Technical Manual

 

  

Version 6.1
Rev. 30.9.14

 

 

Patent # 5,746,912 (US); 2,195,822 (CDN)

 

 

 

Prop 65 Warning

 

 

 

1 Product Overview

Drainage and wastewater contaminated with oils, fuels, grease and suspended solids are common in many commercial, institutional, and industrial businesses due to the products produced, used, distributed, and/or stored. Increasingly, stringent environmental regulations require that oil, grease and suspended solids be restricted to certain levels prior to being discharged into receiving sewer systems. In addition, increasing sewer-use surcharges for effluent exceeding regulatory limits (i.e., oil, grease, BOD, pH, and suspended solids) means discharging over-strength wastewater is more costly.

Proceptor® oil, grease and solids separator effectively remove floatables (i.e., free oil, grease) and allow solids to settle resulting in reduced and/or eliminated sewer-use surcharges and penalties to end users.

Developed by Green Turtle® (GT), Proceptor separators achieve maximum removal treatment efficiency of free oil, grease, and suspended solids from wastewater flows because of the unique hydraulic flow patterns. The controlled hydraulic flow patterns further ensure that captured contaminants will not scour or re-suspend. Proceptor is ideal as a point-source spill control device, eliminating the possibility of soil and/or ground water contamination and costly remediation. The elliptical design of the unit allows for enhanced treatment efficiency and ease of cleaning.

The large capacity volume of the Proceptor ensures that adequate wastewater retention time is achieved for maximum contaminant removal efficiency. The large storage capacity also reduces the need for frequent cleaning, thereby saving the operator/owner significant maintenance expenses.

Proceptor separators are constructed from Fiberglass Reinforced Plastics (FRP). Fiberglass is the preferred material for industrial and commercial waste streams since FRP is chemically inert, and impermeable to retained waste. The fiberglass construction eliminates the concern for internal and external corrosion of the tank that can result in leakage to the surrounding soil and causing contamination. Fiberglass has a longer projected life span (50+ years) as compared to concrete and/or steel. As the manufacturer of Proceptor separators, GT ensures maximum manufacturing quality using computer controlled rotational molding, strand roving reinforcement and hand lay-up with various types of woven and non-woven reinforcements. A 30-year Proceptor warranty is standard protection against leakage, corrosion, and structural failure.

Proceptor units are available in a variety of sizes and configurations to meet site and performance requirements. Accessories and options include suction pipes, oil draw-off fittings, custom wall reinforcements for deep burial and double wall design. Electronic monitoring devices and automatic shutdown systems can be installed to ensure that appropriate cleaning cycles are implemented and to notify the owner/operator of any operational problems (large spills or high oil content in effluent discharge).

The systems are also available with parallel plate style coalescers, which are designed to increase the efficiency of free oil separation for certain applications.

For over a decade, Green Turtle has helped thousands of commercial, institutional and industrial customers meet local effluent requirements.

1.1 The Proceptor Separator Advantage

  • Short payback period – eliminates or reduces sewer-use surcharges
  • Engineered systems – ensure better separation efficiency of oil, grease, and solids
  • Engineered hydraulics to ensure compliance with sewer discharge regulations
  • Variable wastewater flows accommodated
  • Prevents scouring or re-suspension of contaminants during peak flows (when adequately sized)
  • Enhanced removal of free or mechanically dispersed mineral oil with coalescer option
  • Larger storage capacity significantly reduces waste disposal/maintenance frequency lowering operational costs
  • Easy-to-maintain by vacuum or pump truck
  • Easy-to-install and handle due to its light weight
  • Non-corrosive, inert, and impermeable fiberglass material
  • Sound structure – units built to withstand pressures for below ground installation; and can be installed above ground
  • Models available from 50 to 10,000 US gallons (190 L to 37,850 L). Custom-designed separators are available
  • Accessories and options such as alarms, monitors and remote suction are available
  • Industry leading 30-year warranty against corrosion, leaks, and structural failures

1.2 Applications

Proceptor can be used in various commercial, institutional, and industrial settings including:

  • Restaurants (including fast food outlets and cafeterias)
  • Automotive and truck repair shops
  • Hospitals, senior facilities and schools
  • Service stations
  • Wholesale food outlets
  • Car washes
  • Food processing plants
  • Factories
  • Grocery stores
  • Spill control applications
  • Hotels
  • Light and heavy industrial operations
  •  

    1.3 Warranty Information

    This warranty is provided by Green Turtle Technologies Ltd. for products sold in Canada, and by Green Turtle Americas Ltd. for products sold in the continental U.S. Although the companies are collectively referred to herein as "Green Turtle," each company only warrants products sold in its respective market. Proceptor oil and grease separators are not intended for residential or consumer use, and may not be purchased or sold for those applications. Green Turtle warrants to the original purchaser that all Proceptor oil and grease separators purchased from Green Turtle will be free from defects in materials and workmanship for a period of one (1) year following the date of initial delivery to the purchaser, subject to the terms and conditions below. Green Turtle further warrants that if the Proceptor separators are installed, operated, and maintained in accordance with Green Turtle instructions and applicable state/provincial and federal regulatory requirements, the Proceptor devices:

    1. Will not leak for a period of 30 years from date of initial delivery due to natural external corrosion.

    2. Will not leak for a period of 30 years from date of initial delivery due to internal corrosion, provided the Proceptor is used solely in respect of the treatment of commercial/institutional wastewater (other applications, including but not limited to residential, and consumer not being covered by the warranty).

    3. Will not leak for a period of 30 years from date of original delivery due to structural failure, which shall be defined as spontaneous breaking or collapse.

    All of the warranties herein are subject to the following conditions:

    1. The Proceptor is used in the manner described in the warranty.

    2. Oil Multi-Cell (OMC) and Grease Multi-Cell (GMC) models up to 4000 gallons are installed as shallow burial having a maximum depth of 6 feet from the top of the tank to grade. Models 4000 gallons or more have a maximum depth of 4 feet from the top of the tank to grade. (For deeper installation, a custom reinforced Proceptor must be authorized and stamped by Green Turtle.)

    3. Extension collars supplied by Green Turtle Technologies Ltd. must be installed where applicable.

    4. There are no post-installations or repairs of the original Proceptor separator.

    5. The original installation has been carried out in Canada or the Continental United States.

    6. The original installation was performed following the Proceptor installation procedures by a trained contractor with all his/her required registrations, certificates and/or licenses, to complete the installation, repair or alteration in accordance with recognized industry practices and applicable regulatory requirements.

    7. The Proceptor has been operated and maintained in accordance with regulatory requirements designed to minimize the possibility of structural failures and releases of regulated substances.

    8. The Proceptor shall not be installed or used in any application other than commercial, industrial, or institutional use.

    9. If the Proceptor is remanufactured, moved, or removed from the ground for any reason prior to the expiration of this warranty, the structural warranty protections will terminate unless the Proceptor is inspected, repaired (as necessary), and re-certified by Green Turtle and, upon reinstallation, the purchaser continues to satisfy the other conditions of the warranty.

    GREEN TURTLE'S LIABILITY UNDER THIS WARRANTY IS LIMITED, AT GREEN TURTLE'S DISCRETION, TO REPAIR THE DEFECTIVE PROCEPTOR, TO REPLACE PROCEPTOR IN EXCHANGE FOR THE DEFECTIVE TANK, OR TO REFUND OF THE ORIGINAL PURCHASE PRICE. GREEN TURTLE IS NOT LIABLE FOR ANY LABOR, SHIPPING, OR OTHER INSTALLATION COSTS, AND SHALL NOT BE LIABLE FOR ANY SPECIAL, INDIRECT, PUNITIVE, CONSEQUENTIAL OR OTHER DAMAGES IN CONNECTION WITH SUCH PROCEPTOR INCLUDING, WITHOUT LIMITATION, COSTS, EXPENSES, OR LIABILITIES ASSOCIATED WITH ENVIRONMENTAL CONTAMINATION, FINES OR PENALTIES, FIRES, EXPLOSIONS, OR ANY OTHER CONSEQUENCES ALLEGEDLY ATTRIBUTABLE TO A BREACH OF THE WARRANTY OR DAMAGES UNDER DECEPTIVE TRADE PRACTICES OR SIMILAR CONSUMER PROTECTION ACTS. THE FOREGOING CONSTITUTES GREEN TURTLE'S EXCLUSIVE OBLIGATION AND GREEN TURTLE MAKES NO EXPRESS OR IMPLIED REPRESENTATION OR WARRANTY, OR ANY WARRANTY OF NON-INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSES WHATSOEVER. NO EMPLOYEE OF GREEN TURTLE OR ANY OTHER PARTY IS AUTHORIZED TO MAKE ANY OTHER REPRESENTATIONS OR WARRANTIES OTHER THAN THE WARRANTY SET FORTH HEREIN.

    10. The sole warranty for accessories, including but not limited to frames and covers, extension collars, alarms, pumps, valves coalescers, suction pipes, sludge judge, draw-off pipes strainers, etc. is that they are warranted for a period of one (1) year against defects in materials and workmanship from date of shipment.

    11. Customer assumes the risk of and agrees to indemnify Green Turtle against and hold Green Turtle
    harmless from all liability relating to (i) assessing the suitability for Customer's intended use of the Proceptor and of any system design or drawing and (ii) determining the compliance of Customer's use of the Proceptor with applicable laws, regulations, codes and standards. For Proceptors resold by Customer, Customer retains and accepts full responsibility for all warranty and other claims relating to, or arising from, Customer's Proceptor system which includes or incorporate Proceptor or components thereof manufactured or supplied by Green Turtle, and Customer is solely responsible for any and all representations and warranties regarding the Proceptor system made or authorized by Customer. Customer will indemnify Green Turtle and hold Green Turtle harmless from any liability, claims, loss, cost or expenses (including reasonable legal fees) attributable to Customer's Proceptor system or representations or warranties concerning same.

     

    1.4 Contact Green Turtle

    Green Turtle Americas (USA)
    Green Turtle Technologies (CAN)
    2709 Water Ridge Parkway
    880 Rangeview Road
    Suite 410
    Mississauga, ON
    Charlotte, NC 28217
    L5E 1G9
    T 877 428 8187 | 704 295 1733
    T 877 966 9444 | 416 966 9400
    F 704 295 1734
    F 416 966 3439
    Email: infous@greenturtletech.com
    Email: infoca@greenturtletech.com

     

    2 Design and Operation

    2.1 Components & Configurations

    Proceptor is constructed out of fiberglass reinforced plastic (FRP) and the piping arrangement is constructed of polyvinyl chloride (PVC) pipe. A drop pipe with a tee opening directs wastewater into the mid-section of the Proceptor. A baffle separates the unit into two chambers while the flow distributor regulates flow into the second chamber. A riser pipe in the second chamber allows cleaner water to displace out of the Proceptor. The Proceptor tank is equipped with vent ports, inspection ports and an access way for regular inspection and maintenance. Figure 2.1 depicts components of a standard single tank Proceptor separator. A variety of configurations and sizes are available (See Section 3).


    Figure 2.1 : Proceptor Components

    2.2 Principles of Operation

    Wastewater enters the unit through an inlet drop pipe, typically a 4” or 6” PVC sewer pipe, which discharges the wastewater below the normal liquid surface in the tank (see Figure 2.1 and Figure 2.2). The inlet drop pipe is configured to discharge wastewater horizontally along the tank walls. The standard separator tank has two chambers separated by a baffle and UPC separator tanks have three chambers separated by baffles. For larger Proceptor systems consisting of two or more tanks in series, each tank represents a chamber and is baffle-less. Upon entering the tank, oil, grease and other liquids with a specific gravity less than water rise to the surface in the first chamber, while suspended solids settle to the bottom by gravity. The wastewater then flows into the second chamber by a means of a flow distributor on the baffle wall, ensuring a smooth flow path, where further separation occurs. Cleaner water from the middle elevation of the tank is displaced through the riser pipe into the downstream sewer system.


    Figure 2.2 : Proceptor in Operation

    Proceptor separators are engineered to ensure a smooth flow path. This is accomplished by the use of elliptical chambers, which is critical in minimizing the formation of turbulent eddy currents. A non-turbulent state within the separator promotes the separation of oil, grease, and solids from process wastewater. The separator design also minimizes the potential for short-circuiting, ensuring the required wastewater retention time within the separator. Furthermore, the configuration of Proceptor separators reduces the potential for influent wastewater from passing through the oil/grease or sludge layers at the top. This feature prevents scouring and/or re-suspension of contaminants if actual flow rates exceed the design flow rate.

     A standard Proceptor contains two 3” diameter PVC vent connections (one per chamber) for venting gases to the outside (see Figure 2.3). The contractor installing a Proceptor is required to provide piping from the vent connections to the venting system. A 24” diameter extension collar located at the center or at both ends of the separator provides access for maintenance. Maintenance is performed by a liquid disposal company using a vacuum or pump truck. The curved bottom design on the Proceptor promotes easy maintenance including removal of contaminants.


    Figure 2.3 : Typical Proceptor Profile

    Proceptor separators are available with an extension collar, a frame and cover (cast iron for traffic loading, fiberglass composite for pedestrian conditions or  above ground applications). All other external piping, including pipes required for inlet and outlet connections, venting, suction piping (optional), etc., must be supplied by the contractor unless otherwise stated.

    3 Sizing Guidelines

    Proceptor sizing information is based on best available data including laboratory testing (in-house), field testing, theoretical modeling, and monitoring studies. Proceptor sizing information is continually being updated with the most accurate available information to assist in sizing a proper unit for a specific application.

    Incorrect sizing, improper installation and/or inefficient maintenance will affect the performance of Proceptor separators.

    3.1 Standard Sizing Considerations

    The following are standard sizing considerations for typical sites.  If the site conditions are different from the below, please contact a Green Turtle Representative for assistance.

    1.  Flow Type. The separator must be gravity fed.

    2.  Pollutant. Proceptor separators remove free oil, grease and settleable solids. The standard sized separator cannot remove chemically emulsified or dissolved oils. Consult a Green Turtle Representative for sizing assistance if emulsified oil/grease are present.

    3.  Temperature. The inlet water temperature must be between 4ºC (39ºF) and 60ºC (140ºF). For industrial applications, please contact a Green Turtle Representative for assistance.

    4.  Specific Gravity. The oil and grease specific gravity must be less than 0.95. Specific gravity of the wastewater must be equal to or greater than 1.0.

    5.  Detergent Use. For equipment wash-down, car wash, or any other applications where soaps and detergents will be used, oil and grease emulsification may be a problem and can reduce the effectiveness of the separator.  It is recommended that “Quick Break Soaps” be used since the chemical emulsification will break quickly thus allowing the oil and grease separator to operate as designed.

    6.   Wastewater Strength. Notify a Green Turtle Representative if chemicals of any kind are expected to be present in the process water or if the effluent is high temperature.  A special resin may be required in tank manufacturing.

    7.  Discharge Limits. Many local authorities have minimum size requirements or very conservative factors. Please verify with your local municipal sewer authority and plumbing code regulations.

    8.  Installation Depth. Separators up to 3000 gallons buried more than 6’ from the top of the tank to grade, and separators 4000 gallons or more buried more than 4’ from the top of the tank to grade will require reinforcement at an additional charge.

    3.2 Other Design Considerations

    Gravity separators rely on retention time (the amount of time wastewater is retained in the separator) to allow oil and grease to float to the top and solids to settle to the bottom.

     The retention time required to meet regulated discharge limits is a function of the type of contaminants present in the wastewater, initial loading rates, particulate size, specific gravity, and the interactive potential of certain pollutants and the separator design. Although flow rates are important design criteria for the selection of a separator, they are not the only criteria.

    Other factors need to be considered as well, a few of which are listed below:

    1.  Monitoring Oil/Grease Level. Manual monitoring must be performed before a regular cleaning schedule can be established. If and when increased activity occurs, the cleaning schedule must be adjusted accordingly. Green Turtle takes the guesswork out of servicing the separator when an electronic alarm is used to indicate when the system needs maintenance.

     2.  Remote Suction Maintenance. Remote suction pipe are available for indoor application where the maintenance cover is not easily accessible by pump trucks, or where opening the maintenance cover is undesirable due to odor issues.  The Proceptor can be equipped with a factory installed suction pipe which extends from the bottom of the tank.  The suction pipe is connected to a camlock fitting on an exterior wall for pump truck access.   

    3.  High Contaminant Loading. High contaminant loading in processed wastewater requires a larger separator to allow for a longer retention time and more storage capacity. 

    4.  Reduce Frequency of Maintenance. Increasing the size of the separator may reduce the frequency of maintenance, a cost-effective solution for many applications.

    5.  Light Emulsification. Larger capacity separators should be used in wash-down or car wash applications where oil globule sizes are quite small as a result of the interaction with high pressure water. Also, the soaps or detergents used will chemically emulsify oil and a longer retention time is required for the oil emulsion to break down.

    6.  Space Restriction. Coalescers can be used to reduce the size of the separator for the same treatment flow rate (oil applications only). Solids must be separated prior to entry into the coalescer since solids tend to plug coalescing filters quickly. Coalescers are not recommended for high solids/sediment wastewater applications due to the frequency of maintenance.

    7.  Above Ground Installation in Cold Climate. Separators intended to be installed above the frost line may be required to be insulated and/or equipped with explosion proof heaters.

    3.3 Grease Separators

    Proceptor gravity grease interceptors are available in several design configurations to meet applicable Plumbing Code standards throughout North America.

    Sizing for Proceptor grease interceptors should always comply with applicable local, Provincial, State and Federal Codes. The sizing guidelines provided below are Minimum Provincial Code Calculated 1 minute residence time sizing - Section 3.3, or Manufacturer Sizing - Section 3.3.1 and 3.3.2, or CSA / PDI (Plumbing and Drainage Institute) Sizing - Section 3.3.3, and are included as guidelines only.

    Minimum 1 Minute Residence Time Proceptor Grease Separator Sizing Chart

    Model Number

    Flow Rating

    Minimum Grease Capacity

    1 Minute Residence Time

    (US gpm)

    Pounds

    GMC 50

    50

    100

    GMC 100

    100

    200

    GMC 150

    150

    300

    GMC 200

    200

    400

    GMC 250

    250

    500

    GMC 300

    300

    600

    GMC 500

    500

    1000


    3.3.1 Manufacturer Sizing Guidelines - For All Proceptor GMC Models EXCEPT PDI & CSA Certified Models

    STEP 1: Determine Flow Rate

    Determine the peak flow rates (Q): add up all the fixture loads discharging to the grease separator (these include: rinse, prep, 3-compartment sinks, floor drain, mop sink, etc.) and establish peak flow rate by dividing fixture capacity by the drain down time (one or two minutes depending on local code).

    If fixture quantity and/or volume are unknown, assume worse case scenario by establishing peak flow rate based on drain size connecting to grease separator.
    For example: 4 in drain at 1/4 in/foot or 2mm/100mm = 110 US gpm

    STEP 2: Determine Hydraulic Retention Time Required

    In order to meet a 100 mg/l effluent discharge regulation, Proceptor separators require the following hydraulic retention time (HRT):

    • 5 minutes retention for non-emulsified grease
    • 30 minutes retention for emulsified grease from sinks only
    • For heavily emulsified wastewater, call a Green Turtle Representative for assistance

    STEP 3: Calculate Size of the Proceptor

    Multiply the peak flow rate (Q) by the hydraulic retention time (HRT) to determine the volume of the separator (V)

     

    V = Q x HRT

     STEP 4: Choose a Proceptor Size

    Choose the Proceptor size equal or closest to the value of V. Please refer to Grease Separator Sizing Chart in Section 3.3.2.

    For example:

    1.   Restaurant with wash sink (30 US Gal) at one minute drain down time = 30 US gpm

           Recommendation: 30 US gpm  x 5 minutes = Proceptor GMC 150 US Gal 

    2.   Restaurant with 3-pot sink (30 US Gal) with soaps at one minute drain down time = 30 US gpm

           Recommendation: 30 US gpm x 30 minutes = 900 US Gal  = Proceptor GMC 1000 US Gal

    For high flow rates or high grease content in wastewater such as from large commercial and industrial applications, please call for a Green Turtle representative for support.

    3.3.2 Manufacturer Grease Separator Sizing Chart

    3.3.3 Proceptor PDI and CSA Sizing – for Proceptor GMC-100, GMC-150, GMC-200,
    GMC-250, GMC-300 as published in PDI- G101 standard – revised March 2010

    Sizing by Known Compartment Sizing

         

     

     

    3.3.4 Standard Grease Separator Capacity and Dimensions


    System 1: Single Tank


    System 2: Two Tanks in Series


    System 3: Three Tanks in Series

    3.3.5 UPC | IAPMO | Florida Grease Separator Capacity and Dimensions


    System 4: UPC | IAPMO Approved
    (Dual Accessway, Single Tank or Two Tanks in Series Design)

     

    3.4 Oil Separators

    3.4.1 Sizing Guidelines

    STEP 1: Determine the Flow rate

    Determine peak flow rates (Q): add up all fixtures (e.g., hose bibs) and other sources of liquid discharge to oil separator and establish peak flow rate.

    If fixture quantity and/or volume are unknown, assume worse case scenario by establishing peak flow rate based on drain size connecting to oil separator. (For example: 4 in drain at 1/4 in/foot or 2mm/100mm = 110 gpm (US))

     STEP 2: Determine the Retention Time Required

    In order to meet the 10 mg/l effluent discharge regulation enforced by most pre-treatment authorities, Proceptor requires the following retention times (HRT)

    • 10 minutes retention for non-emulsified oil with the use of a coalescer
    • 30 minutes retention for non-emulsified oil without the use of a coalescer
    • 60 minutes retention for light emulsified oil (mechanical mixing)

    STEP 3: Calculate the Size of the Proceptor

    Multiply the peak flow rate (Q) by the hydraulic retention time (HRT) to determine the volume of the separator (V)

     V = Q x HRT

    STEP 4: Choose a Proceptor Size

    Choose the Proceptor size equal or closest to the value of V. Please refer to Oil Separator Sizing Chart in Section 0.

    For example:

    1.  Spills containment 10 US gpm of potential flow from spills

    Scenario 1: 10 US gpm x 10 min. = Proceptor OMC 100 US gallon with a coalescer

    Scenario 2: 10 US gpm x 30 min = Proceptor OMC 300 without coalescer

     

    2.    Mechanics shop rinsing floor lightly with soap and using two (2) 1/2” hose bibs = 2 X 5 US gpm = 10 US gpm (30 psi) 

    Scenario 1 (if continuous flow exist for more than 60 minutes): 10 US gpm x 60 min. = Proceptor OMC 750 US gallon

    Scenario 2 (if it is a batch flow where wash time is less than 60 minutes): Wash time = 30 minutes, 10 US gpm x 30 min. wash time = Proceptor OMC 300 without coalescer                    

    If flow rate is unknown, assume worse case scenario by establishing peak flow rate based on size of drain size connecting to the oil separator. For example: 4in drain at 1/4 in/foot = 110 gpm).

    3.4.2 Oil Separator Sizing Chart

    3.4.3 Standard Oil Separator Capacity and Dimensions


    System 1: Single Tank


    System 2: Two Tanks in Series


    System 3: Three Tanks in Series

    3.4.4 UPC | IAPMO Oil Separator Capacity and Dimensions


    System 5: UPC | IAPMO Approved
    (Triple Accessway, Single Tank or Two Tanks in Series Design)

     

    4 Accessories and Options

    4.1 Alarm

    The  alarm is an electronic monitoring system designed to trigger a visual and audible alarm when a pre-set level of oil or grease is reached within the treatment chamber. The feature acts as a safeguard against spills caused by exceeding the oil/grease storage capacity of the separator and eliminates the need for manual  inspection.


    Figure 4.1: Alarm Mounted in Proceptor

    4.2 Coalescing Filter for Small Diameter Oil Globules (>20 µm)

    Coalescing elements cause fine free oil droplets to agglomerate into larger droplets, thus enhancing gravity separation. According to Stokes’ Law, the rise velocity of a droplet of oil is directly proportional to the square of its diameter. Coalescers will not remove chemically emulsified or dissolved oil. Solids must be separated prior to entry into the coalescer since solids tend to plug coalescing filters quickly. The addition of a coalescer within the separator can allow for a reduction in the required sizing of the separator. For sizing information for Proceptor oil separators with coalescers refer to Section 0. (Not recommended where soaps are present in wastewater).   Not for food grease applications.

    4.3 Suction Pipe for Indoor Installations

    A suction pipe is used when remote tank cleanout is desired.  Internal piping allows the system to be maintained if a servicing vehicle logistically cannot access the top of the tank. The schedule pipe extends to the bottom of the separator to permit for all liquid and solid waste to be suctioned out. This piping is to be plumbed to an exterior wall allowing for a pumping truck to attach to the  wall port instead of opening the frame and cover for traditional servicing.


    Figure 4.3: Suction Pipe Accessory with Proceptor

    4.4 Double Wall

    Proceptor separators can be supplied with a secondary wall made from durable fiberglass for added protection against leaks.

    4.5 Level Monitor for Double Wall or Oil Reservoir

    The system uses an ultrasonic level sensor field  installed in the interstitial space between the tank walls or within an oil reservoir at a pre-set level for cleanout. Once the sensor comes into contact with liquid, it sends a signal through an externally mounted relay controller and indicator panel, to alert  personnel that there is fluid in the interstitial space or a high level within the oil reservoir. 

    4.6 Automatic Pump-Out System

    Proceptor units can be installed with an automatic pump-out system to remove oil from the system once it reaches a predetermined depth. The system, custom designed for each specific application, involves the use of a level sensor, 1” suction line (typical), a relay controller, and an electric or pneumatic pump.  

    4.7 Shut-Off Valve System with Alarm

    Proceptor separators may be equipped with an actuated shut-off valve. A valve chamber upstream of the separator is the recommended configuration. By using both a shut-off valve and oil alarm, optimal protection against spills is achieved by ensuring oil is not discharged into the sewer system. The alarm is configured to automatically close the shut-off valve and stop flow into the separator when the oil reaches a pre-set depth within the separator.  

    4.8 Fiberglass Products

    Large capacity and custom oil separators are available for special applications. To compliment its oil and grease separators, Green Turtle also manufactures a wide range of fiberglass products including above-ground tanks, holding tanks, emergency spill holding tanks, surge tanks, catch basins, sump tanks, neutralizing systems, valve chambers, sample chambers and other.

    For more information, please visit www.greenturtletech.com or contact a Green Turtle Representative.

    5 Installation and Maintenance

    5.1 Installation

    Proceptor separators must be installed in accordance with the provided installation instructions.  The installer must ensure that all Federal, State/Provincial, and local codes such as the National Fire Code, Municipal Building and/or Plumbing codes and municipal pretreatment sewer-use regulations are followed.

    Refer to Drawings: Installation Section for detailed installation procedures, and drawings.

    5.2 Maintenance

    Proceptor separators have no moving parts and are constructed of materials that are non-reactive in their intended environment. Regularly scheduled removal of captured materials and cleaning of the internal surfaces are the only forms of maintenance required.

    If the Proceptor installed at your facility contains a coalescing filter, it will be necessary for the filter to be removed and pressure washed whenever the Proceptor is pumped out or if testing indicates non-compliance with local effluent standards.  See Owner’s manual for detailed instructions.

    If the Proceptor contains an oil draw off pipe, it may need to be adjusted post-installation based on the operating conditions, in order to capture the oil and not the water.  The maximum normal operating flow / water level in the tank will govern the setting.   See the Owner’s Manual for detailed instructions.

    5.3 Importance of Maintenance

    Maintenance of a Proceptor unit is critical to ensure that separation efficiency is not compromised. The build-up of floatables and solids within the separator reduces the potential treatment volume and could, therefore, reduce the water retention time within the separator resulting in reduced separation efficiency. Furthermore, if contaminants are allowed to accumulate, the maximum storage capacities may be exceeded, resulting in the release of previously captured oil, grease, and solids.

    5.4 Maintenance Frequency

    The frequency of maintenance depends on the application and the model of the Proceptor. Some applications have very little oil, grease and/or solids in the waste stream and, therefore, reaching the maximum storage capacities will take a longer period of time. For other applications, the maximum storage capacities will be reached in a shorter period of time. Maintenance should be performed when the storage capacity reaches 50% or annually, whichever comes first.

    The following table describes when maintenance should be performed on the various standard Proceptor models.

    5.5 Inspection Procedures

    Measurements must be taken of the oil/grease and/or solids levels in order to determine if maintenance is required.  See the Owner’s Manual for detailed instructions.  There are two main methods of inspecting a Proceptor separator to determine if maintenance is required:

    Manual Sludge Level Inspection

    Manual Sludge Level Inspection measures the depth of solids or sludge within a Proceptor using a transparent dipstick tube equipped with a built-in ball check valve to hold the sludge sample. The tube should be graduated to indicate the depth of sludge, water level, and grease or oil layer in the Proceptor separator.

    Follow the manufacturer’s instructions which generally will tell you to slowly lower the device to the bottom of the tank.  Do NOT plunge it to the bottom, which will result in an inaccurate reading and possibly damage the ball check valve.  Keep the unit as vertical as possible when raising it up, without allowing it to bend or bounce while it is full of water.  Look at the sample through the markers on the device and then empty it before further use.

    Manual Oil/Grease Level Inspection

    Manual oil/grease level inspection can be performed with a dip stick, measuring tape or gauge rod.  Spread a thin coating of a water level indicator paste on the dip stick, measuring tape, or gauge rod in the area where water is likely to appear.  Slowly lower the measuring device into the tank to where the oil/water interface is anticipated.  Slowly remove the measuring device from the tank. The absence of color change by the water paste indicates that the measuring device did not reach the oil/water interface therefore re-measurement is necessary.  A change in color by the water paste indicates where the oil/water interface occurs and the depth of oil can be determined.

    Automatic Oil/Grease Alarm

    An automatic oil/grease level sensor can be installed within any Proceptor unit to indicate, via an audio and visual alarm, when the oil/grease level has reached a preset storage volume. The oil alarm can be used in conjunction with a shutoff valve or an automatic oil removal system.

     

    5.6 Maintenance Methods

    Proceptor units are normally serviced by a vacuum or pumping removal technique. The Vacuum or Pumping Service Industry that cleans underground tanks, sewers and catch basins is a well-established sector of the service industry. Costs to clean a Proceptor vary based on the size of unit and transportation distances.  Consult your local Waste Management Authority for an approved list of licensed “Liquid Waste Handlers”.

     Maintenance of a Proceptor separator is simple. The 24-inch diameter manhole cover is removed and the vacuum hose is inserted into the unit. OMC models with a reservoir, which should contain only oil if adjusted properly, may be pumped out via the 6-inch pump-out port by a liquid waste removal or oil recycling company. For models with suction pipes, maintenance can be performed without lifting the manhole cover. Always fill the interceptor with clean water after cleaning the unit for optimum treatment efficiency.

    5.7 Spills

    Should an oil or grease  spill occur that drains into the interceptor,  it must be cleaned immediately. The appropriate governing agency should also be notified in the event of a spill.

    5.8 Disposal

    The disposal of oil, grease and sediment collected in Proceptor separators will be included in the price from the vacuum service industry. Some wastes generated by food facilities are acceptable for farm disposal or use as biodiesel feedstock. Transporting and disposing of accumulated oil, grease, and solids should be carried out in accordance with the authority having jurisdiction.

    6 Specification Sheets


    7 Installation

    7.1 Installation Procedures

    7.2 Traffic Relieving Slab Drawings

    7.2.1 AASHTO H-20 Loading Slab Drawing

     

    7.2.2 Relieving Slab Drawings GMC/OMC 50 - 10000

    • To ensure you retrieve the most current drawings, links to drawings take you to the Green Turtle web site where you will be able to select files in PDF or CAD formats.

    • You must have internet access in order to view and download drawings from the links that follow.

    Relieving Slab Drawings

    o Single Slab Small
    o Single Slab Single Access
    o Double Slab Single Access
    o Double Slab 92in Tanks
    o Triple Slab 92in Tanks
    o Single Slab Dual Access
    o Double Slab Dual Access
    o Single Slab Triple Access

    7.3 Installation Drawings GMC/OMC 50 - 10000

    • To ensure you retrieve the most current drawings, links to drawings take you to the Green Turtle web site where you will be able to select files in PDF or CAD formats.

    • You must have internet access in order to view and download drawings from the links that follow.

    Installation Drawings

    o GMC PDI
    o GMC / OMC 50 – 300
    o GMC / OMC 500 – 1500
    o GMC / OMC 1000(2) – 3000(2)
    o GMC / OMC 4000(2) – 7000(2)
    o GMC / OMC 8000(3) – 10000(3)

    o GMC 500 – 1500 FL-IAP
    o GMC 2000 – 2600 IAP
    o OMC 500 – 1500 IAP

     

    7.4 Cover Drawings

    • To ensure you retrieve the most current drawings, links to drawings open PDF files from the Green Turtle web site.

    • You must have internet access in order to view and download drawings from the links that follow.

    Cover Drawings ( http://www.greenturtletech.com/hub-pc-options.php )

    o FC FRP B8 (PDF)
    o FC AG F (PDF)
    o FC GH4 (PDF)
    o FC GH4 B (PDF)
    o FCH 36 (PDF)
    o EC2 (PDF)
    o EC3 (PDF)
    o Collar Height (PDF)
    o Coupling EC2 (PDF)
    o Collar Reducer (PDF)

     

    8 Drawings: Grease Separators

    • To ensure you retrieve the most current drawings, links to drawings take you to the Green Turtle web site where the Proceptor model will be highlighted in blue. There, you will be able to select files in PDF or CAD formats.

    • You must have internet access in order to view and download drawings from the links that follow.

    Drawings: Grease Separators Go to the Grease Interceptors tab now

    GMC 50
    GMC 100
    GMC 100 PDI-IAPMO
    GMC 150
    GMC 150 PDI-IAPMO
    GMC 200
    GMC 200 PDI-IAPMO
    GMC 250 PDI-IAPMO
    GMC 300
    GMC 300 PDI-IAPMO
    GMC 500
    GMC 750

    GMC 1000
    GMC 1300
    GMC 1500
    GMC 1000 (2)
    GMC 1500 (2)
    GMC 2000(2)
    GMC 2600(2)
    GMC 3000(2)
    GMC 4000(2)
    GMC 5000(2)
    GMC 6000(2)
    GMC 7000 (2)

    GMC 8000(3)
    GMC 9000(3)
    GMC 10000(3)
    GMC 500 IAP
    GMC 750 IAP
    GMC 1000 IAP
    GMC 1300 IAP
    GMC 2000 IAP
    GMC 2600 IAP
    GMC 750 FL-IAP
    GMC 1000 FL-IAP
    GMC 1250 FL-IAP

     

    9 Drawings: Oil Separators

    • To ensure you retrieve the most current drawings, links to drawings take you to the Green Turtle web site where the Proceptor model will be highlighted in blue. There, you will be able to select files in PDF or CAD formats.

    • You must have internet access in order to view and download drawings from the links that follow.

    Drawings: Oil Separators Go to the Oil Separators tab now

    OMC 50
    OMC 100
    OMC 150
    OMC 200
    OMC 300
    OMC 500
    OMC 750
    OMC 1000
    OMC 1300
    OMC 1500 (1)
    OMC 1000 (2)
    OMC 1500 (2)

    OMC 2000(2)
    OMC 2600(2)
    OMC 3000(2)
    OMC 4000(2)
    OMC 5000(2)
    OMC 6000(2)
    OMC 7000 (2)
    OMC 8000(3)
    OMC 9000(3)
    OMC 10000(3)
    OMC 500 UPC
    OMC 750 UPC

    OMC 1000 UPC
    OMC 1300 UPC
    OMC 1500 UPC

     

    10 Drawings: Solids Separators

    • To ensure you retrieve the most current drawings, links to drawings take you to the Green Turtle web site where the Proceptor model will be highlighted in blue. There, you will be able to select files in PDF or CAD formats.

    • You must have internet access in order to view and download drawings from the links that follow.

    Drawings: Solids Separators Go to the Solids Separataors tab now

    SMC 50
    SMC 100
    SMC 150
    SMC 200

    SMC 300
    SMC 500
    SMC 750
    SMC 1000

    SMC 1300
    SMC 1500

     

    11 Drawings: Decontamination & Holding Tanks

    • To ensure you retrieve the most current drawings, links to drawings take you to the Green Turtle web site where the Proceptor model will be highlighted in blue. There, you will be able to select files in PDF or CAD formats.

    • You must have internet access in order to view and download drawings from the links that follow.

    Drawings: Decontamination & Holding Tanks Go to the Decontamination & Holding Tanks tab now

    EHT 50
    EHT 100
    EHT 150
    EHT 200

    EHT 300
    EHT 500
    EHT 750
    EHT 1000

    EHT 1300
    EHT 1500