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 45ᴼ. 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:
 Incomplete set of bolts/studs.
 Part of saddle clamp missing.
 gaskets unavialability.
 Mating flanges missing
 Fittings for polymer dosing tank missing.
 Solenoid valve wiring tempered.
 Hypo dosing system fitting tempered.
 Antique type of filter press.
 Cast iron butterfly valve missing.
 Contardiction in given isometric drawing and
actual fitting.