12.07.20. O&M Manual 41013 - New PLC

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BiogasCleaner With QSR®

Project 41013

O&M manual for BiogasCleaner with QSR page 1 June 2012


Content:

1. Application, warning labels and door arrester


2. Description of the BiogasCleaner
3. Design criteria, specification and standards
4. Layout of the process technique unit (PTU)
5. Navigating the display
6. Alarms and alarm handling
7. Trouble-shooting
8. Adjusting and testing via the display
9. Preparing for operation
10. Maintenance
11. QSR® cleaning and restart (also for 2 tank system)
12. Recommended spare parts and measuring equip-
ment

Annexes:

1. Layout drawings
2. Process diagram
3. Electrical schematics

O&M manual for BiogasCleaner with QSR page 2 June 2012


1. Application, warning signs and door arrester

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:

RISK OF FIRE RISK OF ETCHING RISK OF SQUEEZING

LOW CEILING HEIGHT HIGH VOLTAGE RISK OF NOISE

RISK OF TRIPPING RISK OF HOT SURFACE

O&M manual for BiogasCleaner with QSR page 3 June 2012


Application, warning signs and door arrester, continued
The prohibition labels are circular and have a white background and a red ring—the labels are
shown below with a text, explaining each sign. The labels on the PTU do not have any text:

SMOKING PROHIBITED OPEN FIRE PROHIBITED NO DRINKING WATER

O&M manual for BiogasCleaner with QSR page 4 June 2012


2. Description of the BiogasCleaner

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.

To ensure a problem-free operation of the BiogasCleaner it is vital that maintenance is car-


ried out according to the instructions in 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.

Raw water/effluent system:


The water/effluent is added in app. 12 - 24 cycles per day. The quantity of water per cycle
can be adjusted in the display. The water flow is measured and the total flow is shown in
the display.
If soft water is used the fertilizer is brought into the tank via a dosing unit, which is using
the pressure of the water to inject the fertilizer into the soft water. If effluent is used there
is no need for additional fertilizer.

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.

O&M manual for BiogasCleaner with QSR page 5 June 2012


Description of the BiogasCleaner, continued
Explosion protection system:
Inside the PTU is installed an explosion proof gas detector which is connected to the EX con-
troller board. The EX controller board shall be installed in a non-explosion area and in accord-
ance with the local rules. In the event the CH4 level is higher than 25% of the lower explosion
level (LEL) the gas detector will cut the power to the PTU to prevent the risk of explosion.

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.

Additional supervision possibilities:


Difference meter for measuring the pressure drop between the biogas inlet and outlet.
Water level indicator for visual inspection for the water level inside the tank.
Temperature in the tank is shown in the display.
Potential free contacts in the EX controller board.
Ethernet connection (optional) in the EX controller board.

O&M manual for BiogasCleaner with QSR page 6 June 2012


3. Design criteria, specification and standards
Design criteria
Biogas flow 960 Nm3/h
H2S inlet 5.000 ppmv
H2S outlet 250 ppmv
Pressure -10 to +90 mbar
Voltage 3 x 400 + neutral + protection earth
Frequency 50 Hz
Current 25 A
Noise <65 dbA

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)

Soft water specification


Ca (Calcium) + Mg Max content = 50 mg/liter (higher values requires MUW tanks)
(Magnesium)

NPK fertilizer,
chlorine poor
N (Nitrogen) 10%
P (Phosphor) 2%
K (Potassium) 1%

O&M manual for BiogasCleaner with QSR page 7 June 2012


3. Design criteria, specification and standards
Standards

ASME RPT-1 Reinforced Thermoset Plastic Corrosion Resistant Equipment


ASTM D-3299 - 08 Standard Specification for Filament-Wound Glass-Fiber-Reinforced Ther-
moset Resin Corrosion-Resistant Tanks
Machinery Directive 2006/42/EU
Low Voltage Directive 2006/95/EU
EMC Directive 2004/108/EU
Low Voltage Switchboard EN60439
Safety of machinery, electrical equipment EN60204-1
ATEX 94/9/EC (Gas Detector)

O&M manual for BiogasCleaner with QSR page 8 June 2012


4. Layout of the process technique unit (PTU)

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

Flow meter for


water system

Motor valve for


water system

Filter for water


system

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

O&M manual for BiogasCleaner with QSR page 9 June 2012


5. Navigating the display, Overview

O&M manual for BiogasCleaner with QSR page 10 June 2012


5. Navigating the display

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

To activate the menu, press  in the


left side of the panel. This opens the
PANELS LIST screen.

PANELS LIST

The arrow to the right of text


PANELS LIST is blinking.
Press  in the right side of the panel.
This opens the GO TO screen.

Other options are ALARMS LIST,


ALARMS HISTORY, PASSWORD and
SYSTEM. These options will be de-
scribed later.

From the screen GO TO you can choose menus 1 to 10 by pressing  a number of times.
The following options are available:

Text Shows / action


1 MAIN PANEL Return to START-UP
2 ACT FLOW Gas flow m3/h
Airflow m3/h
3 ACT O2 -TEMP Oxygen% to generator
4 ACT AIR Airflow inject m3/h
Airflow inject %
5 ACT TEMP Tank temperature
6 COUNT WATER Inlet of Water m3
7 COUNT EFFLU Inlet of Effluent m3
8 COUNT DRAIN Outlet of Drain m3
9 FORCE WATER Test Water supply
10 FORCE EFFLU Test Effluent supply
11 FORCE DRAIN Test Drain system

O&M manual for BiogasCleaner with QSR page 11 June 2012


Navigating the display, continued
GO TO
The arrow to the right of text
1 MAIN PANEL is blinking.
Press  to go to
2 ACT FLOW
The arrow to the right of text
2 ACT FLOW will start blinking.
Press  in the right side of the panel to
read the values.

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.

O&M manual for BiogasCleaner with QSR page 12 June 2012


Navigating the display, continued

5 ACT TEMP

In the GO TO screen press  4 times


to go to 5 ACT TEMP. On screen is
shown:
Temperature in tank 1/2 (if two tanks
are installed)
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 Fahrenheit.

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

In the GO TO screen press  6 times


to go to 7 COUNT EFFLU. On screen is
shown:
AMOUNT EFFLUENT m3 (Total oper-
ating 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.

8 COUNT DRAIN

In the GO TO screen press  7 times


to go to 8 COUNT DRAIN. On screen
is shown:
AMOUNT DRAIN m3 (Not used in all
applications).
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.

O&M manual for BiogasCleaner with QSR page 13 June 2012


Navigating the display, continued

9 FORCE WATER

In the GO TO screen press  8 times


to go to 9 FORCE WATER.
To test the Water supply: First read
screen 5: AMOUNT WATER, then go
to this screen.
Press MOD in bottom of the panel—on
the display ACK starts flashing. Press
ENTER in the bottom of the panel— in
the display OFF changes to ON. 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).

O&M manual for BiogasCleaner with QSR page 14 June 2012


6. Alarms and alarm handling (in case of Gas or O2 Alarm go to trouble
shooting section chapter 7)

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.

You find the ALARMS LIST in the screen PANELS LIST.

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

To turn off the alarm:


1: Press the reset button on the PLC con-
troller board. If the alarm is still active,
solve the problem.

Date and time of the alarm is shown in the top text.


The numbers in the top right side will show the number of alarms—for example 001/003,
meaning that this is the first of three alarms that need to be solved. Press  in the right side
of the panel to read the next alarm (002/003).

When the alarms are solved the display will turn back to normal operation mode.

O&M manual for BiogasCleaner with QSR page 15 June 2012


Alarms and alarm handling, continued

List of alarms.

Alarm handling:

Text in the display Action

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.

O&M manual for BiogasCleaner with QSR page 16 June 2012


Alarms and alarm handling, continued:

Text in the display Action

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.

TANK VALVE 1 / 2 1. Press Reset.


NOT OPEN 2. Check motor valves for the spray system at the next cycle.
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.
(Only used in 2 tank applications)

TANK VALVE 1 / 2 As above.


NOT CLOSED

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.

DRAIN VALVE As above.


NOT CLOSED

O&M manual for BiogasCleaner with QSR page 17 June 2012


Alarms and alarm handling, continued:

Text in the display Action

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.

HIGH OXYGEN 1. Press Reset.


2. Make measurement of oxygen at the outlet of the BiogasClean-
er with handheld equipment.
3. Check and calibrate the oxygen sensor according to suppliers
instructions.
4. Check the setting of air injection control in the PLC according to
the instructions for settings and restart.

EMERGENCY STOP 1. Press Reset.


2. Check if emergency stop on the EX/PLC controller board is acti-
vated.
3. Check if external emergency stop is activated.
4. Check wiring to external emergency stops.

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

O&M manual for BiogasCleaner with QSR page 18 June 2012


Alarms and alarm handling, continued:

Text in the display Action

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.

LESS GAS FLOW 1. Reset.


2. Check that the external gas flow signal 4—20 mA is according
to flow meter range and specifications.
3. Check the gas flow meter according to the supplier instruc-
tions.

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.

O&M manual for BiogasCleaner with QSR page 19 June 2012


Alarms and alarm handling, continued:

Text in the display Action

TANK LEVEL LOW The water level in the tank is too low. Circulation/drain pump will
stop.

1. Check the water / effluent supply.


2. Check that manual drain valves are closed and not leaking, if
close or replace valves.
3. Check that automatic drain valve are fully closed and not leak-
ing. If the valve are leaking, repair or replace the valve, refill
liquid manually or with “Force Water or Effluent” in PLC. Reset
and restart.

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

CHANGE A backup of the settings is kept in the PLC.


BACKUP BATTERY
Change the battery according to this O&M. The battery must be of
the type:
TSXPLP01, 1/2AA, 3,6V Lithium
The battery must be changed within 2 weeks, after the alarm shows.
If the battery is not changed all settings in the PLC will be lost.
Normal duration of this battery is up to 3 years. See the annex of the
manual for instructions to install the battery

O&M manual for BiogasCleaner with QSR page 20 June 2012


Alarms and alarm handling, continued:

Text in the display Action

LESS DRAIN Insufficient draining from the tank.

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.

O&M manual for BiogasCleaner with QSR page 21 June 2012


7. Trouble-shooting

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.

To reset the system:


1. Push the red reset button on the Ex controller board. Wait app.
1 minute, and restart the PLC controller board.
2. Check the print card in the EX controller board - if a green LED
is blinking regularly and a yellow LED is on constantly, then the
system is in normal operation mode. ( thiscan only be done
with open cabinet and power on, therefore this procedure mus
be done by a trained electrician)

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.

O&M manual for BiogasCleaner with QSR page 22 June 2012


7. Trouble-shooting continiued

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

Action:  Open EX panel and measure the O2 signal supplied to BC.


 If signal is lower than 3.5mAmp the problem is related to cabling
or O2 transmitter error.
 If signal is over 4.0 mAmp the problem is related to O2 content in
the gas after BiogasCleaner or calibration of the O2 transmitter.
 Measure O2 after BC with a hand held instrument to see if it
agrees with the reading from the fixed O2 transmitter.
 If not—Calibrate or replace O2 transmitter.
 If O2 reading is correct , but too high also measure O2 level before
BC to clarify if there is O2 in the gas entering the BC.
 In case of high O2 before BC the problem is related to the gas sys-
tem before the BC.
 If the O2 is low before BC but high after BC the problem can be
low pressure in the BC tank resulting in the Vacuum relief valve to
take in air on top og the BC tank.
 In case of vacuum the problem can be related to blowers or valve
settings before the BC tank.
 If non of the above problems mentioned are relevant the problem
can be high setting of Air injection on the PLC. Flush out the O2
from the system and reset the O2 alarm, restart PLC and check
setting for Air injection in the PLC.
 If the air injection % is put higher than normal for the H2S level in
the raw gas when the system was commissioned, readjust to nor-
mal air injection %
 3,000 ppm = 5% Air
 6000ppm = 7% Air
 10,000 ppm = 10% Air
 15,000 ppm = 15% Air
 20,000 ppm = 20% Air
 30,000 ppm = 30% Air
 After restart fine tune air injection to a level where O2 after BC is
app 1.5%

O&M manual for BiogasCleaner with QSR page 23 June 2012


8. Adjusting and testing the system via the display

For users with code—level C

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

The arrow to the right of text


PASSWORD is blinking.
Press  in the right side of the panel.
This opens the screen for entering the
password.

To enter the 4 digits password press


MOD and then . A box in the top
right side starts blinking. Press  or 
until correct digit is shown, then press
 to move to next digit. After all 4 dig-
its are chosen press ENTER. In the
bottom left side will be shown
CURRENT C LEVEL.
Press ESC to return to PANELS LIST.

O&M manual for BiogasCleaner with QSR page 24 June 2012


Adjusting and testing the system via the display, continued:
Removing of 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

The arrow to the right of text


PASSWORD is blinking.
Press  in the right side of the panel.
This opens the screen for entering and
clearing the password.

In the bottom left side will be shown


CURRENT __C LEVEL.
Press  and the RESET V in the box in
the bottom right side starts blinking.
Press  to clear the password, screen
will show
CURRENT ___ LEVEL.
Press ESC to return to PANELS LIST.

O&M manual for BiogasCleaner with QSR page 25 June 2012


Adjusting and testing the system via the display, continued:

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.

HINT—there is a shortcut. When looking at the GO TO screen it is possible to jump directly


to another screen—for example screen 20 TANK 1 DRIVETIME.

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.

It is possible to make adjustments in the following screens.

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.

Adjusting OPERATE __ SEC is done in the same way.

Press  to show the preset value for


OPERATE __ SEC. 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
OPERATE __ 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).

O&M manual for BiogasCleaner with QSR page 26 June 2012


Adjusting and testing the system via the display, continued:
For applications with 2 tanks there is a screen no. 21 for adjusting the PAUSE and
DRIVETIME for Tank 2.

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.

Adjusting OPERATE __ SEC is done in the same way.

Press  to show the preset value for


OPERATE __ SEC . 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 ad-
just the other digits press  until the cor-
rect digit is blinking. After adjusting
OPERATE __ 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).

22. TIME DRAIN


This screen shows the preset values for
PAUSE and DRIVETIME for the drain.
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.

Adjusting OPERATE __ SEC is done in the same way.


Press  to show the preset value for
OPERATE __ SEC . 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 ad-
just the other digits press  until the cor-
rect digit is blinking. After adjusting
OPERATE __ 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).
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.

Adjusting DRIVETIME is done in the same way.


Press  to show the preset value for
WATER CYCLE TIME. 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 ad-
just the other digits press  until the cor-
rect digit is blinking. After adjusting
WATER CYCLE TIME 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).

O&M manual for BiogasCleaner with QSR page 28 June 2012


Adjusting and testing the system via the display, continued:

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.

Adjusting DRIVETIME is done in the same way.


Press  to show the preset value for
EFFLUENT CYCLE TIME. 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 cor-
rect digit is blinking, then press  to in-
crease or  to lower the digit. After adjust-
ing EFFLUENT CYCLE TIME 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).

O&M manual for BiogasCleaner with QSR page 29 June 2012


9. Preparing for Operation

Before the filter can be started it has to be filled with biogas in a safe way.

Start up with gas free tank:

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

There are two options for purging the tank:

1. Purging with water:


 Fill the tank with water up to the top manhole.
 Close manhole and open the bypass valve (1 step system) or open the purge valve
(2 step system).
 Drain water through the QSR valve while biogas is replacing the water.
 The tank is now filled with biogas and ready to bring in operation.

2. Purging with inert gas


 Inject inert gas in the bottom of the tank and measure O2 at top manhole.
 When O2 in top of tank is lower than 5% stop injection of inert gas.
 Open for biogas to the tank and vent inert gas until CH4 is in the range for consump-
tion in flare, boiler or engine.
 The tank is now filled with biogas and ready to bring in operation.

Before the start up.

 Fill water / liquid up to the high level indication.


 Start heating the liquid, with the heat valve in position 3 ~ 40° C. (if installed)
 Add the biological active material for the process to the tank.
 Add 1 liter of nutrient, if used.
 Start the biogas flow.
 Check that the pumps have been filled up with liquid.
 Ensure that everything is ready including circulation, water, treated digester, efflu-
ent, drain, nutrient etc.

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.

O&M manual for BiogasCleaner with QSR page 30 June 2012


10. Maintenance.

To ensure a problem-free operation of the BiogasCleaner it is vital that maintenance is car-


ried out according to the instructions in this manual.

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”.

Following data is required as a minimum:

 Actual Biogas flow


 Actual Airflow on injection in PLC panel
 Biogas treated over the last 24 hours, alternatively power produced.
 Liquid added
 Fertilizer added
 Flow on the circulation pump
 Flow on air injection
 Temperature on the process
 pH on BC tank
 pH on MUW tank 2 (if installed on your system)
 H2S after the BiogasCleaner (if over normal check inlet also)
 Alarms registered
 Note if the BiogasCleaner has been stopped in the last 24 hours
 Signature from the staff in charge

Weekly.
Fill in the “Weekly Check Sheet”.

 Stop the circulation/drain pump and check the filter


 Close the ball valve for the liquid supply and check the filter
 H2S before the BiogasCleaner
 Check the differential pressure in the tank, if it exceeds 10 mbar the tank must be
QSR-cleaned, see process in chapter 11. The pressure is measured at the test valve at
the biogas inlet and outlet. Note to compare with previous measurements the biogas
flow has to be app. the same.
 Check the level of the filter liquid
 Check the supply of fertilizer (not all applications)
 Check the pH value of the filter liquid
 Check the adding of liquid function, by using the force option in the display
 Take measurement of oxygen using a hand-held instrument. The readings of the hand-
held instrument and the display of the PLC must match.

O&M manual for BiogasCleaner with QSR page 31 June 2012


Maintenance, continued

Every 3 months:

Fill in the “3 Months Check Sheet”.

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).

Procedure for packing media inspection: (Time consumption 1-2 hours)

 Stop the gas flow to the BiogasCleaner (BC).


 Press stop and Emergency stop on the PLC board.
 Make sure that there is no ignition sources or open fire in the area to minimize risk for
igniting any biogas leaving the tank during inspection.
 Close inlet and outlet gas valves to the BC.
 Use proper protection, rubber gloves, protection mask for H2S, goggles and work with
the wind in your back. Never work alone.
 Blow of pressure from the BC tank on the top of the tank by manually opening the pres-
sure release valve or loosening the top manhole (manhole must stay on not to enter air
to the tank).
 Prepare tools for opening bottom manholes. Prepare a new gasket if the existing will be
damaged.
 Open only one manhole at the time to minimize gas outflow and air intake from / to the
tank.
 Leave 1 bolt in the manhole and open slide the manhole aside, take out approximately
10-20 peaces of packings and close manhole immediately and install bolts / tighten.
 Repeat operation on second lower manhole (if available) some tanks have only one low-
er manhole.
 Take pictures of samples and evaluate thickness of bio-film / sludge layer on the pack-
ing media.

If the sludge formation is acceptable bring the BC back in operation:


Tighten bolts on top and bottom manholes. Open gas valves to tank, release emergency stop
and reset and start the PLC again.

O&M manual for BiogasCleaner with QSR page 32 June 2012


Maintenance, continued

Every 3 months:

Example of used packing media with


less than 1 mm. of biofilm and minor
sludge deposits.
This will not give any problems for
the operation and performance of
the BiogasCleaner.

Example of used packing media with


approximately 1-2 mm. of biofilm
and minor sludge deposits.
This will not give any problems for
the operation and performance of
the BiogasCleaner.

Example of packing media with 3-5


mm of bio-film.
This will give problems for the perfor-
mance of the BiogasCleaner, and QSR
cleaning is needed.

O&M manual for BiogasCleaner with QSR page 33 June 2012


Maintenance, continued

Optional on systems with MUW tanks / ponds:


Every 3 month or if there is more than 0.5 meter of solid sludge can be de-
tected in the MUW tank. Sludge level Can be detected with a piece of pvc pipe
or similar from the top manhole of the tank(s).

It is recommended to clean only one tank or pond chamber per day to


prevent decreasing performance on the BC!
By-pass The MUW tank or pond chamber that need’s cleaning, drain it and
flush out the sludge in the tank to the drain system with water. When the
tank is clean close drain and fill the tank with particle free water and put it
back in operation. Activate “Force Effluent” on the PLC to add nutrient.

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.

Fill in the “3” months Check Sheet”.

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.

O&M manual for BiogasCleaner with QSR page 34 June 2012


Maintenance, continued

Every year

Fill in the “1 Year Check Sheet”.

 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.

O&M manual for BiogasCleaner with QSR page 35 June 2012


11. QSR® Cleaning and restart
(For 2 tank systems look at next page for By-Pass opertion)

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

Preparing the work:

 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.

O&M manual for BiogasCleaner with QSR page 36 June 2012


QSR® Cleaning and restart, continued

Operation of 2-tank BiogasCleaner with one tank bypassed

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)

Close all valves between PTU and tank 1.


Open the bypass for the biogas for tank 1.
Close the for the biogas to the tank 1
Open the air valve and water injection for tank 2.

Start the QSR procedure.

After the QSR is completed:


Put system back in operation including the setting for the drive/pause in the PLC

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)

Close all valves between PTU and tank 2.


Open the bypass for the biogas for tank 2.
Close the for the biogas to the tank 2
Open the air valve and water injection for tank 1.

Start the QSR procedure.

After the QSR is completed:


Put system back in operation including the setting for the drive/pause in the PLC

O&M manual for BiogasCleaner with QSR page 37 June 2012


QSR® Cleaning and restart, continued

Precaution for air compressor:

 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.

Evaluate the packing media:

 After draining, open lower manhole(s), and inspect the result.


 Take pictures of the packing media and evaluate the thickness of the bio film /
sludge layer on the media.
 If there is a high pressure drop after the QSR cleaning, try to inject air into the test
valves on the biogas inlet and outlet to remove sludge.
 Evaluate if further cleaning is needed.

Flexible 1” pipes

Air Compressor
6 - 8,000 l/ minute
6 - 8 Bar max pressure

BiogasCleaner
Manifold Tank.

PTU

O&M manual for BiogasCleaner with QSR page 38 June 2012


Before and after QSR pictures

O&M manual for BiogasCleaner with QSR page 39 June 2012


QSR® Cleaning and restart, continued

Start up after QSR cleaning:

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:

1. Purging with water:


 Fill the tank with water up to the top manhole.
 Close the manhole and open the bypass valve (1 step system) or open the purge valve
(2 step system).
 Drain water through the QSR valve while biogas is replacing the water.
 Now the tank is full of biogas and ready to bring back in operation.

2. Purging with inert gas. (N2, CO2 , inert gas generator)


 Inject inert gas in the bottom of the tank and measure O2 at top manhole.
 When O2 in top of tank is lower than 5% stop injection of inert gas.
 Close the manhole.
 Open for biogas to the tank and vent inert gas until CH4 is in the range for consumption
in flare, boiler or engine.
 Now the tank is full of biogas and ready to bring back in operation.

Startup:

 Fill water / liquid up to the high level indication.


 Start Heating the liquid, with the heat valve in position 3 ~ 40° C. (if installed)
 Open valves to pumps and blower
 Add the saved filter liquid to the process tank.
 Start the biogas flow.
 Check that the pumps have been filled up with liquid.
 Close the main switch on the EX controller board and the PLC controller board. Press
reset on the EX controller board and the PLC controller board.
 Start the proces.
 Check that pump and blowers are running and PLC control shows no warnings.
 Ensure that liquid, nutrient and other peripherals are ready.
 The process will increase in performance over the next hours and will normally be on
full efficiency after 12—24 hours.
 After startup : Test differential pressure over the BiogasCleaner at 100% biogas
flow

O&M manual for BiogasCleaner with QSR page 40 June 2012


12. Recommended spare parts and measuring equipment

Recommended spare parts


Filter Type
FLT-110-filter 3,3 mm Filter for 110 mm filter
FLT-75-filter 3,3 mm Filter for 32 mm filter

Accessories for flow meter Type


FMS bistable ALF Switch bistable for flow meter
FMS 4-20 mA ALF Sensor for flow meter

Flow meter
FMV-DFT Flow meter for liquid
FMV-SO30 Flow meter house

Pump Type
PU Circulation/drain pump

Air blower Type


AB-Becker Air blower

Motor valve Type


MV D25 C100 Ball valve with electric actuator 1"
MV DN50 C100 Ball valve with electric actuator 2"

Nozzle Type
SN-Nozzle Nozzle 170 deg

PLC Controller board G1 Type


PLC, pre-programmed
Power supply PLC
Analog input module
Analog output module
Isolation amplifier 4-20 mA

Recommended measuring equipment


Kitagawa pump and tubes for H2S
Calibration gas for analyzer
Handheld oxygen meter

O&M manual for BiogasCleaner with QSR page 41 June 2012

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