Klargester BioFicient 1-3 Installation Manual
BioFicient Sewage Treatment Plant - Installation & Operation
HEALTH AND SAFETY
You must read these warnings carefully before installing or using the equipment. Always ensure that all relevant documents are supplied with the equipment transferred to a new owner. Observe all hazard labels and take
appropriate action to avoid exposure to the risks indicated. Take care to maintain correct posture, particularly when lifting. Use appropriate lifting equipment when necessary.
- Only experienced contractors should carry out installation, following the guidelines.
- The unit should have a Pre-Service Agreement Inspection by an approved engineer.
- A qualified electrician should carry out electrical work.
- Covers must be kept locked.
- Observe all hazard labels and take appropriate action to avoid exposure to the risks indicated.
We recommend the use of a dust mask and gloves when cutting GRP components.
Any person carrying out maintenance on the equipment should wear suitable protective clothing, including gloves.
- If you wish to inspect the operation of the equipment, please observe all necessary precautions, including those listed below, which apply to maintenance procedures.
- The power supply to the equipment must be isolated at the control panel(s) before lifting the covers.
- If the equipment should run with the covers off, all care must be taken to avoid contact with moving parts and electrical components or conductors.
- Once power has been isolated, the control panel must be kept locked shut to avoid accidental re-connection whilst work or inspection is being carried out.
- Ensure that the working area is adequately lit.
- Ensure that you are familiar with the safe working areas and accesses.
- Use only the designated access walkways. Do not walk on the cover or deep well safety mesh(es).
- Always keep proper footing and balance to avoid any sharp edges.
Desludging should be carried out by a licensed waste disposal contractor holding the relevant permits to transport and dispose of sewage sludge.
|Model||BFP 1||BFG 2||BFG 3|
|Primary Settlement Tank||2000 Litres (440 gal)||3600 Litres (800 gal)||3600 Litres (800 gal)|
|Final Settlement Tank||54 Litres (12 gal)||90 Litres (20 gal)||90 Litres (20 gal)|
|Desludge Period||12 Months Maximum||12 Months Maximum||12 Months Maximum|
The delivery paperwork will have 2 no. items listed; check that the Tank Code (Item 1) & Blower Assembly Code (Item 2) are the same as the codes on the units delivered.
Top Level Product Code – BFP1GPPK
Item 1 – BFPTANK1GK (Tank Code)
Item 2 – BHBF1GPPK (Blower Assembly Code)
You should receive:
- Item 1: Sewage Treatment Tank
- NB: Storage tanks vary in design and volume (6PE to 10PE). Please check your order and cross reference with relevant sales drawing.
- Item 2: Blower Housing Assembly
- The Blower Assembly consists of the Blower Unit, Control Panel or Isolator, Solenoid Valve and associated pipework and fittings.
- 13 mm Hose Coil – 15 Metres
- 13 mm Hose required to connect from 1/2” Hose Connector in Blower Housing to Sludge-return Pipework located with the Tank (Supplied inside Blower Housing Packaging).
- 19 mm Hose Coil – 15 Metres
- 19 mm Hose required to connect from 3/4” Hose Connector in Blower Housing to Air Diffuser Manifold located with the Tank (Supplied inside Blower Housing Packaging).
To minimise the need for dealing with emergency situations we recommend that Sewage Treatment Plants have a Pre-service Agreement Inspection, and then is regularly serviced by us or an approved Service Engineers. Provided that your plant is installed, operated correctly and serviced, you should not need to get into much – if any – self-help. However, some of the most likely question and answer situations are listed below.
- Check the unit is switched on, the incoming power supply circuit and
Blower works but no water distribution inside the plant:
- Check hose connections.
- Check distributor heads.
- If the air lift pipes are suspected to be blocked, call for service which number and other details you can find on the back page of this manual.
- Check regulating valve is not closed.
- Check for blocked outlet system.
- If pumped outlet is all right, check for pump operation, check floats and pump power supply.
- Check blower working.
- If blower working, plant probably needs desludging.
- Check vent circuit is clear.
- Check that the air duct entering the blower housing has been sealed with foam.
Do take out a service agreement and let the experts look after your plant.
Do contact us for advice if you have any cause for concern. All contact details are at the end of this manual.
Don’t pump feed the plant without seeking advice from Kingspan or installer.
Don’t use a waste disposal unit as you will be adding to the biological load, and your system may not be large enough to cope with the waste. If you are unsure please refer to our sales team for guidance.
Don’t throw any medicines down the toilet.
Don’t empty large quantities of bleach or similar cleaning reagents into the system.
Don’t empty cooking oil or similar down the sink.
Don’t cover the plant with soil material or prevent access for service and desludging.
Don’t apply a hose or jet wash to the biological filter unless specifically advised to do so.
Don’t try to enter the plant.
Don’t put sanitary towels, incontinence pads, nappies, tampons or other non-biodegradable items down the toilet.
1. Evacuate a hole & lay concrete bed.
|Model||Diameter / Width (mm)||Length (mm)||Inlet Invert* (mm)||Outlet Invert ** (mm)||Installation Depth ** (mm)|
*Bioficient 1 inverts available – 500 to 810, 1000 & 1500mm.
*Bioficient 2 & 3 inverts available – 500, 1000 & 1500 mm
**Based on 500 mm invert
- For DRY CONDITIONS excavate a hole to appropriate depth allowing minimum clearance on all sides and
base of the unit of 200mm and level the base.
- For WET CONDITIONS excavate a hole at least 300mm deeper than the tank, for lean mix concrete and hardcore base. Allow for tank width plus at least 400mm with additional allowance for any necessary shuttering.
- De-water the excavation using suitable pumping equipment. Ensure that the pump discharge does not saturate the ground in the immediate vicinity. The installer should ensure that the base is adequate to support the weight of the tank and its contents. Place a sheet of polythene over the hard-core and up the sides of the excavation before putting in the concrete cradle.
- For UNSTABLE BASE of the excavation, i.e. running sand or similar, excavate an additional 250-300mm below
concrete levels and fill up with compacted hard-core.
- A base of at least 150 – 200mm of lean mix concrete should be provided. (FOR CONCRETE SPEC. SEEBELOW).
- It is recommended to back fill with C25 SEMI-DRY MIX.
For the general concrete specification (in accordance with BS EN 206-1 (BS 8500-1), please refer to the downloadable manual.
2. Lower unit onto concrete & ensure it is level.
- Lower the tank in the hole using a sling through the lifting points provided on the tank.
- Under no circumstances should the sling be attached to the inlet pipe or the outlet pipe.
- Tank should not be lifted with any water inside.
- Check that the Inlet and Outlet pipe orientation is correct.
- Check if the unit is levelled.
- It is required to haunch the concrete under the tank to provide full support to the GRP case.
3. Strap tank to concrete base when using pea gravel
- ONLY TO BE USED IN DRY SITE CONDITIONS.
- When using Pea gravel or similar as a backfill material ONLY.
- Permanent ratchet strap should be at least 50mm wide, rated to 500kg.
- Pea Shingle – 6 mm to 10 mm rounded pea shingle, offering low point loading characteristics is the most suitable material for back filling in dry ground installation.
- Make sure that voids are not left under and around the sides of the
tank and that there are no localised stress concentrations.
4. Backfill the tank unit
- The backfill should be free from organic material, large stones, brick or sharp objects.
- Backfilling should be carried out in layers, making sure that voids are not left under and around the sides of the tank and that there are no localised stress concentrations.
- It is most important that the installer progressively fills the tank via a hose while keeping the water level 300 mm above the backfill to stabilise pressures on the tank.
- It is also important that the water level is always above or equal to the backfill level while backfilling the main body of the tank to avoid cracking of the tank.
Make sure tank is ballasted with water in all chambers as you backfill.
Note: The feet on the tank are for transportation purposes only and are not load bearing.
Make sure the concrete backfill is spread underneath the tank to take pressure off the
5. Second backfill stage
- Ballast the tank with another 300mm of water in all chambers.
- Add the same level of the backfill around the tank.
- It is most important that the installer progressively fills the tank with water to a level above the backfill to stabilise pressure on the tank.
- Backfill evenly all-round the tank, consolidating in layers. The backfilling should start before the base has hardened and be a single continuous operation so that the tank has a full concrete jacket without joins.
6. Further backfill stage
- Continue to fill up tank with water and backfill evenly all round the tank, consolidating in 300mm layers.
- DO NOT use vibrating pokers to consolidate concrete.
- DO NOT discharge concrete directly on to the tank.
- Ensure that the concrete is not too wet and that is tamped in around the tank.
- Continue until just below inlet / outlet pipework.
- Remove covers and connect inlet and outlet pipework.
- Continue to backfill.
- Installer must ensure adequate venting is provided for treatment plant to work efficiently.
- A vent connection is supplied in the tank neck and is clearly marked. This vent connection should only be
used to connect to venting pipework.
- It is also important to seal off the air duct to the blower housing with expanding foam.
- This prevents odour from reaching the blower housing and ensures blower is only drawing in clean air.
BioFicient IPS HLA
BioFicient 1 HLA Installation
- Remove the loose float located in the blower housing.
- Thread the float cable through the gland in the HLA bracket fixed to the Final Settlement Tank (FST) in the plant.
- Position bottom of the float 200mm from top of the FST and tighten gland to secure the float cable.
- Connect hoses to Sludge Recycle and diffusers.
BioFicient 2-3 HLA Installation
- Remove the loose float, pivot weight & cable gland located in the blower housing.
- Drill Ø20mm hole & fit cable gland in position shown above the FST, approx. 100mm below the top of the turret.
- The bottom of the float to be approx. 250mm from the top of the pivot weight.
- Pass the float cable through the cable gland and align the top of the pivot weight with the top of the FST. Tighten the cable gland up.
- Ensure the operation of the float will not foul on any pipework.
- If required, float cable to be extended to control panel.
- Connect hoses to Sludge Recycle and diffusers.
For information on installing the control panel, and the control panel fault codes and fuses, please refer to the downloadable manual.
Klargester BioFicient Installation Guidelines Manual
- Health and Safety
- System Overview
- BioFicient Checklist
- Self Help
- Bioficient IPA HLA
- Control Panel Installation
- Warranty Information
- Fault Finding
- Start Up