“ANKUR” BIOMASS GASIFIER SYSTEM MODEL WBG - 400

For

POWER GENERATION APPLICATION

IN 100% PRODUCER GAS FUELED GAS-250 PLANT

To

M/s. C-BEND, C/o DESERT RESEARCH FOUNDATION OF NAMIBIA (DNRF)

7 ROSSINI STREET, WINDHOEK WEST, NAMIBIA

OWNER’S MANUAL

“Ankur”, Near Navrachana School, Vadodara – 390 008, India 0265 2793098 / 2794021 Fax: 2794042 Grams : Ankur

E-Mail: ascent@ankurscientific.com Web Site: www.ankurscientific.com ISO 9001 / ISO 14001 / OHSAS 18001

Ankur Scientific Energy Technologies Pvt. Ltd.,

FOREWORD

Dear Customer, Thank you very much on your wise purchase of proven Non-Conventional Energy Technology device, “Biomass Gasifier System”. This device comes to you from the technology leaders worldwide in converting traditional biomass fuels into modern energy carriers. The device you have purchased has undergone all demanding tests and quality checks to provide you trouble-free service for years together. However, we request you to go through this manual carefully to be able to make the device always perform at the rated performance level. As the last word, should you really require any service help, please do call us. We would like to assure you beforehand that with our strong team of Technical Personnel & Service Engineers shall be at your service at the earliest.

“Ankur”, Near Navrachana School, Vadodara – 390 008, India

0265 2793098 / 2794021 Fax : 2794042 Grams : Ankur E-Mail : ascent@ankurscientific.com Web Site : www.ankurscientific.com

ISO 9001 / ISO 14001 / OHSAS 18001

Ankur Scientific Energy Technologies Pvt. Ltd.,

3

CONTENTS SR. NO TITLE PAGE

Introduction 6 1.1 What is Biomass Gasification? 6 1.2 Why Biomass Gasification? 6 1.3 Thermal Applications 7

1.0

1.4 Electrical Applications 7 Technical Specifications for GAS-250 Plant 8 2.1 Gasifier System 8 2.2 Power Generating Set 9 2.0

2.3 Important Operating Parameters 11 Gasifier System Description 12 3.1 Brief Description 12 3.2 Feeding System/Feed Shell 12 3.3 Hopper 13 3.4 Reactor 13

3.0

3.5 Gas Cooling And Cleaning System 1. Cyclone 2. Hot Gas Line 3. Promiser 4. Wet Blower 5. Separation Box 6. Water Seal Assembly 7. Heat Exchanger 8. Chiller 9. Mist Eliminator 10. Fine Filter Active 11. Fine Filter Passive 12. Pleated Filter 13. Main Flare with test flare

14

4.0

IMPORTANT OPERATING PARAMETERS

21

4

4.1 Operational and Safety Logic Of Gasifier –Engine Genset

1. Control Equipments and Indication Sensors Indicating Instruments and Data Collection

2. HMI Indications 3. Gasifier Start up Logic 4. Cyclone Ash Collection 5. Dry Ash Collection 6. Biomass Feeding and Skip Charger Logic 7. Filtering System : Filter Line1 and 2 Operation Logic 8. Gasifier - Engine Generator Set Interface 9. Engine Generator Set Safeties Logic 10. Shut-Off Logic Of Emergency Stop and Any Gasifier Shut

Down Condition

21

4.2 Engine Startup and shut down procedure

1 Check list before starting the Engine: 2 Engine starting procedure 3 Check list after starting the Engine 4 Engine shut down procedure

29

Installations and Commissioning 32 5.1 Installations and Commissioning of Gasifier 32 5.2 Installation and Commissioning of Gasifier and Engine

Cooling Tower 34

5.3 Erection and Commissioning of PLC Panel 1. Gasifier PLC Panel 2. Engine Breaker PLC Panel

36

5.4 Installation & Commissioning of WWTS 53 5.5 Connection of all Water Pumps and Pipes for Gasifier

System, Gasifier Cooling Tower, WWTS and Intermediate Settling Tank.

54

5.0

5.6 Engine GENSET Installation and Commissioning Recommendation

55

Operating Procedures 56 6.1 Biomass Feed Cycle 56 6.2 Hopper Unloading Procedure 57 6.3 Start-up Procedure 58 6.4 Running Instructions 59

6.0

6.5 Shut-Down Sequence 60

5

7.0 Specifications of Auxiliaries 62 8.0 Filter Media Preparation 64 9.0 Do’s and Don’ts 65

Maintenance Schedule 66

10.1 Gasifier Maintenance Schedule 66 10.0

10.2 Engine Maintenance Schedule 67

Trouble Shooting 70 11.1 Gasifier Trouble Shooting 70 11.0 11.2 Engine Trouble Shooting 71

12.0 Safety Precautions 77 13.0 Annexure and Enclosures 78

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1.0 INTRODUCTION 1.1 What is Biomass Gasification?

Biomass Gasification is basically conversion of solid biomass (i.e. wood/ wood waste, agricultural residues etc.) into a combustible gas mixture normally called “Producer Gas”. The process can theoretically be used for any biomass and it involves partial combustion of such biomass. Partial combustion process occurs when air supply (or, more precisely, oxygen) is less than adequate for combustion of biomass to be completed. Given that biomass contains carbon, hydrogen and oxygen molecules, complete combustion would produce carbon dioxide (CO2) and water vapor (H2O). Partial combustion produces carbon monoxide (CO) as well as hydrogen (H2), which are both combustible gases. “Ankur’ currently offers three specific series of Gasifiers – “WBG” series for woody biomass, “FBG” series for fine biomass/low density biomass like rice husk etc and “COMBO” series for using both woody as well as fine biomass in separate mode with one day change over time.

1.2 Why Biomass Gasification?

Solid biomass fuels are usually inconvenient, have low efficiency of utilization and can only be used for certain limited applications. Combustion is the normal conversion process and while direct thermal use in cooking, heating space and water or generation of steam is possible (usually with low efficiencies), generation of power, for example, requires high/medium pressure steam boiler along with steam engine or turbine with accessories. For small power needs (a few kilowatts to a few hundred kilowatts), this conversion technology is not only capital intensive and complex, it is also very inefficient. Conversion of the same biomass to a combustible gas mixture like producer gas removes most of these problems with use of solid biomass fuels. While conversion to gas results in loss of energy of 10 to 25%, use of gas can be highly efficient and hence overall efficiency could be very high. Furthermore, the gas can be directly fed into internal combustion engine (IC engines) wherein it could save precious petroleum fuels. Also, it can be employed at any scale (above a few kilowatts) and hence is ideally suited for decentralized applications – whether for shaft power, electricity or thermal energy.

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1.3 Thermal Applications Producer gas being a combustible gas, the most natural application of the same is production of direct thermal energy through burning. The scope of this application being very vast, it involves numerous possibilities in industry as well as in institutional applications like community kitchen etc. Industrial applications by itself cover various kinds of drying, heating, boiler application, CO2 manufacture etc. In most of these applications, switching to Biomass Gasification from existing conventional method leads to substantial gains.

1.4 Electrical Applications

In case of electricity, the gas is basically burnt inside an engine. The engine can be either diesel based (i.e. compression ignition or C.I. engine) or a petrol (gasoline) engine (i.e. spark ignition or S.I. engine). Given that the producer gas-air mixture does not auto-ignite at normal engine pressure and temperatures, running diesel engine 100% on gas is not possible and pilot diesel injection is needed to start combustion. In case of S.I. engines, spark plug initiates combustion and hence such engines can run totally on gas. Wherever diesel engines are used, “diesel replacement” therefore becomes key parameters as economics largely depends on what percent of total normal diesel consumption can be replaced by gas.

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2.0 TECHNICAL SPECIFICATIONS FOR GAS-250 PLANT

2.1 Gasifier System Model “ANKUR” WBG-400 Mode of Operation Cold & Ultra Clean Gas Gasifier Type Downdraft Rated Gas Flow 1000 Nm3/hr Average Gas Calorific Value 1,100 Kcal/Nm3 Gasification Temperature 1050 – 1100 0C Fuel Feeding Automatic: On-line mode, depending on the

signal given by the wood level sensor. Ash Removal Automatic Dry Ash discharge from the gasifier

through water cooled screw conveyor Start-up Through Promiser and Wet Blower Biomass Fuel Type Wood Chips Biomass Fuel Specifications Minimum : 15 x 15 x 10 mm

Maximum: 25 x 25 x 10 mm Permissible fines less than 5%.

Permissible moisture content in biomass 5 to 20% (wet basis) Rated hourly consumption 300 – 350 kg Ash Discharge Up to 7 % Typical Conversion efficiency of gasifier > 75%

Typical gas composition CO - 19 ± 3% H2 -18 ± 2% CO2 - 8 ± 3% CH4 -Up to 3% N2 - 50%

Gas parameters at the inlet into engines Temperature– Ambient Temperature Pressure – 100 mmwc at Full Engine Load

Gas impurities Tars < 15mg/m3 Particulate matters < 10 mg/m3 Moisture content ~ 2 %

Chiller Capacity : 10 TR Water Flow Rate : 5.34 m3/hr Water Inlet Temperature : 12°C Water Outlet Temperature : 7°C

Promiser Process Water Cooling Tower Capacity : 10 TR Water Flow Rate : 5 m3/hr Inlet Water Temperature : 37°C Outlet Water Temperature : 32°C

Promiser Clean Water and Engine Cooling Tower

Capacity : 150 TR Water Flow Rate : 90 m3/hr Inlet Water Temperature : 37°C Outlet Water Temperature : 32°C

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Waste Water Treatment System Treatment Capacity – 2500 L/cycle Settling Tank Capacity – 3000 L Charcoal Filter Capacity – 105 Kg Sand Filter Capacity – 350 kg

2.2 Power Generating Set

Engine UNIT VALUE Sound level at 1m distance dB(A) 105 Length Mm 4500 Height Mm 2500 Weight Mm 7500 Gas connection Mm 150 Exhaust pipe Mm 2 X 125 Engine make and model Cummins GTA 1710G

Generator make and model Stamford HC 4F (380KVA)

RPM 1/Min 1500 Voltage/Frequency V/Hz 400/ 50 Hz Cylinder displacement Volume Ltr. 2.33 No. of cylinders and mode 12 CYLINDER

Total Displacement Ltr. 28 Generating Set Power kW 250 Cal. Value of Wood gas 1000-1100 kcal / Nm³ Max. inlet temperature cooling water 35° Max. outlet temperature cooling water 40° C

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PERFORMANCE DATA % load 100 75 50 Thermal energy input kW 850 685 510 Consumption Wood gas M³ / hour 731 589 439 Thermal energy in cooling water kW 320 276 210 Thermal energy in exhaust gas kW 270 208 167 Thermal efficiency % 69.4 70.7 73.9 Electrical capacity kW 250 187.5 125 Electrical efficiency % 29.4 27.4 24.5 El. Characteristic = el. eff. / th. eff. 0.424 0.388 0.332 Cos phi DESIGN LAYOUT DATA UNIT VALUE Exhaust gas volume flow rate Nm³ / Hr 2150 Exhaust gas mass flow rate moist Kg/ Hr 2580 Exhaust gas mass flow rate dry Kg / Hr. 2400 Exhaust gas temperature at engine °C 430 Exhaust gas release temperature without heat exchanger

°C 400

Exhaust gas release temperature with heat exchanger

°C 115

Combustion air volume Nm³ / Hr 1180 Lubrication oil consumption Kg / Hr. 0.4 Cooling water temperatures ( inlet , outlet ) °C Inlet 60°C–80°C/Outlet 78°C–

90°C Cooling water flow rate M³ / Hr 40 Exhaust Emission values ( NOx < 500 mg, CO < 1000 mg)

Within limits

GAS SPECIFICATIONS UNIT MIN MAX

Carbon Monoxide CO Vol % 15 21 Hydrogen H2 Vol % 15 18 Methane Vol % 1.5 3 Nitrogen Vol % 48 54 Oxygen Vol % 0.0 0.5 Others Vol % 6 8 Tar content Mg / m³ 2 10 Particles content Mg / m³ 2 10 Relative Humidity % 80 90 Pressure at entry to Engine mbar 100 mmwc 600 mmwc Pressure variation % 50 15

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2.3 Important Operating Parameters

Gas Flow Measurement * - Indicative Nozzle Pressure Drop (ΔPN) at

rated flow - Nozzle Pressure Drop (ΔPN) at lowest

permissible rating

: :

35 mm of H2O 25 mm of H2O

Gasifier Pressure Drop * - Indicative Gasifier Pressure Drop (ΔPG) at

rated flow - Permissible ΔPG limits at rated flow

• Maximum

• Minimum

: : :

150 mm of H2O 200 mm of H2O

Outlet Gas temperature 400 - 500°C Promiser Gas Temperature < 45 °C Cold Gas Temperature < 20-25 °C Hopper Temperature 50 - 100 °C Pressure Drop in Filter Line 1 and Line 2 150mmwc Wood Level Sensor 1 & 2 Alarm when Wood level is

Low Lube Oil Pressure 80 psi Engine Coolant Temperature High 95 °C maximum (Engine

Trip)

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3.0 GASIFIER SYSTEM DESCRIPTION: 3.1 Brief Description:

A schematic of the ‘Ankur’ Biomass Gasifier System WBG-400 is given in Drg. AST063-W400P-SD-P000 (Rev. 1) wherein the critical components have been identified. The biomass in the form of wood chips is fed through the skip charger into feed shell having pneumatic double door assembly and is stored in the hopper. Limited and controlled amount of air for partial combustion enters through the Air Nozzles. The throat (or hearth) ensures relatively clean and good quality gas production. The Reactor holds charcoal for reduction of partial combustion products while allowing the ash to escape. The dry ash/discharge that falls out of reactor gets collected in the Slanted table of reactor and from there it is taken out with the help of a screw conveyor. The screw conveyor outlet has a two valve Dry Ash Collection Box which holds the dry ash/discharge for a particular duration of time. The gas passes through the annulus area of the Reactor from upper portion of perforated sheet. The gas outlet is connected with Reactor outlet, bellow, bellow distance piece, cyclone distance piece, cyclone, Promiser, Water Seal Header Assembly, Wet Blower, Separation box with gas control valve, Heat exchanger with Chiller, Mist Eliminator, Parallel set of Active Fine Filters, Passive Fine Filters and Pleated Filters, Dry Blower, Header box with Flare assembly & FCV (Fully closed valve) valves for the engine and Engine to facilitate running of the System in Ultra Clean Gas Mode. System installation is to be carried out as per the drawings & procedures mentioned in the manual or as per the instructions of company’s installation supervisors/ engineers.

3.2 Feeding System/Feed shell:

The feed shell stores biomass in air tight compartment before discharging it into the hopper of the gasifier. The feed shell has two pneumatically operated doors, one on top and other at the bottom. This is to prevent ingress of excess air into the gasifier. An Operating Air pressure of 5–7kg/cm2 is required for the pneumatic cylinders. When biomass is fed into the feed shell, the bottom door is closed and the top door is open. When biomass is fed

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Hopper

into the gasifier, the top door is closed and the bottom door is opened. There’s a vibrator motor fitted on the feed shell which operates only when the bottom feed door is in open condition & assists in discharge of biomass into the hopper.

3.3 Hopper: It performs three functions of gasification viz, drying, pyrolysis & combustion. It has Pneumatic/ manual air nozzles for induction of air into combustion zone. Depending on the system rating and mode, upto two wood level sensors could be provided to give signals for controlling biomass feed as well as safe shut down of the gasifier system. There’s a vibrator motor for uniform flow of biomass. A pressure point is provided for reading of pressure drop across nozzles (∆PN) to determine air flow. For WBG mode operation, a combustion cone is used and this is installed between the hopper and the reactor. The combustion cone is generally supplied with a flange for easy and convenient change / replacement.

3.4 Reactor: It performs the reduction function and thus production of producer gas. In case of WBG system, the reactor is filled with recommended size charcoal. The reactor table with proprietary rotor holds the charcoal bed and the comb rotor helps in maintaining a consistent charcoal bed by removing ash from it. The comb rotor is

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coupled with a gear box and a motor. A pressure point is provided on the reactor, for reading the pressure drop up to the exit of the charcoal/rice char bed (i.e. ∆PG) which determines the charcoal bed condition. A water column manometer / pressure transmitter is connected to measure the gasifier pressure drop, known as ∆PG. The Ash removal system from the reactor is dry discharge. In case of dry ash discharge system, there is a screw conveyor connected at the bottom of the reactor. Water is circulated in the jacket of the screw conveyor. This brings down the temperature of charcoal to almost ambient temperature. There are two pneumatic/manual valves and an ash collection box at the outlet of screw conveyor. While the screw conveyor is in operation, the top valve provided before dry ash collection box is to be kept OPEN and the bottom valve after the dry ash collection box is kept CLOSED. For periodically removing the charcoal online from the gasifier, the top valve is CLOSED first and then only the bottom valve should be OPENED to prevent any air ingress into the system and charcoal can be collected in pit/container placed below. After the charcoal drops down, the bottom valve of dry ash collection box is CLOSED and then the top valve OPENED. Both the valves should never be open at the same time. This charcoal/dry ash can be either collected in a pit and then shifted to an appropriate storage place for disposal or for bag filling/storing at suitable place. (Vibrator Motor shown in reactor bottom is only for FBG systems).

3.5 Gas Cleaning and Cooling System: The hot

gas cleaning and cooling system could consist of Cyclone, Promiser, Wet blower, Heat Exchanger with Chiller, Mist eliminator, Active Fine Filter, Passive Fine Filter, and Safety Filter.

1. Cyclone: The carbon particulates from the hot

gas settle down on passing through the cyclone

1

2

1. Promiser 2. Cyclone

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1. Wet Blower 2. Gas Control Valve 3. Separation Box

and are collected in the ash collection box. There are two pneumatic/manual valves and an ash collection box at the bottom of the cyclone. A temperature sensor to measure hot gas temperature is fitted on the hot gas line from cyclone to promiser.

2. Hot Gas Line: The hot gas line carries the hot producer gas having temp. of 4000 C to 5000C

from the gasifier outlet to the Promiser inlet. 3. Promiser: Promiser is proprietary equipment which is used to clean and cool the gas. As seen

in the above photograph, gas inlet is from the top and out let is from the bottom side of the Promiser. The external jacket water enters from the bottom side and leaves from the top side of the Promiser. There are tubes in the inner shell of the Promiser where water is sprayed over the gas. Also water is circulated in the external jacket of the Promiser. This cools down the temperature of the gas from 400 0C – 500 0C to around 40 0C. From Promiser the producer gas then goes to the wet blower.

4. Wet Blower: The wet blower is a part of systems supplied as per our standard. The blowers

help in suction of controlled amount of air into the gasifier for partial combustion and suction and delivery of producer gas to the point of end use. The wet blower performs gas flow control and additional cleaning of gas through water injection. There’s a ball valve to control water injection to blower. The ball valve is set at a particular position to set the flow of water to 1000 LPH.

5. Separation Box: Producer gas and water get carried forward to the separation box, where water and producer gas get separated. There is a gas control valve between the blower and the separation box. This can be adjusted to set the ∆PN within specified limit.

3

1

2

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1. Heat Exchanger 2. Gas inlet 3. Chilled water Inlet 4. Warm water Outlet

6. Water Seal Assembly: As shown in the photograph beside, the water seal assembly is provided to drain the water from wet blower, separation box, heat exchanger and Mist Eliminator. All this water lines are then connected to water seal tub. Precautions:

• Always check the direction of blower. If the direction is not correct, then the same should be corrected by interchanging any of the 2 phases.

• Never allow water to flow in the wet blower before starting it and until it achieves full speed.

• Keep the blower drain valve open before starting the blower and keep it open until the system is in operation (if provided).

• Water in the blower should be adjusted with a valve provided at the water inlet, such that the wet blower current does not exceed 90% of the rated current. This is very important for effective functioning of the wet blower.

• The flow rate of water in wet blower can also be measured at the drain outlet pipe of the separation box after the wet blower.

7. Heat exchanger: Cold water from chiller is circulated in

the heat exchanger and producer gas passes through the tubes in the heat exchanger. The temperature of the chilled water should be maintained around 10-120C under Indian conditions. The chilled water enters from the bottom of the heat exchanger, circulates across the tubes and comes out from the top of the heat exchanger. The water vapor and traces of light tar condenses and drains out from the drain tub at the bottom of the heat exchanger. Water seal

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1. Water Outlet 2. NRV 3. Make-up water inlet 4. Water Inlet

1. Active Filter 2. Passive Filter 3. Pleated Filter 4. Dry Blower

has been provided. Normal operating pressure is 35 – 40 mmwc, but if this pressure reaches 90 – 95 mmwc, then the pipes are to be cleaned.

8. Chiller: The chiller is of 10 TR capacity having water flow rate: 5.34 m3/hr. The Water Inlet

Temperature is 12°C and Water Outlet Temperature is 7°C. The water inlet is 2” NB and water outlet is 2 “NB. The make-up water line is ½” NB. The chiller is used to circulate chilled water to the external jacket of heat exchanger. The chilled water from chiller outlet is fed to heat exchanger inlet. The water from Heat Exchanger is then returned back to the chiller for cooling. An NRV is provided at the chiller outlet. The chilled water in heat

exchanger is used to condense the vapor content in the producer gas. There is a port given to connect make up water line. This maintains the water level inside the chiller.

9. Mist Eliminator: It assists in removal of mist particles present in the producer gas after the

wet blower or the heat exchanger, but before the Active Fine Filter. The producer gas in the mist eliminator enters from the bottom inlet pipe and comes out from the top outlet pipe after passing through the filter media. The Mist eliminator is filled with wood chips (size: 25 mm x 25 mm x 10 mm thk.) or wood pieces (size: 25 mm dia. X 25 mm long) up to bottom of gas outlet pipe. At the bottom of the mist eliminator there’s a drain outlet for the removal of condensates and the drain pipe is dipped in the drain tub.

10. Active Fine Filter:

• This filter performs the function of cleaning the gas.

• The filter media used here is graded saw-dust.

• Producer gas enters the fine filters

1

4

3

2

2

3

41

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from the inlet at center ``top and after filtering comes out from the outer shell outlet.

• All the filters are provided with pressure points to measure pressure drop across the filter media.

• Close the bottom doors tightly and filter media as supplied by the company is to be filled through the top door up to the media level mark and its top layer should be reasonably leveled horizontally. Shut the top door when the filter media has been filled. This is very important for effective functioning of the filter.

• When ΔP of Active Fine Filter touches approximately 80 mm, rotate the rotor provided

at the bottom of the filter (this action is generally built-in through an automatic timer controlled rotor). However, if the drop does not fall substantially, remove the used filter media and fill fresh filter media again up to the level marked. Generally, after 100-150 hours, the entire filter media should be changed by emptying the filter from the bottom doors.

• Dry the used Filter Media and then sieve it through a 0.5 X 0.5 mm sieve to get rid of the fine carbon particulates. The sieved filter media can again be used in the Fine Filter.

• No other material for filter except the company specified sawdust based material is acceptable. Material, which is not as per company specifications, should never be used.

11. Passive Fine Filter: • These filters perform the function of further cleaning of gas.

• Fine particles from the producer gas get trapped in the filter media (graded saw dust).

• Producer gas enters the fine filters from the inlet at center top and after filtering comes out from the outer shell outlet.

• All the filters are provided with pressure points to measure pressure drop across the filter media.

• Close the bottom doors tightly and filter media as supplied by the company is to be filled through the top door up to the media level mark and its top layer should be reasonably leveled horizontally. Shut the top door when the filter media has been filled. This is very important for effective functioning of the filter.

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1. Gas Inlet 2. Gas Outlet 3. Top Door 4 Pressure Points

• No other material for filter except the company specified sawdust based material is acceptable. Material, which is not as per company specifications, should never be used.

• If filter media is filled as above, initial filter pressure drop, ΔPFF must never be below

30-35 mm at rated condition (as per specified ΔPN or ΔPG)

• Mix the top layer of saw dust daily and observe the pressure drop. When ΔP of the

Passive fine filter reaches up filter 80 mm, change the entire filter media by emptying the filter from the bottom doors. This may happen after 200 hours (or more) of gasifier operation

• Replace the filter media with fresh/rejuvenated media.

• Dry the used Filter Media and then sieve it through a 0.5 X 0.5 mm sieve to get rid of the fine carbon particulates. The sieved filter media can again be used in the Fine Filter.

12. Pleated Filter:

• It performs the function of final cleaning of the producer gas and also acts as a check / safety filter to block the gas flow in case of dirty gas reaching up to this point.

• Pleated filter is provided with pressure tapings to measure the pressure drop across the cartridge filters.

• It has three nos. pleated cartridge filters tightened with 3 wing nuts as

shown in the photo. Proper installation of the cartridge filters totally eliminates any direct gas flow Passages and is extremely critical for proper function of pleated filter.

1

3

2

4

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• Initial pressure drop ΔP for pleated filter with new cartridge filters is likely to be 5 mm

on the manometer (which is connected across both the pressure points on the pleated filter).

• When ΔP reaches 50 mm, cartridge filters should be replaced with new ones and the

used ones should be spray cleaned with diesel/NC thinner and then with air.

• Generally, these filters should be checked after every 500 hours of gasifier operation. When dirty, the used cartridge filters should be cleaned by brushing it with diesel or dipping it in NC thinner and once diesel/Tiner evaporates should be washed in diesel and then with detergent, rinsed, dried and stored for future use.

• Long life of pleated filter mostly depends on proper maintenance of the filtering system before it and also normal operation of gasifier.

• A water tapping is given below the pleated filter. Please remove condensate water daily from it when the gasifier is not running.

• When the pressure drop of any one of the filter line reaches 150 mmwc, manually change over to the other line. To change the filter line, first bring the switch to middle position and then to the other filter line.

13. Main Flare with Test Flare: Main Flare is used at the start up of the Gasifier. When

sufficient quality of producer starts generating, the main flare is by-passed and the gas goes to the engine. The test flare is provided to check whether the producer gas gets ignited or not. Swing valve and Rupture disks are provided as safety devices.

4

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4.0 IMPORTANT OPERATING PARAMETERS 4.1 OPERATIONAL AND SAFETY LOGIC OF GASIFIER – ENGINE GENSET 1. Control Equipments and Indication Sensors , Indicating Instruments and Data Collection:

Sr. No.

Sensor Action Remarks

1. Wood Level Sensor – 1 & 2

Feeding cycle auto start, System shut down with tripping and indication

Through: PLC with Scada

2. Hopper temperature Set 150oC

System shut down with indication & Data Recording

Through PLC with Scada

3. Hot gas temperature. set

500 oC

Indication Through PLC with Scada

4. Cold gas temperature set

50 oC

System shut down with indication

Through PLC with Scada

5. Pressure transducer (Delta

PN)

System shut down Through PLC with Scada 0-250 mmwc

6. Pressure transducer (Delta

PG)

Controlling & system shut down Through PLC with Scada 0-500 mmwc

7. Pressure transducer (Filter

Line-1)

Controlling & system shut down Through PLC with Scada 0-250 mmwc

8. Pressure transducer (Filter

Line -2)

Controlling & system shut down Through PLC with Scada 0-250 mmwc

9. Low Lube oil pressure

System shut down with indication.

Through PLC with Scada

10. Engine water temp. High

System shut down with indication.

Through PLC with Scada

11. Engine Over Speed

System shut down with indication.

Through PLC with Scada

12. Chilled Gas Temp. High

Set Point 25 oC

System shut down with indication.

Through PLC with Scada

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2. HMI INDICATIONS:

Sr. No.

Parameter Action Remarks

1 Engine KW Indication in HMI & Breaker Panel Meter

Through PLC with Scada

2 Engine KWh Unit counting Indication in HMI & Breaker Panel Meter

Through PLC with Scada

3 (a)

Hour meter for Gasifier

Hour counting Indication in HMI Through PLC with Scada

3 (b)

Hour meter for Engine

Hour counting Indication in HMI Through PLC with Scada

4 Grid Voltage Indication in Breaker Panel 5 Generator

Voltage Indication in Breaker Panel Meter

6 Generator Current

Indication in Breaker Panel Meter

7 Power Factor Indication in Breaker Panel Meter

8 Frequency Indication in Breaker Panel Meter

3. GASIFIER START UP LOGIC:

Manual Mode:

• In manual mode, all electrically operated devices can be switched “ON/OFF” with the help of start/ stop push button switches provided individually.

Auto Mode:

• Put Auto / Manual selector switch in Auto. • Press “Auto Start” Pushbutton. • Air nozzle will open. After set delay time Promiser pump will start and after set delay time

Promiser cooling water pump will start. . • After set time Wet Blower will start after change over to delta Vibrator motor, Gasifier

Cooling Pump & Fan, Screw Conveyor Motor, Fine Filter Motor, Vibratory Sieve motor, Dry Blower and one of the last selected lines is also opened simultaneously and vent flare will close .

• Comb Rotor will start by three position selector switch. Position 1: Signal from pressure transducer (Delta PG) to PLC will rotate the Comb Rotor Motor ON/OFF for specified time periods as required based on the PG values. Position 0: (Manual mode) by pressing start push button. Position 2: Timer mode

4. CYCLONE ASH COLLECTION:

Cyclone Ash Collection will start by two position selector switch. Position 1: Auto mode

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Position 2: Manual mode

Manual Mode: Top door & Bottom door should operate individually through their respective Push Buttons in Manual mode for maintenance purpose.

Auto Mode:

• Initially both doors should be closed. • For set OFF time of timer top door is open and bottom door is closed. • For set ON time of timer bottom door is open and top door is closed. • When either of the doors is closed, the other door will open after set delay time of 5 sec. • Door close feedback is given through close position reed switch of both the doors.

5. DRY ASH COLLECTION:

Position 1: Auto mode Position 2: Manual mode

Manual Mode: Top door & Bottom door should operate individually through their respective Push Buttons in Manual mode for maintenance purpose.

Auto Mode:

• Initially both doors should be closed. • For set OFF time of timer top door is open and bottom door is closed. • For set ON time of timer bottom door is open and top door is closed. • When either of the doors is closed, the other door will open after set delay time of 5 sec. • Door close feedback is given through close position reed switch of both the doors.

6. BIOMASS FEEDING AND SKIP CHARGER LOGIC: Skip Charger will start by two position selector switch. Position 1: Auto mode Position 2: Manual mode Manual Mode: Skip Charger up/down, Feed door top/bottom will open & close, Feed shell vibrator start/stop by push button.

Auto Mode: Single Cycle Logic: Single cycle can be run by pressing a push button when gasifier is operating in auto mode. In this situation following sequence will run. - Initially, Feed Shell Top and bottom doors are closed, feed shell vibrator OFF and trolley should be down.

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- When push button is pressed, skip charger trolley starts moving upwards and a timer starts. After delayed time, feed Shell top door is opened and biomass is delivered in Feed Shell. - After this there is a set delay for the trolley and top feed door. After delay is over, the trolley starts moving down and top door closes, bottom door is opened and feed shell vibrator will start for set time. After set time, bottom door is closed and feed shell vibrator also stops. - After skip charger trolley reaches down, single cycle stops.

Continuous Auto Cycle Logic:

• This cycle will have same sequence as mentioned in single cycle but this cycle will be triggered by Wood level sensor-1 or Wood level sensor-2 instead of push button.

• When wood level sensor-1 or wood level sensor-2 gives signal continuously for 60

seconds, feeding cycle will be triggered. Touch Panel Messages: Following messages will be displayed for this section of logic. 1. Feed cycle not initiated 2. Feed shell vibrator motor tripped. 3. Wood Level sensor 2 activated. 4. “Skip Charger Motor Tripped”. 5. Top Feed Door not open fully 6. Top Feed Door not closed fully 7. Bottom Feed Door not open fully 8. Bottom Feed Door not closed fully

7. FILTERING SYSTEM: Filter Line1 and 2 Operation Logic. Filter System will start by two position selector switch. Position 1: Auto mode Position 2: Manual mode A. Manual Mode:

Line selector switch will be remaining active in manual mode only. • In Manual Mode, by putting the filter line selector switch in Line-1 position, Line-1 will get

open & a lamp indication for Line-1 will be ‘ON’. • Similarly, by putting the filter line selector switch in Line-2 position, Line-2 will open & lamp

indication for Line-2 will be ‘ON’. • When filter line selector switch is put in center (zero) position both Line-1 & Line-2 are

open and both the lamps for Line-1 & Line-2 will be ‘ON’. • Also, in Manual Mode Fine Filter-1 & 2 motor can be switched ON/OFF with help of

start/stop Push button.

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NOTE: When switch is in ‘Auto Mode’ Line Selector Switch is INACTIVE.

B. Auto mode: During Auto mode operation of Filter following logic should be performed.

• During Auto start of Gasifier, last selected line will be open for operation. • Now, the cyclic timer for fine filter in last open line will start in ‘ON & OFF’. • When pressure in open line reaches to Alarm set value (120mmwc for 60 sec) it will

generate a alarm message and in case of set high pressure (150mmwc for 60 sec) also alarm and message will appear and line change over will occur and other line will open and after a suitable set time (2 min.), Previous line will close and Vice-Versa.

• Now if differential pressure across any line goes beyond set limit within an hour of line changeover then Gasifier shut down will occur in sequential mode.

Touch Panel Messages: Following messages will be displayed for this section of logic. - “Differential pressure across Line 1 High.” - “Differential pressure across Line 2 High” - “Both Lines are choked”.

8. GASIFIER- Engine Generator Set Interface:

• Start the engine oil pump manually before the start of engine and keep it ON for 60

sec (max). There are two locations of push button for Engine Oil Pump; 1. Gasifier Control Panel 2. Mounted on Engine.

• After the Gasifier has been ignited, press synchronizing ON push button provided on the gasifier panel. After pressing the button engine coolant pump, engine cooling Pump & Fan will start simultaneously and engine start contact will be ON.

• After the Engine shuts down, the engine cooling tower pump, Engine cooling tower fan and Engine coolant pump will stop after set delay time.

• With engine start and when we put engine in run mode, Main flare valve will close. Main flare valve will open and gas valve will close with the shut down of engine.

9. ENGINE GENERATOR SET SAFETIES LOGIC:

• The following engine safeties, such as, over speed, low lube oil pressure & water

temperature high are provided on the engine. • If engine safety fails then engine shut down occurs and flare valve will open and gas valve

will close. 10. SHUT-OFF LOGIC OF EMERGENCY STOP AND ANY GASIFIER SHUT DOWN

CONDITION: • If in any case gasifier safety fails gas valve will close and simultaneously all pumps, motors

and blower will stop.

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• Promiser pump, Promiser cooling pump and Air nozzle will remain ‘ON’ for preset delay time after the system will stop/shut-down.

ALL THE SHUTDOWN SAFETY COMES INTO PICTURE WHEN GASIFIER IS RUNNING IN AUTO AND BLOWER MAIN CONTACTOR IS ON SR-1 Gasifier Auto to Manual Shutdown When Gasifier changed from auto to manual, immediate Shutdown occurs. SR-2 Air Pressure Low Shutdown If air pressure is greater than the specified limit, immediate Shutdown occurs. SR-3 Promiser Process Water spray Pump MPCB trip or OFF Shutdown If Promiser Pump MPCB trip or OFF, Shutdown occurs. SR-4 Delta PN Low Shutdown If PN is below the set value for 5 min. Shutdown occurs. SR-5 Delta PN High Shutdown If PN is greater than the set value for 5 min. Shutdown occurs. SR-6 Delta PG Low Shutdown If PG is below the set value for 5 min. Shutdown occurs. SR-7 Delta PG High Shutdown If Delta PG is high for 10 sec., Shutdown occurs. SR-8 Hopper Temperature too high Shutdown When hopper temperature is more than 150°C for 30 sec., Shutdown occurs. SR-9 Wood Level Sensor 1 Triggered for long Shutdown When WLS-1 active for 30 min., Shutdown occurs. SR-10 Wood Level Sensor 2 Shutdown When wood level sensor 2 remains on for 10 min., Shutdown occurs. SR-11 Trolley remain at bottom for long Shutdown If Skip Charger sits at bottom for 30 min., Shutdown occurs. SR-12 Skip Charger MPCB OFF or Trip Shutdown If Skip charger MPCB OFF or trip for 30 min., Shutdown occurs. SR-13 Vibrator trip or MPCB OFF Shutdown When Vibrator trips or MPCB OFF, Shutdown occurs after 1 hour. SR-14 Feed Shell Top Door remained closed for very long time Shutdown When Blower is ON and feed door top doesn’t open for 30 min., Shutdown occurs.

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SR-15 Comb Rotor trip or MPCB OFF Shutdown When Comb Rotor trips or MPCB OFF, Shutdown occurs after 1 hour. SR-16 Cold Gas Temperature High Shutdown If cold gas temperature is greater than 50o C, Shutdown occurs. SR-17 MPCB Blower OFF Shutdown When blower MPCB is turned OFF, immediate Shutdown occurs. SR-18 MPCB Blower Trip Shutdown When Blower MPCB is Tripped, immediate Shutdown occurs. SR-19 Fine Filter Pressure Low Shutdown If one of the FF is below the set value for 5 min. Shutdown occurs. SR-20 FF Pressure High Shutdown If pressure in both the lines is greater than the set value for 5 min. within an hour of line changeover, Shutdown occurs. SR-21 Engine OFF Shutdown Once engine is OFF, Shutdown in 2 min. SR-22 Low Lube Oil Pressure Shutdown If engine is ON and lube oil pressure is low (digital input), Engine will Shut Down. SR-23 Engine Over speed Shutdown If engine RPM is more than 1800, Shutdown occurs. SR-24 Engine Water Temperature High Shutdown If engine is ON and water temperature is high (digital input), Engine will shutdown. SR-25 Chilled Gas Temperature High Shutdown If chilled gas temperature is greater than 25oC for one hour then shut down occurs. Annunciations / Audio visual alarms are provided for the following faults.

1. Promiser Process water spray Pump Faulty 2. Promiser Clean Water pump Faulty 3. Wet Blower Faulty 4. Hopper Vibrator Motor Faulty 5. Gasifier Cooling Tower Pump Faulty 6. Comb rotor Motor Faulty 7. Screw Conveyor Faulty 8. Feed shell Vibrator Motor Faulty

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9. Skip Charger Motor Faulty 10. Fine Filter Line-1 Faulty 11. Fine Filter Line-2 Faulty 12. Dry Air Blower Motor 13. Hot Air Blower Motor 14. Vibratory Sieve Motor 15. Cold Gas Temp. High 16. Outlet Gas Temp. High 17. Empty Wood 18. Danger Wood 19. Engine Cooling Tower Pump Faulty 20. Engine Coolant Pump Faulty 21. Engine Cooling Tower Fan 22. Engine Oil Pump Faulty 23. Chilled gas temperature high 24. Gasifier Cooling Tower Fan Faulty 25. Engine Cooling Tower Fan Faulty

FEED CYCLE FAULTS FCF-1 Feed Shell Top Door Not Open When feed cycle is running in auto and when feed cycle top limit switch is pressed, at that time if top door open limit switch is not pressed this message will come. FCF-2 Feed Shell Bottom Door Not Open When feed cycle is running in auto and feed top door open limit switch is pressed, one timer starts and with in set time if bottom door open limit switch is not pressed, this message will come. FCF-3 Skip Charger Top Limit Switch Faulty When feed cycle is running in auto and when skip charger starts moving forward, one timer is started ( ). if within this time top limit switch is not pressed, this message will come. FCF-4 Skip Charger Bottom Limit Switch Faulty When feed cycle is running in auto and when skip charger starts moving downwards, one timer is started. if within this time bottom limit switch is not pressed, this message will come.

1. Feed cycle can be started in three ways. a. Manually b. By pressing single feed cycle button in auto mode c. By receiving signal from wood level sensor.

Changes: Now “c” will happen only if blower is ON.

2. For “b” and “c” Feed cycle will not start if both top and bottom feed doors are not closed.

3. For “b” and “c” Feed cycle will not start if skip charger bottom limit switch not close and top limit switch not open.

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4. When skip charger top limit switch is pressed, feed top door open limit switch must have been already pressed. If that has not happened, skip charger will come back to bottom and further feed cycle in auto mode will not happen. The fault will be reset by:

a. Feed top door open limit switch is pressed

5. If feed shell bottom door open limit switch is not pressed with in a set time (40 seconds) from top door opens, skip charger will come back to bottom and further feed cycle in auto mode will not happen. The fault will be reset by:

a. Feed bottom door open limit switch is pressed

6. Once skip charger starts moving upwards, a timer starts and if within set time (69 seconds), top limit switch is not pressed, skip charger will stop and wait time will start. After the wait time skip charger will come back to bottom and further feed cycle in auto mode will not happen. The fault can be reset by:

a. After repair if top limit switch is pressed

Here important point is that, normally (i.e. for e.g. the skip charger reaches at top in 62 Seconds). Which means from 62 second to 6 second, motor will keep trying to move on when top limit switch is not working. However it will not be able to move on as there is a dead end. After 67 seconds, motor will be switched off and wait time will be started. This wait time is normally kept at 10 seconds. After the wait time, skip charger will come back to bottom and further feed cycle in auto mode will not happen.

7. Once skip charger starts moving downwards, a timer starts and if within set time (69

seconds), bottom limit switch is not pressed, skip charger will stop and further feed cycle in auto mode will not happen. The fault can be reset by:

a. After repair if bottom limit switch is pressed

4.2 GAS ENGINE START UP and SHUT DOWN PROCEDURE

1. Check list before starting the Engine:

a. Check the Engine electrical connections, water line, battery connections, earthing,

pneumatic air line (Pressure 5 – 7 kg-cm2), etc. b. Check the oil and water level in the engine. c. Check the quality of the gas at the test flare, it should be invisible, otherwise, if the gas is

visible then check the gas filtering system. Before feeding the gas to the engine ensure that the test flare is extinguished by first closing the test flare manual valve fully and then again opening it to ensure that it has extinguished and should remain closed. Now, the engine can be started.

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d. Press the “Request Synchronizing ON” push button on Gasifier Control Panel and automatically engine cooling tower pump, Engine cooling tower fan, engine coolant pump and contact to engine will be ON.

e. Check that the idle/run switch on the engine control panel is in “Idle” position and check that the engine gas valve opens by switching on the starter key and pressing the by-pass button.

f. Engine Breaker panel has a Woodward synchronizing relay card on top of it. Press START push button on that relay. This will give 60 sec delay. If after this delay the Engine does not start then again press the START button on the Woodward synchronizing relay card.

2. Engine starting procedure:

a. Switch ON the Engine Oil pump using START push button provided on the Engine and

Gasifier Panel. Run it for 1-2 minutes. Stop the Engine Oil Pump. b. There is a push button on the Engine Header box. Using this push button, OPEN the Gas

Control Valve to 25-30 degree. c. Place the engine ignition switch to ‘ON’ position and press the engine safety by-pass

button(and keep it pressed, until engine RPM reaches approx. 400), turn the engine starter key (at this moment the engine gas valve (FCV) will open) and slightly open the manual gas valve on the engine. The engine will start and now open the manual valve fully. If it doesn’t start due to cold condition, then try to start it again for 2 – 3 times.

d. Allow the engine to run at about 1000 rpm for at least 1-2 minutes. Now, put the idle/run switch in “run” position, so that the flare valve gets closed and the gas is diverted to the engine and 1400-1500 RPM is achieved.

e. Wait for 1-2 minutes. The Woodward Synchronizing Relay card will automatically adjust the voltage and frequency and then the breaker will be switched ON.

f. The load will automatically increase to 240-250 kW and maintain it. NOTE: Please check that grid line is always ON before the Engine is STARTED.

3. Check list after starting the Engine:

a. Gas temp. after the after-cooler should remain below 55 0C, then increase the cooling

water flow or check the cooling tower, pump and spray nozzles. b. The engine jacket water temp. should remain below 93 0C. At 95 0C and above, the

engine will trip automatically. When the temp. reaches 930C, then check the raw water pump flow rate and pressure. Check whether engine room is properly ventilated.

c. The engine exhaust temp. should be 450 to 520 0C. If, the exhaust temp. is not within specified limit, then check the engine cooling circuit, input gas temp. and spark ignition. Otherwise call an engine technician.

d. The engine oil pressure and temp. should remain in the Green area on the Oil pressure and oil temp. meters.

e. On load, if any abnormal sound is heard from the engine exhaust, then the following points should be taken care of: a. Incase of excess gas, slightly reduce the gas control valve on the blower delivery. b. Check the ignition timing. (24-25 0 before TDC).

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c. Check the spark plug, HT cable and ignition coil. d. Get the Valve tappet, compression checked by a authorized engine technician.

f. If the rupture plate flap is damaged due to any reason, then stop the engine and change it. g. A provision of 0-900 mmwc manometer is made after the engine gas manual valve, where

the minimum positive pressure should be 50 mmwc at full load (A slightly higher value of 100 mm will give more stable operation). In case, it goes below this limit, then check the pressure drops of the gasifier and filters and if they are within the specified limits then increase the gas by opening the gas control valve at the blower delivery. If the pressure drops of the gasifier increases (refer gasifier troubleshooting section) or if filter drop increases, then action should be taken as per instructions in the gasifier manual.

4. Engine shut down procedure:

a. There is an Engine Shutdown key provided in the touch screen of Gasifier Panel. Press

this key to shutdown the Engine. b. After pressing this key, the load will automatically reach to 0 kW in set delay time. c. Press Breaker OPEN push button on the breaker panel and synchronization will get

disconnected. d. On Engine Starter panel put the “idle/run” switch in “Idle” position and flare valve will be

opened. e. Wait for 2 -3 minutes before shutting off the manual engine gas valve and after that switch

off the engine starter key as well as the ignition switch. f. Slightly reduce the gas control valve at the blower. g. As soon as engine shuts down, all the engine pumps and engine fan switches off after set

delay time. h. As soon as the engine goes into “IDLE” mode, the gasifier goes in the sequential shut

down mode after set delay time. (Note: For further information, refer engine manual as well as gasifier manual)

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5.0 INSTALLATIONS AND COMISSIONING 5.1 INSTALLATIONS AND COMISSIONING OF GASIFIER

• Ensure that firm Concrete foundation for Gasifier is made as per Drawing AST063-

W400P-GF-P 003 (Rev. 0).

• Mount the Reactor on the foundations and ensure that the foundation bolts are adequately tightened.

• Install the Gasifier Control Panel and connect it with power supply and check power supply indication as well as functioning of the main MCB.

• Connect the Rotor motor with the Control Panel. Check direction of rotation of the motor and also check whether it is smoothly running without any abnormal noise, vibrations etc. for one full rotation of Scrapper Arm.

• Fill recommended quality charcoal pieces (charcoal size 30 - 35 mm) into the

reactor up to the height marked by an arrow ⇔ on Reactor Inner Wall and level it

properly. Run the Comb rotor manually and check the movement of the Comb rotor and current drawn. (The amperage should not exceed the full load current capacity of Comb rotor). Note: This procedure is to be followed only for first commissioning and

subsequent re-commissioning of gasifier when the charcoal bed is freshly created.

• Apply rubber adhesive in the groove of the Reactor flange and place asbestos rope (25 mm dia.) in the groove and go on tapping it by wooden mallet, moving around the groove. The joint where two ends of the rope meet should be carefully done by forming overlapping edges in order to avoid leakage.

• Place combustion cone on the reactor flange such that groove on the bottom of the combustion cone flange properly sits on the asbestos rope. Repeat the procedure for laying asbestos rope (25 mm dia.) on the combustion cone as on the reactor.

• Before placing the hopper on the reactor, ensure that both U bolts and all 4 mounting bolts of vibrator motor are fully tightened. Place the side covers on Vibrator motor cover and tighten the bolts.

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• Before placing the hopper on the combustion cone, fill charcoal up to a height of about 250 mm above the cone throat.

• Now, place the hopper carefully on the combustion cone without damaging the asbestos rope, such that the vibrator is at 90 deg. w.r.t. both the hot gas outlets. After the hopper is properly located, fasten the flanges with bolts, spring & plain washers & tighten all bolts uniformly. Then place the platform & railings over the hopper, match the holes of platform w.r.t. Hopper & tighten the bolts.

• Place the Pneumatic Air Nozzles as per the nos. marked on them and nozzle fixture flanges on the hopper with champion gaskets in between. Now tighten all the nut-bolts of the air nozzles.

• Now, fit the feed doors and the feed shell by laying asbestos rope (19 mm dia.) and place carefully on the hopper such that groove on its flange properly sits on the sealing rope (19 mm dia.) on the hopper flange. Ensure that the Feed Door sliding rods should be opposite to the skip charger/conveyor, without damaging asbestos rope on the hopper flange groove. After the feed shell with double door is properly located, fasten the flanges with nut-bolts, spring & plain washers & tighten all bolts uniformly.

• Now, open the doors of the feed shell and fill dry and prepared biomass of recommended size having less than 20% moisture into the hopper on top of the charcoal layer, up to the top of the hopper such that the top Feed Door can be conveniently closed. Ensure that the biomass should be free from foreign materials such as metal parts, stones, big wooden pieces, grass, sand etc.

• Close the Feed Door.

• Connect the downstream sub-systems viz. Reactor outlet box, bellow, bellow distance piece, junction box, cyclone distance piece, cyclone, Promiser, Drain Box, Wet Blower, Separation box with gas control valve, Heat exchanger, Mist Eliminator, Parallel set of Active & Passive Fine Filters and Pleated Filters, header box with Flare assembly & FCV (Fully closed valve) valves for the Engine. Tighten the hardware to secure various sub-systems. (Refer drg. AST063-W400P-PL-P 001 and AST063-W400P-SD-P 000).

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• Connect Chiller outlet to Heat Exchanger Inlet. The Heat Exchanger outlet is again taken to Chiller Inlet.

• Connect the Screw conveyor with the reactor ash discharge port, Tub for cyclone ash collection box and all water seal assembly. The outlet of the water seal tub goes to the cooling pond.

• Connect manometers at various pressure probes provided at Air nozzle pressure point (i.e. on the hopper), Reactor pressure point, Mist Eliminator pressure point, Active & Passive fine filters pressure point & Pleated filter pressure point.

• Check grease in the bearing block of the blowers. Make up this level, if required.

• Connect Comb rotor motor, Vibrator motor, Active Fine Filter motors, Wet Blower motor, Feed shell vibrator motor, Wood level sensors, double door feed shell limit switches, Screw conveyor cooling pump, Promiser pump and Cooling tower pump with the Gasifier Control Panel.

• Check direction of rotation of Vibrator, Wet blower, Feed shell vibrator motor, Active fine filter motors, all the pumps and also check for any abnormalities in running i.e. abnormal noise, motor drawing excessive current etc.

• The Comb- Rotor timing: 15 Sec "ON", 90 Sec "OFF" (may change depending on biomass)

• Vibrator weight Positions: 465 Grams on both sides at minimum position.

5.2 INSTALLATION AND COMMISSIONING OF GASIFIER AND ENGINE COOLING TOWER

1. Check the inner dimension of the basin. It should match with the dimensions specified by Ankur Scientific.

2. Place the base channel. Fix all four arms with nuts and bolts. 3. Grout/anchor the base channel on basin walls. 4. Fix vertical angles in pockets. 5. Fix top frame. 6. Fix vertical Tee members. 7. Fix middle angle and support members. 8. Fix headers. 9. Connections with common return hot water header/s.

9.1 The common header is basically part of return water pipe line. 9.2 It should not be pre-fabricated 9.3 It should be properly supported externally by proper STEEL/RCC masonary structure.

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9.4 Individual connections from common header to spray headers are to be carried out only after spray headers are fixed.

9.5 Spray header and Return header connections must be Tension/Pressure Free and any push-pull forces due to uneven nozzles/pipes are to be avoided.

10. Fix the Louvers. TROUBLE SHOOTING Problem Correcting Measures No Proper cooling

Check the WBT. If cold water temperature is WBT +4 °C, problem is seasonal, will get corrected automatically.

Range is same but cold water temperature is high. (more than required)

Check the water spray pattern of nozzles. If jet umbrella is small or weak, flow might be less than required. Execute following

a. Clean foot valve, bends etc. b. See for air pressure pocket zone in piping due to improper positioning

of valves in pipeline. c. Clean Nozzles. This can be done in running conditions also. d. If needed, check water flow.

Drift is more

a. Inspect the direction of nozzles. If tilted, please correct(vertically down) b. Check the louvers. If louvers are loose or removed please fix them c. Check water level in basin. If found very high or very low with respect

to cooling tower bottom channel frame, bring it back to normal. d. Check water flow rate. Reduce if found more than the rated one.

Kindly refer the detailed Cooling Tower manual for more information (ANNEXURE)

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5.3 Erection and Commissioning Of PLC Panels 1. Gasifier PLC panel

During Erection and Commissioning of Gasifier PLC panel following care must be taken care of:

• Panel should be locked while placing the panel on the platform.

• Nuts must be tightly screwed to the bolts of the platform.

• The height of the panel stand is 300mm as per our standards.

• Panel must be placed in the covered area or separate cabin should be provided.

• In case the panel is located in covered area it should not be placed near heat emitting systems or devices.

• Before connecting supply to the PLC panel, check the output voltage of all the three phases from the distribution panel.

• Switch off all the MCB’s and MPCB’s and

check the connections of the control devices and push buttons it should not be lose, before connecting the input supply to the panel.

• The connections of the field devices to the terminal block of the panel must be tight and

correct.

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• Proper shielding must be provided in case any cable carrying digital signals is passed through the cable trench.

• No open cable connections should be there in the cable trench.

Panel Startup Procedure • Switch On the panel supply and check the input

voltages (it should be 3 phase 415V, 50Hz) at the MCBs and MPCBs.

• Switch On the MCBs and MPCBs and check ON, OFF and Trip functionality of each.

• Switch On the Control supply MCB and put the PLC in run mode check all the screens in HMI.

• Check the status of the inputs to the PLC by switching On the MPCBs and tripping them, the corresponding actions must be reflected on the HMI screens for startup requirements and alarms and hooter should be ON accordingly and on pressing the reset button hooter should go off.

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PLC

HMI Unit

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Gasifier Manual Startup and Shutdown Procedure • Put the Gasifier, comb rotor, skip charger and fine filter Auto / Manual selector switch in

manual mode. • Press all the ON / OFF push buttons sequentially as per the start up control logic

document to check the proper functioning of the push buttons and to verify the PLC program for operational logic.

• Now set the time of all the timers required for the gasifier manual operations. • Generate shut down conditions to test the safety features of the system and watch out for

hooter, alarm messages and shut down timers in the HMI unit for their proper operation. Gasifier Auto Startup and Shutdown Procedure

• Put the Gasifier, comb rotor, skip charger and fine filter Auto / Manual selector switch in auto mode.

• Set all the timers required for the auto operation of the gasifier. • Press the start push button. • Watch out for all the timers and process parameters in the HMI unit for auto start up of the

gasifier. • Generate shut down conditions to test the safety features of the system and watch out for

hooter, alarm messages and shut down timers in the HMI unit for their proper operation

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2. Engine Breaker PLC panel During Erection and Commissioning of Engine Breaker PLC Panel, following care must be taken care of:

Air Circuit Breaker

Voltage, Ampere and Frequency Meter

KWH, KW and PF Meter

Generator Phase Sequence Indicator

Grid Phase Sequence Indicator

Synchronizing Relay

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Charging Lever Mechanical ON

Ready to close Indicator

Stored Energy Spring Mechanism Charge Indicator

Switching Position Indicator

Mechanical

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easYgen-3000 OPERATION The generator protection and synchronizing unit has the following duties and Operation modes: • Auto, Manual, Test (load & no load) • Breaker configuration: GCB, MCB, no breaker • Load sharing with CAN bus • Breaker control: Synchronization, open-close control, only-open control, breaker monitoring. • Load transfer features: Open/closed transition, interchange, soft loading/soft unloading, mains parallel • Process-dependent start-stop logic by freely configurable inputs: Water temperature, fuel reserve, reserve power, timers, and others • Complete engine & generator protection • Mains monitoring features • Multi-lingual capability: 6 languages easYgen-3000 Synchronizing Relay

Synchronizing Procedure After gasifier start up press Engine cooling tower pump, engine coolant pump and engine cooling tower fan start push button and start the engine oil pump till required oil pressure is indicated after that press synchronizing request push button and put the ON/OFF selector switch on breaker panel in ON position and then press the start key on the synchronizing relay after that start the engine manually by opening the gas control valve to about 20o

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and as we put the engine in run mode 1500 rpm should be indicated if 1500rpm is not reached then press the open gas valve push button to increase the gas flow to engine till 1500 rpm is attained.

Once 1500 rpm is indicated then synchronizing relay will compare the voltage and frequency and generate the output accordingly to the Motorized POT

The output of the Motorized POT is fed to the Woodward governor card which in turn will control the voltage and frequency of the genset.

Gas valve

RPM and Hour indicator

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Installation

Connecting the main and protective conductor

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Connecting the auxiliary conductors

Attaching the racking handle

Note : The racking handle can also be attached on the right-hand side.

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Interlocking device

Connecting the main conductor

Connecting the circuit breaker with front connections

1. Disconnect the main/control circuits from the power supply and set the withdraw able circuit breaker to the maintenance position.

2. Open the circuit breaker mechanically (see below).

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Connecting the main conductor

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Connecting the auxiliary conductor

Notice : Only route the auxiliary conductor in the front section of the circuit breaker.

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Connection for protective conductor

Commissioning

NOTICE : To charge the stored-energy spring mechanism, grasp the charging lever securely and move it as far as it will go. Make sure that each movement is as smooth as possible. The fifth stroke must be made as far and as smoothly as the previous four strokes, even though the force required to actuate the level increases considerably. Once the stored-energy spring mechanism has been fully charged, the charging lever can be moved without resistance.

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Preparing for operation

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Note :

1. The circuit breaker must only be closed when the over current release has been installed (with the exception of non-automatic circuit breakers).

2. Never remove over current releases under load since this can damage the over current release / current transformer.

Closing operation

Opening operation

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1. Charcoal Filter 2. Sand Filter 3. Ball Valves 4. Trolley

Re commissioning after opening operation by means of over current release

5.4 Installation & Commissioning of WWTS

• The wastewater treatment system is skid mounted and only settling tank of wastewater treatment plant is civil construction.

• The two charcoal filters on the skid should be filled with charcoal above 2 mm size.

• The sand filter should be filled with sand of size 2-3 mm.

• One charcoal filter shall always remain in by-pass. Hence check the open-close position of ball valves accordingly.

• Check all the pump and water circuit connections. • Verify the flow of water according to the specified value. • Check the alum solution tank and coagulant tank. They should be filled upto specified level. • Switch on the WWTS plant and monitor the timers initially according and adjust them if not

appropriate.

1 12

4

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• Initially the sand filter and charcoal filter may absorb some quantity of wastewater and retain some water in its voids.

• Initially the clean water coming out of charcoal filter may carry certain carbon particles. Not to worry. They are just the initial fines along with fresh charcoal.

• Other details are mentioned in O&M manual of Wastewater treatment plant. 5.5 Connection of all Water Pumps and Pipes for Gasifier System, Gasifier Cooling Tower,

WWTS and Intermediate Settling Tank

All the connections of water pumps, pipes for Gasifier System, Gasifier Cooling tower, Wastewater treatment system and Intermediate setting tank can be also seen in the P&I Diagram attached with this manual.

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5.6 Engine GENSET Installation and Commissioning Recommendation:

A separate manual of Engine Installation and Commissioning is being provided along with this manual (PLEASE REFER THE ANNEXURES AND ENCLOSURES).

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6.0 OPERATING PROCEDURES: 6.1 Biomass Feed Cycle 1. Feed cycle can be started in three ways.

a. Manually b. By Pressing single feed cycle button in auto mode c. By receiving signal from wood level sensor.

Changes: Now “c” will happen only if blower is ON.

2. For “b” and “c” Feed cycle will not start if both top and bottom feed doors are not closed. 3. For “b” and “c” Feed cycle will not start if skip charger bottom limit switch not close and top limit switch

not open. 4. When skip charger top limit switch is pressed, feed top door open limit switch must have been already

pressed. If that has not happened, skip charger will come back to bottom and further feed cycle in auto mode will not happen. The fault will be reset by two methods a. Either press reset button given on touch panel or b. Feed top door open limit switch is pressed

5. If feed shell bottom door open limit switch is not pressed with in a set time (40 seconds) from top door

opens, skip charger will come back to bottom and further feed cycle in auto mode will not happen. The fault will be reset by two methods a. Either press reset button given on touch panel or b. Feed bottom door open limit switch is pressed

6. Once skip charger starts moving upwards, a timer starts and if within set time (69 seconds), top limit switch is not pressed, skip charger will stop and wait time will start. After the wait time skip charger will come back to bottom and further feed cycle in auto mode will not happen. The fault can be reset by two methods. a. Press reset button given on touch panel. Top limit switch must be repaired. b. After repair if top limit switch is pressed

Here important point is that, normally the skip charger reaches at top in 62 seconds. Which means from 62 second to 6 second, motor will keep trying to move on when top limit switch is not working. However it

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will not be able to move on as there is a dead end. After 67 seconds, motor will be witched off and wait time will be started. This wait time is normally kept at 10 seconds. After the wait time, skip charger will come back to bottom and further feed cycle in auto mode will not happen.

7. Once skip charger starts moving downwards, a timer starts and if within set time (69 seconds), bottom

limit switch is not pressed, skip charger will stop and further feed cycle in auto mode will not happen. The fault can be reset by two methods. a. Press reset button given on touch panel. Bottom limit switch must be repaired. b. After repair if bottom limit switch is pressed

6.2 Hopper Unloading Procedure: The hopper can be unloaded along with the combustion cone to avoid damage of the air nozzles. The following steps needs to be followed: 1. Disconnect all the electrical and pneumatic connections to double door feed shell assembly. 2. Disconnect the electrical

and pneumatic connection to the Pneumatic Air Nozzle Closure.

3. Disconnect electrical connection to both the wood level sensors.

4. Remove the Hopper and the Reactor nut-bolts, the combustion cone and hopper nut-bolts should not be removed.

5. Connect proper lifting hooks and hook them to

Precaution: The hopper should be opened only after 15-20 hours after gasifier has been stopped, since the hopper would be hot from inside. Always use safety equipments (Fire extinguisher: water line) before unloading the hopper. Extinguish fire in the Reactor bed.

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the hook provided on the hopper and lift the hopper until the combustion cone is about 2 - 3 inches above the reactor flange to avoid damage of the sealing rope.

6. Move the chain pulley block to the clear unloading position and land the hopper on the floor. 7. Incase, only the hopper is to be unloaded, then the Auto Air nozzles have to be dismantled first to

avoid damage to the Air nozzles as shown in the photo below. 6.3 Start-Up Procedure

• Ensure that all the important points mentioned under “INSTALLATION & PRE-COMMISSIONING “are completed.

• Check water level in the manometers & clean the pressure probe ports.

• Top up the hopper with biomass if its level is lower and close the top feed door (not necessary in first commissioning)

• In either Manual of Auto mode, check that air compressor is ON and sufficient air pressure is available.

• Check level of water in chilled water tank. Switch On the chiller. Check that the set temperature is 7 °C.

• In Auto Mode, the gasifier cooling tower pump will start immediately after the wet blower starts. Check that the spray is on and sufficient. Keep a check on water temperature of pond.

• Start the WWTS after 1 hour of gasifier operation. Separate panel and working logic is mentioned in the manual of WWTS.

• After the Gasifier has been ignited, press start push button of “synchronizing request” provided on the gasifier panel. After pressing the button engine coolant pump, engine cooling tower pump, engine After-Cooler heat exchanger pump will start automatically.

• For starting gasifier, open all Air Nozzles, start screw conveyor and it cooling water pump, Promiser pump, wet blower. Adjust the gas control valve to read approx. 15 mm on the

(ΔPn).

• Light the igniting torch and ignite through gasifier air nozzles one after the other.

• Maintain Δ PN around 10 - 12 mm as the gasifier heats up. Within 5 to 10 minutes, proper

gas will start coming through the flare. Ignite the gas emitting through the test Flare to check the quality of the gas.

• Start the Vibrator motor. Comb rotor is normally switched ON after about half-an-hour of gasifier starting as otherwise the motor may trip due to overload.

• Now, the system is ready for regular operation.

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• Now, the engines can be started as described in the Engine Start-up procedure. (PRECAUTION: Ensure that the test flare is extinguished before feeding the gas to the engine. To confirm this, first close the tests flare and then again open the valve and check whether it is still ignited, if not, feed the gas to engine).

6.4 Running Instructions

• The gasifier can be feed on-line at regular intervals with the help of the skip charger in “Auto” mode. The skip charger is connected with the top wood level sensor. As the wood level drops below the sensor, the sensor will give signal to the skip charger and the wood loaded bucket travels upward. After a certain delay time the bottom door of the feed shell shuts-down and the top door opens. After the wood is feed into the shell, the bucket starts traveling down and the top door shuts down & the bottom door opens and simultaneously the feed shell vibrator will start.

• Keep a check that the chiller water circuit remains on. The temperature of chilled water should remain between 7-10 °C

• At Gasifier cooling tower, keep a check that the spray is even and sufficient water flow is available. If spray is insufficient, check if any spray nozzle or pump is choked. Clean the nozzle or pump and again check the spray. The temperature of gasifier cooling pond should remain around 32-33°C

• Keep a check on flow rate of water and alum solution pumps. Keep a check on the differential pressures of sand filter to avoid choking of sand filter. Once the color absorption capacity of filter gets exhausted, the water will retain its color after filtration. Change the charcoal if this happens.

• At Engine Cooling tower also check that the spray is even and sufficient water flow is available. If spray is insufficient, check if any spray nozzle is choked. Clean the nozzle and again check the spray. The temperature of gasifier cooling pond should remain around 32-33 °C

• There is another wood level sensor below the top wood level sensor, which will determine the low wood level/ danger level and give signal to the hooter.

• In case, the wood is feed in Manual mode, press the Auto cycle push button after an interval of approx. 15 minutes, observing proper safety. The wood loaded bucket travels upward. After a certain delay time the bottom door of the feed shell shuts-down and the top door opens. After the wood is feed into the shell, the bucket starts traveling down and the top door shuts down & the bottom door opens.

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• Feed proper size biomass having specified size and moisture content. Eliminate foreign material such as metal parts, nails, stones, grass etc. Ensure feeding of biomass in the gasifier at the scheduled time.

• Comb rotor, Vibrator rotor operations must be regular and as per factory setting. DO NOT change the settings.

• If the Comb rotor drive stalls at any time, DO NOT rotate it manually or with the wrench.

• Never exceed gasifier rated gas output as per recommended air nozzle pressure drop.

• Monitor gasifier pressure drop, nozzle pressure drop, Mist eliminator pressure drop, Fine filter pressure drops, Pleated filter pressure drops and maintain the record in log book.

6.5 Shut Down Sequence

• Reduce the ΔPN value to 10 - 15 mmwc.

• Shut-down the Heat Recovery system.

• Shut down both the engines as described in Engine start-up procedure and the flare will open.

• Press the Emergency button. (Incase of Auto mode operation).

• All the drives will shut down except the Air nozzles, Promiser pump and Dry Ash discharge vibrator.

• Air nozzles & Scrubber pump will shut down after set delay time of their timer.

• Gasifier Cooling Tower will shut down automatically after some set delay time.

• Dry ash discharge vibrator will shut down after set delay time of its timer.

• Engine Cooling Tower will shut down automatically after some set delay time.

• While the gasifier is run in Manual mode, the following shut down sequence should be followed

• Switch off the Wet blower.

• Shut off the pneumatic air nozzles.

• Switch off the vibrator motor.

• Switch off the comb rotor motor.

• Wait for a couple of minutes.

• Switch-off the Promiser pump.

• Switch-Off the Screw conveyor, its cooling pump and dry ash vibrator.

• Switch-Off the Air Compressor.

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• Switch-Off the Chiller.

• Wait for couple of minutes.

• Switch-Off the Engine cooling tower.

• Wait for couple of minutes.

• Switch-Off the Gasifier cooling tower.

• Switch-off the main MCB of the Gasifier Control Panel.

• Allow one cycle of WWTS to complete after gasifier is shut down.

• After that switch-off the panel of WWTS.

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7.0 SPECIFICATIONS OF AUXILARIES:

VIBRATOR MOTOR “ELCEN” MAKE Sr. No. 86531 HP 1.0 RPM 1420 Voltage 415 VIBRATOR MOTOR SPARE “ELCEN” MAKE Sr. No. 84237 HP 1.0 RPM 1400 Voltage 415 MOTOR FOR COMB ROTOR “SIEMENS” MAKE Sr. No. 0705 180500 HP 0.75 RPM 1410 Voltage 415 GEAR BOX FOR COMB ROTOR “ELECON” MAKE Sr. No. 351574 Size 2.25/50 INCH Type NUVD Reduction Ratio 3000:1 GEAR BOX (Active Fine Filter) “ ELECON” MAKE Sr. No. 397071 Size 1-3/4/30 INCH Type SNUVD Reduction Ratio 3000 : 1 MOTOR (Active Fine Filter) 1 “SIEMENS” MAKE Sr. No. 0611 141045 HP 0.75 RPM 1400 Voltage 415 MOTOR (Active Fine Filter) 2 “SIEMENS” MAKE Sr. No. 0611 2022544 HP 0.75 RPM 1400 Voltage 415 GEAR BOX (Active Fine Filter) 2 “ ELECON” MAKE Sr. No. 397070 Size 1-3/4/30 INCH Type SNUVD Reduction Ratio 3000 : 1

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SCREW CONVEYOR GEAR BOX “BONFIGLIOLI” MAKE Sr. No. L 11334280031 Type AS 25 P19.35 P80 B5 B3, Ratio 19.35 Torque 94 Nm SCREW CONVEYOR MOTOR- 1 (FOR DRY ASH REMOVAL SYSTEM) “CG” MAKE Sr. No. IML0708

HP 1 RPM 1415 Voltage 415 WET BLOWER MOTOR (DIRECT DELIVERED TO UNITED ENGG.) “SIEMENS” MAKE Sr. No. SDF 0911-2174914

HP 7.5 RPM 2905 Voltage 415 DRY BLOWER MOTOR (DIRECT DELIVERED TO UNITED ENGG.) “SIEMENS” Make Sr. No. 0906-2139322

HP 5 RPM 2900 Voltage 415 FEED SHELL VIBRATOR MOTOR “ELCEN” MAKE Sr. No. 86528 HP 0.5 RPM 1370 Voltage 415 SCRUBBER PUMP “KIRLOSKAR” MAKE, MODEL – KDS-822++ HP 7.5 RPM 2900 Voltage 415 ENGINE COOLING TOWER PUMP – 2 Nos. “KIRLOSKAR” MAKE, MODEL – KDS-520+

HP 5 RPM 2900 Voltage 415 GASIFIER COOLING TOWER PUMP “KIRLOSKAR” MAKE, MODEL- KDS-520+ HP 7.5 RPM 2900 Voltage 415

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WASTE WATER TREATMENT PLANT PUMP

Transfer to Intermediate Settling Tank “KIRLOSKAR” MAKE, MODEL- SP 1HM HP 2 RPM 2900 Voltage 415 From Intermediate Settling Tank to WWTP “KIRLOSKAR” MAKE, MODEL – GMC 1.522+

HP 1.5 RPM 2900 Voltage 415 Alum Solution Dosing “INDO SUB” MAKE, Flow Rate 150 LPH Phase Single Voltage 230 AFTER COOLER H.E. PUMP “KIRLOSKAR” MAKE MODEL- GMC 1.522+ HP 1.5 RPM 2900 Voltage 415

8.0 FILTER MEDIA PREPARATION:

Active and Passive Filter Media: The filter media is sieved through the 2.5 X 2.5 mm sieve. The coarser material above it should be rejected. The sieved material is further sieved through a 0.5 X 0.5 mm sieve and the material above it is the Usable Filter Media, which is to filled in the Active and Passive Fine Filter. Rejuvenation of used Active Filter Media: Dry the used Active Filter Media and then sieve it through a 0.5 X 0.5 mm sieve to get rid of the fine carbon particulates. The sieved filter media can again be used in the Active Fine Filter.

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9.0 DO’S AND DON’TS:

• Always use recommended size wood pieces/chips with less than 20% moisture. Eliminate foreign matter, metal, stones etc.

• Ensure feeding of wood pieces in the gasifier at the scheduled time. • Comb Rotor, vibrator rotor operations must be regular and as per factory setting. Do Not

change the settings. • If the Comb rotor drive stalls at any time, DO NOT rotate it manually or with a wrench.

Stop gasifier, thoroughly check, understand and solve the problem and then restart. • Scrubber water must never stop. Ensure effective cooling by regular cleaning of ponds,

nozzles etc. • Strictly maintain all filters viz. fine filters and pleated filter. Use recommended media and

ensure regular maintenance (refer detailed instructions). Proper and effective operation of filters is critical to ultra clean gas.

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10.0 MAINTENANCE SCHEDULE 10.1 Gasifier Maintenance Schedule:

DAILY EVERY 150 HOURS EVERY 400 HOURS EVERY 600 HOURS EVERY 1000 HOURS Check Manometer water levels.

Check Hopper feed door rubber sealing cord and replace if required

Check Hopper-Reactor flange sealing rope and replace if required.

Check tips of Air nozzles & replace the tips if found damaged.

Open the gasifier & check the throat of the combustion cone, repair if necessary.

Check & make up water level in cooling pond

Check Air Nozzle plugs /pneumatic air nozzle closure gasket & replace if required.

Check the blower impeller & casing thru’ the window provided for the same. If any deposits found, clean it.

Check Gasifier Control Panel and clean with portable air blower. Tighten loose connections, if any.

Flush oil from all the gearboxes of gasifier, check all oil seals & bearings. Replace if required.

Check Hopper- Reactor flange bolts.

Check the Gas valve operation & replace its gland sealing rope if required.

Check oil seal & oil level of all the gearboxes.

Check hot gas pipeline and Scrubber assembly for choking & clean it if required.

Check the flexible pipes, and if found damaged/dirty, replace it.

Check lube oil in the engine where applicable

Check all the nut-bolts of all the drives

Check the wet blower shaft seal, pumps gland seal & all motor love-joy coupling (if applicable), replace if required.

Clean and replace the pleated filter. If required change the pleated filter.

Whenever, gasifier is open for maintenance, check reactor by filling water in Reactor for comb rotor shaft gland seal leakage or any weld leakage.

Remove ash from cyclone wherever applicable.

Check fasteners of all flanged joints, clamps of flexible hoses.

Clean the pneumatic doors of ash/fine particulates accumulation.

Change the filter media & fill up to marked level.

Change the gasifier cooling pond water, if required.

Drain out condensate water wherever applicable.

Check cleaning ports at the bottom of the reactor for charcoal /ash accumulation clean it if required.

The swing valve at the flare should be cleaned and its movement should be free.

Check and clean all the valves.

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10.2 Engine Maintenance Schedule

Check each operation as performed

Daily Check (A) Air Intake System (1) Check for leaks and correct it. (2) Observe the air cleaner restriction indicator (B) Gas Pipe Line (1) Check for leaks and correct it. (2) Check Gas Pressure Inlet. (C) Lubrication System (1) Check for leaks and correct it. (2) Check Engine Oil level. (3) Check Governor Oil Level (D) Cooling System (1) Check for leaks and correct it. (2) Check coolant level and top up with pre-mixed coolant, if required. (E) Ignition System (1) Check wiring connections are proper (F) Misc. Checks (1) Check Governor & mixture valve and gas valve linkages are free

500 Hours - Check Repeat Daily Check (A) Cooling System (1) Check Heat Exchanger Zinc Plugs (B) Misc. Checks (1) Check and Adjust belt tension (2) Check connection and gauges (C) Intake Manifold Temp. For turbocharged after cooled engines check and ensure, intake manifold temp. is less than 55'C (130'F)

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For 3000 Hrs. Repeat Daily, 500 Hrs. and 1000 Hrs. check (A) Ignition System (1) Replace champion make spark plug RL - 15 B (2) Replace HT cables with spark plug connectors. (B) Misc. Check (1) Check fan Hub. Apply greases to the Bearings (2) Check cylinder compression. Check cylinder compression Satisfactory engine operation depends upon adequate and uniform compression in all cylinders. Loss of compression results in loss of power and non-uniform compression in cylinders causes unsatisfactory or rough operation. When making a compression test it is essential the engine be at operating temperature, the engine lubricating oil be of the proper grade and the cranking motor be operating properly. The engine should be disconnected from any driving unit by removing drive shaft, belts or disengaging the clutch if so equipped to make the compression test. Proceed as follows : 1. Close manual gas valve to engine. 2. Remove air cleaner piping at gas mixture. 3. Remove all spark plugs.

1000 Hours Repeat Daily check and 500 Hrs. check (A) Lubrication System (1) Change engine lube oil. Use only special Gas engine oil SAE Grade 15 W 40 for fill and top up. (2) Change Lub oil filters. (3) Clean Crankcase Breather (4) Lubricate water pump & fan hub bearings. (5) Check engine blow-by. (B) Cooling System (1) Check coolant additive concentrate level and add concrete if required (2) Check auxiliary water pump (C) Ignition System (1) Check/Clean spark plug and adjust spark plug gap if equipped with Champion make spark plugs - RL 15 B. (2) Clean and tighten electrical connections including ignition system (3) Check transformer resistance Primary - 0.2 to 0.3 ohm Secondary - 6 to 8 Kilo-ohm (4) Replace MICO Spark plug. (5) Check Ignition timing and adjust if required (D) Misc. Checks (1) Check and adjust valve clearances (E) Air Intake System (1) Check intake manifold vaccum (F) Gas pipeline check (1) Check gas pressure.

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4. Attach compression gauge by utilizing a 14 mm spark plug adapter to No. 1 cylinder spark plug opening.

5. Remove wiring harness from Altronic connector at the Altronic. 8. Crank the engine with the starter motor a minimum of 6 revolutions at which time the compression gauge should reach maximum pressure. To obtain accurate readings, each cylinder should be checked at the same cranking speed and revolutions. 9. Proceed to check each cylinder as per above.

Compression pressure will vary depending on the cranking speed, altitude, air density and sealing ability of the engine. The maximum pressure is not as important as the pressure variation of the individual cylinders, and any one or more cylinders indicating a pressure differential of 7% or more, would indicate excessive compression loss in that cylinder.

For 6000 Hours Repeat All the above checks (A) Lubrication System (1) Check engine blow-by (B) Cooling System (1) Check Thermostat (2) Clean Heat Exchanger (3) Clean Heat - Exchanger core tube internally to remove the scaling. (4) Replace water line hoses (C) Ignition System (1) Check disc altronic ignition timer coupling (D) Misc. Check (1) Clean Engine (2) Tighten engine mounting bolts and nuts (3) Check AVM and mounting (4) Check Crankshaft end clearance (5) Check damper for fluid leak and wooble, and replace if required (E) Reconditioning (1) Recondition cylinder head if intake manifold vaccum is low.

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11.0 TROUBLE SHOOTING: 11.1 Gasifier Trouble Shooting

Symptom Reason Action

Very high ΔPG Choked charcoal bed Operate Comb Rotor in manual mode for 5 to 10 minutes. If no improvement, stop the gasifier, allow it to cool and check for excessive ash or clinker accumulation in the reduction bed

Very low ΔPG Charcoal bed depleted. Leakage through the screw conveyor dry ash collection doors.

Stop the comb rotor in manual mode for 5 to 10 minutes and observe increase in ΔPG. If it increases, allow it to reach to recommended value and change the comb rotor back to Auto mode. Check & clean the dry ash collection doors.

Backfires through Air Nozzles

Choked charcoal bed or excessive air entering into the Gasifier other than through Air Nozzles

Check for ingress of air into the gasifier other than Air Nozzles. Check rubber sealing cord of the Feed Door, Hopper-Reactor flange bolts and Air Nozzle flange bolts.

Very high pressure drop across Fine Filters i.e. ΔPFF

Choking of filter media bed Operate agitator of the Fine Filter in manual mode. If no improvements, replace the media and restore its level as marked.

Very low pressure drop across Fine Filters i.e. ΔPFF

Not covered with filter media up to specified level.

Fill the filter media up to specified level.

High gas temperature at scrubber outlet

Scrubber Pump faulty or choked Spray Nozzle

Check Scrubber Pump and clean the Spray Nozzle

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11.2 Engine Trouble Shooting Engine Will Not Crank (Please refer Engine manual for more details) CAUSE CORRECTION OK OK

OK

OK OK OK Engine Crank But Will Not Start (Fuel System) CAUSE CORRECTION OK OK

Crankshaft rotation restricted.

Replace starting motor.

Solenoid or starting motor restriction.

Check key switch line circuit for open circuits or loose connections

Key switch malfunction.

No voltage to starter solenoid.

Starting motor operating but not cranking engine.

Starting circuit connections loose or corroded.

Clean and tighten connection.

Remove the starting motor & check for broken teeth on flywheel or broken starting motor spring.

Check battery voltage to solenoid.

Bar the engine to check for rotational resistance.

No fuel pressure at filter and gas quality is not good.

Ignition firing circuit grounded.

Check ignition switch. Check instrument panel ground.

Check main line gas pressure and gasifier.

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OK OK OK OK Engine Runs Rough or Misfires CAUSE CORRECTION OK OK OK

Check spark plug adapter for water leakage at O-ring and for cracked adapter

Spark plug adapter.

Check for type, gap, damage, electrodes & ceramic insulators. Check for water in cylinder.

Spark Plug.

Ignition generator.

Ignition Coils (Transformers) Inspect for cracks, moisture, broken connections. Check primary & secondary resistance.

Check for proper voltage. Check primary leads for voltage. Check wiring harness for moisture.

Ignition System failure.

Intake or exhaust valves adjusted wrong.

Compression in one or more cylinders is low.

Camshaft out of time. Check/correct gear train timing alignment.

Perform a compression check and repair as needed

Adjust valves. Refer to maintenance section for proper valve adjustment.

Refer to Ignition System Trouble Shooting, HT cable, HT coil, Connector and spark plug.

Ignition Timing. Check and correct ignition timing.

Check ignition timing marks alignment.

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OK Engine Noise Excessive CAUSE CORRECTION OK OK OK OK OK OK OK

Inspect camshaft and tappets.

Camshaft or tappets damaged.

Drive belt squeal, insufficient tension or abnormal high loading.

Refer to "Engine runs rough and or misfires".

Pre-Ignition or detonation.

Visually inspect and measure gear backlash. Replace gears as required.

Gear train noise.

Intake air or exhaust leaks.

Valve lash excessive.

Turbocharger noise. Check turbocharger impeller and turbine wheel for housing contact.

Adjust valves. Make sure push rods are not bent or rocker levers worn.

Check for intake or exhaust leaks.

Check belt tension and inspect drive belts. Make sure water pump, fan hub, and alternator turn freely.

External voltage supply. Verify that there are no external voltage supply paths to the On-Off switch.

Check oil specifications. Change to correct specifications if required.

Oil specifications incorrect.

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Engine Vibration Excessive CAUSE CORRECTION OK OK OK OK OK OK OK OK

Engine not running smoothly.

Check / replace alternator. Alternator bearing worn or damaged.

Inspect / replace fan hub.

Fan hub malfunctioning.

Engine low idle speed set too low.

Engine mounts loose or broken.

Fan damaged or accessories malfunctioning.

Check / replace the vibrating component.

Check / replace engine mounts.

Re-adjust low idle speed.

Refer to troubleshooting logic for "Rough Running or Misfiring".

Vibration damper malfunctioning. Inspect / replace the vibration damper.

Check / repair according to manufactures procedures.

Drive line components worn unbalanced, or out of alignment.

Flywheel housing misaligned. Check / correct flywheel alignment.

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Governor Instability / Speed Variation CAUSE CORRECTION OK Check Ignition System OK OK OK OK OK OK OK OK

Engine Misfiring & vibrating.

Check mixture valve and gas valve and adjust.

Inadequate mixture valve and gas valve travel.

Check air intake restriction and change air cleaner element if required.

Air cleaner restriction is excessive.

Timing is incorrect.

Inadequate gas flow.

Gas pressure is too low or too high. Adjust gas blower valve and check auto control gas valve.

Check and correct as per recommended in fuel system. Request that customer have pipeline size corrected as per engine datasheet.

Specifications as stated in the O & M Manual. Refer trouble shooting logic.

Check Ignition System. Check fuel system.

Throttle shaft and body are in a bind. Check throttle shaft and body for binding and correct.

Check ball ends for binding and correct.

Throttle lever & linkage ball Ends are binding.

If engine not taking load.

Engine oscillation. Check gas valve and linkage.

Check gas quality, gas pressure, Auto control gas valve and check ignition system.

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The following maintenance / component replacement activities are extremely critical for reliable Engine operation. Lubrication System Every

1000 Hrs Every 3000 Hrs

(1) Change engine lube oil. Use only special Gas engine oil SAE Grade 15 W 40 for fill and top up.

√

√

(2) Change Lub oil filters √ √ Ignition System (3) Replace HT Cables - √ (4) Replace Spark Plug Connectors - √ (5) Replace Spark Plug (I) If MICO make Spark Plug (II) If Champion make Spark Plug

√ -

√ √

For Preventive Maintenance, the following Spares should always be kept in stock:

Sr. No. Description Q’ty. 1. MICO make spark plug W5DC or 24 Nos. Champion make spark plug RL 15B 12 Nos.

2. Ignition Transformer (3873589) 06 Nos. 3. HT Cable 01 Set 4. Spark plug connector (3874262) 12 Nos. 5. Tube Connector (3873426) 06 Nos.

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12.0 SAFETY PRECAUTIONS: • Do not open any part of the gasifier and downstream sub-systems other than Hopper

Feed Door, while the gasifier is in operation. Open them only when the gasifier is shut-off and cooled down.

• Avoid physical contact with hot surfaces. Always use the Sight Screen to look into the Air Nozzles while the Gasifier is in operation or hot. Always use protective hand gloves while running the Gasifier.

• Do not flare gas into the atmosphere without igniting it. • Check flexible gas hoses for leakage in order to prevent inadvertent inhalation of leaking

gas. • Whenever the gasifier is to be opened for maintenance, it should be allowed to cool down

at least for 10 to 12 hours after shutting down. • Do not allow foreign matter e.g. stones, nails, sand etc. to go along with prepared

biomass into the Hopper. • Ensure that rupture discs provided at the separation box, mist eliminator, both the fine

filters, pleated filters and junction box are not punctured. If found punctured, immediately stop the engine and the gasifier and replace the rupture disc. (Use safety masks)

(Note: These rupture disc will get punctured only in case of some back fire). • Use proper safety masks and equipments while replacing the filter media in the fine

filters or cartridge filter in the pleated filter. • Ensure that the test flare is extinguished before feeding the gas to the engine. To

confirm this, first close the test flare and then again open the valve and check whether it is still ignited.

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13.0 ANNEXURES:

Schematic Diagram AST063-W400P-SD-P 000 (Rev 1) Plan Layout AST063-W400P-PL-P 001 (Rev 0) Gasifier Foundation AST063-W400P-GF-P 003 (Rev 0) P & ID Diagram AST063-W400-PID Wood Level Sensor Manual Engine-GENSET Installation Manual Operating and Maintenance Manual of Wet Blower Operational and Maintenance Manual for Water Chilling Plant Operation and Maintenance Manual of Wastewater Treatment Plant Erection and Commissioning of Cooling Tower Plant