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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 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. | + | |
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| | <br/> | | <br/> |
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| | <u>Consider these basic operation and maintenance principle:</u> | | <u>Consider these basic operation and maintenance principle:</u> |
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| | *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> |
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| | === Design Interaction === | | === Design Interaction === |
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| | *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 |
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| | === 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 |
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| | + | <u>Storage of spare parts:</u> |
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| − | '''Storage of spare parts'''
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| | *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. |
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| | *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 |
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| − | = Comminutors =
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| | + | = 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> |
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| − | === External Comminutors ===
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| | + | === 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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| − | === In-pipe Comminution Agitators<br/> ===
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| | + | === 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. |
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| | {| 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. |
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| | | 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 |
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| | | bgcolor="#ccffcc" style="width: 30%" | Advantages & Disadvantages | | | bgcolor="#ccffcc" style="width: 30%" | Advantages & Disadvantages |
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| | + 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) |
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| | *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 |
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| | === Comminutors Combined with Conveyor Technology in Single Units<br/> === | | === Comminutors Combined with Conveyor Technology in Single Units<br/> === |
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| | 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 |
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| − | = Hygienisation Tanks<br/> =
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| | + | = 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. |
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| | = Pre-digester Pit<br/> = | | = Pre-digester Pit<br/> = |
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| | 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. |
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| | = Infeed of the Substrate = | | = Infeed of the Substrate = |
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| | === Pumps === | | === Pumps === |
| | + | ► [[Pumps_for_Biogas_Plants|Pumps for Biogas Plants]] |
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| | '''Rotary pumps''' | | '''Rotary pumps''' |
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| − | === Infeed Screw Conveyors ===
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| | + | === 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. |
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| − | === Infeed with Ram Feeder ===
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| | + | === 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. |
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| | <br/> | | <br/> |
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| | = Digester<br/> = | | = Digester<br/> = |
| | + | ► [[Material_for_Biogas_Digesters|Material for Biogas Digesters]] |
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| − | === Stirred-tank Biogas Reactors ===
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| | + | === Stirred-tank Biogas Reactors === |
| | Manhole facilitates accessibility. | | Manhole facilitates accessibility. |
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| | *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 |
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| | === Integrated Heating Systems === | | === Integrated Heating Systems === |
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| | *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 |
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| − | = External Heat Exchangers =
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| | + | = External Heat Exchangers = |
| | Very good accessibility for maintenance and cleaning | | Very good accessibility for maintenance and cleaning |
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| | = Machinery for Mixing in the Digester = | | = Machinery for Mixing in the Digester = |
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| | *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 |
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| | === Long-shaft Agitators === | | === Long-shaft Agitators === |
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| | *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 |
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| | === Axial Agitators === | | === Axial Agitators === |
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| | *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 |
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| | === Paddle/paddle-wheel Agitators === | | === Paddle/paddle-wheel Agitators === |
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| | *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 |
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| | === Pneumatic Mixing === | | === Pneumatic Mixing === |
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| | *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 |
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| − | === Hydraulic Mixing ===
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| | + | === 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. |
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| | = Sediment Discharge and Removal Systems = | | = Sediment Discharge and Removal Systems = |
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| | *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 |
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| | <br/> | | <br/> |
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| − | = Gas Storage Tanks =
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| | + | = Gas Storage Tanks = |
| | Maintenance-free to a very large extent. | | Maintenance-free to a very large extent. |
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| | <br/> | | <br/> |
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| − | = Flare System =
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| | + | = Flare System = |
| | Maintenance-free to a very large extent. | | Maintenance-free to a very large extent. |
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| | <br/> | | <br/> |
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| − | = Further Information =
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| − | *[http://www.biogaschannel.com/en-us/dettaglio/watch?id=e_r62nefo3&channel=Le soluzioni per la gestione impianto&title=The proper maintenance of a cogeneration plant - Alexandru Drob Maintenance of a Cogeneration Plant] | + | |
| | + | = 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] |
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| | <br/> | | <br/> |
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| − | = References =
| |
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| | + | = References = |
| | <references /> | | <references /> |
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| | [[Category:Biogas]] | | [[Category:Biogas]] |
| − | [[Category:Maintenance]]
| |
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]
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.
Freestanding units can be serviced quickly without long outages. Easily accessible apertures significantly speed up cleaning.
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
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.
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.
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.
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. Servicing of the ram feeder necessitates what can be considerable downtime, possibly also associated with emptying of the digester.
