|
|
| Line 1: |
Line 1: |
| | | | |
| − | = General = | + | = 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. | | 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. |
| Line 6: |
Line 6: |
| | <br/> | | <br/> |
| | | | |
| − | '''Consider these basic operation and maintenance principle''':
| + | <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> |
| Line 13: |
Line 13: |
| | <br/> | | <br/> |
| | | | |
| − | <br/>
| + | === Design Interaction === |
| − | | + | |
| − | [[File:OM illustration.JPG|frame|center|180px|Illustration of value of controlled operation and pro-active planned maintenance. Source: Christensen, 2012.]]<br/>
| + | |
| − | | + | |
| − | === Design interaction === | + | |
| | | | |
| | *Suitable and sturdy equipment | | *Suitable and sturdy equipment |
| Line 30: |
Line 26: |
| | <br/> | | <br/> |
| | | | |
| − | === Spare part management === | + | === Spare Part Management === |
| | | | |
| | *Keep strategic spare parts and wear parts on stock! | | *Keep strategic spare parts and wear parts on stock! |
| Line 56: |
Line 52: |
| | <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/> |
| Line 62: |
Line 58: |
| | <br/> | | <br/> |
| | | | |
| − | === In-pipe comminution agitators<br/> === | + | === In-pipe Comminution Agitators<br/> === |
| | | | |
| | [[File:In pipe comminution.JPG|thumb|right|180px|In pipe comminution.JPG]]Freestanding units can be serviced quickly without long outages.<br/>Easily accessible apertures significantly speed up cleaning. | | [[File:In pipe comminution.JPG|thumb|right|180px|In pipe comminution.JPG]]Freestanding units can be serviced quickly without long outages.<br/>Easily accessible apertures significantly speed up cleaning. |
| Line 68: |
Line 64: |
| | <br/> | | <br/> |
| | | | |
| − | {| cellspacing="1" cellpadding="1" align="center" border="1" style="width: 100%;" | + | {| cellspacing="1" cellpadding="1" border="1" align="center" style="width: 100%" |
| | |- | | |- |
| − | | bgcolor="#ccffcc" style="width: 30%;" | Characteristic values | + | | bgcolor="#ccffcc" style="width: 30%" | Characteristic values |
| | | | | | |
| | *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 |
| Line 76: |
Line 72: |
| | | | |
| | |- | | |- |
| − | | bgcolor="#ccffcc" style="width: 30%;" | Suitability | + | | bgcolor="#ccffcc" style="width: 30%" | Suitability |
| | | | | | |
| | *Perforated-plate comminutors suitable for substrates with fibre content | | *Perforated-plate comminutors suitable for substrates with fibre content |
| Line 82: |
Line 78: |
| | | | |
| | |- | | |- |
| − | | 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) |
| | | | |
| | |- | | |- |
| − | | bgcolor="#ccffcc" style="width: 30%;" | Designs | + | | bgcolor="#ccffcc" style="width: 30%" | Designs |
| | | | | | |
| | *Perforated-plate comminutor: rotary blades in front of strainer | | *Perforated-plate comminutor: rotary blades in front of strainer |
| Line 96: |
Line 92: |
| | <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 |
| Line 104: |
Line 98: |
| | <br/> | | <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. |
| | | | |
| − | = 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 118: |
Line 112: |
| | <br/> | | <br/> |
| | | | |
| − | = Infeed of the substrate = | + | = Infeed of the Substrate = |
| | | | |
| | === Pumps === | | === Pumps === |
| Line 142: |
Line 136: |
| | <br/> | | <br/> |
| | | | |
| − | === Infeed screw conveyors === | + | === Infeed Screw Conveyors === |
| | | | |
| − | [[File:Infeed conveyer.JPG|thumb|right|180px|Infeed conveyer.JPG]]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/> |
| | | | |
| − | <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. |
| − | | + | |
| − | [[File:Ram feeder.JPG|thumb|right|180px|Ram feeder.JPG]]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/> |
| Line 158: |
Line 150: |
| | = Digester<br/> = | | = Digester<br/> = |
| | | | |
| − | === Stirred-tank biogas reactors === | + | === Stirred-tank Biogas Reactors === |
| | | | |
| | Manhole facilitates accessibility. | | Manhole facilitates accessibility. |
| | | | |
| − | === Biogas reactor with plug-flow === | + | |
| | + | |
| | + | === 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. | | *At least one manhole is necessary so that the interior of the reactor can be accessed in the event of a breakdown. |
| Line 169: |
Line 163: |
| | <br/> | | <br/> |
| | | | |
| − | === Integrated heating systems === | + | === Integrated Heating Systems === |
| | | | |
| | *Heaters have to be cleaned regularly in order to ensure that heat transfer remains effective | | *Heaters have to be cleaned regularly in order to ensure that heat transfer remains effective |
| Line 177: |
Line 171: |
| | <br/> | | <br/> |
| | | | |
| − | = External heat exchangers = | + | = External Heat Exchangers = |
| | | | |
| | Very good accessibility for maintenance and cleaning | | Very good accessibility for maintenance and cleaning |
| | | | |
| − | = Machinery for mixing in the digester = | + | = Machinery for Mixing in the Digester = |
| | | | |
| − | === Submerged-motor propeller-type agitators === | + | === Submerged-motor Propeller-type Agitators === |
| | | | |
| | *In some cases difficult, because the motor has to be lifted out of the digester | | *In some cases difficult, because the motor has to be lifted out of the digester |
| Line 191: |
Line 185: |
| | <br/> | | <br/> |
| | | | |
| − | === Long-shaft agitators === | + | === Long-shaft Agitators === |
| | | | |
| | *Motor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process | | *Motor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process |
| Line 200: |
Line 194: |
| | <br/> | | <br/> |
| | | | |
| − | === Axial agitators === | + | === Axial Agitators === |
| | | | |
| | *Motor maintenance is straightforward on account of siting outside the digester; no need to interrup in the process | | *Motor maintenance is straightforward on account of siting outside the digester; no need to interrup in the process |
| Line 209: |
Line 203: |
| | <br/> | | <br/> |
| | | | |
| − | === Paddle/paddle-wheel agitators === | + | === Paddle/paddle-wheel Agitators === |
| | | | |
| | *Motor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process | | *Motor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process |
| Line 218: |
Line 212: |
| | <br/> | | <br/> |
| | | | |
| − | === Pneumatic mixing === | + | === Pneumatic Mixing === |
| | | | |
| | *Gas-compressor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process | | *Gas-compressor maintenance is straightforward on account of siting outside the digester; no need to interrupt the process |
| Line 226: |
Line 220: |
| | <br/> | | <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. |
| Line 232: |
Line 226: |
| | <br/> | | <br/> |
| | | | |
| − | = Sediment discharge and removal systems = | + | = Sediment Discharge and Removal Systems = |
| | | | |
| | *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 |
| Line 239: |
Line 233: |
| | <br/> | | <br/> |
| | | | |
| − | = Gas storage tanks = | + | = Gas Storage Tanks = |
| | | | |
| | Maintenance-free to a very large extent. | | Maintenance-free to a very large extent. |
| Line 245: |
Line 239: |
| | <br/> | | <br/> |
| | | | |
| − | = Flare system = | + | = Flare System = |
| | | | |
| | Maintenance-free to a very large extent. | | Maintenance-free to a very large extent. |
| Line 251: |
Line 245: |
| | <br/> | | <br/> |
| | | | |
| − | = Templates for regular maintenance<br/> = | + | = Further Information = |
| | | | |
| − | [[File:Check and control of a biogas plant.JPG|frame|center|180px|Periodic check and control of specific biogas plant parts. Source: Krieg&Fischer]] | + | *[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] |
| − | | + | *[http://www.pro2.de/t/25_146.html Maintenance tips from PRO 2] |
| − | <br/><br/>
| + | *[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)] |
| − | [[File:Maintenance plan.JPG|frame|center|180px|Maintenance plan. Source: Krieg&Fischer]]
| + | *[http://www.expo21xx.com/renewable_energy/19348_st3_renewable_maintenance/default.htm Maintenance service provider MT-Energie] |
| | | | |
| | <br/> | | <br/> |
| − |
| |
| − | <br/>
| |
| − |
| |
| − | [[File:Maintenance plan for motorplants.JPG|frame|center|180px|Maintenance plan for motorplants. Source: Krieg&Fischer]]
| |
| − |
| |
| − |
| |
| − | = <span style="font-size: 22.22222328186035px; line-height: 30.464000701904297px;">Biogas Box</span> =
| |
| − |
| |
| − | [https://www.dropbox.com/sh/q5cxxmhvqpwhhcb/t3Pjq9gywd Collection of literature on Maintenance]
| |
| − |
| |
| − | <br/>
| |
| − |
| |
| − |
| |
| − |
| |
| − | = WEB =
| |
| − |
| |
| − | [http://www.biogaschannel.com/en-us/dettaglio/watch?id=e_r62nefo3&channel=Le%20soluzioni%20per%20la%20gestione%20impianto&title=The%20proper%20maintenance%20of%20a%20cogeneration%20plant%20-%20Alexandru%20Drob Maintenance of a Cogeneration Plant]
| |
| − |
| |
| − | [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://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]
| |
| − |
| |
| − | <br/>
| |
| − |
| |
| | | | |
| | = References = | | = References = |
| Line 293: |
Line 259: |
| | <references /> | | <references /> |
| | | | |
| − | <references />
| + | [[Category:Biogas]] |
| | + | [[Category:Maintenance]] |
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.
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.
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.
