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VGS Oily Water SeparatorTechnical ManualVertical Gravity Separatorsare proudly manufactured in Australia by:Industrial Separation SystemsACN: 105 667 374Unit 10-141 Taren Point Road,TAREN POINT, NSW 2229 Australia.Phone: +61 2 9524 6654Facsimile: +61 2 9524 6685Email: sales@issproject.com.auWeb Site: www.issproject.com.auVersion: OWS-July 2008 30 July 2008 Page 2

VGS Oily Water SeparatorTechnical ManualThis Technical Manual has been produced to aid designers, engineers, plumbers andregulatory authorities in the identification, selection, installation & maintenance of the VerticalGravity Separator (VGS)ContentsIntroductionProduct overview ............................................................................ 4Features & Benefits ........................................................................ 4Approvals........................................................................................ 5The TechnologyPrinciple of Operation..................................................................... 6VGS OptionsFlow Rates...................................................................................... 7Material........................................................................................... 7Mounting......................................................................................... 7Oil Level Control ............................................................................. 7Pumps............................................................................................. 7Electric Motor.................................................................................. 7Control Panels ................................................................................ 7Pump Types for VGS Systems....................................................... 8VSG Specifications......................................................................... 9VGS Coding.................................................................................... 10Compliance Plate Details ............................................................... 11Dimensions - Free Standing, Polyethylene .................................... 12Installation- Stand Mounted, Polyethylene ................................... 13- Free Standing, 304 Stainless Steel........................... 14Location .......................................................................................... 15Assembly ........................................................................................ 15Pipe Connections ........................................................................... 16Sewer Connections ........................................................................ 17Electrical Connections.................................................................... 17Typical Installation Schematic ........................................................ 18CommissioningPre-Set Oil Level Models................................................................ 19Adjustable Oil Level Models ........................................................... 19Maintenance ............................................................................... 20Maintenance Schedule................................................................... 21Trouble Shooting ..................................................................... 22Warranty .........................................................................23Apendix A.......................................................................24Apendix B.......................................................................25Version: OWS-July 2008 30 July 2008 Page 3

VGS Oily Water SeparatorTechnical ManualIntroductionProduct OverviewThe Vertical Gravity Separator (VGS) is an oil/water separator developed toeffectively remove free oil, grease and low density suspended solids fromwastewater.The VGS operates by ingenious control of both fluidvelocity and pressure. These forces gently coax nonemulsifiedimpurities from water by allowing high densitycontaminants to fall into a sludge retaining area at thebottom of the vessel, and oil droplets and low densitysuspended solids to rise to the top of the vessel. The oiland suspended solids then drain off into a waste tank fordisposal.Acclaimed by major water authorities around the worldas "the best technology of its kind", the VGS can beused as a stand-alone separator or to supplement theperformance of existing systems.Because it stays clean it maintains its performance!Features & BenefitsPerformanceDue to its ingenious design the VGS is capable ofcontinually meeting the performance standards set bythe Sydney Water Corporation, and other regulatoryauthorities, in respect to Petroleum Hydrocarbons, TotalOil & Grease, Suspended Solids and Flammability.Suspended SolidsLow density suspended solids are encapsulated by the oil and progress to the top ofthe VGS for discharge to the waste tank. Heavy solids settle to the base of the unitand are removed from the system by the way of a control valve.FlammabilityThe turbulent flow principle of the VGS ensures the vapour content of the wastewaterbeing treated is reduced to safe levels.ConstructionBy utilizing a vertical cylinder design the VGS requires far less floor space comparedto a coalescing plate separator.MaintenanceUnique design features enable quick, on-line cleaning of the unit; a feature onlyfound on the VGS. There is no need to remove the oleophilic cones and use highpressure jets or chemicals to clean the VGS, as is the case with conventionalseparators.Version: OWS-July 2008 30 July 2008 Page 4

VGS Oily Water SeparatorTechnical ManualApprovalsSince its invention in 1992 the VGS has progressively gained approval from watertreatment authorities, local councils & other government bodies throughout Australia.Approvals include:AuthoritySydney Water CorporationDept. Land & Water ConservationHunter Water Corporation LimitedA.C.T.E.W. Australian Capital TerritorySouth Australian Water CorporationWestern Australian Water P.T.LBrisbane City CouncilTownsville City CouncilIpswich City CouncilPower & Water AuthorityStateNSWNSWNSWACTSAWAQLDQLDQLDNTVersion: OWS-July 2008 30 July 2008 Page 5

VGS Oily Water SeparatorTechnical ManualThe TechnologyPrinciple of OperationThe Vertical Gravity Separator (VGS) is a flooded system in which the inlet and outletcolumns form a U - tube configuration. The free oil and low density suspended solidsare trapped on one side of the main body and the treated water flows out the otherside.The main body of the unit containsa continuous truncated conicalspiral pack (SPAK) which ismanufactured from an oleophilicmaterial. Oily water is delivered intothe bottom of the main body whereit then flows upwards through thecentre of the SPAK assembly.At the top of the main body free oiland low density suspended solidsare held and eventually they flowout of the system into a waste tank.The partially cleaned water isdirected to the outside perimeter ofthe conical SPAK. It then follows atortuous path cascading down andaround the SPAK.Here the lower density fluid (oil) isdrawn up the incline of theoleophilic surface of the SPAK andback into the low pressure centre ofthe VGS, where it co-mingles withthe incoming fluid and is redirectedto the top of the main body.A convection current is thuscreated within the SPAK by thedensity variation down the fluidcolumn and the upward flow of theincoming oily water.The ‘treated’ water will enter theoutput leg, at a point when the fluidis most free of contaminants, andflow up and out of the system.Fig. 1 - VGS Schematic DiagramHeavy solids and sludge are removed from the system via a sludge valve at the baseof the main body.Version: OWS-July 2008 30 July 2008 Page 6

VGS Oily Water SeparatorTechnical ManualVGS OptionsThe modular design of the VGS allows for a variety of different options to be ordereddepending on the specific site requirements.Flow RatesThe range of VGS’s covers flow rates from 1000 L/h up to 3000 L/h. Flow ratesabove this can be achieved by installing multiple units.Please contact ISS or your local distributor for further assistance.MaterialThe main body and the rotating lid of the VGS is manufactured from either:• 6 mm High Density Polyethylene which has been roto-moulded using thelatest production techniques.• 1.6 mm 304 grade Stainless Steel, which is designed for installation in themost harsh environments.MountingWhere the amount of sludge within the waste water being treated is minimal, a flatbottom/free standing VGS is available. (1000 and 1500 L/h models only)Standard VGS units have an extended cone shape bottom for sludge retention. Athree post stand is supplied with the VGSOil Level ControlTwo types of oil level control are available:Pumps• Pre-Set Level of oil held within the VGS is pre-set in the factory.• Adjustable Level of oil held within the VGS is adjustable on site.The “Pump Types for VGS Systems” table on page 8 lists the different types ofpumps that can be utilised within a VGS system.Electric MotorEither single phase 240 V or three phase 415 V, standard or flameproof, motors areavailable depending on the application.Control PanelsBuilt to specification, depending on the application.Version: OWS-July 2008 30 July 2008 Page 7

VGS Oily Water SeparatorTechnical ManualPump Types for VGS SystemsVGS DetailsPump DetailsModelFlowRateType Brand Model Speed kWV10P0FP 700 L/h Positive Displacement Mono CP11RJ 1450 rpm 0.18V10P0FD 1000 L/h Diaphragm ASM DS25 30 spm 0.25V15P3FP 1600 L/h Positive Displacement Mono CP25RJ 1450 rpm 0.37V15P0FDV15P3FD1500 L/h Diaphragm ASM DS25 42 spm 0.37V15P3ADV20P3AD 2000 L/h Diaphragm ASM DS32 48 spm 0.37V30P3AP 2700 L/h Positive Displacement Mono CP800RJ 960 rpm 0.55V30P3ADV30S0FD3000 L/h Diaphragm ASM DS38 36 spm 0.55• Minimum size pump well before VGSSydney Water require that the pump well is to have a working volume of at least 500litres, ie the volume held by the well between the high level (ON) switch and the lowlevel (OFF) switch level.• Specifications for progressive cavity Mono CP range pumpsRotor: 316 Stainless steel, Hard Chrome Plated (HCP)Stator: NB70HND Accelerated nitrile (RJ)Version: OWS-July 2008 30 July 2008 Page 8

Version: OWS-July 2008 30 July 2008 Page 9ModelV10P0FV15P0FV15P3FV15P3AV20P3AV30P3AV30S0FFlowRateinL/h1000150015001500200030003000Tank(Thickness/Type)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Stainless Steel(1.6mm/304)MaterialLid(Thickness/Type)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)Polyethylene(6mm/H.D.)SPAKHDPolyethyleneHDPolyethyleneHDPolyethyleneHDPolyethyleneHDPolyethyleneHDPolyethyleneHDPolyethyleneD- DiaphragmBase(FreeStanding)(FreeStanding)GalvanisedStandGalvanisedStandGalvanisedStandGalvanisedStand(FreeStanding)P- PositivedisplacementA – AdjusterF - Fixed AdjusterValvesBackwash - 50mm Poly.Sludge - 25mm BrassBackwash - 50mm Poly.Sludge - 25mm BrassBackwash - 50mm Poly.Sludge - 50mm BrassBackwash - 50mm Poly.Sludge - 50mm BrassBackwash - 50mm Poly.Sludge - 50mm BrassBackwash - 50mm Poly.Sludge - 50mm BrassBackwash - 50mm Poly.Sludge - 50mm BrassS - Stainless steelP – H.D Polyethylene30 – 3000 L/hExternal Pipe& FittingsPolypropylene &UPVC Class 12Polypropylene &UPVC Class 12Polypropylene &UPVC Class 12Polypropylene &UPVC Class 12Polypropylene &UPVC Class 12Polypropylene &UPVC Class 12Polypropylene &UPVC Class 1220 – 2000 L/h15 – 1500 L/h10 – 1000 L/hWeightinkgV – VGS25253535353843Model DetailsVGS SpecificationsVGS Oily Water Separator Technical Manual

VGS Oily Water SeparatorTechnical ManualVGS CodingFeatures Details Basic Coding Optional ExtrasSeparator Vertical Gravity Separator V1000 L/h 10Nominal flow rate1500 L/h 152000 L/h 203000 L/h 30MaterialPolyethylene - High DensityP304 Stainless Steel SFree Standing (1000 & 1500 L/h flow only) 0Mounting3 Post Galvanised Stand 3Oil level controlPumpElectric MotorControl PanelAdjustableAFixed Pre-SetF/Progressive CavityPDiaphragm PumpDStandard 240 volt 1Standard 415 volt 3Flameproof 415 volt - AS2380-1 & AS2380-2 4Polyethylene 240/24 VAC Starter w/-- Manual/Off/Auto- Pump & float terminals.Polyethylene 415/24 VAC Starter w/-- Manual/Off/Auto- Pump & float terminals.Metal 240/24 VAC Starter w/-- Manual/Off/Auto- Pump running light- Pump & float terminalsMetal 415/24 VAC Starter w/-- Manual/Off/Auto- Pump running light- Pump & float terminalsMetal 415/24 VAC INTRINSICALLY SAFE Starter- Manual/Off/Auto- Pump running light- Pump & float terminals/ABCDFControl panel option High level visual/audible alarm & mute button 1Version: OWS-July 2008 30 July 2008 Page 10

VGS Oily Water SeparatorTechnical ManualCompliance Plate DetailsAll VGS units have a “Compliance Plate” permanently attached to the tank.The details are as follows:Material:Size:1.0 mm thick aluminium80mm x 40mmVGS Flow rate – L/hVGS Serial NumberVGS Model NumberISS Ph (02) 9524 6654MODELS/No.L/hrPUMPMODELPUMPRATE L/hPUMPSERIAL NO.AUTHORISATION NUMBER 2003-XXPump Serial No.Sydney WaterAuthorisation NumberPump Flow rate – L/hPump ModelVersion: OWS-July 2008 30 July 2008 Page 11

VGS Oily Water SeparatorDimensionsTechnical ManualVGS Models:V10P0FDV10POFPV15P0FD950 mm435 mmSPAK AssemblyVersion: OWS-July 2008 30 July 2008 Page 12

VGS Oily Water SeparatorDimensionsTechnical ManualVGS Models:V15P3FDV15P3FPV15P3ADV20P3ADV30P3ADV30P3APTOP VIEWSIDE VIEW(OILY WATER INLET)FRONT VIEWVersion: OWS-July 2008 30 July 2008 Page 13

VGS Oily Water SeparatorTechnical ManualDimensionsVGS Models:V30SOFDTOP VIEWNo Back flushvalve shownSIDE VIEW(OILY WATER INLET)REAR VIEWVersion: OWS-July 2008 30 July 2008 Page 14

VGS Oily Water SeparatorTechnical ManualInstallationLocationThe VGS should be placed on a level concrete base to Australian Standard tosupport a minimum 250 kg.Note: The VGS must be installed LEVELPosition the VGS in a location that has no less than 1100 mm of clear space abovethe unit to allow for future removal of the SPAK.AssemblyThe Oily Water Inlet 1 must be assembled by:1. Screwing the ‘T’ piece to the blanked off 50 mm male thread at the top ofthe main body labelled OIL WATER INLET.2. Fixing the Oily Water Inlet assembly to the ‘T’ piece.Fig 2 - Oily Water Inlet190 mm125 mmSTRAINER BASKET FITTED IN THE TOP OFTHE VGS UNITVersion: OWS-July 2008 30 July 2008 Page 15

VGS Oily Water SeparatorTechnical ManualPipe Connections1. Connect the discharge pipe from the pump to the Oily Water Inlet 1(Fig 3 &4) using class 6 PVC pressure pipe. Refer to ASM appendix A and Monoappendix B, pages 24 & 25 respectively.2. Install a 50 mm DWV PVC discharge pipe between a sewer tundish (see SewerConnection on page 17) and the Clean Water Outlet 2.A minimum vertical fall of 600 mm from the Clean Water Outlet must bemaintained to ensure correct operation of the VGS.3. Install a suitable oil resistant discharge pipe from the Oil Outlet 3 to a wastetank. (Not supplied), same size as the pump discharge line. Polyethylene is asuitable material.4. Fit the gate valve supplied with the VGS to the Sludge/Solids Outlet 4 at thebase of the tank.Fig 3 - Installation details“Free Standing” type VGS units.Fig 4 - Installation details“Stand Mounted” type VGS units.Version: OWS-July 2008 30 July 2008 Page 16

VGS Oily Water SeparatorTechnical ManualSewer ConnectionsThe treated water from the VGS should be discharged to sewer via an inlet riser to agully as detailed in Fig 5 below. This point can be used for sampling the quality ofthe effluent being discharged.Fig 5 - VGS Sewer Connection DetailExtract fromSydney WaterdocumentationElectrical ConnectionsA licensed Electrical Contractor must connect the pump supplied with the VGS, to theelectrical supply.If the wastewater being treated has flammable Class 3 liquids present, such aspetrol, kerosene or other solvents, all electrical equipment within a defined area mustbe suitably rated.Version: OWS-July 2008 30 July 2008 Page 17

VGS Oily Water SeparatorTechnical ManualTypical Installation SchematicBUNDED AREAVersion: OWS-July 2008 30 July 2008 Page 18

VGS Oily Water SeparatorTechnical ManualCommissioningPre-Set Oil Level ModelsThe following procedure should be carried out when commissioning a VGS that has apre-set oil level.Step 1 Place waste tank under the oil outlet.Step 2 Charge the VGS by filling the main body, via the opening in the lid,with clean tap water (using a hose). The VGS is full when waterstarts to flow out of the clean water outlet.Step 3 Prime the pump by filling both the suction and discharge lines withwater then start the pump.The VGS is now set correctly and will perform without further adjustment.Note: Oil will not be seen to discharge from the oil outlet untill sufficient oil has builtup in the top of the unit. This may take some time depending on the quality of thewastewater being treated.Adjustable Oil Level ModelsThe following procedure should be carried out when commissioning a VGS fitted withan adjustable oil level controller.Step 1 Place waste tank under the oil outlet.Step 2 Charge the VGS by filling the main body, viathe opening in the lid, with clean tap water(using a hose).Step 3 Prime the pump by filling both the suction anddischarge lines with water then start the pump.Step 4 Loosen the adjuster locking screw.Step 5 Rotate the ‘T-Bar’ in an ANTICLOCKWISEdirection, thus raising the ‘T-Bar’, until waterflows out of the oil outlet.Step 6 Rotate the ’T-Bar’ in a CLOCKWISE direction,thus lowering the ‘T-Bar’, untill the flow from theoil outlet is reduced to a ‘drip’.Step 7 Using the 10 mm graduations as a guidecontinue to rotate the ‘T-Bar’ clockwise a further10 mm lower.Step 8 Tighten the adjuster locking screw onto the ‘T-Bar’.The VGS is now set correctly and will perform without furtheradjustment.Fig 6 - Oil Level AdjusterNote: Oil will not be seen to discharge from the oil outlet untill sufficient oil has builtup in the top of the unit. This may take some time depending on the quality of thewastewater being treated.Version: OWS-July 2008 30 July 2008 Page 19

VGS Oily Water SeparatorTechnical ManualMaintenanceThe objective of regular maintenance/cleaning of the VGS is to:• Fluidise (break-up) any encrustation of surface sludge in the top of the unit.• Remove any sludge that has become attached to the Continuous Spiral Pack (SPAK).• Remove settled sludge from the bottom of the unit.Daily1) Check the level of the oily waste in the waste tank.2) Check the operation of the VGS to ensure that there is no oil in the waterflowing out of the CLEAN WATER OUTLET.Monthlyrefer to Fig 7 for component recognition1) Carry out a routine Maintenance Procedure as detailed below:Step 1 Ensure the waste tank is empty and situated under the oil outlet.Step 2 Start the pumping cycle by filling the collection pit or switch the Manual/Off/Autoswitch to Manual, if fitted.Step 3 Crack open the SLUDGE/SOLIDS OUTLET4 valve at the base of the unit and drainuntil the sludge is removed. DO NOTEMPTY THE VGS.Step 4 Close the BACK FLUSH VALVE 5Step 5 Grip the STIRRING HANDLES 6 on the lidof the unit & rotate the SPAK in an anticlockwisedirection for approximately 15seconds. This will break up any encrustedsurface sludge.Step 6 Any waste oil will flow into the waste tank.Allow this to continue until only water flowsinto the waste tank. This indicates that theunit is fully backwashed.Step 7 Open the BACK FLUSH VALVE 5Step 8 Either allow the pit to empty or switch theManual/Off/Auto switch back to the Autoposition, if fitted.Fig 7 - Maintenance Diagram2) Ensure that oil, sludge and water outlets are free of blockages at all times.Version: OWS-July 2008 30 July 2008 Page 20

VGS Oily Water SeparatorTechnical ManualMaintenance ScheduleDAILY1. Check the level of the oily waste in the waste tank.2. Check the operation of the VGS to ensure that there is no oil inthe water flowing out of the CLEAN WATER OUTLET.3. Check the strainer in the top of the centre column is clear.MONTHLYFollow maintenance procedure. Sign off below.MONTH SIGNATURE MONTH SIGNATUREJanuaryJulyFebruaryAugustMarchAprilMayJuneSeptemberOctoberNovemberDecemberYEARLYRemove and inspect the plates of the SPAK.Version: OWS-July 2008 30 July 2008 Page 21

Version: OWS-July 2008 30 July 2008 Page 22VGS ModelAdjustable Oil Level ModelsAll VGS ModelsProblemWater flowing out of theoil outlet.Oil, mixed with water,flowing from the cleanwater outlet.Water flowing out of theoil outlet.Odour/smell emanatingfrom the VGSWaste water not beingpumped into the VGS.CauseAdjustment set too highAdjustment set too lowBack flush valve has beenclosed.Build up of sludge within theVGS.Occurs when the VGS is notoperated frequently - waterbecomes stagnant.Float switch is not operatingcorrectly.Blocked suction line.Pump is not working.SolutionRe-Adjust the ‘T-Bar’ as describedin the commissioning section of themanualRe-Adjust the ‘T-Bar’ as describedin the commissioning section of themanualOpen back flush valve.VGS requires servicing. Refer tomaintenance section of the manualRun fresh water, from a hose, intothe top of the VGS for 5 minutes.Re-adjust the high & low setting ofthe float. - If faulty, contact anelectrician to repair or replace.Remove suction line and clean.(the holding pit is probably full ofsilt and requires cleaning)Over load tripped out - Re-set theoverload switch on the motor.Cracked suction line - replace.Trouble ShootingVGS Oily Water Separator Technical Manual

VGS Oily Water SeparatorTechnical ManualWarranty1) Vertical Gravity Separators manufactured by ISS. are covered by warranty for aperiod of 10 years from installation.2) ISS will make good by repair, or at their option, the replacement of faulty partsunder warranty, provided always that:• The equipment was correctly installed and properly used inaccordance with ISS installation and operating instructions andaccepted codes of good engineering practice.• Any claim under warranty arises solely from faulty design, material orworkmanship.• Repairs are carried out with the written approval of ISS who maychoose to carry out the repairs themselves or at their option nominatean approved repairer for the purpose.• All costs other than the direct repair costs are borne by the purchaser.3) Auxiliary equipment not of ISS manufacture but supplied by ISS as part of apackage will be protected by the original manufacturers warranty. ISS warrantyis limited to that extent. i.e ASM and Mono pumps warranty is currently 12months.4) ISS warranty does not cover any of the following:• Claims for third party liability for damage caused by the failure of anyof the company’s products.• Damage caused by abnormal operating conditions, war, violence,storm cataclysm or any other force.• Damage caused by equipment being used for an application for whichthe product is not recommended.5) The decision of ISS in relation to any claims or disputes over warranty is final.6) The warranty is in lieu of all other warranties and conditions expressed orimplied, written or oral, statutory or otherwise, which are hereby negated andexcluded.7) This express warranty does not exclude any conditions or warranty implied bythe Trade Practices Act 1974 or separate state laws and is in addition to anyother right that the original purchasers or any subsequent purchaser may haveat law.8) In case of claim please contact your authorised ISS distributor or contact ISSPty Ltd.Version: OWS-July 2008 30 July 2008 Page 23

VGS Oily Water SeparatorTechnical ManualAppendix AVersion: OWS-July 2008 30 July 2008 Page 24

VGS Oily Water SeparatorTechnical ManualAppendix BVersion: OWS-July 2008 30 July 2008 Page 25