Difference between revisions of "Maintenance of a Biogas Plant"
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| − | + | [[Portal:Biogas|►Back to Biogas Portal]] | |
= Overview = | = Overview = | ||
| − | + | As a general rule, maintenance of [[Agitation of Digesters|agitation]], [[Biogas Technology|pumping and flushing equipment]] should always be performed above ground level [5-6]. If this is not possible, a forced ventilation system must be permanently installed in order to counteract the risk of asphyxiation and poisoning in the event of an escape of gas. | |
| − | As a general rule, maintenance of [[ | ||
<br/> | <br/> | ||
<u>Consider these basic operation and maintenance principle:</u> | <u>Consider these basic operation and maintenance principle:</u> | ||
| + | |||
| + | |||
*To strive and perform optimal, “life support systems” must work at all times, and “living conditions” shall be kept stable and in harmony with process requirements<ref name="Christensen">GIZ, FECC, 2012. Christensen: Operation and Maintenance, Pilot Training for biogas plant technicians</ref> | *To strive and perform optimal, “life support systems” must work at all times, and “living conditions” shall be kept stable and in harmony with process requirements<ref name="Christensen">GIZ, FECC, 2012. Christensen: Operation and Maintenance, Pilot Training for biogas plant technicians</ref> | ||
*Proper biogas O&M is all about stability and harmony, well in line with old Chinese Confucianism principles.<ref name="Christensen">_</ref> | *Proper biogas O&M is all about stability and harmony, well in line with old Chinese Confucianism principles.<ref name="Christensen">_</ref> | ||
*General good practise O&M procedures can be defined, but also a “feeling” for the individual plants requirements is needed by the O&M staff. <ref name="Christensen">_</ref> | *General good practise O&M procedures can be defined, but also a “feeling” for the individual plants requirements is needed by the O&M staff. <ref name="Christensen">_</ref> | ||
| + | <br/> | ||
| − | |||
=== Design Interaction === | === Design Interaction === | ||
| Line 23: | Line 24: | ||
*Drain and flushing connections where service is foreseen | *Drain and flushing connections where service is foreseen | ||
*Process indication instruments and logging to be able to follow equipment state and trends, in order to react in time | *Process indication instruments and logging to be able to follow equipment state and trends, in order to react in time | ||
| + | <br/> | ||
| − | |||
=== Spare Part Management === | === Spare Part Management === | ||
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*Remember to replenish stock as soon as spare parts are used | *Remember to replenish stock as soon as spare parts are used | ||
*Consider to refurbish replaced equipment to keep as emergency spare units | *Consider to refurbish replaced equipment to keep as emergency spare units | ||
| + | <u><br/></u> | ||
| + | |||
| + | <u>Storage of spare parts:</u> | ||
| − | |||
| − | |||
*Keep storage facility dry, clean and ventilated. | *Keep storage facility dry, clean and ventilated. | ||
*Keep spare parts organized so you know where to find the parts for different equipment. | *Keep spare parts organized so you know where to find the parts for different equipment. | ||
| Line 43: | Line 45: | ||
*Upon receiving of parts: Check that it is the right parts and quantity. Put them in place. | *Upon receiving of parts: Check that it is the right parts and quantity. Put them in place. | ||
*Spare parts are normally preserved for shipment and storage when delivered, so keep in original packing | *Spare parts are normally preserved for shipment and storage when delivered, so keep in original packing | ||
| + | <br/> | ||
| − | |||
= Comminutors = | = Comminutors = | ||
| − | |||
According to information supplied by the manufacturers, the equipment is of low-maintenance design. It should be possible to carry out maintenance '''during the breaks in feeding'''.<ref name="Leitfaden">FNR, 2012: Guide to biogas. p. 38.</ref> | According to information supplied by the manufacturers, the equipment is of low-maintenance design. It should be possible to carry out maintenance '''during the breaks in feeding'''.<ref name="Leitfaden">FNR, 2012: Guide to biogas. p. 38.</ref> | ||
<br/> | <br/> | ||
| + | |||
=== External Comminutors === | === External Comminutors === | ||
| − | |||
Maintenance can be arranged by contract with the manufacturer and is a necessity, depending on the substrates<br/>worked. A supply of comminuted material to bridge downtimes for maintenance can be stocked on site.<br/> | Maintenance can be arranged by contract with the manufacturer and is a necessity, depending on the substrates<br/>worked. A supply of comminuted material to bridge downtimes for maintenance can be stocked on site.<br/> | ||
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<br/> | <br/> | ||
| + | |||
=== In-pipe Comminution Agitators<br/> === | === In-pipe Comminution Agitators<br/> === | ||
| − | |||
Freestanding units can be serviced quickly without long outages. Easily accessible apertures significantly speed up cleaning. | Freestanding units can be serviced quickly without long outages. Easily accessible apertures significantly speed up cleaning. | ||
<br/> | <br/> | ||
| + | |||
{| cellspacing="1" cellpadding="1" border="1" align="center" style="width: 100%" | {| cellspacing="1" cellpadding="1" border="1" align="center" style="width: 100%" | ||
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*Perforated-plate comminutors up to 600 m<sup>3</sup>/h delivery rate, motor power ratings between 1.1 and 15 kW | *Perforated-plate comminutors up to 600 m<sup>3</sup>/h delivery rate, motor power ratings between 1.1 and 15 kW | ||
*Inline twin-shaft comminutors based on rotary displacement pumps: comminution rates up to 350 m3/h • Characteristic values depend heavily on dry matter content. Delivery rate drops off sharply as dry matter content increases. | *Inline twin-shaft comminutors based on rotary displacement pumps: comminution rates up to 350 m3/h • Characteristic values depend heavily on dry matter content. Delivery rate drops off sharply as dry matter content increases. | ||
| − | |||
|- | |- | ||
| bgcolor="#ccffcc" style="width: 30%" | Suitability | | bgcolor="#ccffcc" style="width: 30%" | Suitability | ||
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*Perforated-plate comminutors suitable for substrates with fibre content | *Perforated-plate comminutors suitable for substrates with fibre content | ||
*Inline twin-shaft comminutors also suitable for pumpable substrates containing higher proportions of solids | *Inline twin-shaft comminutors also suitable for pumpable substrates containing higher proportions of solids | ||
| − | |||
|- | |- | ||
| bgcolor="#ccffcc" style="width: 30%" | Advantages & Disadvantages | | bgcolor="#ccffcc" style="width: 30%" | Advantages & Disadvantages | ||
| − | | | + | | |
+ Easy accessibility to the equipment in the event of a breakdown<br/>+ The units are easily opened and serviced in the event of clogging<br/>+ Interfering substances are stopped by built-in separator trap (perforated-plate comminutor)<br/>- Dry matter content in the digester can be increased only up to the limit of pumpability of the substrate<br/>- Substrates containing interfering substances can cause accelerated wear (inline twin-shaft comminutor) | + Easy accessibility to the equipment in the event of a breakdown<br/>+ The units are easily opened and serviced in the event of clogging<br/>+ Interfering substances are stopped by built-in separator trap (perforated-plate comminutor)<br/>- Dry matter content in the digester can be increased only up to the limit of pumpability of the substrate<br/>- Substrates containing interfering substances can cause accelerated wear (inline twin-shaft comminutor) | ||
| Line 89: | Line 89: | ||
*Perforated-plate comminutor: rotary blades in front of strainer | *Perforated-plate comminutor: rotary blades in front of strainer | ||
*Inline twin-shaft comminutor: shafts fitted with cutting or ripping tools | *Inline twin-shaft comminutor: shafts fitted with cutting or ripping tools | ||
| − | |||
|} | |} | ||
| + | <br/> | ||
<br/> | <br/> | ||
| − | |||
=== Comminutors Combined with Conveyor Technology in Single Units<br/> === | === Comminutors Combined with Conveyor Technology in Single Units<br/> === | ||
| − | |||
Freestanding pumps can be serviced quickly without long outages; submersible pumps are easily removed from the substrate for servicing. Maintenance apertures make for much shorter downtimes.According to information supplied by the manufacturers, the equipment is of low-maintenance design. Maintenance contracts are available.<br/>It should be possible to carry out maintenance during the breaks in feeding | Freestanding pumps can be serviced quickly without long outages; submersible pumps are easily removed from the substrate for servicing. Maintenance apertures make for much shorter downtimes.According to information supplied by the manufacturers, the equipment is of low-maintenance design. Maintenance contracts are available.<br/>It should be possible to carry out maintenance during the breaks in feeding | ||
<br/> | <br/> | ||
| + | |||
= Hygienisation Tanks<br/> = | = Hygienisation Tanks<br/> = | ||
| − | |||
The tank must have at least one manhole. Comply with applicable health and safety regulations for working inside enclosed spaces<br/>(due consideration also has to be given to gas safety regulations) The equipment as such (temperature sensors, agitators, pumps) has to be serviced; the tank itself should be maintenance-free. | The tank must have at least one manhole. Comply with applicable health and safety regulations for working inside enclosed spaces<br/>(due consideration also has to be given to gas safety regulations) The equipment as such (temperature sensors, agitators, pumps) has to be serviced; the tank itself should be maintenance-free. | ||
<br/> | <br/> | ||
| + | |||
= Pre-digester Pit<br/> = | = Pre-digester Pit<br/> = | ||
| − | |||
Depending on the type of agitator, maintenance can be undertaken outside the pre-digester pit or the digester, without process interruption. | Depending on the type of agitator, maintenance can be undertaken outside the pre-digester pit or the digester, without process interruption. | ||
| Line 115: | Line 113: | ||
<br/> | <br/> | ||
| + | |||
= Infeed of the Substrate = | = Infeed of the Substrate = | ||
| − | === [[Pumps_for_Biogas_Plants|Pumps]] | + | === Pumps === |
| + | ► [[Pumps_for_Biogas_Plants|Pumps for Biogas Plants]] | ||
| + | |||
| + | |||
'''Rotary pumps''' | '''Rotary pumps''' | ||
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<br/> | <br/> | ||
| + | |||
=== Infeed Screw Conveyors === | === Infeed Screw Conveyors === | ||
| − | |||
Moving parts, so outlay for regular servicing must be taken duly into account. Manual intervention required to clear clogging or remove trapped interfering substances. Servicing of the screw that feeds to the digester necessitates what can be considerable downtime. | Moving parts, so outlay for regular servicing must be taken duly into account. Manual intervention required to clear clogging or remove trapped interfering substances. Servicing of the screw that feeds to the digester necessitates what can be considerable downtime. | ||
<br/> | <br/> | ||
| + | |||
=== Infeed with Ram Feeder === | === Infeed with Ram Feeder === | ||
| − | |||
Moving parts, so outlay for regular servicing must be taken duly into account. Servicing of the ram feeder necessitates what can be considerable downtime, possibly also associated with emptying of the digester. | Moving parts, so outlay for regular servicing must be taken duly into account. Servicing of the ram feeder necessitates what can be considerable downtime, possibly also associated with emptying of the digester. | ||
<br/> | <br/> | ||
| − | = [[Material_for_Biogas_Digesters| | + | |
| + | = Digester<br/> = | ||
| + | ► [[Material_for_Biogas_Digesters|Material for Biogas Digesters]] | ||
| + | |||
=== Stirred-tank Biogas Reactors === | === Stirred-tank Biogas Reactors === | ||
| − | |||
Manhole facilitates accessibility. | Manhole facilitates accessibility. | ||
<br/> | <br/> | ||
| + | |||
=== Biogas Reactor with Plug-flow === | === Biogas Reactor with Plug-flow === | ||
| Line 164: | Line 169: | ||
*At least one manhole is necessary so that the interior of the reactor can be accessed in the event of a breakdown. | *At least one manhole is necessary so that the interior of the reactor can be accessed in the event of a breakdown. | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
=== Integrated Heating Systems === | === Integrated Heating Systems === | ||
| Line 172: | Line 177: | ||
*Access to heaters integrated into the digester or the structure is very difficult, if not impossible | *Access to heaters integrated into the digester or the structure is very difficult, if not impossible | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
= External Heat Exchangers = | = External Heat Exchangers = | ||
| + | Very good accessibility for maintenance and cleaning | ||
| − | |||
= Machinery for Mixing in the Digester = | = Machinery for Mixing in the Digester = | ||
| Line 186: | Line 191: | ||
*Maintenance hatches and engine-extraction hatches have to be integrated into the digester | *Maintenance hatches and engine-extraction hatches have to be integrated into the digester | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
=== Long-shaft Agitators === | === Long-shaft Agitators === | ||
| Line 195: | Line 200: | ||
*Maintenance hatches have to be integrated into the digester | *Maintenance hatches have to be integrated into the digester | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
=== Axial Agitators === | === Axial Agitators === | ||
| Line 204: | Line 209: | ||
*Maintenance hatches have to be integrated into the digester | *Maintenance hatches have to be integrated into the digester | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
=== Paddle/paddle-wheel Agitators === | === Paddle/paddle-wheel Agitators === | ||
| Line 213: | Line 218: | ||
*Maintenance hatches have to be integrated into the digester | *Maintenance hatches have to be integrated into the digester | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
=== Pneumatic Mixing === | === Pneumatic Mixing === | ||
| Line 221: | Line 226: | ||
*Repair of biogas injection equipment difficult, because the digester has to be emptied | *Repair of biogas injection equipment difficult, because the digester has to be emptied | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
=== Hydraulic Mixing === | === Hydraulic Mixing === | ||
| − | |||
Equipment specific maintenance is similar to that of the pumps stated above. | Equipment specific maintenance is similar to that of the pumps stated above. | ||
<br/> | <br/> | ||
| + | |||
= Sediment Discharge and Removal Systems = | = Sediment Discharge and Removal Systems = | ||
| Line 234: | Line 239: | ||
*Maintenance of permanently installed systems requires emptying the digester, so out-of-tank drives or removal equipment have advantages | *Maintenance of permanently installed systems requires emptying the digester, so out-of-tank drives or removal equipment have advantages | ||
*Comply with applicable health and safety regulations for working inside the digester | *Comply with applicable health and safety regulations for working inside the digester | ||
| + | <br/> | ||
| − | |||
= Gas Storage Tanks = | = Gas Storage Tanks = | ||
| − | |||
Maintenance-free to a very large extent. | Maintenance-free to a very large extent. | ||
<br/> | <br/> | ||
| + | |||
= Flare System = | = Flare System = | ||
| − | |||
Maintenance-free to a very large extent. | Maintenance-free to a very large extent. | ||
<br/> | <br/> | ||
| − | |||
| − | *[http://www.biogaschannel.com/en-us/ | + | |
| + | = Further Information<br/> = | ||
| + | |||
| + | *[[:Category:Biogas|All Biogas Articles]] | ||
| + | *[http://www.biogaschannel.com/en-us/home.aspx Biogas Channel](The proper maintenance of a cogeneration plant - Alexandru Drob) | ||
*[http://www.pro2.de/t/25_146.html Maintenance tips from PRO 2] | *[http://www.pro2.de/t/25_146.html Maintenance tips from PRO 2] | ||
*[http://www.mbconnectline.com/index.php/en/biogas/item/Remote-maintenance-of-biogas-plants Remote maintenance] | *[http://www.mbconnectline.com/index.php/en/biogas/item/Remote-maintenance-of-biogas-plants Remote maintenance] | ||
*[http://bio-gas-plant.blogspot.de/2011/04/biogas-plant-notes-chapter-11-operation.html Biogas plant maintenance at blogspot (for domestic biogas)] | *[http://bio-gas-plant.blogspot.de/2011/04/biogas-plant-notes-chapter-11-operation.html Biogas plant maintenance at blogspot (for domestic biogas)] | ||
*[http://www.expo21xx.com/renewable_energy/19348_st3_renewable_maintenance/default.htm Maintenance service provider MT-Energie] | *[http://www.expo21xx.com/renewable_energy/19348_st3_renewable_maintenance/default.htm Maintenance service provider MT-Energie] | ||
| − | + | <br/> | |
| − | |||
= References = | = References = | ||
| − | |||
<references /> | <references /> | ||
| − | |||
[[Category:Biogas]] | [[Category:Biogas]] | ||
Latest revision as of 11:36, 8 April 2015
Overview
As a general rule, maintenance of agitation, pumping and flushing equipment should always be performed above ground level [5-6]. If this is not possible, a forced ventilation system must be permanently installed in order to counteract the risk of asphyxiation and poisoning in the event of an escape of gas.
Consider these basic operation and maintenance principle:
- To strive and perform optimal, “life support systems” must work at all times, and “living conditions” shall be kept stable and in harmony with process requirements[1]
- Proper biogas O&M is all about stability and harmony, well in line with old Chinese Confucianism principles.[1]
- General good practise O&M procedures can be defined, but also a “feeling” for the individual plants requirements is needed by the O&M staff. [1]
Design Interaction
- Suitable and sturdy equipment
- Automatic protection and safety instrumentation to avoid serious break downs
- Redundant installation on key functions, or quickly replaceable complete components on stock
- Operation quickly restored
- Proper service off-line
- Shut off possibilities and easy access where relevant
- Drain and flushing connections where service is foreseen
- Process indication instruments and logging to be able to follow equipment state and trends, in order to react in time
Spare Part Management
- Keep strategic spare parts and wear parts on stock!
- Strategical spare parts can be foreseen to be needed to keep vital functions running and/or parts with long delivery time
- Wear parts are parts which can be foreseen to wear out periodically, to be able to schedule service without need to wait for parts
- Update relevant spare and wear parts to have on stock according to experience
- Remember to replenish stock as soon as spare parts are used
- Consider to refurbish replaced equipment to keep as emergency spare units
Storage of spare parts:
- Keep storage facility dry, clean and ventilated.
- Keep spare parts organized so you know where to find the parts for different equipment.
- Keep parts according to manufacturers recommendation
- Upon receiving of parts: Check that it is the right parts and quantity. Put them in place.
- Spare parts are normally preserved for shipment and storage when delivered, so keep in original packing
Comminutors
According to information supplied by the manufacturers, the equipment is of low-maintenance design. It should be possible to carry out maintenance during the breaks in feeding.[2]
External Comminutors
Maintenance can be arranged by contract with the manufacturer and is a necessity, depending on the substrates
worked. A supply of comminuted material to bridge downtimes for maintenance can be stocked on site.
In-pipe Comminution Agitators
Freestanding units can be serviced quickly without long outages. Easily accessible apertures significantly speed up cleaning.
| Characteristic values |
|
| Suitability |
|
| Advantages & Disadvantages |
+ Easy accessibility to the equipment in the event of a breakdown |
| Designs |
|
Comminutors Combined with Conveyor Technology in Single Units
Freestanding pumps can be serviced quickly without long outages; submersible pumps are easily removed from the substrate for servicing. Maintenance apertures make for much shorter downtimes.According to information supplied by the manufacturers, the equipment is of low-maintenance design. Maintenance contracts are available.
It should be possible to carry out maintenance during the breaks in feeding
Hygienisation Tanks
The tank must have at least one manhole. Comply with applicable health and safety regulations for working inside enclosed spaces
(due consideration also has to be given to gas safety regulations) The equipment as such (temperature sensors, agitators, pumps) has to be serviced; the tank itself should be maintenance-free.
Pre-digester Pit
Depending on the type of agitator, maintenance can be undertaken outside the pre-digester pit or the digester, without process interruption.
If the design lacks provision for removing settlement layer material, this material has to be removed manually. Apart from this, virtually no maintenance outlay; maintenance of the various technical items of equipment is described in the corresponding sections.
Infeed of the Substrate
Pumps
Rotary pumps
More difficult in the case of submersible pumps, although relatively easy access through removal apertures. Comply with applicable health and safety regulations for working inside the digester. Outages tend to be slightly longer than for other types of pump.
Eccentric single-rotor screw pumps
Very durable!
The design is inherently service-friendly; outages are short on account of the quick-change design of the screw drive.
Hopper pumps for solids infeed into piped liquid
The design is inherently service-friendly; outages are short.
Rotary displacement pumps
The design is inherently service-friendly; outages are short.
Infeed Screw Conveyors
Moving parts, so outlay for regular servicing must be taken duly into account. Manual intervention required to clear clogging or remove trapped interfering substances. Servicing of the screw that feeds to the digester necessitates what can be considerable downtime.
Infeed with Ram Feeder
Moving parts, so outlay for regular servicing must be taken duly into account. Servicing of the ram feeder necessitates what can be considerable downtime, possibly also associated with emptying of the digester.
Digester
► Material for Biogas Digesters
Stirred-tank Biogas Reactors
Manhole facilitates accessibility.
Biogas Reactor with Plug-flow
- At least one manhole is necessary so that the interior of the reactor can be accessed in the event of a breakdown.
- Comply with applicable health and safety regulations for working inside the digester
Integrated Heating Systems
- Heaters have to be cleaned regularly in order to ensure that heat transfer remains effective
- Access to heaters integrated into the digester or the structure is very difficult, if not impossible
- Comply with applicable health and safety regulations for working inside the digester
External Heat Exchangers
Very good accessibility for maintenance and cleaning
Machinery for Mixing in the Digester
Submerged-motor Propeller-type Agitators
- In some cases difficult, because the motor has to be lifted out of the digester
- Maintenance hatches and engine-extraction hatches have to be integrated into the digester
- Comply with applicable health and safety regulations for working inside the digester
Long-shaft Agitators
- Motor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process
- Repairs to propeller and shaft difficult, because they have to be taken out of the digester or the fill level inside the digester has to be lowered
- Maintenance hatches have to be integrated into the digester
- Comply with applicable health and safety regulations for working inside the digester
Axial Agitators
- Motor maintenance is straightforward on account of siting outside the digester; no need to interrup in the process
- Repairs to rotors and shaft difficult, because they have to be taken out of the digester or the fill level of the substrate in the digester has to be lowered
- Maintenance hatches have to be integrated into the digester
- Comply with applicable health and safety regulations for working inside the digester
Paddle/paddle-wheel Agitators
- Motor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process
- Repair of paddles and shaft difficult, because the digester has to be emptied
- Maintenance hatches have to be integrated into the digester
- Comply with applicable health and safety regulations for working inside the digester
Pneumatic Mixing
- Gas-compressor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process
- Repair of biogas injection equipment difficult, because the digester has to be emptied
- Comply with applicable health and safety regulations for working inside the digester
Hydraulic Mixing
Equipment specific maintenance is similar to that of the pumps stated above.
Sediment Discharge and Removal Systems
- Maintenance of permanently installed systems requires emptying the digester, so out-of-tank drives or removal equipment have advantages
- Comply with applicable health and safety regulations for working inside the digester
Gas Storage Tanks
Maintenance-free to a very large extent.
Flare System
Maintenance-free to a very large extent.
Further Information
- All Biogas Articles
- Biogas Channel(The proper maintenance of a cogeneration plant - Alexandru Drob)
- Maintenance tips from PRO 2
- Remote maintenance
- Biogas plant maintenance at blogspot (for domestic biogas)
- Maintenance service provider MT-Energie
References
- ↑ 1.0 1.1 1.2 GIZ, FECC, 2012. Christensen: Operation and Maintenance, Pilot Training for biogas plant technicians Cite error: Invalid
<ref>tag; name "Christensen" defined multiple times with different content Cite error: Invalid<ref>tag; name "Christensen" defined multiple times with different content - ↑ FNR, 2012: Guide to biogas. p. 38.
