12.07.20. O&M Manual 41013 - New PLC
12.07.20. O&M Manual 41013 - New PLC
12.07.20. O&M Manual 41013 - New PLC
Project 41013
Annexes:
1. Layout drawings
2. Process diagram
3. Electrical schematics
Application:
The BiogasCleaner may only be used for cleaning biogas as per design criteria in this manual.
Do not use the equipment for other purpose than for cleaning H2S from the biogas.
Only trained and instructed personal may work on the BiogasCleaner.
Do not stay in the technical house if the gas alarm is active.
Do not stay in the technical house unless it is in a working situation.
Do not use the ladder on the tank unless it is in a working situation.
Do not stay on the top of the tank unless it is in a working situation.
Do not climb the tank in bad weather.
Do not open any manholes or flanges during operation.
Do not stand on or place anything on the equipment and pipes.
Do not use the technical house as storage room.
Respect the site regulations and instructions.
Study the warning labels and manual before working on the BiogasCleaner.
Warning labels.
At the front of the PTU (technical house) 8 warning signs and 3 signs for prohibited actions
are fitted. Please study the signs of warning and prohibited actions before working on the
system.
The warning signs are triangular and have a yellow background—the signs are shown below
with a text, explaining each sign. The signs on the PTU do not have any text:
The function of the BiogasCleaner is to remove the sulfur from the biogas via a biological
process. The sulfur is in the form of hydrogen sulfide (H2S). The BiogasCleaner consist of
two main items, the Process Technique Unit (PTU) and the acid proof tank. The PTU con-
tains the circulation/drain pump, air blower, water supply control, heating control and PLC
switchboard for controlling the process. The tank has the internal piping for controlling the
biogas and the filter liquid. The tank is filled with packing media which purpose it is to pro-
vide surface for the bacteria culture.
The installation of the PTU and the FRP tank is described in the Installation Manual, see the
annex of this manual.
Spray system:
The circulation/drain pump is pumping the filter liquid to the top of the tank, where a spray
nozzle is distributing the filter liquid over the complete surface of the packing media. Dur-
ing normal operation the circulation pump has a cycle of starting and stopping.
The flow of the circulation/drain pump can be read in the visual flow meter. In case there
are two tanks the liquid flow swap between the two tanks in preset time in the PLC.
Drain system:
The water inside the tank has to be drained in order to remove the sulfur and create space
for adding additional water or treated water. The motor valve for the drain system will
open app. 12 - 24 times per day, and drain a volume corresponding to the added liquid.
Air system:
Atmospheric air is added via an air blower to the inlet of the biogas. If the air is missing
the biological process will rapidly decrease. The speed of the air blower is controlled by a
frequency converter depending of the load of the BiogasCleaner. After the BiogasCleaner
an oxygen meter must be installed as safety back-up of the air injection. During normal
operation there shall be a surplus of oxygen in the outlet of the biogas between 1 %.
If the oxygen level exceeds 1,75% the air blower will reduce and it will stop if the level
reaches 2,75%. In the event the oxygen level should increase to 3% the safety relay
will shut down the BiogasCleaner as if the emergency stop was triggered.
QSR® system:
The QSR (quick sludge removal) system makes it possible to clean the tank for sludge by fill-
ing the tank with water and injecting compressed air into the tank. The QSR ® cleaning shall
be done minimum once per year - or sooner if the pressure drop is above 10 mbar, if the
packing media is heavily coated or if the packing media is compressed by 10-15%. The QSR®
cleaning process is described in detail in chapter 11 in this manual.
Specification
Type BiogasCleaner with QSR® system
Tank type FRP-tank with 40 mm insulation
Tank size 3,8 x 11,5 m
PTU FRP with 50 mm insulation
Switchboard RPC
Circulation/drain pump Stübbe SHB40-125/4 kW
Flow meter liquid Stübbe DFM350/10-50 m3/h
Air blower Becker SV8-130/0,75 kW
Flow meter air Stübbe DFM350/10-100 m3/h
Motor valve Stübbe C-100 230V
Nozzle TF 1’’
Pressure relief valve -10 and 100 mbar
Gas detector The power is cut at 25% of lower explosion level
Oxygen alarm levels 1,75%: Air blower will reduce speed
2,75%: Air blower stops and alarm is given
3%: The safety relay cuts off power, as if emergency stop
Treated digester
effluent specification
pH 6-8
N (Nitrogen) >300 mg/liter
P (Phosphate) >60 mg/liter
K (Potassium) >30 mg/liter
Ca (Calcium) + Mg <50 mg/liter (higher values requires MUW tanks)
(Magnesium)
COD (Chemical Oxygen <1.000 mg/liter (higher values requires MUW tanks)
Demand)
TTS (Total Suspended Sol- <5.000 mg/liter (higher values requires MUW tanks)
ids)
Particles <100 my (0,1 mm)
NPK fertilizer,
chlorine poor
N (Nitrogen) 10%
P (Phosphor) 2%
K (Potassium) 1%
Ball valve for Ball valve for Check valve for Pressure gauge
air system spray system water system
Flow meter for Water level Ball valve for Gas detector Dosing unit for
air system system flush system Liquid fertilizer
PLC controller Circulation/ Flow meter for Drain valves for Ball valve for
board (note is drain pump circulation/drain circulation pump drain system
now placed out-
side the PTU)
Filter for spray Motor valve for Ball valve for
system drain water system
Air
blower
The BiogasCleaner is controlled by the PLC control. Adding of liquid, the drain function, ox-
ygen level, pump flow and all important parameters are monitored by the PLC. Alarms will
be shown on the display and the red lamp on the control PLC controller board will be lit.
START-UP
PANELS LIST
From the screen GO TO you can choose menus 1 to 10 by pressing a number of times.
The following options are available:
2 ACT FLOW
On screen is shown:
GASFLOW m3/h
AIRFLOW m3/h
After reading, press ESC in the bottom
left side of the panel to return to the
GO TO screen.
The unit is also available in SFCM.
3 ACT O2
In the GO TO screen press 2 times to go
to 3 ACT O2
The arrow to the right of text
3 ACT O2 starts blinking.
Press to enter the screen. On screen is
shown:
GEN SET O2 %
After reading, press ESC in the bottom left
side of the panel to return to the GO TO
screen.
4 ACT AIR
In the GO TO screen press 3 times
to go to 4 ACT AIR
The arrow to the right of text
4 ACT AIR starts blinking.
Press to enter the screen. On screen
is shown:
AIR INJECT m3/h
AIR INJECT %
After reading, press ESC in the bottom
left side of the panel to return to the
GO TO screen.
The unit is also available in SFCM.
5 ACT TEMP
6 COUNT WATER
In the GO TO screen press 5 times
to go to 6 COUNT WATER. On screen
is shown:
AMOUNT WATER m3 (Total operating
life)
After reading, press ESC in the bottom
left side of the panel to return to the
GO TO screen.
The unit is also available in Gallon.
7 COUNT EFFLU
8 COUNT DRAIN
9 FORCE WATER
Water has been added, the pump will stop and in the display ON changes to OFF.
Press ESC in the bottom left side of the panel to return to the GO TO screen.
Check in screen 5: COUNT WATER that the preset amount of water has been added.
The unit is also available in Gallon.
10 FORCE EFFLU
In the GO TO screen press 9 times to go
to 10 FORCE EFFLU.
To test the Effluent supply: First read
screen 6 COUNT EFFLU, then go to this
screen.
Press MOD in bottom of the panel—on the
screen ACK starts flashing. Press ENTER in
bottom of the panel— in the display OFF
changes to ON. Effluent is added, the Liq-
uid Supply pump is running. After the pre-
set amount of effluent has been added, the pump will stop and in the display ON changes to
OFF. Press ESC in the bottom left side of the panel to return to the GO TO screen.
Check in screen 6: COUNT EFFLU that the preset amount of effluent has been added.
The unit is also available in Gallon.
11 FORCE DRAIN
In the GO TO screen press 10 times to
go to 11 FORCE DRAIN.
To test the Draining: First read screen
7 COUNT DRAIN, then go to this screen.
Press MOD in bottom of the panel—on the
screen ACK starts flashing. Press ENTER in
bottom of the panel— in the display OFF
changes to ON. Draining runs for the pre-
chosen time, check that the Motor Valve is
opening. After the draining sequence -
in the display ON changes to OFF. Check that the Motor Valve closes.
Press ESC in the bottom left side of the panel to return to the GO TO screen.
Check in screen 7: COUNT DRAIN that draining is effected (Not used in all applications).
If an alarm is registered, a text will be shown in the display, describing the problem. At the
same time a red warning lamp is lit on the PLC controller board.
The ALARMS LIST shows the alarms that have occurred—the lower number being the first
registered. Always solve the problem with the lower number first.
ALARMS LIST
Choose the ALARMS LIST by pressing .
The arrow on the right side of the text
ALARMS LIST starts blinking. Press to
enter the screen CONSULTATION.
CONSULTATION
The arrow to the right of text
CONSULTATION is blinking.
Press in the right side of the panel. This
will show the alarm—see example in the
next picture.
EXAMPLE OF ALARM
When the alarms are solved the display will turn back to normal operation mode.
List of alarms.
Alarm handling:
AIR BLOWER 1 / 2 This alarm is active when the frequency converter is in fault mode.
FAULT
1. Press Reset.
2. Turn off the power supply to the blower and check that the air
blower can rotate easily by pushing the fan on the end of the
blower motor. If not follow the instructions in the O&M from the
manufacturer . After repair turn on the power to the blower
again and press “Reset” “Stop” and “Start” on the plc panel. If
the blower do not start go to next step.
3. Turn off the power supply on the main switch on the PLC con-
troller board for 30 seconds and then turn on again. Press
“Reset” and “ON” on the PLC controller board to restart. I f the
blower do not start go to next step.
4. If the alarm returns, causes for the overload of the blower op-
eration must be examined. If the blower will not start the fre-
quency drive in the PLC cabinet must be replaced. Contact
dealer for delivery and replacement. If the blower rotates and
operates for a while but later stops again it can for example be
due to high back pressure on the blower. To check the dis-
charge line of the blower, turn power off to the blower and
close valve against the BC tank and inspect pipes and valves,
replace or clean parts and restart the system.
LESS EFFLUENT This alarm will occur if the required volume of liquid for the system is
CYCLE PERIOD not reached. The PLC controller board is preset to add liquid to the
system, liquid volume added is changed automatically according to
system gas flow. A liquid meter is counting the volume added and
will give feed-back to the PLC.
1. Press Reset
2. Check if liquid is missing in the external tank or pond, where
the pump takes the liquid. If needed, fill up external tank or
pond and reset PLC.
3. Check if the liquid supply filter is clogged. Switch off power on
the safety switch of the pump, open the filter and inspect for
clogging, clean filter, reinstall and restart.
4. Check if the pump is switched off or power is missing.
5. Check if the pump is clogged, turn off pump and follow O&M
from manufacturer, after repair or cleaning restart the pump.
6. Check if the motor valve is opening, there is an indicator on the
top of the valve showing the position, if the valve is broken,
replace and restart. Check the counter on the display of the PLC
go to “9 FORCE EFFLU” and run this routine, if the counter does
not react, turn off the supply pump, close valves before and
after liquid meter and uninstall and clean the meter with clean
water, the impeller in the meter must rotate easy, if not replace
meter and make a new test.
DRAIN VALVE 1. Press Reset. (The valve gives position signal back to PLC)
NOT OPEN 2. Check motor valves for the drain system at the next cycle, or
activate “Forced Drain”.
3. Check the power supply to the motor valve, if there is power
but no action by the valve, contact dealer or replace the valve
and make a new test.
LIQUID FLOW PUMP This alarm will occur if the circulation pump does not provide flow
1 / 2 MISSING when running or if the switch on the flow meter is failing or wrongly
adjusted.
1. Press Reset
2. Working with the filter remember to use goggles and rubber
gloves. Check if the suction filter for the pump is clogged by
fibres or impurities by switching off power on the safety switch
of the pump to prevent it from starting, close valves before and
after open the filter and check the clogging material. Clean the
filter, close the safety switch and restart.
3. Check if the switch on the flow meter is adjusted correctly or
damaged.
4. Adjust the switch to 75% of normal operating flow.
5. Close valves on inlet and outlet of pump and Check the circula-
tion pump and motor according to the instructions from the
manufacturer and restart.
6. Check the electrical connections and wiring to the pump and
restart.
LESS WATER This alarm will occur if the required volume of liquid for the system is
CYCLE PERIOD not reached. The PLC controller board is preset to add liquid to the
system, liquid volume added is changed automatically according to
system gas flow. A liquid meter is counting the volume added and
will give feed-back to the PLC.
1. Press Reset
2. Check if liquid is missing in the external tank or pond, where
the pump takes the liquid. If needed, fill up external tank or
pond and reset PLC.
3. Check if the liquid supply filter is clogged. Switch off power on
the safety switch of the pump, open the filter and inspect for
clogging, clean filter, reinstall and restart.
4. Check if the pump is switched off or power is missing.
5. Check if the pump is clogged, turn off pump and follow O&M
LESS WATER 6. Check if the motor valve is opening, there is an indicator on the
CYCLE PERIOD— top of the valve showing the position, if the valve is bro ken,
continiued replace and restart. Check the counter on the display of the
PLC go to “9 FORCE EFFLU” and run this routine, if the counter
does not react, turn off the supply pump, close valves before
and after liquid meter and uninstall and clean the meter with
clean water, the impeller in the meter must rotate easy, if not
replace meter and make a new test.
TANK LEVEL HIGH The system will automatically start draining when the sensor is acti-
vated and the drain pump has not been able to remove water from
the system.
1. Reset.
2. Check that the circulation / drain pump is running and the mo-
tor valve for the drain can open and that the flow meter is
counting the drained liquid. On the display of the PLC go to “10
FORCE DRAIN” and run this routine.
3. Check that manual valves are open to drain line, if not open
and reset / restart.
4. Check the water / effluent supply. If supply valves are leaking
the system can be added water or wastewater exceeding the
amounts requested by the PLC control, repair or replace valves
and reset.
TANK LEVEL LOW The water level in the tank is too low. Circulation/drain pump will
stop.
OVERLOAD 1. Check the overload relays for the circulation pump, drain pump
LIQUID PUMP 1 / 2 and liquid adding pump in the PLC controller board.
2. When the tripped relay is located, reset by pressing the black
button on the relay after it has cooled down for some minutes.
3. Check that the setting of the relay (Ampere setting) is correct
according to the pump specifications.
4. Check the respective pump for abnormalities and electrical sup-
ply for damages or problems. Solve problems according to
manufacturers instructions and restart system.
OVERLOAD As above.
DRAIN PUMP
OVERLOAD As above
EFFLUENT PUMP
1. Check that the drain valve opens and there is flow in the drain
line when the drain is activated, to test this activate 10 “Forced
Drain” on PLC and inspect the discharge line outflow point.
2. If the Drain valve is not opening, check the motor actuator po-
sition. It the position is not changing check the electrical con-
nections and wiring are ok.
3. If the valve still not operates contact dealer or replace the
valve.
LESS AIR Insufficient air supply to the system, if the air flow is lower than 75%
of the demand.
1. Check the air intake filter outside the PTU. Follow instructions
in this O&M.
2. Check the location of the sensor. There is an marking on the
transmitter that shal point on 50% on the scale of the meter.
3. Check if there id normal pressure on the gassystem and thet
the discharge line from the blower are fully open and have free
passage.
4. Check the 4—20 mA signal from the sensor at the PLC
5. Press the reset button on the sensor (be careful and use only
minimum of force), located under the small plastic cover by
means of a small screw driver or similar. Reset and restart.
LOW LIQUID TEMP The alarm is given when the temperature of the liquid in the tank
FREEZE ALARM comes below 10o C. When the temperature goes lower than 25oC the
performance of the system will reduce.
1. Check the heating system and supply of hot water, and if there
id pressure available.
2. Check that the temperature of the water is rising
3. If the temperature keeps dropping drain all water from the tank
in order to avoid damage on the tank and equipment due to
freezing water.
4. After the heating is re-established follow the start up procedure
in this O&M.
Problem Action
High level of H2S in 1. Make measurement by hand-held Kitagawa pipe in the inlet and
the outlet of the outlet of the biogas. Compare the measurements to the design
biogas criteria.
2. Make measurement by hand-held instrument of the O2 level in
the outlet of the biogas - (it should be in the level app. 1.5%).
If the Oxygen level is to low investigate the air injection sys-
tem, blower and PLC setting mentioned in other sections of this
O&M.
3. Check the present water / treated water supply. If water and or
wastewater is not supplied the bacteria cannot perform. If there
is problems in the supply, re-establish the normal situation and
restart.
4. Check the water / treated water supply for the last 48 hours.
Shall be according to the load of the system. (50% gas flow
will result in 50% of the consumption of water and
wastewater).
5. Check the presence of fertilizer (not all applications). Some
system only using soft water and liquid industrial fertilizer can
only perform if fertilizer is available for the dozing pump.
6. Check the circulation/drain pump. If the pumt does not operate
properly the bacteria will not perform. Check the pump like de-
scribes in other sections of this O&M.
Gas alarm The Geopal gas detector will cut the power in the EX controller board
and the process will stop. When the gas level is again below the set
value the gas detector will automatically reset. Gas Alarm will be
transferred to the potential free alarm relay in the EX Box.
If the green LED of the print card in the EX controller board is not on
check the power supply to the gas detector and print card.
If the yellow LED of the print card in the EX controller board is not on
the gas detector is in fault mode:
1. Check the connections from the gas detector to the print card
in the EX controller board.
2. If needed, recalibrate the gas detector.
If one of the two red LEDs of the print card in the EX controller board
(low level/high level gas alarm) is on:
1. Check if there is a gas leak in or near the PTU.
2. Check if other activities in the PTU are causing the alarm.
3. If needed, recalibrate the gas detector. Contact the dealer.
Problem Action
O2 + Alarm on ex- This alarm will cut out power to PLC panel in case 1&3.
ternal EX panel The “O2 Alarm” will occur in following cases:
1. O2 signal to EX panel is lower than 3.5 mAmp.
2. O2 signal exceeds preset O2 alarm limit
3. O2 signal is higher than 3% O2 in gas after BC
Users who have a level C authorisation will have access to an expanded menu, with the ability
to making adjustments to the biogas cleaning process.
If the panel is left untouched for more than 5 minutes, the panel will automatically switch to
screen PANELS LIST. If a password was entered earlier, it will have to be entered again.
For accessing the extended menu, the user must enter a password. For entering the pass-
word, start in the PANELS LIST as shown below.
Entering of password
PANELS LIST
The arrow to the right of text
PANELS LIST is blinking.
Scroll down (press ) until
PASSWORD appears on the screen
with a blinking arrow to the right side.
PASSWORD
Authorized personnel must remember to remove (clear) the password after finishing the ad-
justments to the system. In order to do so, go to the PANELS LIST and scroll down to
PASSWORD.
PANELS LIST
The arrow to the right of text
PANELS LIST is blinking.
Scroll down (press ) until
PASSWORD appears on the screen
with a blinking arrow to the right side.
PASSWORD
Level C authorized personnel can make adjustments to the biogas cleaning process in the
screens no. 20—25, as shown in the following. Navigating between the screens is done in the
same way as in the previous chapters.
GO TO
The arrow to the right of text
MAIN PANEL is blinking.
Press MOD at the bottom of the panel.
The “0” at the top right of the display
becomes 2 digit and starts blinking.
Enter values by pressing or at the
bottom of the panel. When number 20
is showing, press ENTER. You will now
jump to the chosen screen
20. TIME TANK 1.
20. TIME TANK 1 This screen shows the preset values for
PAUSE and DRIVETIME for tank 1. To
make an adjustment:
PAUSE __ SEC is showing. Press MOD
and the box with numbers starts blink-
ing. Press to enable adjusting the
first digit. Press to increase or to
lower the digit. To adjust the other dig-
its press until the correct digit is
blinking. After adjusting
PAUSE __ SEC press ENTER.
When all adjusting is finished press ESC until you return to GO TO screen (OR pressing will
bring you back to PANELS LIST).
21. TIME TANK 2 This screen shows the preset values for
PAUSE and DRIVETIME for tank 2. To
make an adjustment:
PAUSE __ SEC is showing. Press MOD
and the box with numbers starts blink-
ing. Press to enable adjusting the
first digit. Press to increase or to
lower the digit. To adjust the other dig-
its press until the correct digit is
blinking. After adjusting
PAUSE __ SEC press ENTER.
When all adjusting is finished press ESC until you return to GO TO screen (OR pressing will
bring you back to PANELS LIST).
When all adjusting is finished press ESC until you return to GO TO screen (OR pressing will
bring you back to PANELS LIST).
O&M manual for BiogasCleaner with QSR page 27 June 2012
Adjusting and testing the system via the display, continued:
23. AIR % This screen shows the preset values for
AIR INJECTION to the process. To make
an adjustment:
AIR INJEKT % __ is showing. Press MOD
and the box with numbers starts blinking.
Press to enable adjusting the first digit.
Press to increase or to lower the digit.
To adjust the other digits press until the
correct digit is blinking. After adjusting
AIR INJEKT % __ press ENTER.
When all adjusting is finished press ESC until you return to GO TO screen (OR pressing will
bring you back to PANELS LIST).
24. CYCLE WATER This screen shows the preset values for
AMOUNT OF WATER and
DRIVETIME for the WATER CYCLE.
To make an adjustment:
__ L is showing. Press MOD and the
box with numbers starts blinking. Press
to enable adjusting the first digit.
Press to increase or to lower the
digit. To adjust the other digits press
until the correct digit is blinking. After
adjusting __ L press ENTER.
When all adjusting is finished press ESC until you return to GO TO screen (OR pressing will
bring you back to PANELS LIST).
25. CYCLE EFFLU This screen shows the preset values for
AMOUNT OF WATER and
DRIVETIME for the EFFLUENT CY-
CLE. To make an adjustment:
__ L is showing. Press MOD and the
box with numbers starts blinking. Press
to enable adjusting the first digit.
Press to increase or to lower the
digit. To adjust the other digits press
until the correct digit is blinking. After
adjusting __ L press ENTER.
When all adjusting is finished press ESC until you return to GO TO screen (OR pressing will
bring you back to PANELS LIST).
Before the filter can be started it has to be filled with biogas in a safe way.
If the tank is gas free after inspection or QSR cleaning it has to be purged from atmos-
pheric air and filled with biogas. Please take following precautions:
The area has to be cleared and there must be no sources of ignition present in
the area (open fire, welding, grinding, smoking, cars, motorcycles, hot air weld-
ing or similar)
Never work alone!
At inspection of packing media at lower manhole the staff must use fresh air
supply or a mask with a filter for H2S to protect against poisoning.
Filter liquid has a low pH-value, therefore use rubber gloves and safety glasses.
In case of contact with skin : Wash with clean water.
In case of contact with eyes : Wash with eye washing liquid and afterwards con-
sult doctor.
Never enter the tank before checking the level of CH4, O2 and H2S
Start up.
Close the main switch on the EX controller board and the PLC controller board. Press
reset on the EX controller board and start the PLC controller board.
Check that pumps and blowers are running and PLC control shows no warnings.
Check that the motor valves for the drain and water supply are open.
Warranty and technical support from BioGasclean A/S or its representatives require
that the customer can supply the check sheets as per below instructions correctly
filled in, and that maintenance is done as per following instructions. Check sheets
shall be send to BioGasclean on request.
Maintenance — including calibration — of flow meters and oxygen meters positioned after the
BiogasCleaner must be carried out in accordance with instructions from the suppliers. It is
essential for the BiogasCleaner’s operation and economy that the flow meters and oxygen
meters are correctly calibrated.
Daily check:
Fill in the “Daily Check Sheet”.
Weekly.
Fill in the “Weekly Check Sheet”.
Every 3 months:
The BiogasCleaner must be stopped every 3 months in order to inspect the packing media in
the lower manhole(s). The inspection includes following points:
Inspect the packing media - a bio film covering the media up to 1 or 2 mm thickness is
considered acceptable.
Take pictures of the packing media.
Analyze the effluent (wastewater) or soft water mixed with fertilizer used for the pro-
cess for the following components: pH, N (Nitrogen), P (Phosphate), K (Potassium), Ca
(Calcium), Mg (Magnesium), COD (Chemical Oxygen Demand),
TS (Total Solids).
Every 3 months:
Next day:
Repeat the procedure for the second MUW tank or chamber in pond .
It can result in reduced performance of the BiogasCleaner the clean both
tanks / chambers on the same day.
Every 6 month
Stop the system and close all valves to Pumps and blowers and check
them for wear and tear according to manufacturer instructions.
Check packing media like on 3 month inspections.
Every year
Electrical test and calibration of the gas detector—see maintenance instruction in the
gas detector manual.
QSR cleaning has to be done minimum once a year, see process in chapter 11.
Stop the system and close all valves to the gas system. Check the pres-
sure/relief valve - see instructions in the O&M manual for the pressure
relief valve.
On systems with flame arrestors on Air injection and Pressure/ Vacuum release
valves the flame arrestors must be taken out for cleaning and inspection.
Check that there is no damage at the nozzle and that spraying of the packing media
is even. This has to be done using safety equipment and procedures for working in
confined spaces.
Every 3 year
Change the battery in the PLC, see instruction in the annex of the manual. An alarm
will be shown in the display on the PLC when the capacity of the battery is low.
Every 5 year
Full tank inspection including removal of packing media from the tank.
First step is to make a QSR cleaning of the tank, and thereafter the pack-
ing media can be removed from the bottom manholes and stored in for
example big-bags with lifting lugs to ease refilling of the media after tank
inspection.
During the removal of the packing media some media can be damaged by
mechanical impact and must be replaced by new packing media according
to BioGasclean’s specifications. Be aware that the packing media has
some delivery time, if media is damaged the performance of the BC will
reduce until the missing media is refilled.
All internal piping and chemical barrier must be inspected for damages or
wear from QSR cleaning.
The inspection of the chemical barrier on tank and pipes must be focussed
on any sign of cracks or damages that can allow the acidic liquid to enter
the structural layer in pipes and tank parts. The Barrier is approximately
2.5 mm thick and are made of Vinyl Esther which are highly resistant to
acid and temperature.
Any crack or damage must be repaired by professional FRP technicians
with the correct Vinyl Esther materials, and the structural layer behind the
barrier damage must be examined for damages from acid which can result
in weakening of the tank structure.
If the structural layer (provides the strength of the tank structure) is
damaged it must be repaired or replaced to give the structure the original
strength again.
When the tank inspection and possible repairs are completed the media
can be refilled and the system can be put in operation after the procedure
for restart after QSR cleaning.
The QSR® cleaning must be carried out minimum once a year. Please note that the
QSR® cleaning must be carried out immediately if:
1: The pressure drop in the tank is above 10 mbar
2: The packing media is heavily coated
3: The packing media is compressed by 10-15%
Safety first
When doing the QSR-cleaning procedure and packing media inspection, one has
to be aware of:
The area has to be cleared and there must be no sources of ignition present
in the area (open fire, welding, grinding, smoking, cars, motorcycles, hot
air welding or similar)
Never work alone!
At inspection of packing media at lower manhole the staff must use fresh
air supply or a mask with a filter for H2S to protect against poisoning.
Filter liquid has a low pH-value, therefore use rubber gloves and safety
glasses.
In case of contact with skin : Wash with clean water.
In case of contact with eyes : Wash with eye washing liquid and afterwards
consult doctor.
Never enter the tank before checking the level of CH4, O2 and H2S
Save as much liquid from the process as possible (at least 1000 liter) to an
external tank in order to make a swift start after the QSR ® cleaning.
Stop the filter. Press the “emergency stop button”. Close all valves with
connection to the tank, including blowers, pumps, liquid supply, water level
indicator, differential pressure meter etc.
Fill in clean water or particle free water from pond, river or similar via the
QSR drain flange until the tank is filled. The biogas will escape through the
gas pipe.
When the tank is filled with water, open the top manhole fully (remove all bolts
except one) and drain water until the packing media is covered +50 cm.
Add a foam inhibitor - for example 5 liters of cooking/ Palm oil.
By pass tank 1:
Stop the system.
Change set point in PLC to:
”Drive time tank 1 on ” = 0 (zero)
”Pause time tank 1 off” = 0 (zero)
By pass tank 2:
Stop the system.
Change set point in PLC to:
”Drive time tank 2 on ” = 0 (zero)
”Pause time tank 2 off” = 0 (zero)
Connect a diesel air compressor with flexible 1” pipes to all the QSR ® connections
and blow in air (6-8 m3/minute at 6-8 bar) for 30 – 60 minutes in 1”
connections on shift and in the end at the same time to all QSR injection valves until
the filter packing is flowting / circulating in all the surface of the filter.
In order to avoid backflow of water from the tank to the compressor, there has to
be check valves mounted on the compressor before flexible air pipes.
Continue running the air compressor and drain the filter as fast as possible to get
out sludge.
Flexible 1” pipes
Air Compressor
6 - 8,000 l/ minute
6 - 8 Bar max pressure
BiogasCleaner
Manifold Tank.
PTU
The tank is gas free after the QSR cleaning - it has to be purged from atmospheric air and
filled with biogas.
There are two options for this:
Startup:
Flow meter
FMV-DFT Flow meter for liquid
FMV-SO30 Flow meter house
Pump Type
PU Circulation/drain pump
Nozzle Type
SN-Nozzle Nozzle 170 deg