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DPR TILL 15-06-15

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Ahsan Shakil
Ahsan Shakil

The monthly progress report summarizes the work done on an RB project wastewater treatment system until June 15th. Key activities included cleaning the septic tank, installing the aeration header and diffusers, fabricating supports for piping and trays, constructing a pit for the bar screen, installing the blower, setting up bioreactor and membrane tank piping including pumps and valves, and placing foundations for equipment. Some items were missing from shipments including bolts, gaskets, flanges and fittings.

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MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 1. EQUALUZATION TANK: The project started with septic tank cleaning. It is 60 m3 tank in which industrial waste/ effluent of entire plant would accumulate. The tank has rectangular base area of 40 ft2 approximately. Submersible pumps were used to remove water and subsequently, sweepers put out all the sludge manually and disposed it into drain. All safety measures were adopted during the entire cleaning process. Compressed air line was provided so as to avoid short of breath problem. The man holes were kept open throughout in order to avoid accumulation of toxic gases inside the tank. Once the cleaning process was completed, floor was leveled using concrete. It was strengthened using SBR binder. The floor was allowed to cure and dry. Then concrete blocks for the aeration header were plastered to the surface. They were installed in such a way that the aeration header lies along the centre of the tank. As there are three portions in the tank, core cutting was done to allow passage of header from one compartment to another. The header (3’’) was then installed, 100 mm from the underground level, supported by blocks. They were further clamped with u bolts and were then coated with concrete. All remaining pebbles were removed from the tank after installation. Diffusers serve the medium for the aeration. They are coarse bubble diffusers, which provide efficient mixing followed by growth of micro-organisms, which are actually responsible to carry out the process, i.e. decreasing COD & BOD. Diffusers are attached to the aeration header. Silicone is used to provide water proofing.
MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 Two submersible pumps are also placed, that will transfer the water to the bio reactor, delivering pressure of about 1.5 bar. 2’’ line is connected to the pump outlet, evolving from a cut out provided for this purpose. These lines connect to a header from which a common emerges, connecting the septic tank and the reactor. Double union ball valves are provided followed by NRV to prevent back flow. Line (1/2’’) for pressure gauge is also provided. A frame is fabricated for the cut out, coated with red oxide to prevent corrosion. Checkered plates have been fabricated. Ropes are provided to facilitate easy removal of pumps when required. A drain line is provided to with draw water outside the factory. This is provided for safety measures, i.e. avoiding entry of dead organisms into the reactor. Supports are fabricated as required.
MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 2. SUPPORTS FABRICATION AND INSTALLTION: Three types of E supports were designed and fabricated for the piping spool and cable trays. They were coated with red oxide and painted royal blue color. The spool and cable trays were then run on the supports. 3. CONSTRUCTION OF PIT: It started with excavation of pit having approx. dimensions of 5*5*5 ft. during excavation seepage water starts accumulating. Therefore, padlo was used to cater this problem. After then pit was given physical structure using wooden planks. Iron reinforced concrete was used for its construction. It was then left for some days to cure and dry. The floor was later on plastered.
MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 An enclosure of material SS 316, was fabricated for the bar screen. Bar screen having dimensions of about 1600*900 mm, will be placed at an angle of 45á´¼. This bar screen is responsible to retain all the solid material present in the effluent. Rawl bolts and concrete support the enclosure. Later on ceiling for the pit is laid using reinforced concrete.
MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 A cavity is provided for manhole frame and checkered plate. Finally bitumen diluted in turpentine oil is coated on the outside wall to prevent entry of seepage water into the pit. 4. BLOWER INSTALLATION: Blower is palced on the foundation pad. The line (3’’) originating from the septic tank is connected with the 1.5’’ line, attached to the blower, through a reducing bush. A bellow is provided on the dsicharge side to prevent breakage of nozzle.
MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 5. BIOPLUG/MEMPAC PIPING & AUXILIARIES: Bioreactor is responsible for the entire waste water treatment. Its capacity is 35m3 and material of construction is mild steel. Epoxy lining is done on the interior side to prevent corrosion. It acquires the feed through the septic tank’s submersible pumps. The line merges to header. The header itself consist of two lines, to carry the liquor to the membrane tank. These two lines are attached to the submersible pumps placed in the bioplug. These pumps have 68 ip (ingress protection) value. A recycle line is attached to the header, for recirculation purpose. Butterfly valves are used in the line, connected to the header. A mini screen is placed at the feed inlet to prevent entry of foreign solid material. Air is introduced into the reactor by means of aeration header to which diffusers are attached. These diffusers evenly distribute air, through a blower, present in the membrane container. Pipeline used for air is galvanized iron. An air breather/filter is attcahed a the suction of blower to prevent entry of dust/ debris present in the environment.
MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 this blower supplies air to reactor as well as to the membrane tank as required, i.e. air can be used as cleaning agent for membrane. This process is referred as membrane scouring. The water is filtered through UF membrane. These membranes are composed of PVDF (poly vinyl difluoride). The filtering phenomemon is done by creating a negative pressure by means of permeate pump. As a result of which, sludge is reatined in the membrane tank, where as water is transferred to the permeate tank. Back pulse tank is also filled side by side as the water flows through permeate pump. A recycle line is provided to feed sludge back to the reactor, once the membrane tank over flows. Through this line, a tee is provided to fill the sludge to the sludge tank. This is done by means of gravity. Supports have been fabricated to run pipe spools and cable trays. Butterfly valves are used in the drain connection. Drain lines have not been completed as they are to be concealed as required by client. Trench will be dug by client. Screw pumps for the transfer of sludge from the sludge tank to the filter press have been placed. Their suction header have been fabricated.
MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 Polymer dosing tank has been placed. Its foundation platform has been fabricated. It is responsible to agglomerate the sludge, inorder to facilitate sedimentation phenomenon. Frame for air conditioner, to be placed in container, has been fabricated. MISSING FITTINGS IN THE SHIPMENT: ï‚· Incomplete set of bolts/studs. ï‚· Part of saddle clamp missing. ï‚· gaskets unavialability. ï‚· Mating flanges missing ï‚· Fittings for polymer dosing tank missing. ï‚· Solenoid valve wiring tempered. ï‚· Hypo dosing system fitting tempered. ï‚· Antique type of filter press. ï‚· Cast iron butterfly valve missing. ï‚· Contardiction in given isometric drawing and actual fitting.

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DPR TILL 15-06-15

  • 1. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 1. EQUALUZATION TANK: The project started with septic tank cleaning. It is 60 m3 tank in which industrial waste/ effluent of entire plant would accumulate. The tank has rectangular base area of 40 ft2 approximately. Submersible pumps were used to remove water and subsequently, sweepers put out all the sludge manually and disposed it into drain. All safety measures were adopted during the entire cleaning process. Compressed air line was provided so as to avoid short of breath problem. The man holes were kept open throughout in order to avoid accumulation of toxic gases inside the tank. Once the cleaning process was completed, floor was leveled using concrete. It was strengthened using SBR binder. The floor was allowed to cure and dry. Then concrete blocks for the aeration header were plastered to the surface. They were installed in such a way that the aeration header lies along the centre of the tank. As there are three portions in the tank, core cutting was done to allow passage of header from one compartment to another. The header (3’’) was then installed, 100 mm from the underground level, supported by blocks. They were further clamped with u bolts and were then coated with concrete. All remaining pebbles were removed from the tank after installation. Diffusers serve the medium for the aeration. They are coarse bubble diffusers, which provide efficient mixing followed by growth of micro-organisms, which are actually responsible to carry out the process, i.e. decreasing COD & BOD. Diffusers are attached to the aeration header. Silicone is used to provide water proofing.
  • 2. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 Two submersible pumps are also placed, that will transfer the water to the bio reactor, delivering pressure of about 1.5 bar. 2’’ line is connected to the pump outlet, evolving from a cut out provided for this purpose. These lines connect to a header from which a common emerges, connecting the septic tank and the reactor. Double union ball valves are provided followed by NRV to prevent back flow. Line (1/2’’) for pressure gauge is also provided. A frame is fabricated for the cut out, coated with red oxide to prevent corrosion. Checkered plates have been fabricated. Ropes are provided to facilitate easy removal of pumps when required. A drain line is provided to with draw water outside the factory. This is provided for safety measures, i.e. avoiding entry of dead organisms into the reactor. Supports are fabricated as required.
  • 3. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 2. SUPPORTS FABRICATION AND INSTALLTION: Three types of E supports were designed and fabricated for the piping spool and cable trays. They were coated with red oxide and painted royal blue color. The spool and cable trays were then run on the supports. 3. CONSTRUCTION OF PIT: It started with excavation of pit having approx. dimensions of 5*5*5 ft. during excavation seepage water starts accumulating. Therefore, padlo was used to cater this problem. After then pit was given physical structure using wooden planks. Iron reinforced concrete was used for its construction. It was then left for some days to cure and dry. The floor was later on plastered.
  • 4. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 An enclosure of material SS 316, was fabricated for the bar screen. Bar screen having dimensions of about 1600*900 mm, will be placed at an angle of 45á´¼. This bar screen is responsible to retain all the solid material present in the effluent. Rawl bolts and concrete support the enclosure. Later on ceiling for the pit is laid using reinforced concrete.
  • 5. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 A cavity is provided for manhole frame and checkered plate. Finally bitumen diluted in turpentine oil is coated on the outside wall to prevent entry of seepage water into the pit. 4. BLOWER INSTALLATION: Blower is palced on the foundation pad. The line (3’’) originating from the septic tank is connected with the 1.5’’ line, attached to the blower, through a reducing bush. A bellow is provided on the dsicharge side to prevent breakage of nozzle.
  • 6. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 5. BIOPLUG/MEMPAC PIPING & AUXILIARIES: Bioreactor is responsible for the entire waste water treatment. Its capacity is 35m3 and material of construction is mild steel. Epoxy lining is done on the interior side to prevent corrosion. It acquires the feed through the septic tank’s submersible pumps. The line merges to header. The header itself consist of two lines, to carry the liquor to the membrane tank. These two lines are attached to the submersible pumps placed in the bioplug. These pumps have 68 ip (ingress protection) value. A recycle line is attached to the header, for recirculation purpose. Butterfly valves are used in the line, connected to the header. A mini screen is placed at the feed inlet to prevent entry of foreign solid material. Air is introduced into the reactor by means of aeration header to which diffusers are attached. These diffusers evenly distribute air, through a blower, present in the membrane container. Pipeline used for air is galvanized iron. An air breather/filter is attcahed a the suction of blower to prevent entry of dust/ debris present in the environment.
  • 7. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 this blower supplies air to reactor as well as to the membrane tank as required, i.e. air can be used as cleaning agent for membrane. This process is referred as membrane scouring. The water is filtered through UF membrane. These membranes are composed of PVDF (poly vinyl difluoride). The filtering phenomemon is done by creating a negative pressure by means of permeate pump. As a result of which, sludge is reatined in the membrane tank, where as water is transferred to the permeate tank. Back pulse tank is also filled side by side as the water flows through permeate pump. A recycle line is provided to feed sludge back to the reactor, once the membrane tank over flows. Through this line, a tee is provided to fill the sludge to the sludge tank. This is done by means of gravity. Supports have been fabricated to run pipe spools and cable trays. Butterfly valves are used in the drain connection. Drain lines have not been completed as they are to be concealed as required by client. Trench will be dug by client. Screw pumps for the transfer of sludge from the sludge tank to the filter press have been placed. Their suction header have been fabricated.
  • 8. MONTHLY PROGRESS REPORT FOR RB PROJECT TILL 15/06/15 Polymer dosing tank has been placed. Its foundation platform has been fabricated. It is responsible to agglomerate the sludge, inorder to facilitate sedimentation phenomenon. Frame for air conditioner, to be placed in container, has been fabricated. MISSING FITTINGS IN THE SHIPMENT: ï‚· Incomplete set of bolts/studs. ï‚· Part of saddle clamp missing. ï‚· gaskets unavialability. ï‚· Mating flanges missing ï‚· Fittings for polymer dosing tank missing. ï‚· Solenoid valve wiring tempered. ï‚· Hypo dosing system fitting tempered. ï‚· Antique type of filter press. ï‚· Cast iron butterfly valve missing. ï‚· Contardiction in given isometric drawing and actual fitting.