The following is a detailed description of the installation details of the sewage treatment integrated machine:

1、 Preliminary preparation work

1. Site survey and planning

-Based on the equipment size and process flow, determine the layout of the installation area and reserve sufficient operating space (it is recommended to leave a 1-2 meter passage around the equipment).

-Verify the geological conditions of the site to ensure that the soil bearing capacity is ≥ 150kPa. If it is soft soil, reinforcement treatment is required.

-Measure the groundwater level to ensure it is at least 0.5 meters below the bottom of the foundation pit to prevent rainwater from flowing back.

2. Technical document review

-Check the equipment manual, installation drawings, and process parameters, clarify key information such as inlet/outlet positions, sludge return pipe diameters, and aeration system interface specifications.

-Develop a specialized construction plan, including data on lifting routes, excavation depth of foundation pits (generally 30-50cm deeper than equipment height), concrete mix proportions, etc.

3. Preparation of materials and tools

-Purchase supporting pipes (such as UPVC or HDPE materials), valves, flanges, etc. in advance, and prepare auxiliary materials such as waterproof tape and sealant.

-Equipped with level gauges, laser rangefinders, multimeters and other testing tools, as well as installation equipment such as welding machines, cutting machines, hydraulic jacks, etc.

2、 Basic construction stage

1. Excavation and support of foundation pit

-According to the design drawings, when using mechanical excavation, reserve 20cm of manually cleared bottom layer to avoid disturbing the original soil.

-For excavations deeper than 1.5 meters, steel sheet piles or wooden planks should be used for support, with a slope controlled within 1: 0.75.

-Lay a 10cm thick crushed stone cushion layer on the base and compact it, with a flatness error of ≤± 5mm.

2. Pouring of concrete foundation

-The template is made of steel or wood, with tight joints and no leakage of grout. When embedding the anchor bolts, positioning plates are used to fix them with a deviation of ≤± 2mm.

-C30 concrete is compacted layer by layer, and after the surface is polished, it is covered with a thin film for moisture preservation and curing. The formwork can only be removed after the strength reaches 70%.

-Pre embedded steel plates or channel steel at the top of the foundation are used for later equipment leveling, with a horizontal deviation of ≤ 1/1000.

3. Waterproof and moisture-proof treatment

-Set up drainage ditches (width × depth=300 × 400mm) around the foundation pit, and connect them to the collection well for timely pumping and drainage.

-Apply cement-based permeable crystalline waterproof coating on the foundation sidewall, with a thickness of ≥ 1.5mm, and make a curved transition at the corner.

3、 Equipment positioning and fixation

1. Lifting and transportation specifications

-Use nylon straps or steel wire ropes to tie the center of gravity of the equipment, and do not directly hang the pipeline interface.

-Lifting angle ≤ 60 °, slowly descend above the foundation, and adjust the position through the guide chain to avoid collision damage.

2. Horizontal calibration and anchoring

-Using a frame level with an accuracy of 0.02mm/m for detection, the longitudinal/transverse levelness is ≤ 1/1000.

-Before secondary grouting, clean the debris in the bolt holes, inject CGM high-strength non shrink grouting material, and tighten the nuts again after final setting.

3. Shock absorption and noise reduction measures

-Rubber shock-absorbing pads with a thickness of ≥ 10mm should be installed below the fan and pump units, and the compression should be controlled at 30% -50% of the rated load.

-Flexible rubber joints should be used at the connection of the inlet and outlet pipes, with matching diameters and no forced alignment allowed.

4、 Key points for pipeline system installation

1. Sewage pipeline laying

-A grid well is installed at the inlet, and the spacing between the grid bars is determined according to the water quality (usually 10-20mm for domestic sewage).

-Adopting a plug-in flexible interface, the insertion depth is 1.5 times the diameter of the pipe, the annular gap is uniform, and the outer side is filled with asphalt hemp thread.

-Install a check valve at the outlet of the lift pump, and consider the flow rate (recommended v=0.8-1.2m/s) and local resistance coefficient when calculating the head loss.

2. Assembly of aeration system

-Micro porous aeration tubes are horizontally arranged with a spacing of 0.5-1.0m, and the end exceeds the pool wall by ≥ 30cm.

-The main air pipeline is equipped with a condensate discharge valve, and the branch slope is ≥ 1% to prevent liquid accumulation and blockage.

-Install silencers at the inlet and outlet of the blower, with a noise level of ≤ 85dB (A).

3. Mud reflux pipeline

-The reflux ratio is calculated using the formula Qr=(Xw Xe)/(Xr Xw), where Xw is the concentration of the mixed solution, Xe is the concentration of the effluent, and Xr is the concentration of the reflux sludge.

-Choose wear-resistant rubber lined steel pipes, with a curvature radius of ≥ 3D for elbows, and regularly check for wear.

5、 Electrical control system configuration

1. Installation of distribution cabinet

-The protection level shall not be lower than IP55, the grounding resistance shall be ≤ 4 Ω, and the accuracy of the zero sequence current transformer shall be level 0.5.

-The frequency converter is matched with the motor power, and the carrier frequency is set to avoid mechanical resonance points.

2. Sensor wiring

-The immersion depth of the DO probe is ≥ 1/3 of the effective stroke, and the pH meter electrode is immersed in a dedicated filling solution.

-The liquid level switch is installed vertically, with an action height error of ≤± 10mm, and the signal line is separately shielded from interference by passing through a pipe.

3. Interlocking protection settings

-Write PLC programs to implement functions such as "low water level pump stop" and "overload alarm", and upload key parameters to the monitoring platform.

-The resolution of the analog input module is set to 16 bits, and the sampling period is ≤ 1 second.

6、 Debugging, operation and acceptance

1. Single machine no-load test

-The fan runs continuously for 2 hours, with a bearing temperature rise of ≤ 40 ℃ and a vibration speed of ≤ 4.5mm/s.

-Pump forward and reverse rotation test, flow error ≤ ± 5%, pressure gauge pointer swing amplitude<1/4 of the maximum scale.

2. Linkage load test

-Gradually increase the water inflow to 50%, 75%, and 100% of the design value, and observe the membrane formation of the packing material (with a biofilm thickness of approximately 2-3mm).

-COD removal rate ≥ 85%, ammonia nitrogen conversion rate ≥ 90%, SS effluent concentration<20mg/L.

3. Handover of completion documents

-Organize completion drawings, change certification forms, equipment qualification certificates and other documents, and prepare the "Operation and Maintenance Manual".

-Train operators to master the start stop process, emergency response, and daily inspection items.