS wall sides, top and bottom. Rotate
the nozzle sufficiently and often so that all areas are reached with
the spray.
Visually inspect the OWS interior and components for any damage.
www.highlandtank.com • 37
Petro-Screen Coalescer Coalescer packs can be removed through the manways for
IMPORTANT: cleaning. Mechanical lifting equipment may be required to
remove oil-filled packs and coalescer packs in larger units.
Hook a lifting rod or other device to the lifting lug on the coalescer
pack directly below the manway and lift straight up to remove it from
the OWS. Use lifting rod or other device to slide an adjacent pack
into position below the manway for removal. Continue process until
all packs have been removed.
Visually inspect the OWS interior and components for any damage.
NOTE: If any visual damage exists, contact Highland Tank for further
instructions.
Reinstall the Oil Level Sensor in the 2” diameter Interface and Level
Sensor Pipe. Reconnect all non-voltage carrying sensor lines to the
Oil Level Sensor.
38 • www.highlandtank.com
Troubleshooting Problems which occur during OWS operation can be the result of
Guide many factors. The following list identifies the most common
problems, their possible causes and suggested remedies.
Excessive oil concentrated Wastewater pumped into the OWS Adjust pump, change
in OWS effluent water causing emulsification of oil droplets to different pump or
in the clean water change to gravity flow.
www.highlandtank.com • 39
Troubleshooting
Guide continued
Storm water back-up in Excessive sludge or debris build-up Clean out OWS.
drainage area
Closed inlet or effluent piping valves Open piping valves
completely.
High suspended solids Excessive sludge or debris build-up Clean out OWS.
content in clean water
effluent
Excessive solids in storm water Install Highland
drainage area Collection Catch Basin
in front of OWS and
clean OWS.
If you have any additional questions regarding OWS problems, contact Highland Tank.
40 • www.highlandtank.com
HTC Double-Wall Oil/Water Separator Reference Drawing
4” PUMP-OUT PIPE & EXTENSION 2” INTERFACE & LEVEL OPTIONAL
BY HIGHLAND (IF REQUIRED) SENSOR PIPE & ALARM/CONTROL PANEL
EXTENSION BY
OPTIONAL GRADE-LEVEL MANWAYS WITH COVER HIGHLAND CONTRACTOR
(IF REQUIRED) PROVIDED
CONTRACTOR PROVIDED FLANGED MANWAY WITH COVER VENT PIPING
GRADE-LEVEL CONCRETE PAD & BOLT-ON EXTENSION GAUGE PORT
FLANGED
INLET PIPE MONITORING
& NOZZLE PIPE
INLET
OUTLET
UNDERFLOW BAFFLE CORELLA® COALESCER
OIL/WATER
VELOCITY INTERFACE OUTLET
HEAD DOWNCOMER
DIFFUSION PIPE CONTRACTOR
BAFFLE PROVIDED
FLANGED
WEAR INLET &
PLATE OUTLET
WATER PIPING
CONTRACTOR PROVIDED HOLD-DOWN SLUDGE BAFFLE STRIKER PLATE OPTIONAL INTERFACE PETRO-SCREEN INTERNAL CONTRACTOR PROVIDED
PAD OR DEADMAN ANCHORS & LEVEL SENSOR COALESCER MONITORING PIPE BEDDING & BACKFILL
www.highlandtank.com • 41
Appendix - A - Sample Inspection and Maintenance Log
Facility Name:
Address: City: State: ZIP:
Service/Maintenance Provider
Company Name: License No.:
Address: City: State: ZIP:
The Highland Tank OWS should be inspected on a regular schedule as determined by facility needs.
OWS Maintenance Log WEEK - MONTH - YEAR
Action taken:
Observations/comments:
Action taken:
Observations/comments:
Action taken:
Observations/comments:
Action taken:
Observations/comments:
Stoystown, PA Greensboro, NC
One Highland Road 2700 Patterson Street
Stoystown, PA 15563-0338 Greensboro, NC 27407-2317
T: 814-893-5701 T: 336-218-0801
F: 814-893-6126 F: 336-218-1292
Manheim, PA Lebanon, PA
4535 Elizabethtown Road 2225 Chestnut Street
Manheim, PA 17545-9410 Lebanon, PA 17042-2504
T: 717-664-0600 T: 717-664-0602
F: 717-664-0617 F: 717-664-0631
Watervliet, NY Friedens, PA
958 19th Street 1510 Stoystown Road
Watervliet, NY 12189-1752 Friedens, PA 15541-7402
T: 518-273-0801 T: 814-443-6800
F: 518-273-1365 F: 814-444-8662
www.highlandtank.com
wastewater@highlandtank.com © Highland Tank HT-2050 – 11/2015