Difference between revisions of "Biogas-Plant/C3/Assembly-of-the-Biogas-plant/English"

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Line 66: Line 66:
 
3. check if it is firmly placed.  
 
3. check if it is firmly placed.  
  
4.the pipe will be fixed permanently in this position-
+
 
 +
The pipe will be fixed permanently in this position-
 
* when the outer wall of the dome will be plastered.
 
* when the outer wall of the dome will be plastered.
  
Line 91: Line 92:
  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
On the side of the dome adjacent to where the mixing tank will be placed-
+
On the side of the dome adjacent to where the mixing tank will be placed, make a firm base.  
 
+
 
+
1. make a firm base.  
+
 
+
  
2. this base should be 4 feet and 5 inches higher-
 
* than the dome for placing the mixing tank.
 
  
 +
This base should be 4 feet and 5 inches higher than the dome for placing the mixing tank.
  
3. next, on the side of the dome facing the base of the mixing tank cut chicken mesh.
 
  
 +
Next, on the side of the dome facing the base of the mixing tank, cut chicken mesh.
  
4. use a scissor to cut the mesh and make hole of 6 inch diameter.
 
  
 +
Use a scissor to cut the mesh and make hole of 6 inch diameter.
  
5. Through this hole-
 
* one end of the inlet pipe will be inserted at an angle of 45 degrees.
 
  
 +
Through this hole-
 +
* one end of the inlet pipe will be inserted
 +
* at an angle of 45 degrees.
  
6. Rest the other end of the inlet pipe-
 
  
 +
Rest the other end of the inlet pipe-
 
* at the base of the mixing tank and  
 
* at the base of the mixing tank and  
 
* plaster it with cement mixture.
 
* plaster it with cement mixture.
Line 163: Line 160:
 
* Sand- 200 kgs
 
* Sand- 200 kgs
 
* '''Cement'''- 100 kgs
 
* '''Cement'''- 100 kgs
* Liquid waterproofing material- 150 ml mixed in 20 Ltrs of water
+
* Liquid waterproofing material- 150 ml thoroughly mixed in 20 Ltrs of water
 
* Adequate amount of water
 
* Adequate amount of water
  
Line 180: Line 177:
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| The base of the Digester tank has to be plastered for the second time.
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| The base of the Digester tank has to be plastered for the second time.
 
  
 
|-
 
|-
Line 217: Line 213:
 
Next comes the attaching of the walls of the slurry tank with the dome.
 
Next comes the attaching of the walls of the slurry tank with the dome.
  
* hole of the slurry tank has to be 6 inches lower than the dome.
+
* Hole of the slurry tank has to be 6 inches lower than the dome.
  
* this will ensure free flow of slurry into the slurry tank.
+
* This will ensure free flow of slurry into the slurry tank.
  
 
|-
 
|-
Line 231: Line 227:
 
With the hook, interlock the excess chicken mesh -
 
With the hook, interlock the excess chicken mesh -
  
1. at the base of the dome and  
+
# at the base of the dome and  
2. at the edge of the slurry tank wall
+
# at the edge of the slurry tank wall
  
 
|-
 
|-
Line 251: Line 247:
 
[[Image:]]
 
[[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
Apply this mixture carefully so that there are no gaps at all.
+
Apply this mixture carefully, so that there are no gaps at all.
  
 
|-
 
|-
Line 267: Line 263:
 
|-
 
|-
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
| style="border:0.75pt solid #000000;padding:0.071cm;"| Leaving the dome for curing-
+
| style="border:0.75pt solid #000000;padding:0.071cm;"| Leaving the dome for curing, we will now attach the mixing tank.
 
+
* we will now attach the mixing tank.
+
  
  
Line 288: Line 282:
 
The mixing tank is connected to the digester tank via the Inlet pipe.
 
The mixing tank is connected to the digester tank via the Inlet pipe.
  
* before placing, check the hole at the base of the mixing tank.  
+
* Before placing, check the hole at the base of the mixing tank.  
  
* the hole should be placed just in front of the inlet pipe of 6 inch diameter.
+
* The hole should be placed just in front of the inlet pipe of 6 inch diameter.
  
  
 
Remember -
 
Remember -
  
* this inlet pipe of 6 inch diameter has been already inserted inside the dome
+
This inlet pipe of 6 inch diameter  
  
 +
*has been already inserted inside the dome
 
* at an angle of 45 degrees.
 
* at an angle of 45 degrees.
  
Line 303: Line 298:
  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
For the hole of the mixing tank and the inlet pipe to be in line with each other
+
For the hole of the mixing tank and the inlet pipe to be in-line with each other, do the following:
  
 
|-
 
|-
| style="border:0.75pt solid #000000;padding:0.071cm;"| Slide 8
+
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
+
Now do the following-
+
  
 
[[Image:]]
 
[[Image:]]
| style="border:0.75pt solid #000000;padding:0.071cm;"| do the following:
+
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
  
 
* Place three bricks around these two and plaster it with '''cement.'''
 
* Place three bricks around these two and plaster it with '''cement.'''
Line 318: Line 311:
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
* after plastering, leave it for curing overnight.
+
* After plastering, leave it for curing overnight.
  
 
|-
 
|-
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
* this is how, it will look in a functional '''Biogas plant'''
+
* This is how, it will look in a functional '''Biogas plant'''
 
+
  
 
|-
 
|-
Line 383: Line 375:
  
 
2. The dimensions would be-
 
2. The dimensions would be-
* 1 foot 5 inches length, 1 foot and 5 inches width and 2 feet of height  
+
* 1 foot 5 inches of length, 1 foot and 5 inches of width and 2 feet of height.
  
 
3. Dig another pit at the front of the lower tank as shown in the image.
 
3. Dig another pit at the front of the lower tank as shown in the image.
  
 
4. The dimensions would be-
 
4. The dimensions would be-
* 10 inch of length, 28 inches of width and 2 feet of height
+
* 10 inch of length, 28 inches of width and 2 feet of height.
  
 
5. Lay foundation-
 
5. Lay foundation-
* on both the adjacent sides and the front side of the lower tank using-
+
* on both the adjacent sides  
* gravel, '''cement''' and sand mixture.
+
* and the front side of the lower tank  
 +
* usinggravel, '''cement''' and sand mixture.
  
6. The gravel, sand and cement is mixed-
+
6. The gravel, sand and '''cement''' is mixed-
 
* in the same proportion as mentioned previously.  
 
* in the same proportion as mentioned previously.  
  
Line 401: Line 394:
 
8. Plaster the edges of the walls with '''cement.'''
 
8. Plaster the edges of the walls with '''cement.'''
  
9. The wall with the hole should face the fields  
+
9. The wall with the hole should face the fields.
  
 
10. This will help the slurry to flow out smoothly through the hole.
 
10. This will help the slurry to flow out smoothly through the hole.
Line 409: Line 402:
  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
Coming back on the dome-
+
Coming back to the dome-
  
 
* Place approximately 25 jute gunny bags on the dome.  
 
* Place approximately 25 jute gunny bags on the dome.  
Line 418: Line 411:
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| Slide 10
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| Slide 10
  
* Spray as much is required to wet the outer wall of the dome.  
+
* Spray as much as required to wet the outer wall of the dome.  
  
 
* Jute bags placed on the outer wall help to retain the water.
 
* Jute bags placed on the outer wall help to retain the water.
Line 425: Line 418:
  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
* Spray as much is required to wet the outer wall of the dome.  
+
* Spray as much as required to wet the outer wall of the dome.  
  
 
* Jute bags placed on the outer wall help to retain the water.
 
* Jute bags placed on the outer wall help to retain the water.
Line 464: Line 457:
 
* 2kgs of white '''cement'''
 
* 2kgs of white '''cement'''
  
Apply this mixture on the inside of the digester tank, to seal crack(s), if any.
+
Apply this mixture on the inside of the digester tank, to seal cracks, if any.
  
 
|-
 
|-
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| style="border:0.75pt solid #000000;padding:0.071cm;"| After 17 days of total curing time-
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| After 17 days of total curing time-
  
* raw materials can be put into the''' Biogas plant.'''
+
* raw material can be put into the''' Biogas plant.'''
  
 
|-
 
|-
Line 545: Line 538:
 
|-
 
|-
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
 
| style="border:0.75pt solid #000000;padding:0.071cm;"| [[Image:]]
| style="border:0.75pt solid #000000;padding:0.071cm;"| Now, to check whether '''Biogas''' has been produced?
+
| style="border:0.75pt solid #000000;padding:0.071cm;"| Now, to check whether '''Biogas''' has been produced, do the following-
  
 
+
* Ensure that both the safety valves are in open position, for the gas to be conveyed.
Do the following-
+
 
+
* Ensure that both the safety valves are in open position for the gas to be conveyed.
+
  
 
* Light the burner and check the flame for production of the '''Biogas.'''
 
* Light the burner and check the flame for production of the '''Biogas.'''
Line 569: Line 559:
 
The pipe from the dome towards the kitchen has to be shown in red
 
The pipe from the dome towards the kitchen has to be shown in red
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
The gas conveyer pipe from the dome to towards the kitchen should be-
+
The gas conveyer pipe from the dome towards the kitchen should be-
 
* always in an upward direction.
 
* always in an upward direction.
  
Line 579: Line 569:
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
| style="border:0.75pt solid #000000;padding:0.071cm;"|  
 
This brings us to the end of this '''tutorial '''
 
This brings us to the end of this '''tutorial '''
 
 
The Repair and Maintenance part of the '''Biogas plant-'''
 
* will be explained in next '''tutorial '''under the same series
 
  
 
|-
 
|-
Line 590: Line 576:
  
  
In this''' tutorial,''' we learnt,
+
In this''' tutorial,''' we learnt, how to assemble the following-
 
+
How to assemble the following-
+
  
 
* Digester tank with the dome
 
* Digester tank with the dome

Revision as of 18:47, 3 June 2016

Visual Cue
Narration
Slide 1

Assembly of the Biogas plant.

Hello everyone.

Welcome to this Spoken Tutorial on Assembly of the Biogas plant.

Slide 2

Learning Objectives

We will learn how to assemble-

  • Digester tank with the dome
  • Mixing tank and
  • Slurry tank

[[Image:]]

In this tutorial-

We will learn how to assemble the following:

  • Digester tank with the dome
  • Mixing tank and
  • Slurry tank

Please note that this is an activity of Day 3.

Let us start
[[Image:]]

Transfer the chicken mesh dome to the actual plant site.

[[Image:]]

Place the dome on the raised wall of the digester tank.

[[Image:]]

[[Image:]]

[[Image:]]

Once this is done, fix the main gas pipe of 1 inch diameter, on the top of the dome.


To do this-

1. hold the pipe with the external thread on the top.

2. insert the pipes between the holes of the 3 chicken layers and rotate slightly.

3. check if it is firmly placed.


The pipe will be fixed permanently in this position-

  • when the outer wall of the dome will be plastered.


Remember: the external thread on the gas pipe, will help fit the hose pipe firmly.

[[Image:]]

Show arrow at the external thread

Notice the external thread at the top of the gas pipe.

An important thing to be done, next, is the following-

[[Image:]]

[[Image:]]

Arrow at the inlet pipe and the base to keep mixing tank

On the side of the dome adjacent to where the mixing tank will be placed, make a firm base.


This base should be 4 feet and 5 inches higher than the dome for placing the mixing tank.


Next, on the side of the dome facing the base of the mixing tank, cut chicken mesh.


Use a scissor to cut the mesh and make hole of 6 inch diameter.


Through this hole-

  • one end of the inlet pipe will be inserted
  • at an angle of 45 degrees.


Rest the other end of the inlet pipe-

  • at the base of the mixing tank and
  • plaster it with cement mixture.
Slide 3

Bio-waste will reach the digester tank through this inlet pipe.

Bio-waste will reach the digester tank through this inlet pipe.

[[Image:]]

Encircle the inlet pipe

This is how the inlet pipe will look like from inside the dome.

Slide 4

Once the gas pipe is fitted :

  • Plaster the dome from outside

Once the gas pipe is fitted, we need to plaster the dome from outside.

Slide 5

An interesting fact -

  • The dome is plastered twice
  • Both coats of plaster have different ratio of sand and cement.
An interesting fact -
  • The dome is plastered twice and
  • both coats of plaster have different ratio of sand and cement.
[[Image:]]

[[Image:]][[Image:]]

For first coat of plastering, use the following-
  • Sand- 200 kgs
  • Cement- 100 kgs
  • Liquid waterproofing material- 150 ml thoroughly mixed in 20 Ltrs of water
  • Adequate amount of water
[[Image:]] What you see here, is the mason using the first coat of plaster, on the dome.
Slide 6

Before entirely plastering the outer wall of the dome do the following

Before entirely plastering the outer wall of the dome -
[[Image:]] The base of the Digester tank has to be plastered for the second time.
Slide 7

Ratio of cement mixture to be used is-

[[Image:]]

Ratio of cement mixture to be used is-
[[Image:]]
  • Sand-90 kgs
  • Cement-50 kgs
  • Liquid waterproofing material- 100 ml mixed in 15 Ltrs of water
  • Adequate amount of water as mentioned earlier.


What you see here, is-

  • The mason adding Liquid waterproofing material to the cement mixture.
[[Image:]] Remember -

The thickness of the layer of the plaster should be about 3 inches only.

Show pictorial (graphic) image

Next comes the attaching of the walls of the slurry tank with the dome.

  • Hole of the slurry tank has to be 6 inches lower than the dome.
  • This will ensure free flow of slurry into the slurry tank.
[[Image:]]

Animation for interlocking

Place the slanting wall(s) of the slurry tank at either sides of the entrance to the dome.


With the hook, interlock the excess chicken mesh -

  1. at the base of the dome and
  2. at the edge of the slurry tank wall
[[Image:]]

Carefully-

  • tighten the chicken mesh securely, so as to join the walls to the dome.
[[Image:]]

To seal the joints, use cement mixture with adequate amount of water.

[[Image:]]

[[Image:]]

Apply this mixture carefully, so that there are no gaps at all.

[[Image:]]

Please note that at this point-

  • we have used three of the 7 walls for the slurry tank.
[[Image:]] The plastered dome should now be left for 6-8 hours for curing.
Leaving the dome for curing, we will now attach the mixing tank.


As mentioned earlier-

  • mixing tank will be placed 4 feet and 5 inches higher than the dome
  • to avoid water logging.
[[Image:]]

Show arrow at the hole

[[Image:]]

The mixing tank is connected to the digester tank via the Inlet pipe.

  • Before placing, check the hole at the base of the mixing tank.
  • The hole should be placed just in front of the inlet pipe of 6 inch diameter.


Remember -

This inlet pipe of 6 inch diameter

  • has been already inserted inside the dome
  • at an angle of 45 degrees.
[[Image:]]

For the hole of the mixing tank and the inlet pipe to be in-line with each other, do the following:

[[Image:]]

  • Place three bricks around these two and plaster it with cement.
[[Image:]]
  • After plastering, leave it for curing overnight.
[[Image:]]
  • This is how, it will look in a functional Biogas plant
Slide 9
  • Plaster the outer wall of the dome for second time and
  • Inner wall of the dome as well.

Now, plaster the entire outer dome wall for the second time.

And the inner wall of the dome as well.

[[Image:]] Prepare the cement mixture as follows-
  • Sand- 180 kgs
  • Cement- 100 kgs
  • Liquid waterproofing material- 250 ml mixed in 20 Ltrs of water
  • Adequate amount of water
[[Image:]]

Spread this mixture evenly on the outer wall of the dome.

[[Image:]]

And on the inner wall of the dome, as well.

[[Image:]]

[[Image:]]

Smoothen out the plaster by using the wooden trowel.

Leave the whole structure for curing for 17 days.

This brings us to the end of Day 3
On day 4, we will do the following-
[[Image:]]


[[Image:]]

1. Dig two rectangular pits adjacent to the side walls of the lower tank.

2. The dimensions would be-

  • 1 foot 5 inches of length, 1 foot and 5 inches of width and 2 feet of height.

3. Dig another pit at the front of the lower tank as shown in the image.

4. The dimensions would be-

  • 10 inch of length, 28 inches of width and 2 feet of height.

5. Lay foundation-

  • on both the adjacent sides
  • and the front side of the lower tank
  • usinggravel, cement and sand mixture.

6. The gravel, sand and cement is mixed-

  • in the same proportion as mentioned previously.

7. Now, join the four walls of the upper slurry tank.

8. Plaster the edges of the walls with cement.

9. The wall with the hole should face the fields.

10. This will help the slurry to flow out smoothly through the hole.

[[Image:]]

Coming back to the dome-

  • Place approximately 25 jute gunny bags on the dome.
  • Twice a day, start spraying water on the dome.
Slide 10
  • Spray as much as required to wet the outer wall of the dome.
  • Jute bags placed on the outer wall help to retain the water.
  • This will keep the dome wet for longer hours.
  • Spray as much as required to wet the outer wall of the dome.
  • Jute bags placed on the outer wall help to retain the water.
  • This will keep the dome wet for longer hours.
[[Image:]]

Lastly, the entire dome should be covered-

  • with a plastic sheet held between 2- 4 pillars.
Slide 11
  • Plastic sheet will protect the dome from too much sunlight
  • This plastic sheet will protect the dome from too much sunlight
  • Thereby avoiding too much drying of the dome
This brings us to the end of Day 4
On the 15th day of curing-
Make a mixture of
  • 2 Ltrs of water,
  • 250 gms of Synthetic Resin Adhesive and
  • 2kgs of white cement

Apply this mixture on the inside of the digester tank, to seal cracks, if any.

[[Image:]] At this point, the civil work of the Biogas plant is completed.


We will now learn to connect the main gas pipe to the kitchen.

[[Image:]] Connect the main gas pipe-
  • from the digester tank to the main gas control valve, as shown here.


The joint between-

  • the main gas pipe and gas control valve should be perfectly air-tight.

Otherwise, gas leakage from this joint cannot be stopped easily.

[[Image:]] From the main gas control valve, we have to connect a gas conveyer pipe.
Slide 12

The joint between the main gas and gas control valve should be perfectly air-tight

Once again, connect these using a straight joint and ensure it is air-tight.
[[Image:]] The gas conveyer pipe extends all the way to the kitchen.
[[Image:]] Inside the kitchen-
  • connect the safety valve to the gas conveyer pipe using a straight joint.
  • connect another straight joint on the other end of the safety valve.
[[Image:]]

Then connect the rubber hose pipe to the other end of the water outlet pipe.


Make sure that all the joints are air-tight.

[[Image:]] Lastly, connect the rubber hose to the stove.

After all the connections are made, the Biogas plant is ready for use.

[[Image:]] After 17 days of total curing time-
  • raw material can be put into the Biogas plant.
For the Animator

Create a background image by merging both the images given below.

[[Image:]]

Initial production of Biogas will take about 6 days.


After that, it will be a regular daily production.

[[Image:]] Now, to check whether Biogas has been produced, do the following-
  • Ensure that both the safety valves are in open position, for the gas to be conveyed.
  • Light the burner and check the flame for production of the Biogas.
Slide 13

How to avoid water condensation?

Another issue is water condensation.


So, how can water condensation be avoided?

[[Image:]]

The pipe from the dome towards the kitchen has to be shown in red

The gas conveyer pipe from the dome towards the kitchen should be-

  • always in an upward direction.


If so, water accumulation inside the conveyer pipe is negligible.

This brings us to the end of this tutorial

Slide 14

Summary


In this tutorial, we learnt, how to assemble the following-

  • Digester tank with the dome
  • Mixing tank and
  • Slurry tank

Let’s Summarize-


In this tutorial, we learnt,

How to assemble the following-

  • Digester tank with the dome
  • Mixing tank and
  • Slurry tank
Slide 3

Acknowledgements

This video was created by:

Spoken Tutorial Project with inputs from Rural-ICT team, IIT Bombay.

This video was created by-

Spoken Tutorial Project with inputs from Rural-ICT team, IIT Bombay.

More information on these projects can be found at these links

http://spoken-tutorial.org/NMEICT-Intro

http://ruralict.cse.iitb.ac.in/ in

More information on these projects can be found at these links.

http://spoken-tutorial.org/NMEICT-Intro

http://ruralict.cse.iitb.ac.in/ in

Pictures and technology support:

Courtesy:

Bhagirath Rural Development Foundation

Village- Zarap, Taluka- Kudal,

Dist.- Sindhudurg

Pictures and technology support:

Courtesy:

Bhagirath Rural Development Foundation

Village- Zarap, Taluka- Kudal,

Dist.- Sindhudurg

This is Bella Tony along with the animation team of the Spoken Tutorial project signing off.

Thank you for joining.

Contributors and Content Editors

Bellatony911, Nancyvarkey