Construction Plan for Small scale Integrated Wastewater Treatment Equipment(小型污水处理一体化设备施工方案)The following is a construction plan developed for small-scale integrated sewage treatment equipment, covering key aspects such as pre construction preparation, equipment installation, commissioning and operation, and acceptance to ensure efficient and safe completion of the project:
1、 Preparation before construction
1. On site investigation and scheme confirmation
Topographic survey: Measure the ground flatness and bearing capacity of the equipment installation area, and confirm whether foundation reinforcement (such as concrete foundation) is needed.
Pipeline layout: Plan the direction of inlet, outlet, sludge return, and exhaust pipelines, avoiding underground obstacles such as cables and gas pipelines.
Power access: Determine the location of the equipment control cabinet and reserve a three-phase five wire power interface (voltage 380V, capacity calculated based on equipment power, usually reserved with a 20% margin).
Deepening the plan: Based on the sewage quality (such as COD, BOD, SS concentration) and discharge standards (such as Grade A), confirm the process flow (such as A/O, MBR) and equipment model.
2. Material and personnel preparation
Material List:
Main equipment: Integrated sewage treatment equipment (including biochemical tank, membrane components, fans, etc.).
Pipeline accessories: UPVC/HDPE pipes (DN50-DN200), flanges, valves, rubber joints.
Electrical components: cable (YJV type), control cabinet (including PLC, touch screen), liquid level sensor, flow meter.
Auxiliary materials: sealant, expansion bolt, welding rod, anti rust paint.
Construction team:
Personnel configuration: 1 project manager, 1 technician, 2 electricians, 2 plumbers, 1 welder, and 3 general workers.
Safety training: Conduct specialized training on high-altitude operations, confined space operations, and electrical safety, equipped with safety helmets, safety belts, and insulated gloves.
2、 Equipment installation
1. Foundation construction
Foundation treatment: If the geology is soft soil, it is necessary to excavate to the old soil layer, lay a 200mm thick crushed stone cushion layer, and pour C25 concrete foundation (with a size 100mm larger than the equipment bottom plate and a thickness of 200mm).
Installation of embedded parts: M16 anchor bolts are embedded in the concrete, with a height of 150mm above the ground and a verticality deviation of ≤ 2mm.
2. Equipment positioning and fixation
Lifting operation: Use a 25 ton truck crane to lift the equipment onto the foundation, adjust the levelness (check with a level, deviation ≤ 2mm/m).
Fixed connection: Tighten the anchor bolts, pour concrete twice to fix the equipment, and wait for 7 days for curing before proceeding to the next step.
3. Pipeline connection
Inlet pipeline: UPVC pipe is used, with a slope of ≥ 1%, and a Y-shaped filter (DN100) is installed to prevent impurities from entering the equipment.
Outlet pipeline: Connect the outlet of the membrane module to the clean water tank, and install a check valve (DN80) to prevent backflow.
Sludge pipeline: Install a sludge return pipe (DN50) and a sludge discharge pipe (DN75), with the end of the sludge discharge pipe connected to a sludge well and controlled by a ball valve.
Air duct: The outlet of the fan is connected to the exposure pipe, which is made of ABS pipe with a diameter of DN40. A pressure gauge (0-0.1MPa) is installed to monitor the air pressure.
4. Electrical installation
Cable laying: Lay along cable trays or steel pipes, avoiding parallel connection with strong electrical lines, with a spacing of ≥ 300mm.
Control cabinet wiring: Connect the fan, water pump, and liquid level sensor according to the electrical schematic diagram. The wiring terminals should be firmly crimped and labeled clearly.
Grounding protection: The equipment casing, control cabinet, and metal pipes should be reliably grounded with a grounding resistance of ≤ 4 Ω.
3、 Debugging and Running
1. Equipment debugging
Single machine debugging:
Fan: Run without load for 2 hours, check for vibration, noise (≤ 75dB), and bearing temperature (≤ 70 ℃).
Pump: jog to confirm direction, run for 1 hour, flow and head meet the design values.
Linkage debugging:
Automatic mode: Set liquid level control parameters (such as starting the water pump at high liquid level and stopping at low liquid level), simulate water inflow, and verify the automatic start stop function.
Membrane module cleaning: Start the backwash pump, adjust the backwash cycle (such as backwashing for 1 minute every 2 hours), and observe the recovery of membrane flux.
2. Trial operation
Load test: Gradually increase the inlet water volume to the design value (such as 5m ³/d), run continuously for 72 hours, and record the COD, BOD, and SS removal rates.
Parameter optimization: Adjust the aeration rate (such as controlling DO at 2-3mg/L) and sludge return ratio (50% -100%) according to the effluent quality.
3. Acceptance
Water quality testing: Entrust a third-party testing agency to take samples, including pH, COD, BOD5, SS, NH3-N, TP, and the results must meet the Class A standard of the “Pollutant Discharge Standards for Urban Sewage Treatment Plants” (GB18918-2002).
Document handover: Provide equipment operation manuals, electrical schematics, maintenance records, and train 2 operators.
4、 Construction precautions
1. Safety measures
Limited space operation: Before the internal maintenance of the equipment, forced ventilation should be carried out for 30 minutes, and O2 ≥ 18% and H2S ≤ 10ppm should be detected. The operators should wear positive pressure respirators.
Electricity safety: Temporary electricity use adopts TN-S system, three-level distribution and two-level protection, and the action current of leakage protector is ≤ 30mA.
2. Quality control
Concealed engineering acceptance: Pipeline pressure test (1.5 times the working pressure, holding pressure for 30 minutes without leakage) and cable insulation test (≥ 0.5M Ω) require the signature and confirmation of the supervisor.
Anti corrosion treatment: The equipment casing is coated with epoxy zinc rich primer (2 coats, dry film thickness ≥ 80 μ m) and acrylic polyurethane topcoat (2 coats, ≥ 60 μ m).
3. Environmental requirements
Dust control: Water the construction area to reduce dust, and cover the bare soil with a dense mesh.
Waste disposal: Hazardous waste such as waste paint barrels and batteries should be disposed of by qualified units.
Through the above plan, it can ensure the efficient and stable operation of small-scale integrated sewage treatment equipment, meeting environmental discharge requirements. In actual construction, it is necessary to adjust the details according to the site conditions and strictly comply with national and local construction regulations.
以下是为小型污水处理一体化设备制定的施工方案，涵盖施工前准备、设备安装、调试运行及验收等关键环节，确保工程高效、安全完成：
一、施工前准备
1. 现场勘查与方案确认
地形勘测：测量设备安装区域的地面平整度、承载力，确认是否需要地基加固(如混凝土基础)。
管线布局：规划进水、出水、污泥回流及排空管道走向，避开地下障碍物(如电缆、燃气管道)。
电源接入：确定设备控制柜位置，预留三相五线制电源接口(电压380V，容量按设备功率计算，通常预留20%余量)。
方案深化：根据污水水质(如COD、BOD、SS浓度)及排放标准(如一级A)，确认工艺流程(如A/O、MBR)及设备型号。
2. 材料与人员准备
材料清单：
主体设备：一体化污水处理设备(含生化池、膜组件、风机等)。
管道配件：UPVC/HDPE管(DN50-DN200)、法兰、阀门、橡胶接头。
电气元件：电缆(YJV型)、控制柜(含PLC、触摸屏)、液位传感器、流量计。
辅助材料：密封胶、膨胀螺栓、焊条、防锈漆。
施工队伍：
人员配置：项目经理1名、技术员1名、电工2名、管工2名、焊工1名、普工3名。
安全培训：开展高处作业、有限空间作业、用电安全专项培训，配备安全帽、安全带、绝缘手套。
二、设备安装
1. 基础施工
地基处理：若地质为软土，需开挖至老土层，铺设200mm厚碎石垫层，浇筑C25混凝土基础(尺寸比设备底板大100mm，厚度200mm)。
预埋件安装：在混凝土中预埋M16地脚螺栓，露出地面高度150mm，垂直度偏差≤2mm。
2. 设备就位与固定
吊装作业：使用25吨汽车吊将设备吊装至基础上，调整水平度(用水平仪检测，偏差≤2mm/m)。
固定连接：拧紧地脚螺栓，二次浇筑混凝土固定设备，养护7天后进行下一步。
3. 管道连接
进水管道：采用UPVC管，坡度≥1%，安装Y型过滤器(DN100)防止杂质进入设备。
出水管道：连接膜组件出水口至清水池，安装止回阀(DN80)防止倒流。
污泥管道：设置污泥回流管(DN50)和排泥管(DN75)，排泥管末端接污泥井，安装球阀控制。
空气管道：风机出口接曝气管，采用ABS管，管径DN40，安装压力表(0-0.1MPa)监测风压。
4. 电气安装
电缆敷设：沿桥架或穿钢管敷设，避免与强电线路平行，间距≥300mm。
控制柜接线：按电气原理图连接风机、水泵、液位传感器，接线端子压接牢固，标号清晰。
接地保护：设备外壳、控制柜、金属管道可靠接地，接地电阻≤4Ω。
三、调试与运行
1. 设备调试
单机调试：
风机：空载运行2小时，检查振动、噪音(≤75dB)、轴承温度(≤70℃)。
水泵：点动确认转向，运行1小时，流量、扬程符合设计值。
联动调试：
自动模式：设置液位控制参数(如高液位启动水泵，低液位停止)，模拟进水，验证自动启停功能。
膜组件清洗：启动反洗泵，调整反洗周期(如每2小时反洗1分钟)，观察膜通量恢复情况。
2. 试运行
负荷测试：逐步增加进水水量至设计值(如5m³/d)，连续运行72小时，记录COD、BOD、SS去除率。
参数优化：根据出水水质调整曝气量(如DO控制在2-3mg/L)、污泥回流比(50%-100%)。
3. 验收
水质检测：委托第三方检测机构取样，检测项目包括pH、COD、BOD5、SS、NH3-N、TP，结果需符合《城镇污水处理厂污染物排放标准》(GB18918-2002)一级A标准。
文件移交：提供设备操作手册、电气原理图、维护保养记录，培训操作人员2名。
四、施工注意事项
1. 安全措施
有限空间作业：设备内部检修前，强制通风30分钟，检测O2≥18%、H2S≤10ppm，作业人员佩戴正压式呼吸器。
用电安全：临时用电采用TN-S系统，三级配电两级保护，漏电保护器动作电流≤30mA。
2. 质量管控
隐蔽工程验收：管道试压(1.5倍工作压力，保压30分钟无泄漏)、电缆绝缘测试(≥0.5MΩ)需监理签字确认。
防腐处理：设备外壳涂刷环氧富锌底漆(2道，干膜厚度≥80μm)、丙烯酸聚氨酯面漆(2道，≥60μm)。
3. 环保要求
扬尘控制：施工区域洒水降尘，裸土覆盖密目网。
废料处理：废油漆桶、废电池等危险废物交由有资质单位处置。
通过以上方案，可确保小型污水处理一体化设备高效稳定运行，满足环保排放要求。实际施工中需根据现场条件调整细节，并严格遵守国家及地方施工规范。
