ZURN Proceptor GMC 100 Technical Manual
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ZURN Proceptor GMC 100 Technical Manual

Grease, oil, and sediment separation
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G R E A S E , O I L , A N D S E D I M E N T S E P A R AT I O N
Proceptor
®
Technical Manual
Version 6.1 | Rev. 5.5.19
Patent # 5,746,912 (US); 2,195,822 (CDN)

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  • Page 1 G R E A S E , O I L , A N D S E D I M E N T S E P A R AT I O N Proceptor ® Technical Manual Version 6.1 | Rev. 5.5.19 Patent # 5,746,912 (US); 2,195,822 (CDN)

  • Page 2: Table Of Contents

    PROCEPTOR® TECHNICAL MANUAL PROCEPTOR OVERVIEW THE PROCEPTOR SEPARATOR ADVANTAGE APPLICATIONS WARRANTY INFORMATION CONTACT ZURN DESIGN AND OPERATION COMPONENTS & CONFIGURATIONS PRINCIPLES OF OPERATION SIZING GUIDELINES STANDARD SIZING CONSIDERATIONS OTHER DESIGN CONSIDERATIONS GREASE SEPARATORS OIL SEPARATORS ACCESSORIES AND OPTIONS ALARM COALESCING FILTER for Small Diameter Oil Globules (>20 μm)

  • Page 3: Proceptor Overview

    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, Zurn Green Turtle has helped thousands of commercial, institutional and industrial customers meet local effluent requirements.

  • Page 4: The Proceptor Separator Advantage

    1.3 WARRANTY INFORMATION This warranty is provided by Zurn Industries, LLC for products sold in Canada and the continental US. Although the companies are collectively referred to herein as "Zurn Green Turtle," each company only warrants products sold in its respective market.

  • Page 5: Contact Zurn

    (1) year against defects in materials and workmanship from date of shipment. 11 Customer assumes the risk of and agrees to indemnify Zurn Green Turtle against and hold Zurn Green Turtle harmless from all liability relating to (i) assessing the suitability for Customer's intended use of the Proce ptor 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.

  • Page 6: Design And Operation

    PROCEPTOR® TECHNICAL MANUAL 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 midsection of the Proceptor. A baffle separates the unit into two chambers while the flow distributor regulates flow into the second chamber.

  • Page 7: Sizing Guidelines

    6 Wastewater Strength. Notify a Zurn 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.

  • Page 8: Other Design Considerations

    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. Zurn Green Turtle takes the guesswork out of servicing the separator when an electronic alarm is used to indicate when the system needs maintenance.
  • Page 9 • 5 minutes retention for non-emulsified grease • 30 minutes retention for emulsified grease from sinks only • For heavily emulsified wastewater, call a Zurn 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)
  • Page 10 Pipe sizes shown in standard drawings reflect the lowest flow scenario in all cases. Larger pipe sizes are available. It is the responsibility of the designer to inform Zurn Green Turtle of the design flow rate and pipe size for each project.
  • Page 11 PROCEPTOR® TECHNICAL MANUAL Procedure for Sizing Grease Interceptor Table 8.3.2 is provided to show the standard formula in steps for sizing grease interceptors to suit requirements of specific fixtures. An example of this sizing formula application is inc1uded to illustrate the steps. Table 8.3.2 Procedure for Sizing Grease Interceptors Steps Formula...
  • Page 12 PROCEPTOR® TECHNICAL MANUAL Dishwashers A separate grease interceptor is recommended for each commercial dishwasher. The size of the interceptor is determined by the GPM discharge rate of the dishwasher as specified by the manufacturer. Select proper interceptor of equivalent or next higher rate from Table 8.3 .2.
  • Page 13 PROCEPTOR® TECHNICAL MANUAL System 1 : Single Tank Systyem 2 : Two Tanks in Series PDI & CSA Certified Grease Interceptors PDI Certified CSA Certified Rated Grease Height Top Inlet Invert Outlet Invert Proceptor Proceptor Capacity Capacity of Tank Model Model (gpm) (pounds)
  • Page 14 PROCEPTOR® TECHNICAL MANUAL System 3 : Three Tanks in Series Systyem 4 : UPC | IAPMO Approved (Dual Accessway, Single Tank or Two Tanks in Se ries Design) Standard Grease Separator with Single Accessway System Model Total Storage Capacity Tank Dimension Inlet to Tank Outlet to Tank Type...

  • Page 15: Oil Separators

    PROCEPTOR® TECHNICAL MANUAL 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.
  • Page 16 Pipe sizes shown in standard drawings reflect the lowest flow scenario in all cases. Larger pipe sizes are available. It is the responsibility of the designer to inform Zurn Green Turtle of the design flow rate and pipe size for each project.
  • Page 17 PROCEPTOR® TECHNICAL MANUAL System 1 : Single Tank Systyem 2 : Two Tanks in Series Standard Oil Separator with Single Accessway System Model Total Storage Capacity Tank Dimension Inlet to Tank Outlet to Tank Type Number Liquid L x W x H Bottom, D1 Bottom, D2 Sediment...
  • Page 18 PROCEPTOR® TECHNICAL MANUAL System 3 : Three Tanks in Series Systyem 4 : UPC | IAPMO Approved (Dual Accessway, Single Tank or Two Tanks in Se ries Design) Standard Oil Separator with Single Accessway System Model Total Storage Capacity Tank Dimension Inlet to Tank Outlet to Tank Type...

  • Page 19: Accessories And Options

    PROCEPTOR® TECHNICAL MANUAL 4 Accessories and Options 4.1 ALARM The alarm is an electronic monitoring system designed to trigger a visual and audible alarm when a preset 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.

  • Page 20: Level Monitor For Double Wall Or Oil Reservoir

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

  • Page 21: Importance Of Maintenance

    PROCEPTOR® TECHNICAL MANUAL 5.3 IMPORTANCE OF MAINTENANCE Maintenance of a Proceptor unit is critical to ensure that separation efficiency is not compromised. The buildup 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.

  • Page 22: Inspection Procedures

    PROCEPTOR® TECHNICAL MANUAL 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...

  • Page 23: Specification Sheets

    PROCEPTOR® TECHNICAL MANUAL 6 Specification Sheets GREASE WASTE INTERCEPTORS PART 1 - GENERAL RELATED DOCUMENTS A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section. SUMMARY A. Section Includes: 1.
  • Page 24 Alarm for high oil accumulation. Includes alarm probe to be installed near top of tank accessway and alarm panel with buzzer and light for indoor wall mount. 8. Zurn Green Turtle Proceptor Model: <GMC XXX>. FIBERGLASS ACCESSWAY RISERS A. Fiberglass accessway extensions: Fiberglass wound pipe.
  • Page 25 PART 3 – EXECUTION EARTHWORK A. Excavating and trenching and backfilling are to meet local building code. B. Backfill per Zurn Green Turtle Installation Instructions. Pea gravel is preferred backfill material. INSTALLATION A. Install fiberglass interceptors according to manufacturer's installation instructions.
  • Page 26 Suction port for remote pump-out. b. Alarm for high oil accumulation. Includes alarm probe to be installed near top of tank accessway and alarm panel for indoor wall mount. 8. Zurn Green Turtle Proceptor Model : <OMC XXX>. BACK TO TOC...
  • Page 27 STANDARD PROCEPTOR OIL / GREASE POINT ALARM SPECIFICATION SHEET Description The Zurn Green Turtle Oil/Grease Point Alarm is specifically designed for use in Proceptor Oil or Grease Gravity type separators. The unit contains no moving parts, eliminating maintenance due to mechanical malfunction.
  • Page 28 PROCEPTOR® TECHNICAL MANUAL Specifications (Standard) Power Input: 110 -240 VAC, 50/60 Hz, 0.15A or 24 VDC, 0.25A Relay: 2 x SPDT, 10 amp @ 250 VAC, Dry Contact (relays trigger at same setpoint) Sensitivity: 0.0018 pf Accuracy: +/- 2 mm Time Delay: Field Selectable 0 to 600 seconds Relay:...

  • Page 29: Installation

    PROCEPTOR® TECHNICAL MANUAL 7 Installation 7.1  INSTALLATION PROCEDURES INSTALLATION MANUAL PROCEDURE Use this procedure together with the applicable installation drawing. A) EXCAVATION 1. Excavation for the installation of a Proceptor separator must conform to OSHA and/or local excavation codes and standards.
  • Page 30 Proceptor separators are manufactured with a short neck at the top, which is marginally less in diameter than the extension collar. The fiberglass extension collar slides over the neck. Use only Zurn Green Turtle fiberglass extension collar (EC2 for 24" dia accessways and EC3 for 36" dia accessways). This collar is designed to fit physically and perform structurally for this application.
  • Page 31 Proceptor installation drawings. Slab designs for standard Proceptors are available from Zurn Green Turtle. The contractor must verify that the concrete relieving slab design is suitable for the application and conforms to local codes and standards.
  • Page 32 PROCEPTOR® TECHNICAL MANUAL TRAFFIC RELIEVING SLAB DRAWINGS 7.2.1 AASHTO H-20 LOADING SLAB DRAWING BACK TO TOC...
  • Page 33 RELIEVING SLAB DRAWINGS GMC/OMC 50 - 10000 To ensure you retrieve the most current drawings, links to drawings take you to the Zurn websiteb 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.

  • Page 34: Drawings: Grease Separators

    8 Drawings: Grease Separators To ensure you retrieve the most current drawings, links to drawings take you to the Zurn website 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.

  • Page 35: Drawings: Decontamination & Holding Tanks

    PROCEPTOR® TECHNICAL MANUAL 11 Drawings: Decontamination & Holding Tanks To ensure you retrieve the most current drawings, links to drawings take you to the Green Turtle website 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.
  • Page 36 AVERTISSEMENT: Cancer et effets néfastes sur la reproduction - www.P65Warnings.ca.gov ZURN INDUSTRIES, LLC 511 West Freshwater Way, Milwaukee, WI 53204, 855.663.9876 In Canada: ZURN INDUSTRIES LIMITED 7900 Goreway Drive, Unit 10, Brampton, Ontario L6T 5W6, 877.892.5216 Form No. 700-039, 5/19...

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