2ZCL Gravity Oil/Water Separators Issued 01.05.99 R/11.01.100Table of Contents zc \Water Separators Fundamentals | 1 CilWater Separator Performance Comparison | 4 Schematic Diagram of Oil Separators Function Continuous Operating Mode | 5 ZCL Gravity OilWater Separator Models | 6 Typical Installation For Gravity OilSeparators | 7 ZCL Gravity OilWWater Separators | 8 Engineering and Operating Manual 2CL Gravity OillWater Separator | 10 Appendix i | 17 Appendix ii | 18 Appendix iii | 19 Appendix iv | 20 ZCL Gravity OilWater Separators Maintenance Instructions | 21ZCL Oil/Water Separators Fundamentals “In a fluid medium, all immiscible phases having differing density will separate — sooner or later!” The process of separation of discreet components ina fluid system follows the laws of nature. In context with separators, this applies to the rising of "lighter" than water fractions (oil) and settling of “heavier” than weter fractions (solids) Depending on the magnitude of the difference in “weight” between the water and either the oils or solids, the rate of separation can be fast (large difference) or very slow (small difference). An easy way to visualize this concept is to recall what occurs in a simple oil-vinegar/spice salad dressing. One always shakes the bottle prior to use but within minutes, this mixture separates into distinct layers with the oil on the surface and solid spices on the bottom — a separator in miniature. The analogy is not a lot different than what ‘occurs in a full sized oil water separator. This principle was formalized over 100 years ago by Stokes. The formula that he developed continues to be the governing mathematics used in separator design to this day. Stokes’ Law Formula g V,= (qg,) (564 — 56)" Definitions of: particle rising (or settling) velocity gravitational constant viscosity of water w a " iw = Specific gravity of water wu a " io = Specific gravity of oil 0 " Diameter of oil particleSeparator Performance Factors 2, Specify gravity SG In most systems, the specific gravity Variation in the physical parameters used in the difference (SG, —- 5G,) cannot be altered Stokes’ Law formula can enhance or detract from to any great extent. Hosvever, note that in tie|performance ofa Separator belits simple} processes where salt water is involved, the Gravity separator or a coalescing separator. Some difference will increase because salt water of these factors are controllable and others are has a higher specific gravity than fresh environmental factors. water. To a very minor extent, temperature Physical factors affecting separator affects specific gravity performance 3. Temperature As mentioned above, temperature has a small 1. Particle diameter effect on separator performance. Generally, as By far the most important variable in the the operating temperatures decrease, the stokes formula: Beccuse tite GametenO |e specific gravities of both oil and water are raised to the power of two (0?) it can be greater. Low temperature applications require shown that for an increase in particle special consideration because the diameter of two, the rising rate of the performance is not as e particle will increase be a factor of four (2 = 4), Similarly, for a tripling in diameter, the rising rate will increase by a factor of nine The Table of Rising and Settling (3° = 9), Remember, the larger a particle, the faster a separation. ime shown below illustrates the effect of these factors. Vertical Rise/Fall Time per Stokes’ Law Formula Time for 3 inch vertical distance at 68 degrees F Solids Droplet (setting time) Diameter, Oil Droplet Rise Time (hemin:see) (inicron) (hrimin:sec) $620 36085 36080 0:00:02 300 o:00:12 0:00:15, 0:00:06 150 0:00:42 0:01:03 0:00:08 125 0:01:00 0:01:27 0:00:27 90 corsa 0:02:54 0:00:38 60 0:04:12 0:06:36 0:00:56 50 0:06:18 0:03:18 0:01:27 40 0:09:36 01424 0:02:35 30 0:17:24 0:25:48 0:05:49 20 038-46 05808 0:10:20 15 1:08:54 1:43:22 0:23:15 10 2:35:02 35233 133.01 5 10:02:09 15:30:14 38:45:35 1 258:23:53, 3873549 eeProcess factors affecting separator performance 1. Flow rate and turbulence The flow rate (measured in litres per minute, gallons per minute or cubic feet per minute) affects separator performance in two ways. The flow rate can be associated specific flow velocity for a given cross sectional area. Recalling that separation is a time related process and that more time to rise or settle will result in better separation, any factors that permit more time in the separator by reducing the flow velocity will enhance performance. This can be engineered by increasing the cross sectional area (diameter of the tank) and increasing the flow path (length of the tank). Furthermore, any factors that result in a smooth (non-turbulent) flow will enhance the degree of separation. This “smoothing” can be improved by reducing the incoming flow velocity and by using distribution baffles. 2. Chemicals Generally, any chemicals that tend to emulsify, flocculate and/or dissolve will detract and even negate separator performance. These chemicals are typically soaps, detergents, hydrocarbon solvents and flocculants. Special consideration should be made for applications such as ‘ar washes, truck and engine washdown and degreasing facilities and similar applications. 3. Technical factors Mechanical factors affecting separator performance are those associated with creating smaller particles, turbulence and mechanical emulsions. The most common source of this condition is the use of pumps to feed the separator. Although the separators are intended for Use in “gravity flow” storm water run-off applications, there may be certain applications where some form of pumping is unavoidable (extremely deep burial, poor drainage slopes, etc.) In this case, the recommendation is to use a positive displacement pump such as a diaphragm pump at as low as 20 percent efficiency. Centrifugal pumps that have a great particle shearing effect are definitely ‘not suitable. All pumped applications should be considered as special and referred to ZCL engineering for further assessment and recommendations. 4. Solids Solids in the form of sand and grit have little effect on the overall performance of a separator. However accumulation of this. material in the bottom of a separator that has not been maintained properly, may result in poor performance due to clogging and flow blockage. A good practice is to have a catch basin/drop out sump upstream of the separator inlet. Solids in the form of suspended solids can pose a large problem in relation to both suspended solids carry over and also oil carry over. Because the suspended solids have a nearly neutral density, they have an extremely low vertical settling velocity and are prone to being carried along with the effluent stream. Further complicating the situation, many suspended solids can effectively bind free oil particles and carry these particles into the effluent stream. eeFrom an analytical point of view, this oil may appear as free oil in an oil and grease analysis and thus reflect a poor separator performance. If the process stream has a considerable suspended solids content, measures should be taken to separate the suspended solids upstream of the separator either by filtration, mechanical means, chemical means or a combination of the three. 5. Influent Loading To a lesser extent, the influent hydrocarbon loading has an effect on separator performance. Oil in run-off applications is represented by a population of particle diameters ranging in size from less than 10 microns up to large globules. There is no uniform" sized particle. The size distribution tends to be shaped as a normal curve in terms of percentage of volume. Any analysis using Stokes formula makes the assumption of an average particle size in this population As the oil concentration at the inlet increases, the average particle size of the oil droplets tends to increase thus promoting good separation efficiency (percentage removal) Conversely, a low concentration at the inlet, say 100 ppm, tends to reflect a smaller average particle diameter. Unless this tendency is considered, actual separator performance may not be reflective of calculated values. OiliWater Separator Performance Comparison Tank API Gravity Separator Coalescing Separator Coalescing Separator Capacity 80 - 120 mglitre effluent 15 mgflitre effluent 10 mgllitre effluent (litre) ft'/minute litre /minute | ft'/minute litre / minute | ft'/minute litre / 2500 not available | not available 667 190 46 130 5000 60 168 13.44 380 92 260 10000 75 215 21.93 620 15.56 440 15000 120 340 29.36 830 2087 590 20000 not available | not available sa 1670 4139 1170 25000 180 510 57.66 1630 40.33 1140 35000 240 680 9657 2730 66.86 1890 50000 370 1045 17332 4900 120.27 3400 Based on an effluent free oil concentration as indicated and an oil of 0.85 SG. Oil concentrations, specific gravities, operating conditions vary from site to site. Consult a ZCL Technical Sales Representative for more detailed performance data for different parameters, eee(AHOLOAPVELL ONILLLAS LSIONO1 ONIINDAY INO — NOLWHLSNOWSG HOS G3.L0379S SNO LS3d330 SH) SUN.LXIW HELM AO AWMIOA SIdNvS —— Th “MALY NVETO ~~ ern na sis 34 —- —D uol2uN4 4oze4ed ag 193e///10 JO WesBelq 21;eWIaYISZCL Gravity Oil/Water Separator Models — te lip Sar LLL | HLL J. WU WU WOOL 7 608 8suonanaysul uo!e]|e3suU pay!e32q eySU] Of 1240y uiseq Yy>xe> spuemoy %z adojs Joyesedas uo yajano guy pua weld _ arta eeieia 3B[U spsemoy %z ado|s / soyeiedas uo 6uldno> 1dN 0} syauu0> \ /— Buldid yayuy ssozesedas 4a2eM/[10 ApiAesD 4o4 uol}epJezsuy fed1dALZCL Gravity Oil/Water Separators Product Description If you have a problem with the treatment of cil contaminated water run-off from your facility, ZCL has the reliable and cost effective solution. 2CL Gravity OilWater Separators are designed to clean up hydrocarbon contaminated water, removing and retaining free oils and allowing clean water to be discharged into your sewer or drainage system. ZCL Gravity Oil/Water Separators operate on the principle of differences in specific gravity between two or more discreet components or phases in a water stream. The natural buoyancy of “lighter than water” oll droplets in water forces the droplets to rise to the water surface, where they accumulate, effectively removed from the flow. Similarly, “heavier than water” solids such as sand and grit, settle to the bottom of the separator. Clean water, stripped of free oils and solids migrates to the downstream end of the separator and enters an integral discharge chamber unique to ZCL gravity separators Incoming contaminated water at the separator inlet displaces clean water in the discharge chamber and pushes this clean water out of the vessel through a submerged discharge piping riser, Separated oil is accumulated and retained at the liquid surface inside the separator, where it may be periodically removed. Heavier solids ‘arried into the separator with the flow may have oil droplets adhering to their surfaces. These particles settle to the bottom of the vessel as sludge and are also retained until removed. Standard Appl Gas bars and card locks Truck stops, parking lots Bulk fuel plants Petroleum terminals Rail and ship yards, airports Oil spill e-mediation sites ZCL Gravity OilWater Separators do not require external energy input and contain no moving parts to wear out. Periodic level checks and occasional removal of accumulated contents are the only services required. All CL Gravity OillWater Separators are fabricated using corrosion resistant materials and components and are designed for underground installation. Properly installed and maintained, they will provide a lifetime of reliable and trouble free service ome ee re! Beeches ions Special Applications Vehicle repair garages Car washes Industrial sites Water treatment facilities The ZCL Gravity OilWater Separator effectively employs the powerful forces of nature to protect the natural environment. aeetnies Line of Gravity Oil/Water Separators Corrosion resistant construction throughout the separator assures years of reliable service. No moving parts to wear out or break down. ZCL Gravity OilWater Separators do not require any moving parts to achieve oil or solids separation. The absence of flow control devices, adjustable weirs and baffles and other mechanical components simplifies the maintenance and servicing of this equipment. Compact distribution baffle directs the flow of in‘luent, reducing turbulence and introduces the flow evenly over the cross section of the vessel, making efficient use of the separator's full area end length. Sludge baffle channels the flow to the end of the separation chamber, taking full advantage of the length of the vessel and at the same time, traps sludge at a location removed from the discharge. Discharge chamber is designed to eliminate the need to recharge the separator with water following normal pump out Sampling port facilitates the monitoring of effluent quality at the separator discharge. This port may be used as a clean out in the unlikely event of a blockage in the discharge riser. Emergency shut-off valve is standard on all ZCL Gravity Separators allowing the separator discharge to be shut off in the event of an massive product spill incident.Engineering and Operating Manual ZCL Gravity Oil | Water Separators Introduction The ZCL Gravity OilWater Separator is designed for the purpose of intercepting, separating and containing non-soluble hydrocarbon based fuels, lubricants or solvents. Free phase hydrocarbons and settleable solids are removed from a flowing stream of water and are accumulated within the vessel. Clean water continues through the separator discharge to a sewer or drainage system. Periodically, the accumulated hydrocarbon and solids are removed from the vessel ZCL Gravity Oil/Water Separators are fabricated using the same reliable and cost effective fiberglass reinforced plastic (FRP) construction used in thousands of underground fuel storage tanks placed in service over the past four decades. Only corrosion resistant materials selected for extended service life in underground and immersed applications are incorporated into the gravity fed, cylindrical separator bodies and internal components The operation of the ZCL Gravity OilWater Separator relies on the immiscbility of free hydrocarbons in water and the differences in their respective Specific Gravity. The Separator directs the stream of incoming hydrocarbon, or water and hydrocarbon mixture, through a region of non-turbulent flow where the lighter hydrocarbons are allowed to rise and collect on the surface of the water in the vessel. At the same time, solids settle to the bottom of the Separator. A unique outlet channel design conducts clean water from the vessel to the discharge. There is only one moving part: a Shut- off valve intended for actuation in the event of a ‘major spill so that any potential pollutants can be contained on site. There are no parts that will wear out, that require lubrication or that must be regularly replaced. ZCL Gravity OilWater Separators are available in a variety of sizes to meet a range of performance requirements. Influent hydrocarbon. concentrations ranging from 100% to trace amounts can be processed at rates up to 4300 liters per minute and higher, depending upon separator size and operating conditions. The ZCL Gravity Oil Water Separator is designed to operate at 100% effectiveness with only routine maintenance and occasional servicing throughout the life of the equipment. Only periodic, simple servicing to remove accumulated hydrocarbons and any sludge that may have settled in the retention chamber is required. Typical methods of servicing include removal of hydrocarbons by pumping or skimming or by removal of the entire contents of the retention chamber (including sludge) by suction pump, vacuum hose or vacuum truck. All servicing may be done from grade through standard manway and port openings. The ZCL Gravity Oil/Water Separator is an effective, reliable, low maintenance and cost effective long term solution for preventing hydrocarbon discharge to the environment.Selecting the Appropriate Separator ZCL Gravity Oil/Wate: Separators are manufactured in a variety of standard sizes to closely match the requirements of a range of applications. The ZCL Gravity Oil Water Separator can be used to separate immiscible hydrocarbon based products that are lighter than water. The water phase can be fresh water (rain or melted snow and ice), sea water, industrial process water, brine and other water streams. Use one of the following methods to select the appropriate size separator. The "Quick Select” method may be used for the selection of ZCL Gravity Oil Water Separators in routine applications involving interception of hydrocarbon fuels (such as diesel, fuel oils and gasoline). This method assumes that a hydrocarbon (specific gravity = 0.86) is being separated from precipitation run-off (temperature = 5 degrees C). These conditions may be considered appropriately conservative design values for most fuel service locations. The “Quick Select” method may also be used as a guide for the preliminary selection of a 2CL Gravity OiliWater Separator in situations where exact field data is unknown or uncertain. In most cases, the Separator selected by this method will be of appropriate or conservative design. For applications othe’ than hydrocarbon fuels or where field conditions vary significantly from the above mentioned design assumptions, the “Detailed Selection” method to select the optimum ZCL Gravity Oil/Water Separator should be employed. Additionally, the "Detailed Selection” method can be used to evaluate the performance of a selected Gravity Oil Water Separator under varyng conditions. ‘Quick Select” Method Use this method ifthe following conditions apply: + Hydrocarbon to be captured is diesel fuel, gasoline, heating fuel, jet fuel, av-gas, or any other medium or light hydrocarbon with a specific gravity of 0.86 or less. ‘+ Hydrocarbon concentration range from 100% to trace amounts. + Hydrocarbons are to be separated from water, brackish water or sea water. ‘+ Water temperature at maximum flow rates is 5 degrees C or higher. Selection of a ZCL Gravity OilWater Separator by the “Quick Select” method requires two pieces of information relevant to the site: The “Actual Flow Rate"(in liters per minute) of hydrocarbon and water combined entering the Separator under design conditions. This flow rate is determined by conditions at the site such as source of water and/or hydrocarbon, area to be drained, amount of precipitation, etc. Refer to Section “Flow Rates Resulting From Precipitation Run-off" (page 14) for a Guide to calculating flow rates due to rainfall in Canada This "Actual Flow Rate” is equivalent to the “Standardized Flow Rate” of Figure 1 for the conditions listed above. The “Retention Capacity" (in liters) of the Separator. This is the maximum amount of hydrocarbon that can be retained within the vessel without hydrocarbon carry-over through the Separator discharge. Retention capacity should be selected with consideration to such factors as anticipated spill volumes and servicing frequency.To select a ZCL Gravity OiliWater Separator by the “Quick Select” Methi (Refer to Figure #1) Step 1. Enter Figure #1 on the left hand side at the Standardized Flow Rate that corresponds to the ‘Actual Flow Rate (there is no need to convert the flow rates when using the standard design conditions assumed in the “Quick Select” method). Draw a horizontal line from this point. Step 2. Draw a vertical line from the bottom of Figure #1 at the point corresponding to the desired Retention Capacity Step 3. Select the ZCL Gravity OilWater Separator Model Number whose operating curve appears immediately above or to the right of the point of intersection of the two lines The resulting ZCL Gravity Oil/Water Separator Model determined through this method is appropriately sized for the intended application under the specific conditions listed above. "Detailed Selection” Method Use this method if the following conditions apply: * Hydrocarbon to be captured is insoluble in water and has a Specific Gravity lighter than water. + Hydrocarbon concentrations range from 100% to trace amounts. + Hydrocarbons are to be separated from water, brackish water or sea water including storm run-off and industrial process water. * Water temperature may vary significantly from 5 degrees C. at design flow rates. To use the "Detailed Selection” method the following information about the application is required: 1, The “Actual Flow Rate” (in liters per minute) of hydrocarbon and water combined entering the Separator under design conditions. (See “Quick Select” method). 2. The “Retention Capacity” (in liters) of the Separator. (See "Quick Select” method). 3. The Specific Gravity of the hydrocarbon to be captured. If more than one type of hydrocarbon is to be captured, then the heaviest (highest Specific Gravity) product should be considered for design purposes. High specific gravity products will require longer retention or residence time in the separator to achieve removal efficiency 4, The temperature of the water at design flow conditions, 5. A knowledge of the range of sizes of oil droplet particles in the incoming flow.To select a ZCL Gravity OilWater Separator by the “Detailed Selection” Method: Step 1. Select the appropriate value of factor (Ft) from Table #1 using design values for Hydrocarbon Specific Gravity and Water Temperature. Linear interpolation may be used to estimate intermediate values not shown on the chart. Step 2. Select the appropriate value for factor (F2) from Figure #2 by using the following procedure: * Determine the minmum oil droplet size (in microns) to be recovered. * Entering the chart at the droplet size under consideration, draw a line vertically until it intersects the "% of Capture” line appropriate for the design under consideration. © ) From this point of intersection, draw a line horizontally to the left until it meets the vertical axis. Read the Droplet Size Factor (F2) from the scale. Be The American Petroleum Institute (API) design guidelines recommend a minimum oil droplet diameter of 150 microns as the practical lower size limit for 100% capture by a specific gravity differential separator It becomes increasingly difficult to separate smaller droplets from water flow because of physical limitations. ZCL Coalescing Oil/Water Separators should be considered where regulations or bylaws mandate high quality effluent. Step 3. Calculate a Standardized Flow Rate using the following formula: Standardized Flow Rate = (Actual Flow Rate) x (F1) x (F2) This calculation adjusts the actual flow rates to "standard conditions" to properly account for variations in specific gravity, temperature and droplet size. Refer to Figure #1. Enter the chart on the left hand side at the calculated Standardized Flow Rate. Draw a horizontal line from this point. Step 4. Draw a vertical line from the bottom of the chart at the point corresponding to the desired Retention Capacity. Step 5. Select the ZCL Gravity OilWater Separator Model Number whose operating curve appears immediately above or to the right of the point of intersection of the two lines. Step 6. If the Actual Flow Rate exceeds the "Standardized Flow’ rate calculated in Step 3, it may be necessary to reduce the Maximum Retention Capacity of the selected separator for it to function at full efficiency. Use Figure #3 to verify that the selected separator has sufficient Retention Capacity to meet design conditions. * Draw a vertical line corresponding to the ‘Actual Flow Rate. + Where this line intersects the curve for the selected model of ZCL Gravity OilWater Separator, draw a horizontal line to the vertical axis, + Read the adjusted Retention Capacity from the vertical scale. If the Adjusted Retention Capacity is insufficient, use Figure #3 to select. a larger separator. fa It is not necessary to use Figure #3, Retention Capacity Limits, when using the “Quick Select” method. The ZCL Gravity OilWater Separator selected using the “Detailed Selection” method provides optimal performance for the specific site conditions. eeeFlow Rates Resulting From Precipitation Run-Off For applications where the flow entering the ZCL Gravity OillWater Separator results from precipitation run-off, the following procedure may be used to estimate the “Actual Flow Rate” for the purposes of selection of the appropriate size of Separator, The data presented in this section is based on maximum rainfall intensity for locations in Canada over a one hour duration occurring once every 10 years. This design condition is suggested as being appropriate for most outdoor sites with compacted gravel and asphalt surfaces. The data has been obtained from the "Rainfall Frequency Atlas for Canada”. This publication contains detailed procedures for calculating maximum intensities of rainfall over various time duration and periods for locations in Canada. The publication is recommended as a source of data for determining rainfall intensity for varying time duration, for remote sites and for unusual climatic conditions. Environment Canada offers a fee per use service that provides similar data for Canadian locations. Contact the Environment Canada Information office in the province in question for further details ‘Actual Flow Rat {liters per minute)= (sq, meters) x (millimetersthout) + (liters per minute} 60. Step 1. Determine the area (square meters) of that portion of the site that drains to the separator. Step 2. Refer to Table A1 - Extreme Rainfall Intensity, One Hour Duration - Ten Year Return Period. Identify the city nearest the site. Read the maximum rainfall intensity from the chart (millimeters rainfall per hour). Step 3. Determine the maximum rate (Spill Rate in liters per minute) of the anticipated hydrocarbon spill that may occur coincident with the maximum rainfall Step 4. Calculate the Actual flow Rate using the following formula: (Area x Rainfall intensity / 60) + Spill Rate This value may be used as a guide for the selection of the appropriate model of ZCL Gravity OilWater Separator.Limitations of the Performance of ZCL Gravity Oil/Water Separators The ZCL Gravity OilWater Separator operates 2 on the specific gravity differential principle, which states that liquids (hydrocarbons) with a lower specific gravity than water will float on water and solids with a higher specific gravity will sink in water under suitable conditions, Increased separation is promoted by directing the flow through the Separator in a pre- determined path that maximizes retention time and minimizes turbulence. The floating hydrocarbon accumulated at the liquid surface and solids at the bottom are retained within the vessel while the cleaned water flows through to the discharge. In a ZCL Gravity Oil/Water Separator, this process occurs without requirement for pumps, motors, filters, skimmers or other such mechanical equipment that would require monitoring or maintenance. The laws of physics are utilized to effectively remove liquid and solid hydrocarbon contaminants from water. The ZCL Gravity Oil/Water Separator is designed to take best advantage of these laws of physics However there are certain considerations which must be taken into account in specifying and selecting specific gravity differential separators 1. Hydrocarbons with a specific gravity equal to or greater than the specific gravity of the water with which they are mixed cannot be separated using the specific gravity principle. Additionally, if the specific gravity of the hydrocarbon is only slightly less than that of the water, longer retention time (ie reduced flow rate) will be required to achieve effective separation. For practical purposes, a Specific Gravity of 0.90 is the maximum design condition that should be used without special considerations. Consult with the ZCL Technical representative in your region for recommendations. Any soluble (cutting oils, antifreeze) or partially soluble hydrocarbons (BTEX, VOC's) cannot effectively be separated by the specific gravity differential principle. Specific gravity differential separators have only limited effectiveness for the removal of hydrocarbons in the form of chemical emulsions and for mechanical emulsions or hydrocarbons that have been treated with soaps or detergents. High proportions of hydrocarbons in these forms in the influent may detract from the quality of water in the separator discharge The presence of floating debris, algae, organic material, froth/foam, ice crystals or other similar contaminants may reduce the efficiency of the ZCL Gravity Oil/Water Separator. Excessive accumulation of these materials will also physically reduce the design Retention Volume of the separator. For optimum operation of the Separator, the accumulation of these floating materials should be maintained at a minimum. The viscosity of water is a factor in the design of a specific gravity differential separator. The effectiveness of a ZCL Gravity OilWWater Separator may be reduced when treating waters containing chemicals or materials that increase the viscosity of the water. The presence of large concentrations of suspended solids in the separator influent may reduce the hydrocarbon removal. These materials will have a tendency to bind to or adsorb small oil droplets and carry them through to the separator discharge. The size, shape and make up (organic, inorganic) of the suspended particles can act individually or in combination to affect the separation process. ee7. Turbulence and any other mechanically induced conditions that change the laminar flow pattern in the separator may interfere with the separation process. Vibration, pumping, aeration or even excessive biological gas generation are examples of these conditions. Major modification of ZCL Gravity OilWater Separators by the addition of baffles, flow channels or other appurtenances that may affect flow should not be performed without consulting ZCL. 8. Unusual conditions, neglect and misuse resulting in the excessive accumulation of hydrocarbons and sludge will result in reduced separation efficiency. Accumulated oil and sludge should be removed on a regular basi. It is recommended that hydrocarbon and sludge removal intervals be established in relation to usage conditions, unusual events (spills) and any applicable regulations.DO Appendix i To select an appropriate separator, use the following procedure: Step 1. Step 2. Convert the actual flow rate to a standardized Draw a vertical line on the figure below, flow rate: corresponding to the desired retention capacity. Standardized = Actual xFy xF2, select Fy from Table 1 FlowRate Flowrate select Fy from Figure 2 step 3. Draw a horizontal line across the figure below, Select the separator model having an operating corresponding to the standardized flow rate. curve that lies above and to the right of the point of intersection of these two lines. If the actual flow rate exceeds the Standardized Flow Rate, Proceed to Figure 3 For Quick Select Method: Standardized = Actual Flow Rate Flow rate Figure 1: Operating Curves for ZCL Gravity Separators 8 8 8 8 g é = g g 3 z 4 g 2 b ° 5 10 15 20 2 30 35 40 HYDROCARBON RETENTION CAPACITY ( X 1000 litres )fe Appendix ii Toble 1 Specific Gravity / Temperature Compensation Factors (F1) [SPECIFIC TEMPERATURE "°C re Igpavity! _o- 3 [40 [is 720 s | 30 [35 [40 1 45 0.95 | 3.30 | 2.801] 2.410] 2.101 | 1.852 | 1.647 | 1.477] 1.333] 1.209] 1.104 0.90 | 1.653 | 1.401 | 1.205 | 1.050 | 0.956 | 0.824 | 0.738 | 0.686 | 0.605 | 0.552 [0.85 | 1.101] 0.934 [0.804 [0.700 [0.618 | 0.549 | 0.492 | 0.444 | 0.403 | 0.355 0.80 0.700 | 0.603 | 0.525 | 0.463 | 0.412 | 0.369 | 0.333 | 0.302 |0.276 0.75 0.560 | 0.482 | 0.420 | 0.371 | 0.330 | 0.295 | 0.267 | 0.242 | 0.221 0.70 | 0.551 | 0.487 | 0.402 | 0.350 | 0.309 | 0.275 |0.246 | 0.222 | 0.202 | 0.184 0.85 | 0.472 | 0.400 | 0.344 |0.300 | 0,265 | 0.235 | 0.211 |.0190 | 0.173 [0.158 woo Figure 2. Drovlet size Factors (F2) 20 ZCL Gravity severctors are Gesignes in accordance with API design criteria. 60 The recommended lower lirsit on droplet size is 15 microns. Ine reader muy wish to substitute “9 u_sroplet size limit other thon the desion vuiue of 1S microns. This moy be sccoinplisnea by multipiying so Pefeoen the wetucl flow cate by Fy Oe! Fy es tollows? Step 1 a vertical fine on the graph ous 30100 100 200 280 300 BU aw 450 900 DROF.E: Size (MICHUNS) f Recommendation 20 _ corresponding to ine. tes a at droplet = Step 2- At the point where the vertical fine 5, intersects the 100% capture curve, ; §“"p- | sw @ horizontal line to the ve | | 2 Gee and tud off the wale | ozs | & oe 100% CAPTURE os 2. 19% CAPTURE 2 Fas —— 50% CAPTURE a (25% CAPTURE ry |Appendix ii Figure 3: Retention Capacity Limits Flow rates in excess of the Standardized Flow Rate may require an adjustment to the Allowable Capacity of the separator. The figure below may be used to determine the Allowable Retention Capacity Step 1. Step 2. Draw a vertical line corresponding to the actual Where this line intersects the curve for the flow rate to be processed. separator being considered, draw a horizontal line to the vertical axis and read off the value of the Allowable Retention Capacity If the Allowable Retention Capacity from Step 2 is insufficient, use this figure to select a larger separator. 400004 Mod.822, 30000 20000 4 Q fs} fs} 3 ri = So 3 a S 36 < 2 . 2 3° 2 2 a o = 2 = 1000 2000 3000 4000 MAXIMUM ALLOWABLE FLOW RATE (litres per min.) eeee Appendix iv Table A1: Extreme Rainfall Intensity One Hour Duration — Ten Year Return Period The following data was obtained from the Canadian Climate Program publication, Rainfall Frequency Atlas for Canada, by Hogg and Carr: British Columbia (mm) Ontario (mam) Cranbrook 15 Barrie 39 Ft. Stohn, 2 Hamilton 34 Kamloops " Kenora 40 Penticton B Kingston 30 Prince George 7 London 45 Prince Rupert 15 North Bay a Revelstoke B Ottawa 36 Vancouver 16 St. Catherines 32 Victoria 2 Sarnia a2 ren | Sault Ste. Marie 30 Calgary Cw Sudbury 32 co eke ral Thunder Bay 33 Edmonton 30 Add a Ft. McMurra 2 foronto Grande rane 8 Trenton 2 Lethbridge 29 ney G Medicine Hat 24 Quebec (mam) Red Deer 25 Bagotville 26 Gaspé 4 Saskatchewan (mm) eam au Montreal 37 La Ronge 30 Québec 34 Moose Jaw 32 Sept-isles 19 Ninel Pal ‘Trois Rivigres 34 Prince Albert 26 Newfoundland/Labrador Regina 39 Churchill Falls B Saskatoon 35 Gander B Swift Current 34 Goose Bay 20 Yorkton 37 St. John's Poy Manitoba (mm) Stephenville 2 Brandon 42 New Brunswick (mm) Churchill B Chatham 2 Dauphin 39 Moncton 30 Flin Flon, 4 Fredricton 8 The Pas 26 St.John 30 Thompson a Pr. Edward Is. (mm) Winnipeg 43 Charlottetown 2B Nova Scotia (eam) Halifax 30 sydney 7 Yarmouth 32 Yukon & NWT. (mm) Hay River 19 Whitehorse " Yellowknife 4 eeZCL Gravity Oili/Water Separators Maintenance and Service Instructions Maintenance and Service Instructions for ZCL Gravity Oil/Water Separators Q maintenance The ZCL Gravity Oil/Water Separator is designed Should any other components of the ZCL to provide reliability and ease of operation Gravity Oil/Water Separator require any inspection or servicing, the Separator has Under normal use, the ZCL Gravity Oil Water been designed in sucha manner that almost Separator should not require major maintenance all parts are visible, easy to inspect and os cepa component materi eve been) replaceable either from inside the vessel or selected for continuous exposure to common through the manways and servicing ports, It fuels and hydrocarbons, water, brackish or salt 3 y ‘9 should not be necessary to excavate the ZCL water and soil chemicals and minerals. These Separator to service any parts. In the ‘components are expected to last the life of the me y Pi separator without the need for replacement or allkely Stet tick ceplae m= pats foe the Separator are required, they are refurbishment. available on short notice from ZCL. Your The ZCL Gravity OilWater Separator’s only regional ZCL Representative can assist you in moving parts are the Emergency Shut-off Valve obtaining replacement parts for all ZCL and operator handle, Due to the anticipated low Gravity OilWater Separators. frequency of use, this valve should not require servicing over the life of the Separator. If this should become necessary, the entire valve assembly can be removed for servicing or replacement, from inside the vessel, using common hand tools and without the need to remove internal piping. The valve handle should be rotated through its 90 degree travel on a periodic basis (at least twice a year) to confirm that it is operating smoothlyOservicing The ZCL Gravity OilWater Separator operates continuously and does not require operator involvement for the separation process. To maintain maximum operating ef recommended that the following simple service procedures should be performed at regular intervals a. Determine Water, Hydrocarbon and Sludge Levels Al ZCL Gravity Oil Water Separators are supplied with a calibrated gauge stick for checking fluid levels within the Separator. Level measurement can be performed from grade through a gauging port located on the manway cover. Datum Notches: When the Separator is new and free of sludge, with the liquid level inside the separator under static conditions, the gauge stick should be gently lowered through the gauge port Until it touches bottom. Two reference notches should be made on the gauge stick. The first notch should be made at the top of the “wetted” portion of the stick. This will be a reference mark for future oil layer determination. A second notch, coincident with the top edge of the gauge port fitting or any convenient reference point should be made. This will serve as a datum for determining future sludge levels To perform the hydrocarbon and sludge level determination, proceed as follows: FB This procedure is best performed under static (no flow) conditions. * Apply a coating of water detection paste extending 300 mm (12") below the “oil layer” notch on the gauge stick. « Insert the gauge stick through the gauging port, keeping the stick vertical and SLOWLY lower the stick into the Separator. (i Do not drop the stick into the separator as both misreading of sludge depth and/or damage to the bottom of the vessel may occur. * Continue to lower the gauge stick until a slight resistance is encountered. This represents the top surface of the sludge layer. Note and record the reading on the gauge stick adjacent to the top edge of the gauge port fitting tor reference point. ‘+ Measure the length between the level recorded above and the “sludge layer” notch on the gauge stick. This length is representative of the depth of the sludge layer at the bottom of the separator. * Withdraw the gauge stick and observe the water detection paste. Measure the distance on the stick between the level where the paste has changed color (oilwater interface) and the total wetted liquid level (top of the oil). This length represents the depth of the oil layer. If the paste has not changed color, repeat the test using a new coating of water detection paste but extend the paste 600 mm (24”) below the notch. eeRemoval of Accumulated Hydrocarbons, Sludge and Debi For optimum performance of the ZCL Gravity OiliWater Separator, the accumulated hydrocarbons, sludge and debris should be removed when the following conditions exist: Accumulated free hydrocarbons: 1, the hydrocarbon layer depth is 150 mm (6") or, 2. large spill event has occurred Accumulated sludge: 1. if the sludge depth is 300 mm (12") or greater Floating debris, scum 1. if accumulation is greater than 50 mm (2"). Retained hydrocarbons can be removed by a variety of methods. Typical methods include pumping, skimming end vacuum suction. Removal methods can be manual or automatic. All hydrocarbon removal should be performed using the appropriate fittings in the manway cover or through optional factory installed pump out fittings provided alorg the top of the separator. On smaller size separators, the entire contents (hydrocarbons, water and sludge) are removed and the separator is recharged with clean water. Sludge may be removed using a trash pump hose or vacuum hose inserted through the manway with the manway cover removed or through the fitting in the manway cover. Some of the retained water in the separator will be removed with the sludge. On most separators, itis possible to remove the accumulated sludge from grade working through the open manway. On longer vessels, flushing the separator with clean water from the inlet end while suctioning underneath the access manway will facilitate removal of sludge that has accumulated close to the inlet. It is permissible to remove all of the liquids from the Reter Chamber, along with the sludge, during servicing of the Separator. However, water should be retained behind the sludge baffle in the Discharge Chamber to provide a vapor lock for the outlet piping, If this water is removed during servicing, it must be recharged again. This can be easily accomplished by pouring approximately 500 liters of clean water into the sampling port to fill the Discharge Chamber behind the sludge baffle, or more preferably by filling the entire Separator with at least 450 mm (18") of clean water. Clearing plugged separator components If itis suspected that a component of the Separator has become plugged or fouled as a result of unusual service conditions, neglect or misuse it will be necessary to first determine where the restriction has occurred. Some restrictions caused by debris, rags, branches ‘or other gross solids can be cleared without vessel entry. Although the nature of the blockage will determine the best method, flushing with a hose, plumbing snakes or vacuum suction individually or in combination may remove the source of clogging or obstruction. Access to the interior of the Separator may be made through the tank inlet, the manway or the sampling port. In extreme cases of plugging, it may be necessary to enter the vessel to clear the obstruction. Access to all piping components and chambers may be gained through vessel entry, Blockage of the following components can be cleared through the following access points: Blocked Component | Access Inlet piping tee remove clean out plug in inlet Distribution baffle | flow openings in baffle body Discharge chamber _ | Sampling port or behind sludge baffle at downstream end of the separator removal of the shut-off valve and discharge riser pipe Discharge piping eeSeparators may retain volatile hydrocarbons in the atmosphere and sludge contained within the vessel. These may create an explosion hazard. Separators are confined spaces within which toxic or poisonous gases may accumulate or From which oxygen levels may be depleted. Internal surfaces of the vessel are very slippery especially when wet. Exercise caution and move ‘only along the bottom centerline of the vessel. Avoid stepping on any deflector plates that may be located along the bottom of the separator. Take all appropriate precautions to eliminate hazards before entering the vessel. Federal, provincial or municipal regulations for worker safety may apply. Wear appropriate safety ‘equipment. Only trained and capable personnel should be permitted to enter the vessel. Always post a responsible and capable trained safety spotter outside the vessel at the ingress to the vessel. d. Emergency Valve All ZCL Gravity OilWater Separators are equipped with an emergency shut-off valve on the discharge piping. The purpose of this valve is to stop the flow of ALL liquids from leaving the Separator. In the event of a major product spill reaching and entering the Separator, this valve must be rotated to the “Closed” position thus containing the spilled hydrocarbon (and water) onsite. During normal operation, this valve is set in the “Open” position. This valve can be closed in the event of a major spill entering the vessel when the volume of this spill may cause the Separator to exceed its Retention Capacity and permit the escape of some hydrocarbons through the discharge piping. The spilled product should be removed from the separator using appropriate means and the valve re-opened only under the condition that any remaining hydrocarbons can be safely retained in the Separator. In some locales, regulatory approval may be required prior to returning the Separator to service subsequent to a major spill event. The Emergency Valve is in the “Open” position (full flow) when the valve operator handle is pointing away from the access manway and is in the “Closed” position when the valve operator handle points to either side (right angles to “Open” position). Do not operate the valve in intermediate positions, the valve should only be in full “Open” or “Closed” positions. Sampling Port/ Plumbing Vent All ZCL Gravity OilWater Separators are equipped with a standard Sampling Port directly over the separator discharge riser pipe. Effluent samples may be collected from this port at any ‘time. This port is NOT intended for the checking of liquid levels. The Sampling Port must be vented to atmosphere at all times as it also functions as a plumbing vent so that accidental siphoning of the separator contents to the discharge can not occur. The valve operator handle should be rotated through its 90 degree travel on a periodic basis (at least twice a year) to confirm that itis operating smoothly and through full travel vio Do not drop the stick into the separator as both misreading of sludge depth and/ or damage to the bottom of the vessel may occur. eeeFor more information Toll Free 1-800-661 TANK (8265) www.zcl.com 2CL INC.