Appendix 9 - Manuals - Pravin Amar, Professional Services
Contents
1. 3 4 Checking the ignition electrode 6 5 Gas 3 4 Thermocouple functionality check 6 7 Main Burner Gas Line 3 4 Checking louvre control actuators 6 7 Pilot Burner Gas 3 4 Section 7 Technical Data 7 1 Flare Stack nue nid 3 4 General Arrangement and Dimensions 7 1 Control Panel 3 4 Process and Instrumentation Diagram 7 2 Telemetry Panel 3 5 Component Designation 7 3 Gas Analyser Cabinet 3 5 Operating and Commissioning Compressor 3 5 7 4 Safety Critical Components 3 5 Troubleshooting 7 6 Torque Settings 7 8 Component Manufacturer s Data 7 8 Doc No 3092TM Issue 0 0 iii 2000m h Enclosed Ground Flare and Booster Set System Section 1 Introduction PURPOSE OF THIS MANUAL This manual is intended to assist the user in the safe and efficient installation operation and maintenance of the Biogas enclosed flare and booster set It is divided into the following sections Introduction Introduction this chapter Safety details the safety procedures users should employ to enable the safe installa2. Mr XE qom Flare stack e Pilot burner line ES H a E amp 3 al 2 7 Ll i 2810 5 TO END OF VALVE 5 INLET FROM SITE 10 8 7 6 5 4 3 E ce 8 _ sc EN o _ 1 L 379 0 OUTLET TO ENGINE 383 00 INLET FROM SITE 3868 0 OUTLET TO ENGINE Figure 7 1 General Arrangement Doc No 3092TM Issue 0 0 7 1 2000m3h Enclosed Ground Flare and Booster Set System PROCESS AND INSTRUMENTATION DIAGRAM PROVISION d FOR a CONTINUOUS HHL ALARM SHUTDOWN GAS FLOW RATE AND TEMPERATURE TELEMETRY MODBUS MODULE MASTER AIR CONDITIONED CONTROL PANEL PANEL ANALYSER MODBUS CONTROL LOW FLOW ON OFF AAAA EMMISSION MONITORING Technical Data 3092 E 152 STACK INSULATION EMERGENCY STOP 3092 E 187 3092 E 173 3092 V 174 PRESSURE GAUGE ANALYSIS SAMPLE POINT FLOW TRANSMITTER VACUUM GAUGE FLOW CONDITIONER HIGH LEVEL ALARM HIGH HIGH LEVEL ALARM Doc 3092 Issue 0 0 DAI Fl INNI BUTTERFLY VALVE c w GEAR HANDLE lt bi 400 0 3092 E 181 3092 E 113 COALESCENT DRAIN 3092 V 102 3092 V 103 LEGEND SLAM SHUT VALVE BALL VALVE GATE VALVE INDIC
3. ni Electrical 2 2 General 5 1 Mechanical Safety 2 3 PEnio and ANGIECALONS sm v Safety Inspections Testing Calibration HMI Screen 5 2 and 2 3 Operation nenne 5 3 Section 3 Description 3 1 Starting wanqa 5 3 General sanken 3 1 Shutting Down 5 4 System Description 3 1 Emergency Stop 5 4 Flare 3 1 Section 6 Maintenance 6 1 Power Generation Mode Introduction 6 1 Future Provision 3 2 Maintenance astas 6 1 es 3 2 Maintenance 6 4 Shutdown 3 2 Checking pneumatic valves Yu e 3 3 for air leaks 6 4 Component Description 3 3 Cleaning flame arresters 6 4 Knock Out 3 3 Draining the 6 5 Flowmeters 3 4 Cleaning the KOP demister element 6 5 Extraction Fan
4. Safety Installation operation and maintenance of the Biogas enclosed flare are restricted to personnel who have the necessary qualifications to do so within the jurisdiction s in which the installation is located Nothing in this manual should be taken as contradicting any applicable laws and regulations that have the force of law within the jurisdiction s in which the installation is located This manual describes the complete Biogas enclosed flare and booster set installation Documentation for components of the installation may also contain safety and operating information and can be found in the Technical Information File Before installing operating or maintaining the Biogas enclosed flare and booster set this manual must be read thoroughly paying particular attention to all WARNINGS Cautions and Notes WARNINGS ARE USED TO ALERT THE READER TO A PROCEDURE OR PRACTICE WHICH IF NOT FOLLOWED CORRECTLY COULD RESULT IN PERSONAL INJURY Cautions are used to alert the reader to a procedure or practice which if not followed correctly could result in damage to the equipment or ancillary equipment being damaged or there is risk of environmental damage Notes are used to highlight important information that may assist the reader in carrying out a procedure or in understanding the text D UE gt NOTE Incorrect installation or operation or failure of the user to maintain the equipment in accordance with the Maintenanc
5. Gas quality range O 96 vol lt 5 Methane destruction 99 9 Yes efficiency Hydrogen destruction 99 9 Yes efficiency Retention time RT at 3 9 Yes minimum flow rate s Retention time RT at 0 6 Yes maximum flow rate s RT min EA requirement s 0 3 Flare temperature T 1000 1150 Yes nominal operating range C T min EA requirement C 1000 Emissions Field tests on similar flare at 273 101 3 kPa corrected for 3 dry gas in mg m VOC THC 2 Yes Estimate of uncertainty 30 VOC max EA limit 10 CO 10 Yes CO max EA limit 50 Estimate of uncertainty 10 NOx 92 Yes NOx max EA limit 150 Estimate of uncertainty 15 Doc No 3092TM Issue 0 0 7 5 2000m3h Enclosed Ground Flare and Booster Set System TROUBLESHOOTING Troubleshooting should only be carried out by suitably trained and qualified personnel If in any doubt about the operation of the plant contact Biogas Technical Data Fault Symptoms Action Flare won t start Operating start sequence doesn t start the flare Visually check power availability Contact Biogas or qualified electrician if flare still not operating to check connection Fan doesn t start No movement of the motor Check fan trip alarm and reset if needed If symptoms persist contact Biogas Motor moving no gas flow Check the belts if fitted Che
6. l 2 Turn off both the Flare and Blower by setting the Main Isolator on the control panel to OFF Ensure that the burners are turned off and no gas is flowing in the flare stack Doc No 3092TM Issue 0 0 6 5 2000m h Enclosed Ground Flare and Booster Set System Maintenance WAIT UNTIL THE FLARE STACK COOLS DOWN BE AWARE OF POSSIBILITY OF CONTACT WITH HOT SURFACES USE PROTECTIVE GLOVES 9 Disconnect the electrical connector from the electrode Remove and retain the electrode housing bolts 3 4 6 Carefully withdraw the electrode housing from the flare stack Examine the condition of the electrode If the ceramic casing has cracked replace the electrode Any deposits or spikes on the electrode tip should be removed carefully with a small fine file or similar abrasive tool ideally the tip of the electrode should be squared off The electrode gap is not adjustable but should be between 3mm and 5mm nominally If there have been ignition problems which have not been cured as a result of cleaning the electrode and the electrode gap appears excessive the electrode should be replaced Examine the electrode housing Any deposits creating a spike on the housing should be removed carefully with a fine file or similar abrasive tool to leave a smooth surface on the housing adjacent to the electrode tip Carefully locate the electrode housing into the flare stack and secure using th
7. thermocouple cable damaged or disconnected Check connections Replace the thermocouple or cable Plant fails to start Plant does not start after initiating start sequence Check emergency stop position and connections on the back of emergency stop switch Check MCBs switch position If OFF get appropriately trained person to investigate and repair in accordance to BSM7671 regulations Doc No 3092TM Issue 0 0 7 6 2000m3h Enclosed Ground Flare and Booster Set System Technical Data Fault Symptoms Action UV sensor flame detector Pilot light lighting but not seeing the flame No stable UV signal Debris part of the lining obscuring the hole Broken bulb dirty lens Remove the UV sensor and clean the hole in the ceramic liner Check UV sensor in accordance with manufacturer s instructions No temperature control on the flare Motorised louvre unserviceable Wrong settings of manual louvres Thermocouple fault Check operation of the motorised louvre start and stop the flare Check settings of the manual louvres contact Biogas Contact Biogas Flare goes out Sudden gas composition change not reflected in manual louvre settings Doc No 3092TM Issue 0 0 2000m3h Enclosed Ground Flare and Booster Set System TORQUE SETTINGS The following table gives the bolt tightening torques for Biogas bolts Technical D
8. ISOLATION OF GAS SUPPLY AND ELECTRICAL ISOLATION OF THE PLANT ALL ELECTRICAL AND NON ELECTRICAL EQUIPMENT USED AROUND THE FLARE SHOULD BE APPROPRIATELY RATED TO RELEVANT AREA CLASSIFICATION ZONES AND THE POTENTIAL IGNITION SOURCES SHOULD BE EXCLUDED OR CONTROLLED Doc No 3092TM Issue 0 0 2 2 2000m h Enclosed Ground Flare and Booster Set System Safety MECHANICAL SAFETY DURING VENTING IF SUCH A MODE IS INCLUDED A POTENTIALLY A EXPLOSIVE MIXTURE OF GAS AND AIR PASSES THROUGH THE VENT STACK IF FITTED AND OR FLARE STACK YOU MUST ENSURE THAT NO SPARKS OR FLAMES ARE PRESENT AND YOU MUST MONITOR THE EMISSIONS CONSTANTLY AS SOON AS GAS QUALITY IS RESTORED RETURN THE ENCLOSED FLARE TO GAS DELIVERY OR FLARE MODE DURING OPERATION IN THE VENT MODE THE EXTENT OF THE POTENTIALLY EXPLOSIVE ZONE IS MUCH LARGER IN COMPARISON TO NORMAL FLARING AND ALL NECESSARY PRECAUTIONS IN ACCORDANCE WITH DSEAR AND END USER RISK ASSESSMENT NEED TO BE OBSERVED ALL ELECTRICAL AND NON ELECTRICAL EQUIPMENT USED AROUND THE FLARE SHOULD BE APPROPRIATELY RATED TO RELEVANT AREA CLASSIFICATION ZONES AND THE POTENTIAL IGNITION SOURCES SHOULD BE EXCLUDED OR CONTROLLED THERE MAY BE NOXIOUS GAS AND DUST WITHIN THE PIPELINE YOU SHOULD DO WHATEVER IS POSSIBLE TO AVOID EXPOSURE AND OR INHALATION OF THESE WEAR PROTECTIVE CLOTHING AND A FACE MASK TO AVOID INJURY IRRITATION AND INHALATION OF GAS WHENEVER MAINTENANCE PROCEDURES ARE PERFORMED ON THE SYSTEM
9. THERE ARE A NUMBER OF SAFETY CRITICAL COMPONENTS ON THE SYSTEM A UNAUTHORISED MAINTENANCE OR ADJUSTMENT OF THESE COMPONENTS MAY AFFECT THE SAFE OPERATION OF THE SYSTEM WHICH COULD RESULT IN DEATH OR INJURY TO PERSONNEL THE FOLLOWING COMPONENTS ARE DESIGNATED AS SAFETY CRITICAL FLAME ARRESTERS UV SENSOR FLAME DETECTOR THERMOCOUPLES SAFETY INSPECTIONS TESTING CALIBRATION AND CERTIFICATION It is the responsibility of the user of all equipment obtained from Biogas Technology Ltd to ensure compliance with all current legislation regarding the requirement for safety inspections examinations testing calibration and certification Biogas Technology Ltd will not be liable for either the cost or provision of such services unless contractually agreed Biogas Technology Limited plant has been designed to meet the requirements of EC Directive 94 9 EC the appropriate EC ATEX Declaration of Conformity is enclosed in the Technical Information File together with a copy of the ATEX plate that is mounted on the plant Certification applicable to bought out components is enclosed with the suppliers information in the Technical Information File Doc No 3092TM Issue 0 0 2 3 2000m h Enclosed Ground Flare and Booster Set System Section 3 Description GENERAL Refer to Figure 7 1 Description The Biogas enclosed flare and booster set system uses sophisticated burner technology to achieve low noise low emission burning of land
10. ATES SAPO SAFETY CRITICAL ELECTRONIC SIGNAL COMPONENT NOTE All pressures in mbg AIR LINE EXHAUST GAS LINE 3092 E 115 3092 E 180 S 3 COMPRESSOR HOUSING MPRESSOR 092 V 120 3092 V 184 LOCKABLE GATE 3092 V 161 e E 14H 3092 V 170 FUTURE PROVISION FOR POWER GENERATION ENGINE Figure 7 2 Process and Instrumentation Diagram b 3092 E 149 __ 39 41 E 3092 E 146 23092 V 165 IGNITER SIGHT GLASS 3092 E 153 STOP 3092 E 156 LOUVRE ACTUATOR 3092 E 182 MOTORISED LOUVRE 3092 E 157 2000m h Enclosed Ground Flare and Booster Set System Technical Data COMPONENT DESIGNATION The following table identifies the components shown on the P amp ID 3092 VG 104 Vacuum Gauge Bottom Mounted 3092 E 150 UV Flame Detector UVS6 3092 V 105 Ball Valve 3092 E 151 Thermocouple 3092 V 161 Gate Valve locable 3092 PG 166 3092 PG 123 Pressure Gauge Bottom Mounted 3092 PG 169 Pressure Gauge Bottom Mounted 3092 E 124 Flame Arrestor 3092 V 170 Self Regulating Pressure Control Valve 3092 FC 175 3092 FM 176 3092 FC 177 3092 FM 178 3092 V 182 30535 237 823 123013 023123 Doc No 3092TM Issue 0 0 7 3 2000m3h Enclosed
11. Appendix 9 User and Operations Manuals for the Landfill Gas to Electricity Project at the SLS User and operations manuals that are referred to in this environmental management plan include gt Biogas Technical manual attached e Cat Engine user manual to be supplied on delivery e Generator operations manual to be supplied on delivery and e Ener G Site Operations Manual Confidential document Landfill Gas to Electricity at Shongweni Landfill Site ix SYNERGISTICS ENVIRONMENTAL SERVICES Basic Assessment Report 80388 Biogas 2000m h Enclosed Ground Flare System and Booster Set Technical Manual Prepared by Biogas Technology Ltd Biogas Technology Project No 3092 Site Chloorkop Doc No 3092TM Issue 0 0 2000m h Enclosed Ground Flare and Booster Set System Copyright and Disclaimer Published by Biogas Technology Limited Copyright and Disclaimer All reasonable care has been taken in the preparation of this publication but Biogas Technology Limited its agents and distributors accept no liability for any inaccuracies that may be found This manual reflects the state of the product at the issue date below but modifications may mean that this manual does not fully reflect your particular installation Biogas Technology Limited reserves the right to make changes without notice to both this manual and the product s that it describes Nothing in this publication should be taken as any offe
12. Ground Flare and Booster Set System OPERATING AND COMMISSIONING PARAMETERS The following table details the operating parameters and commissioning installation settings Technical Data Parameter Design Value PPC Alarm Value set at Relevant Value Commissioning Physical Parameters Internal stack orifice diameter 1690 Yes mm Stack height mm 8929 Yes Dimensions approximate W x Lx H mm 2461 x 10995 x 8929 Weight approximate kg Stack 3000 Plant 6000 Total 9000 Operational Design Parameters Flare maximum start 300 temperature C Fan Booster motor 2 stage 45 kW Ex Il 3 G EXn type Pressure rise across the fan 300 booster mbar g Power supply requirement 3 phase 415V 32A Ignition flame detection UV camera Flame present for 10 10 seconds Ignitor type Spark plug Ignition cycle fail min 5 3 Flame failure detection UV camera Flame not present for 5 10 seconds High temperature stack 1200 1200 Air intake Natural aspiration Yes Flame flashback shutdown N A N A temperature Doc No 3092TM Issue 0 0 2000m3h Enclosed Ground Flare and Booster Set System Technical Data Parameter Design Value PPC Alarm Value Set at Relevant Value Commissioning Technical Data Gas flow rate 400 2000 min max Nm h Turn down ratio 5 1 Gas quality range CH 27 65 96 vol
13. ONS ARE STOPPED AND THE CONTROL PANEL ELECTRICAL ISOLATION SWITCH SET TO OFF Uo gt gm THE PIPE SECTIONS MAY CONTAIN A FLAMMABLE MIXTURE OF GAS AND AIR MAINTENANCE TASKS MAY REQUIRE ISOLATION OF GAS SUPPLY AND ELECTRICAL ISOLATION OF THE PLANT ALL ELECTRICAL AND NON ELECTRICAL EQUIPMENT USED AROUND THE FLARE SHOULD BE APPROPRIATELY RATED TO RELEVANT AREA CLASSIFICATION ZONES AND OTENTIAL IGNITION SOURCES SHOULD BE EXCLUDED OR CONTROLLED PRIOR TO ANY TASKS PERFORMED ON THE FLARE THE OPERATOR SHOULD CARRY OUT RISK ASSESSMENT IN ACCORDANCE WITH CURRENT LEGISLATION AND REGULATIONS gt gt gt I m U If the system is not properly maintained the manufacturer s warranty may be voided or limited This may also affect the performance of the flare NOTE IS gt MAINTENANCE SCHEDULES The following schedules detail the routine preventative maintenance that must be carried out to ensure efficient and trouble free operation of the enclosed flare The maintenance tasks and frequency are detailed in Table 6 1 Refer to the Maintenance Procedures for procedures on carrying out the maintenance tasks Reference should be made to the component manufacturer s data in the Technical Information File for component maintenance and replacement instructions The enclosed flare will require a complete overhaul after prolonged operation and it is recommended that this should be carried out at least once every three ye
14. T UNTIL REPAIRS HAVE BEEN MADE OPERATING THE EQUIPMENT WITH DEFECTIVE OR MALADJUSTED COMPONENTS RISKS PERSONAL INJURY E THE PLANT MAY CONTAIN POTENTIALLY EXPLOSIVE ATMOSPHERES THE PLANT MAY GENERATE POTENTIALLY EXPLOSIVE ATMOSPHERE DUE TO GASES PASSING THROUGH ITS PARTS PRIOR TO ANY TASKS PERFORMED ON THE FLARE THE OPERATOR SHOULD CARRY OUT RISK ASSESSMENT IN ACCORDANCE WITH CURRENT LEGISLATION AND REGULATIONS MAINTENANCE TASKS MAY REQUIRE ISOLATION OF GAS SUPPLY AND ELECTRICAL ISOLATION OF THE PLANT ALL ELECTRICAL AND NON ELECTRICAL EQUIPMENT USED AROUND THE FLARE SHOULD BE APPROPRIATELY RATED TO RELEVANT AREA CLASSIFICATION ZONES AND THE POTENTIAL IGNITION SOURCES SHOULD BE EXCLUDED OR CONTROLLED THE PLANT HAS BEEN DESIGNED WITH DUE CONSIDERATION TO THE GUIDANCE GIVEN IN IGE SR 25 HAZARDOUS AREA CLASSIFICATION OF NATURAL GAS INSTALLATIONS ISSUED BY THE INSTITUTE OF GAS ENGINEERS AND THE ATEX 95 DIRECTIVE 94 9 EC AND DSERA IMPLEMENTATION FOR THE WASTE MANAGEMENT INDUSTRY RELEVANT ENVIRONMENTAL SERVICES ASSOCIATION ESA INDUSTRIAL CODES OF PRACTICE THE PLANT WITH EXCLUSION OF THE CONTROL PANEL THAT IS LOCATED IN THE SAFE ZONE IS CLASSIFIED AS E ELECTRICAL SAFETY THE PIPE SECTIONS MAY CONTAIN A FLAMMABLE MIXTURE OF GAS AND AIR PRIOR TO ANY TASKS PERFORMED ON THE FLARE THE OPERATOR SHOULD CARRY OUT RISK ASSESSMENT IN ACCORDANCE WITH CURRENT LEGISLATION AND REGULATIONS MAINTENANCE TASKS MAY REQUIRE
15. THE FLARE THE OPERATOR SHOULD CARRY OUT RISK ASSESSMENT IN ACCORDANCE WITH CURRENT LEGISLATION AND REGULATIONS THERE MAY BE NOXIOUS GAS AND DUST WITHIN THE PIPELINE WEAR PROTECTIVE CLOTHING AND A FACE MASK TO AVOID INJURY IRRITATION AND INHALATION OF GAS The flame arrester elements contain components that can be damaged if exposed to liquids You must use only dry air to clean them Please refer to manufacturer s instructions Refer to the Flame Arrestor manufacturer s Installation and Maintenance Instructions in the Technical Information File including the Torque settings and Torquing Sequence excessive tightening of the bolts may damage the flame arrester element To remove and clean the flame arrester elements Turn off both the Flare and Blower by setting the Main Isolator on the control panel to OFF NYA ta W N Ensure that the inlet slam shut valve is close and that no gas is flowing through the pipeline Purge the system of all residual gas Slacken all the nuts and bolts securing the pipe sections that hold the elements in position Vent the gas from the pipe safely eliminating ignition sources from the classified area Leaving one nut and bolt in position remove and save all the other nuts and bolts For each flame arrester you will now need to release the pipe section furthest from the blower gas booster Slacken all the nuts and bolts securing this pipe section 8 Leaving the nut and bolt c
16. arranty may be voided or limited Operating the system outside of the design parameters may invalidate Biogas warranty and affect the performance of the flare CONTROLS AND INDICATORS All the controls and indicators necessary to operate the flare are on the control panel The emergency stop button is located on the front of the access door to the control panel An emergency stop button is also located on the flare stack Figure 5 1 shows the controls and indicators HMI Screen The operation of the plant is controlled through this screen The screen also allows setting up and monitoring of operating parameters and alarms For full details refer to the Technical Information File Flare Temperature Displays Thermocouple 1 Thermocouple 2 Thermocouple 3 Main ON OFF Isolator Flare Off Red Lamp Flare On Green Lamp Emergency Stop On External Door Figure 5 1 Controls and Indicators Doc No 3092TM Issue 0 0 5 1 2000m h Enclosed Ground Flare and Booster Set System HMI Screen The HMI screen provides the following status information Flare start up status Landfill gas concentrations Pilot re light count Pilot gas ON OFF status Igniter ON OFF status Pilot proved status Extraction fan status Slam shut valve status Flame proved status Extraction fan hours run Flare operating temperature Temperature controller output status Gas inlet flow rate The HMI screen provides the following c
17. ars This can be performed by Biogas Doc No 3092TM Issue 0 0 6 1 2000m h Enclosed Ground Flare and Booster Set System Maintenance Daily Maintenance Item Procedure Condensate drain valves Check and drain as detailed in the manufacturer s instructions Weekly Maintenance Item Procedure Knock out pot KOP Check the vacuum reading on the vacuum gauges on the KOP There should be no or minimal difference between the gauges Clean the wire mesh element if there is any significant vacuum difference Refer to the maintenance procedures for cleaning instructions Main and pilot flame arrester pressure gauges Check the pressure readings on the flame arrester pressure gauges There should be no or minimal pressure drop across the flame arrester Clean the flame arrester if there is any significant pressure drop Refer to the maintenance procedures for cleaning instructions Extraction fan Check that there is no excessive heat being generated by the extraction fan assembly Ensure the fan is running smoothly with no excessive noise or vibration Carry out the weekly servicing detailed in the manufacturer s instructions Pneumatic valves Check the pneumatic valves are free from air leaks Compressor Carry out the weekly servicing detailed in the manufacturer s instructions Doc No 3092TM Issue 0 0 6 2 2000m h Enclosed Ground Fla
18. ata Biogas bolts are normally Grade 8 8 Torques given are for dry unlubricated and unplated bolts Refer to the manufacturers instructions in the Technical Information File for specific component torque settings Bolt Socket Tensile Torque Setting Diameter Spanner Stress Area Nm ft Ibs Size mm mm Grade 8 8 Grade 10 9 Grade 12 0 Bolts Bolts Bolts M5 8 14 2 6 9 5 0 9 4 7 0 11 2 8 0 M6 10 20 1 11 7 9 0 15 9 12 0 18 1 13 0 M8 13 36 6 28 0 21 0 38 0 28 0 46 4 34 0 M10 17 58 0 56 0 41 0 77 0 57 0 92 0 68 0 M12 19 84 3 98 72 0 134 0 99 0 160 0 118 0 M16 24 157 0 244 0 180 0 332 0 245 0 397 0 293 0 M20 30 245 0 476 0 646 0 646 0 476 0 776 0 572 0 M24 36 363 0 822 0 1120 0 1120 0 826 0 1342 0 990 0 COMPONENT MANUFACTURER S DATA The following component data can be found in the Technical Information File Section Component Supplier 2 Control Panel Control Systems Technology 3 Gas Analyser HITECH 4 Telemetry Module Dexdyne 5 Butterfly Valve Bray UK 6 SSV Pneumatic Actuators Bray UK 7 Ignition Electrode Lodge Ignition 8 UV Flame Detector Krom Schroder 9 Louvres Isolated Systems 10 Gas Booster Fans and Blowers 11 Pressure Regulating Valves Duncan 12 Stack Insulation Thermal Ceramics 13 Flowmeter Endress and Hauser 14 Air Compressor Cooper Frier 15 Thermocouples Thermocou
19. ck shaft and coupling if direct drive Contact Biogas Flare won t start or goes out No gas flow Check flame arrester differential quickly after start pressure Clean flame arrester in accordance with manufacturer s instructions or contact Biogas Flare won t start SSV not operating No air Check compressor and air lines If compressed is present and the flare won t start contact Biogas Leaving manual louvre open Pilot light ignites but when main SSV opens the flame flickers or dies Or the flare ignites but the high temperature cannot be controlled due to motorised louvre searching for stable control point Close manual louvre High methane concentration with low oxygen High concentration methane Pilot ignites ok but after opening the main burner s the flame is goes out Open manual louvre Low methane concentration Pilot flame flickering on off Main burners flame flicking on off Balance the field wait for the gas concentration to recover Refer to design operating parameters of the flare Weak igniter signal spark Ignitor sparking but not igniting the gas Check for distance between the tip and the ignitor Check for damp along the ceramic of the igniter Check igniter settings are in accordance with manufacturer s instructions No igniter signal No spark Dry or replace transformer Flashing flare or gas temperature display screens Thermocouple or
20. e Check the green ON lamp is lit 3 If the system fails to ignite check line gas quality is within the operating quality range CHA 25 60 v v O lt 5 v v Ignition Failure 1 If the ignition sequence fails to ignite the pilot gas or the flare fails to reach operating temperature within a preset time the system will shut down The HMI screen will indicate an ignition failure 2 Reset the system by pressing the STOP function on the HMI screen and the cancel the alarm 3 Press the START function on the HMI screen to restart the ignition sequence 4 If the system still fails to ignite check that the gas quality is within the operating quality range Automatic Restart If the system shuts down automatically high stack temperature ignition cycle fail fan trip high KOP level the system will restart automatically after a 30 minute shutdown period Three automatic restarts will be attempted before a reset is required To reset the system press the STOP function on the HMI screen To prevent an automatic restart after an automatic shutdown press the STOP function on the HMI Screen Remote Operation 1 The system can be operated remotely by telemetry On the HMI screen system control select REMOTE 2 The flare will start when a remote start signal is received via the telemetry system Doc No 3092TM Issue 0 0 5 3 2000m h Enclosed Ground Flare and Booster Set System Operation Shutting Down 1 To s
21. e a blockage in the mesh Manual ball valves allow for isolation of the gauges for maintenance An analysis point is provided for connection of sampling equipment Two manual ball valves in the drain line allow the coalesced liquid collected in the base of the KOP to be drained without venting gas Doc No 3092TM Issue 0 0 3 3 2000m h Enclosed Ground Flare and Booster Set System Description Flowmeters Flowmeters are fitted to the gas inlet the main burner gas train and the power generation gas train The flowmeters measure the flow rate of the gas They comprise a flow conditioning plate in the pipeline with a thermal mass flow meter for flow measurement Extraction Fan The extraction fan draws gas from the field at maximum 2000 Nm h Flexible connections to the main pipeline reduce vibration effects on the pipeline A pneumatic slam shut valve and manual butterfly valve are fitted to the inlet of the extraction fan A non return valve and a manually butterfly valve are fitted to the outlet of the extraction fan Gas Analysis The gas data analyser is connected to the system at this point for gas sampling Concentrations of methane carbon dioxide and oxygen are measured and fed into the HMI screen Main Burner Gas Line Gas flow to the main burner is controlled by a pneumatic slam shut valve SSV The SSV is opened by a control signal from the Control Panel when gas flow to the main burner is required and safety condit
22. e fixing bolts 10 Reconnect the electrical connector to the electrode Doc No 3092TM Issue 0 0 6 6 2000m h Enclosed Ground Flare and Booster Set System Maintenance Thermocouple functionality check This operation should only be carried out by a suitably trained and qualified engineer N approved by Biogas CAUTION The thermocouple functionality can only be checked by comparison with a known calibrated instrument which is inserted in an adjacent port in the Flare Stack This check should be conducted in accordance with the Biogas Work Instruction Checking louvre control actuators This operation requires specialist electrical equipment and should be carried out by N qualified electricians only The louvres are designed to operate automatically as gas is flared To check the operation of the louvre actuators a voltage has to be applied to the control connector of the actuator and confirm that the louvre operates Refer to the manufacturer s instructions in the Technical Information File Doc No 3092TM Issue 0 0 6 7 2000m3h Enclosed Ground Flare and Technical Data Booster Set System Section 7 Technical Data GENERAL ARRANGEMENT AND DIMENSIONS Gas inlet manifold manual butterfly valve 10 Flame arrester 2 9150 0 9000 0 wo Manual butterfly valve Manual butterfly valve Extraction fan 7 Gas outlet manifold to engine Sight glass
23. e information given in this manual may relieve the Biogas Technology Limited from any or all responsibility for consequent non compliance damage or injury The Biogas enclosed flare and booster set must not be used in combination with other equipment unless such equipment has been expressly designated as compatible equipment by Biogas Technology Limited Changes and or additions to the equipment should only be carried out by Biogas Technology Limited or by third parties expressly approved by Biogas to do so Such changes and or additions must comply with all applicable laws and regulations that have the force of law within the jurisdiction s in which the installation is located Doc No 3092TM Issue 0 0 2 1 2000m h Enclosed Ground Flare and Booster Set System Safety DO NOT ATTEMPT TO OPERATE THE BIOGAS ENCLOSED FLARE AND BOOSTER SET UNLESS YOU HAVE READ AND FULLY UNDERSTOOD THE EMERGENCY STOP PROCEDURE IN THE OPERATING SECTION OF THIS MANUAL gt BEFORE OPERATING THE BIOGAS ENCLOSED FLARE AND BOOSTER SET MAKE SURE THAT THE TASKS LISTED IN THE MAINTENANCE SECTION OF THIS MANUAL HAVE BEEN FULLY COMPLETED IF THEY HAVE NOT DO NOT USE THE EQUIPMENT UNTIL THE MAINTENANCE PROGRAMME HAS BEEN BROUGHT UP TO DATE OPERATING THE EQUIPMENT WHEN IT HAS NOT BEEN FULLY MAINTAINED RISKS PERSONAL INJURY gt IF ANY PART OF THE BIOGAS ENCLOSED FLARE AND BOOSTER SET IS KNOWN TO BE DEFECTIVE OR MALADJUSTED DO NOT USE THE EQUIPMEN
24. ff for five seconds before another ignition attempt is made This 5 second on 5 seconds off sequence of ignition attempts will continue up to a maximum of 5 minutes A maximum of 3 ignition cycle attempts is allowed before an auto shutdown will be activated Shutdown There are 3 ways of shutting the gas flare Manual Automatic Emergency Manual Shutdown When the gas flare is stopped by selecting OFF on the HMI screen the gas inlet and main burner slam shut valves will close and the extraction fan will be switched off cutting off the gas supply to the main burner Auto Shutdown The following conditions will cause the gas flare to shutdown automatically High stack temperature Ignition cycle fail Extraction fan trip High high liquid level in Gas inlet slam shut valve failure Main burner slam shut valve failure Thermocouple 1 failure Thermocouple 3 failure Doc No 3092TM Issue 0 0 3 2 2000m h Enclosed Ground Flare and Booster Set System Description When an auto shutdown is invoked the gas inlet and main burner slam shut valves will close and the extraction fan will be switched off cutting off the gas supply to the main burner and the generator engine Following an auto shutdown a manual restart is required The alarm must be acknowledged and the system reset on the HMI screen before a restart can be attempted The temperature of the flare stack must be less than 300 C before a re
25. fill gases across a wide range of gas flows from 50 Nm3h to a maximum standard capacity of 2000 Nm3h with typical minimum turn down ratio 5 1 A typical system comprises an inlet manifold a knock out pot with demister a gas extraction fan a main gas burner train a pilot gas burner train a power generation gas train a burner stack and a control and monitoring system Options include GPRS telemetry system emissions monitoring probe inlet and stack gas analysis system and data logging The following describes the enclosed flare system and booster set SYSTEM DESCRIPTION Refer to Figure 7 2 The following describes the operation of the enclosed gas flare and booster set The gas flare has the following modes of operation Flare Mode Power Generation Mode future provision Ignition Shutdown Flare Mode Flare mode is the normal operating mode of the gas flare Gas from the field is drawn by the extraction fan booster through a butterfly valve a Knock Out Pot KOP a slam shut valve and a butterfly valve Total gas flow is measured by the flow meter The KOP has a wire mesh mist eliminator that removes liquid from the gas stream The liquid is collected and drained in the bottom of the KOP Two level switches in the KOP monitors the liquid level If the first level switch is activated then an alarm is shown on the control panel if the second switch is activated the alarm will shut down the plant Vacuum gauges either side
26. heck and tighten all pipework bolts Refer to the Technical Data section for bolt torques System Check the gas flare for correct function in all modes of operation If there are any faults stop the gas flare and contact Biogas Six Monthly Maintenance Item Procedure Wiring Check continuity of all system wiring including all earth points Replace any defective wiring Cables and connectors Check the condition of all cables and connectors Replace any defective items Table 6 1 Maintenance Schedule Doc No 3092TM Issue 0 0 6 3 2000m h Enclosed Ground Flare and Booster Set System Maintenance MAINTENANCE PROCEDURES Checking pneumatic valves for air leaks Any major leak will allow pressurised gas to escape from the line Manually check the circumference of the valve for escaping gas To check the valves for smaller leaks apply a liberal volume of leak detector liquid around the whole circumference of the valve housing If a bubble forms at any point there is a small leak at that location Cleaning flame arresters The flame arresters are bolted between pipe sections as shown in the layout drawings in the Technical Data section of this manual Before the arrester elements can be cleaned they must be removed from the pipeline CAUTION E E UE gt gt THE PIPE SECTIONS MAY CONTAIN A FLAMMABLE MIXTURE OF GAS AND AIR PRIOR TO ANY TASKS PERFORMED ON
27. ion mode provides gas to drive a power generator Gas is drawn from the field in the same way as flare mode but the gas is fed through the power generation gas train and not to the burner Gas flow to the engines is measured by a flow meter Ignition When gas first flows the main burner slam shut valve is closed and the pilot burner piston valve is opened allowing a restricted gas flow through to the pilot burner in the flare stack A gate valve is set during commissioning to adjust the gas flow rate to the pilot burner The pilot burner is ignited by a spark from the igniter Verification that the pilot is alight is provided by the UV sensor which sends a flame present signal to the control panel After a short delay to allow the pilot burner flame to stabilise the main burner slam shut valve is opened allowing gas to flow to the main burner The pilot flame ignites the main burner and when the temperature of the main flare reaches a pre determined level the pilot burner slam shut valve closes and the pilot burner is extinguished If high methane content in the landfill gas creates a too rich mixture that is difficult to ignite a small volume of compressed air is injected into the pilot line immediately prior to the pilot burner gas via a flame arrester and pressure control valve Compressed air is only added during the ignition cycle This feature is optional Should the pilot burner fail to ignite within 5 seconds the igniter will be switched o
28. ions are satisfied Compressed air is provided by the compressor A flame arrester a safety critical component prevents the transmission of flames from the main burner while permitting the gas to flow Pressure gauges upstream and downstream of the flame arrester are provided to indicate blockages in the flame arrester element Pilot Burner Gas Line Gas flow to the pilot burner is controlled by a manual control gate valve and a pneumatic slam shut valve SSV The manual control valve controls the amount of gas flow tapped from the main burner line The SSV is opened by a control signal from the Control Panel when gas flow to the pilot burner is required during the ignition sequence Compressed air is provided by the compressor A flame arrester a safety critical component prevents the transmission of flames from the main burner while permitting the gas to flow Pressure gauges upstream and downstream of the flame arrester are provided to indicate blockages in the flame arrester element Two manual ball valves in the drain line allow the liquid to be drained from the burner lines without venting gas If required compressed air can be added to the pilot burner gas during ignition via a manually adjusted control valve and a flame arrester The control valve is set up during installation to achieve the correct methane O mix Flare Stack The flare stack contains the main and pilot burner igniter UV sensor thermocouples manually adjusted louvre
29. nged and lockable door Compressor The compressor is started when the main electrical isolator on the control panel is set to ON The compressor provides compressed air to the slam shut valves Safety Critical Components THERE ARE A NUMBER OF SAFETY CRITICAL COMPONENTS ON THE SYSTEM UNAUTHORISED MAINTENANCE OR ADJUSTMENT OF THESE COMPONENTS MAY AFFECT THE SAFE OPERATION OF THE SYSTEM WHICH COULD RESULT IN DEATH OR INJURY TO PERSONNEL The following components are designated as safety critical Flame arresters prevents transmission of flames from the burner back into gas line UV sensor provides a flare present signal Thermocouples measure the flare temperature at various points in the flare stack Doc No 3092TM Issue 0 0 3 5 2000m h Enclosed Ground Flare and Booster Set System Installation and Commissioning Section 4 Installation and Commissioning INTRODUCTION The Biogas enclosed flare will be installed by Biogas personnel DO NOT ATTEMPT TO INSTALL THE BIOGAS ENCLOSED FLARE AND BOOSTER N SET UNLESS YOU HAVE READ AND FULLY UNDERSTOOD THE SAFETY INFORMATION IN SECTION 2 OF THIS MANUAL SITE PREPARATION Before the enclosed flare and booster set can be installed a reinforced concrete base must be prepared to support the assembly As the requirements vary between sites and systems the specifications of this base will be supplied by Biogas The system will also require a three phase electricity
30. of the wire mesh mist eliminator provide an indication of any blockage in the mesh The gas from the extraction fan discharge is fed via a non return valve and a butterfly valve and is monitored for gas quality before being fed to the main burner gas line and the power generator gas line The main gas burner is fed via a slam shut valve and a flame arrester to the main burner in the flare stack Gas flow to the flare is measured by a flow meter The slam shut valve opens after a successful ignition sequence to allow gas flow to the main burner The flame arrester prevents flame flashback from the main burner into the gas train Pressure gauges either side of the flame arrester provide an indication of any blockage in the flame arrester The flame in the flare stack is monitored by an Ultra Violet UV sensor and three thermocouples The UV sensor provides a flame present signal to the control panel The thermocouples provide flare temperature signals to the control panel The temperature of the flare is maintained by louvres in the base of the flare stack Coarse control is provided by manual louvres that are set up during installation Fine control is provided by a motorised louvre that is controlled by the control panel according to the flare temperature signal from the thermocouples Doc No 3092TM Issue 0 0 3 1 2000m h Enclosed Ground Flare and Booster Set System Description Power Generation Mode Future Provision Power generat
31. ontrol functions The following auto shutdown alarms are displayed on the HMI screen System control Local Off Remote Extraction fan control Hand Off Auto Temperature control loop for louvre automation Temperature controller setpoint Reset switch Alarm acknowledge High stack temperature Ignition cycle fail Extraction fan trip High high liquid level in KOP Gas inlet slam shut valve failure Main burner slam shut valve failure Thermocouple 1 failure Thermocouple 3 failure Flare off and flame detected Operation The following alarms are provided on the HMI screen but do not generate an auto shutdown Thermocouple 2 failure Doc No 3092TM Issue 0 0 2000m h Enclosed Ground Flare and Booster Set System Operation High liquid level in KOP Gas analyser low flow OPERATION Starting 1 Check that there is no maintenance work being carried on the system 2 Inspect the system for signs of damage and that it is safe to operate Any damage must be rectified before start up Ensure the field gas supply is connected Set the system main electrical isolator to ON Check the compressor is running and there is an air supply to the system O O Ensure that the gas quality is within the flare operating range 25 60 vol methane and 5 vol oxygen Local Operation On the HMI screen system control select LOCAL 2 Select START FLARE and observe start sequenc
32. orresponding to that left in step 5 remove and save all the other nuts and bolts 9 Rotate the released pipe section so that the flame arrester elements are accessible 10 Remove the flame arrester elements from the pipeline Doc No 3092TM Issue 0 0 6 4 2000m h Enclosed Ground Flare and Booster Set System 11 12 13 14 15 16 17 Maintenance Remove and check the gaskets from the pipes on both sides of the elements replace any damaged gasket s Carefully refit all gaskets ensuring they are correctly located within the pipe sections Clean the flame arrester element as described in the manufacturer s instructions If this is not detailed use a compressed air line to clean the flame arrester elements by directing air from the cleaner side of the element Carefully refit the flame arrester elements into the pipeline ensuring that they are correctly located Rotate the displaced pipe section back to its operational position and refit all the removed nuts and bolts Tighten all slackened nuts and bolts See Caution above After gas flow is reinstated check for leaks and rectify them if necessary Draining the KOP 1 2 3 4 Turn off both the Flare and Blower by setting the Main Isolator on the control panel to OFF Ensure that the inlet valve is closed and that no gas is flowing through the pipeline If the drain valve is not connected to a drainage system place a suitable container belo
33. ple Instruments 16 Flame Arresters Knitmesh Protego UK B O C 17 KOP Biogas KOP Filter Element Knitmesh Doc No 3092TM Issue 0 0 7 8
34. r or commitment on the part of Biogas Technology Limited unless expressly stated within a contract No part of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the express prior written permission of the copyright holder Part number 3092 Issue 0 0 12 November 2007 Biogas Technology Limited 2007 Biogas Technology Limited 6 Brookside Industrial Estate Sawtry CAMBRIDGESHIRE PE28 5SB United Kingdom Telephone 44 0 1487 831 701 Fax 44 0 1487 830 962 email info biogas co uk The Biogas name and logo amp any others are trademarks of Biogas Technology Limited All other trademarks and registered trademarks within this publication are the property of their respective owners Doc No 3092TM Issue 0 0 ii 2000m h Enclosed Ground Flare and Booster Set System Introduction Section 1 Introduction 1 1 Section 4 Installation and Purpose of This 1 1 Commissioning 4 1 The Biogas Enclosed Flare 1 1 Introduction 4 1 Tanga 1 1 SS PIE BAUT ne ss e Maintenance and Support 1 2 Site installation 4 1 Section 2 Safety 2 1 E ub General Sales 2 1 SSCHOD S
35. re and Booster Set System Maintenance Three Monthly Maintenance Item Procedure Flame arresters Inspect and clean the flame arrester Refer to the maintenance procedures for cleaning instructions Extraction fan Carry out the three monthly servicing detailed in the manufacturer s instructions Compressor Carry out the three monthly servicing detailed in the manufacturer s instructions Gas inlet main burner and pilot burner slam shut valves Inspect the seals for signs of wear or damage as detailed in the manufacturer s instructions Check the air supply and actuator for leaks Check for correct operation in accordance with the manufacturer s instructions Flare stack cables and connectors Check integrity of connections Check cables and connectors for signs of damage Replace any damaged items Ignition electrode Check condition Refer to the maintenance procedures for removal inspection and replacement instructions Thermocouples Check calibration functionality Refer to the maintenance procedures for calibration instructions UV Sensor Check for correct operation and calibration in accordance with the manufacturer s instructions Manual louvres Check for correct operation and free from obstructions and blockages Automatic louvres Check actuator for correct operation Check louvres are free from obstructions and blockages Pipework C
36. s automatically adjusted louvre and emission monitoring ports The louvres provide flame temperature control The manual louvres are set up during installation and the automatic louvre is set by the control panel according to the output from Thermocouple 2 The UV sensor and the thermocouples are safety critical components The UV sensor detects the presence of a flame and thermocouple 3 monitors the flame temperature All thermocouples provide a high temperature shutdown signal Control Panel The power and control components are contained in an air conditioned IP55 cabinet with a hinged and lockable outer door An emergency stop switch is located on the outer door Doc No 3092TM Issue 0 0 3 4 2000m h Enclosed Ground Flare and Booster Set System Description Telemetry Panel The telemetry components are contained in the control panel cabinet The following telemetry data is transmitted Flare temperature Exhaust gas sample temperature Gas flow rate flare Gas temperature flare Gas flow rate power generation Gas temperature power generation Gas flow rate total Gas temperature total CH concentration inlet gas CO concentration inlet gas Osconcentration inlet gas N concentration inlet gas concentration exhaust gas concentration exhaust gas Gas Analyser Cabinet The gas analysis equipment is contained in an air conditioned IP65 cabinet with a hi
37. start is enabled If the gas flare is stopped manually off or emergency stop pressed the gas flare will have to be restarted manually Emergency Stop When any of the emergency stop buttons are pressed the gas inlet and main burner and power generation slam shut valves will close and the extraction fan will be switched off cutting off the gas supply to the main burner and the generator engine Alarms Alarms are provided on the HMI screen on the control panel For full information on the HMI screen refer to the Technical Information File The following alarms also generate an auto shutdown BAHigh low stack temperature Ignition cycle fail Extraction fan trip High high liquid level in Gas inlet slam shut valve failure Main burner slam shut valve failure Thermocouple 1 failure Thermocouple 3 failure Flare off and flame detected The following alarms are provided on the HMI screen but do not generate an auto shutdown Thermocouple 2 failure High liquid level in Gas analyser low flow COMPONENT DESCRIPTION Refer to Figure 7 2 Knock Out Pot The KOP removes liquid from the gas stream Gas from the field is fed to the KOP via a manual butterfly valve a flow conditioning plate and a flow meter The butterfly valve is set during commissioning Vacuum gauges measure the vacuum either side of the wire mesh mist eliminator A significant difference between the readings 15 20 mbar g would indicat
38. supply and pipework for the gas supply The specifications of electricity supply will be advised by Biogas prior to installation If a telemetry system is fitted an appropriate connection from the control panel to a telephone line GPRS satellite or any other communication device will be required Details of all these requirements will be given by Biogas after the initial site survey SITE INSTALLATION Biogas personnel will install and connect the enclosed flare If the system has to be moved or reinstalled please contact Biogas for advice COMMISSIONING The Biogas installation team will perform all final checks and commissioning to ensure that the system is functioning correctly They will also configure the system to perform within specification Any unauthorised adjustment of the system operating the plant prior to D commissioning and handover may invalidate the Biogas warranty NOTE Doc No 3092TM Issue 0 0 4 1 2000m h Enclosed Ground Flare and Booster Set System Section 5 Operation GENERAL ALL OPERATORS MUST HAVE ATTENDED A FULL TRAINING COURSE SUPPLIED BY BIOGAS AND MUST POSSESS A CERTIFICATE TO CONFIRM THIS DO NOT ATTEMPT TO OPERATE THE BIOGAS ENCLOSED FLARE UNLESS YOU HAVE READ AND FULLY UNDERSTOOD THE SAFETY INFORMATION IN SECTION 2 OF THIS MANUAL AND THE EMERGENCY STOP PROCEDURE BELOW O If the system is not properly commissioned operated and maintained the manufacturer s Operation w
39. tion operation and maintenance of the system System Description provides the information required to explain to the user the function of the product Options provides information on options and accessories that are available Installation gives detailed instructions about all operations necessary to install the system and to bring it up to full working condition Commissioning gives detailed initial setting up procedures and any special tools test and calibration equipment required Operation contains instructions for the complete operation of the system under normal emergency and special conditions Maintenance includes routine maintenance tasks tests checks and inspections fault diagnosis and rectification overhaul instructions Technical Data includes all data that the user may need to install operate and maintain the system THE BIOGAS ENCLOSED FLARE The gas extraction fan and flare stack provide a fully integrated system to extract and flare gas at a variable rate The whole system conforms to the Environment Agency Guidance on Landfill Gas Flaring Version 2 1 November 2002 and TGNO5 Guidance for monitoring enclosed landfill gas flares 2004 The whole system also satisfies the following South African Bureau of Standards SABS Wind Speed 40m s as specified in SABS 0160 1989 Seismic Classification Zone 2 as specified in SABS 0160 1989 peak ground acceleration of 0 16g with a 1046 probability of being e
40. top the system in a controlled manner not an emergency on the HMI screen select STOP FLARE The system will run down and the gas inlet and main burner slam shut valves will close 2 Set the system main electrical isolator to OFF 3 Check the compressor has stopped and the extractor fan has stopped rotating Emergency Stop 1 To stop the system in an emergency press one of the EMERGENCY STOP buttons control panel or flare stack Doc No 3092TM Issue 0 0 5 4 2000m h Enclosed Ground Flare and Booster Set System Section 6 Maintenance INTRODUCTION The Biogas enclosed flare is a high performance gas delivery and disposal system that requires controlled maintenance if it is to operate at peak performance All maintenance and servicing must be performed by staff who have been trained and certified as competent by Biogas Maintenance If the system is not properly maintained the manufacturer s warranty may be invalidated or limited This may also affect the performance of the flare ALL MAINTENANCE AND SERVICE STAFF MUST HAVE ATTENDED A FULL TRAINING COURSE SUPPLIED BY BIOGAS AND MUST POSSESS A CERTIFICATE TO CONFIRM THIS DO NOT ATTEMPT TO MAINTAIN THE BIOGAS ENCLOSED FLARE UNLESS YOU HAVE READ AND FULLY UNDERSTOOD THE TY INFORMATION IN SECTION 2 OF THIS MANUAL AND THE EMERGENCY STOP EDURE IN SECTION 5 BEFORE ANY MAINTENANCE IS CARRIED OUT ON ANY PART OF THE SYSTEM IT IS ESSENTIAL THAT THE FLARE AND BLOWER OPERATI
41. w the drain valve to collect the fluid Open and close the KOP drain valves in turn and allow to drain avoiding venting gas Dispose of the fluid in accordance with local instructions Close the drain valves open the inlet valve and set the Main switch to the ON position Cleaning the KOP demister element 1 NOD AN Dn O Ut 10 11 Turn off both the Flare and Blower by setting the Main Isolator on the control panel to OFF Ensure that the inlet valve is closed and that no gas is flowing through the pipeline Undo and remove all the nuts and bolts securing the lid of the KOP Retain the nuts and bolts Remove the lid of the KOP Vent the gas safely eliminating ignition sources from the classified area Check the inside KOP for presence of gas If safe carefully remove the wire mesh demister element from the KOP Clean the demister element as detailed in the manufacturer s instructions Refit the element into the KOP ensuring that it is correctly located and is a close fit within the pot Refit the KOP lid and secure with the nuts and bolts retained during disassembly Refer to Bolt tightening torques table contained in Technical Data After gas flow is reinstated check for leaks and rectify them if necessary Checking the ignition electrode It is necessary to remove the electrode housing complete with the electrode from the flare stack to examine condition of both the housing and electrode
42. xceeded in a 50 year period TRAINING Biogas provides expert training courses for installation operation and maintenance of the enclosed flare and booster set Training can be provided at Biogas offices in the UK or at a customer s premises To discuss your requirements please contact Biogas Biogas Technology Limited 6 Brookside Industrial Estate Sawtry CAMBRIDGESHIRE PE28 5SB United Kingdom Telephone 44 0 1487 831 701 Fax 44 0 1487 830 962 e mail info 9 biogas co uk Doc No 3092TM Issue 0 0 1 1 2000m h Enclosed Ground Flare and Booster Set System MAINTENANCE AND SUPPORT Full maintenance can be provided for the enclosed flare and booster set by Biogas on either a contract or call out basis Having equipment maintained by Biogas ensures maximum reliability and availability and prevents the warranty being invalidated through inadequate maintenance Introduction Please contact Biogas at the above address to discuss your maintenance requirements Doc No 3092TM Issue 0 0 1 2 2000m h Enclosed Ground Flare and Booster Set System Section 2 Safety GENERAL SAFETY This manual is intended to assist the user in the safe and efficient installation operation and maintenance of the Biogas enclosed flare and booster set This equipment must be used in accordance with all safety procedures described in this manual The equipment must not be used for purposes other than those for which it was designed
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