As all the valves and fittings bought were threaded to ensure air-tight conditions, the pipes had to be threaded as well. An experienced operator would take about 30mins per threading process.
We have a total of 20 valves + more fittings, threading on both sides, calculate yourself the amount of time taken to complete the threading x2. The whole day was pretty much about threading the pipes.
This is the threading machine:
The close-up of a threading machine; the pipe is first clamped onto a metal disc for further cutting:
Video Clip of the tedious and cumbersome threading process:
The above threading process is a process of "agar-ration", wherein the operator runs the machine and attempts to "cut out" the desired thread lining till it fits the valve perfectly. If the 1st run does not fulfill the requirement, deeper threads are made and process is repeated till it fits the valve snugly.
Combination of threading and PVC Cement:
The excess PVC cement was "forced/ squeezed" out of the pipes, making it function like a silicon sealant, ensuring air-tight conditions:
This was how the interior of the aerobic stage looked like, without tightening the flange yet:
This is the agitator. Unfortunately, the supporting rods were made of metal; we got the workers to redo it. Metal are detrimental to the growth of fermentative microbes. All my conflict management and communication skills really came into play...
The Burner Section:
Left: P&ID View
Middle: Unassembled Fittings and parts
Right: Assembled & Completed Burner Section.
Look at the difference between the 3 diagrams, it looks simple on paper, just tee-joints and valves. In the actual thing, nipples - 8 of them are required - this explains the cost and the time taken to do purchase, even with much deliberate planning. It's somewhat amazing that these 20+ fittings only amount to one small burner section of the digestor.
All I can say is: "Welcome to the real world !!!"
Kian How, signing off on 6 October 2010, 12.30 pm
No comments:
Post a Comment