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Biorock ECOROCK-5000 Installation And User Manual

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INSTALLATION AND USER GUIDE
ECOROCK-5000
&
BIOROCK® Multirock systems
BIOROCK Multiple Installations
1 / 52
Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017
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  • Page 1 INSTALLATION AND USER GUIDE ECOROCK-5000 & BIOROCK® Multirock systems BIOROCK Multiple Installations 1 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 2 2 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 3 TABLE OF CONTENTS INSTALLATION GUIDE ......4 USER GUIDE ........... 27 APPENDICES .......... 39 3 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 4 The installation and commissioning of your BIOROCK system should be carried out by a BIOROCK trained and approved installer. Your installer will be able to offer you a maintenance contract. The BIOROCK Warranty is only valid if the required maintenance is carried out by a BIOROCK trained and approved installer.
  • Page 5 A. INSTALLATION GUIDE A. INSTALLATION GUIDE ECOROCK-5000 & BIOROCK Multirock systems BIOROCK Multiple Installations 5 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 6: Table Of Contents

    7. CONFORMITY AND WORK COMPLETION ............24 8. RECOMMENDATIONS OF USE AND MAINTENANCE ..........24 9. COMPLIANCE WITH REGULATIONS AND STANDARDS .......... 24 10. WARRANTY ...................... 25 6 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 7: The Biorock Sewage Treatment System

    The ECOROCK-5000 unit has a capacity of 30 P.E. (Person Equivalent). The capacity of the individual ECOROCK-5000 unit can be increased if the required final effluent quality is of a lower standard than the results, achieved during the EN-12566-3 Performance test The ECOROCK-5000 units can be installed in parallel for larger capacities (BIOROCK Multirock Systems).

  • Page 8: Precautions

    Important precautions for the proper use of the BIOROCK system: Only domestic sewage should enter the system; no rainwater is allowed. To ensure the good working order of the BIOROCK system, the use of automatic toilet cleaners, electric waste-disposal systems and pumps equipped with blades are not to be used.

  • Page 9: Identification

    Before installing please copy the serial number of each tank on to the documents to be kept by the customer (Appendix 5 of this Guide.) When looking at the tank facing the BIOROCK® logo, the serial number is: - On an identification tag inside the tank, and...

  • Page 10: Operating Principle Of An Ecorock Sewage Treatment Plant

    Performance of the Primary Tanks (PT) If the Primary Tank being used is not a BIOROCK tank, make sure that the quality of the effluent from the PT meets the BIOROCK requirements. Proper ventilation of a PT is necessary, not only to avoid smell problems, but also to evacuate the gasses produced.
  • Page 11 A. INSTALLATION GUIDE 2. OPERATING PRINCIPLE OF ECOROCK-5000 UNITS BIOROCK requires the following performance of a PT in front of the ECOROCK unit(s): Composition of normal domestic wastewater (according to EN12566-3+A2 Annex B.3.2): Variation 150 - 500 mg O COD* 300 –...

  • Page 12: The Biorock Treatment Unit (Bioreactor) - Ecorock-5000

    The pre-treated water is spread over the surface of the first layer of BIOROCK media by a distribution system and penetrates into the media for purification.

  • Page 13: Installation Layouts

    A. INSTALLATION GUIDE > 3. INSTALLATION LAYOUTS Installation layouts The installation of the BIOROCK system depends on the available site, gradient, type of ground, the level of the water inlet and the discharge options. When the outlet for final effluent is not accessible, a sampling shaft should be installed. When using a final effluent pump the pump shaft can be used as a sampling shaft.

  • Page 14: Installation Of The Tanks

    INSTALLATION OF THE TANKS INSTALLATION OF THE TANKS This chapter provides a guide to the installation and commissioning of the BIOROCK system. This manual cannot be a substitute for documentation and instructions from manufacturers of non- BIOROCK products integrated into the system by the installer/user, i.e Flow Management Devices or Primary Tank.

  • Page 15: Before The Installation Of The Complete System

     The distance between the side of the excavation and the tanks must be minimum of 300 mm  Connections for the BIOROCK system are made with flexible seals with a diameter of 110 mm  Local rules and legislation must be followed 4.1.2 Installation of the Primary Tank...

  • Page 16: Installation Of The Ecorock Treatment Unit

    The pump is required to lift the effluent (treated water) to a higher level. BIOROCK has developed an optional PE pump well with a diameter of 400 mm. The PE pump well has the same height as the ECOROCK-5000 unit. All the connections are matching with the openings at the ECOROCK units.

  • Page 17: Backfilling In Dry Ground Conditions

    The ECOROCK-5000 units can be installed in high ground water conditions with special precautions. If you don’t use a BIOROCK Primary Tank, please confirm with the manufacturer that this Primary tank is suitable for high ground water conditions. If you don’t use a BIOROCK Primary Tank, please consult the manufacturer to ensure this Primary Tank is suitable for high ground water conditions.
  • Page 18  In all high ground water conditions, the backfilling should be carried out to a level of 20 cm below the tank covers.  We recommend that the tanks are backfilled with (lean mix) concrete instead of a regular backfill 18 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 19: Installation In "Difficult" Areas And Sites

    The thickness and structure of any retaining wall should be specified by a qualified engineer along with the method of construction and backfilling procedure.  At the same time as backfilling around the Primary Tank and BIOROCK unit(s) all tanks should be gradually filled with clear water (increments of 300 mm) ...

  • Page 20: Installations Under Roads, Courtyards Or Storage Areas

    A detailed assessment must be carried out for all installations in difficult ground conditions. If you are not sure about the installation, always consult a local engineer 20 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 21: Ventilation And Water Distribution

    1 m away from any windows or skylights  We recommend a gradient of 1% to avoid any water settling in the air pipe 21 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 22: Ventilation Of The Ecorock-5000 Treatment Unit

     Water should not accumulate on top of the BIOROCK® media  The level of the BIOROCK® media must be just under the water distribution plate  Check that the water from the Primary Tank flows by gravity into the BIOROCK® unit (s) 22 / 52 Installation and User guide –...

  • Page 23: Biorock® Media

    In normal use the BIOROCK Media should not be removed or replaced. The top layer of the BIOROCK Media may have to be rinsed after a period of time if contaminated with solids.

  • Page 24: Stopping And Restarting The System

    The BIOROCK system remains efficient after a shutdown period. CONFORMITY AND WORK COMPLETION In all cases, the owner and the installer will jointly complete the installation checklist for BIOROCK Sewage Treatment Plants (Appendix 5) and send it back to the manufacturer at the address listed.

  • Page 25: Warranty

    10 years warranty on the BIOROCK® media * 25 years warranty on the BIOROCK® tanks * The 10 years warranty shall only apply if the annual maintenance is carried out by a BIOROCK® approved installer or supervised by a trained BIOROCK® Certified professional The 25 years warranty shall only apply if the installation is carried out by a BIOROCK®...
  • Page 26 The maintenance book must be made available in the event of a complaint. BIOROCK warranty: - 10 years on the BIOROCK Media (biological part of the treatment plant). - 25 years on BIOROCK tanks - 2 years on electrical options, supplied by BIOROCK Condition of delivery: In the case of incomplete delivery (missing equipment or accessories) or damage observed on delivery, these remarks / observations should be listed on the carrier delivery note or bill.
  • Page 27 B. USER GUIDE B. USER GUIDE ECOROCK-5000 & BIOROCK® Multirock systems BIOROCK® Multiple Installations 27 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 28 Material recycling ..................31 2.2.3. The BIOROCK® Media ..................31 3. OPERATING AND MAINTENANCE RECOMMENDATIONS ........32 Primary Tank and Effluent filter ...................34 The ECOROCK Treatment Unit ..................36 28 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 29: Safety Instructions

    While installing the tanks, use a sling hung from the 4 corners of the upper part of the tank. Make sure that no one is in the maneuvering area, and do not position yourself under the load. 29 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 30: Sustainable Development

    Sludge produced in the Primary Tank must be removed by a licensed contractor. The used BIOROCK media can be returned to BIOROCK or to a BIOROCK Certified Partner for recycling. The effluent filter for the Primary Tank can be disposed after rinsing.

  • Page 31: Energy Recovery

    2.2.3 The BIOROCK® media The BIOROCK® media is inert but if there is a need to replace some of the media the dirty bags (once removed) must be cleaned before recycling. The used BIOROCK® Media can be returned to BIOROCK for recycling.

  • Page 32: Operating And Maintenance Recommendations

    The summary below indicates the commissioning of your sewage treatment plant. Your sewage treatment plant can be free from any failures as the BIOROCK system does not require electricity. (In normal operation, and following the maintenance recommendations)
  • Page 33 For Multirock only, Each quarter  Clean the Flow Management System  If BIOROCK Flow Control Chamber (FCC) and Splitterbox (SB): Rinse using a hose pipe  Check and re-adjust the float of the FCC if necessary  Check equal distribution of the wastewater through the ECOROCK units 33 / 52 Installation and User guide –...

  • Page 34: Primary Tank And Effluent Filter

    Please check how often you need to empty your Primary Tank in line with local regulations. Please check if the Primary Tank has the required efficiency that is required by BIOROCK. See page 9, Chapter 2.1. MAINTENANCE GUIDE FOR THE PRIMARY TANK (PT) AND THE EFFLUENT FILTER (EF)
  • Page 35 40%. When emptying, the cleaner must leave a few centimeters of sludge at the bottom of the tank; the bacteria that break down the sludge are specific and take a long time to develop. 35 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

  • Page 36: The Ecorock Treatment Unit

    RECOMMENDATIONS FOR OPERATION AND MAINTENANCE 3.2 THE ECOROCK TREATMENT UNIT(S) The 10 years warranty shall only apply if the annual maintenance is carried out by a BIOROCK® approved installer or supervised by a trained BIOROCK® Certified professional MAINTENANCE PLANNING FOR THE ECOROCK-5000 SEWAGE TREATMENT PLANT Only take a sample from running water.
  • Page 37 While replacing the bags of BIOROCK Media, make sure that each layer of bags completely covers the surface of the unit, ensure that there is no free space between the bags. The bags of BIOROCK Media should always overlap each other. Ensure that the aeration rings are put back to the same position and height.
  • Page 38 Clean the distribution plate with clean water using a hose pipe or high pressure cleaner. 1. Adjust the height/level of the water distribution plates using the screws 38 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 39  Should this occur, just shake the BIOROCK media bags manually and placed them back in the tank. Make sure that each layer of bags completely covers the surface of the Treatment Unit with no free space between the bags which should always overlap each other.
  • Page 40 Technical drawings of the various components 1.1 Drawing of an ECOROCK-5000 treatment unit 1.2 Aeration & Water distribution schematic of an ECOROCK-5000 1.3 Cross section of the layers of BIOROCK® Media in an ECOROCK-5000 unit Appendix 2: Installation drawings of BIOROCK® Multirock installations 2.1 Drawing (Cross section) of 1x ECOROCK-5000 plant in dry ground conditions 43...
  • Page 41 APPENDICES APPENDIX 1 41 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 42 APPENDICES APPENDIX 1 Aeration and water distribution scheme (without pumping well) 42 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 43 APPENDICES APPENDIX 1 Drawing (Cross section) showing the layers of BIOROCK® Media in a ECOROCK-5000 unit 43 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 44 APPENDICES APPENDIX 2 44 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 45 APPENDICES APPENDIX 2 45 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 46 APPENDICES APPENDIX 2 46 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 47 APPENDICES APPENDIX 2 47 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 48 APPENDICES APPENDIX 2 48 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 49 APPENDICES APPENDIX 3 49 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 50 APPENDICES APPENDIX 3 50 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 51 If you have not subscribed to any maintenance agreement, please ask a trained, professional contractor to provide maintenance and any work required on your sewage treatment plant. 51 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...
  • Page 52 APPENDICES 52 / 52 Installation and User guide – ECOROCK-5000 & BIOROCK Multirock Systems – 10-10-2017 PAGE...

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