stop of biogas generator set room

8/16/2019 STOP of Biogas Generator Set Room

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LADANG SABAH PALM OIL MILL BIOGAS PLANT

BIOGAS GENERATOR SET ROOM

INTRODUCTION

• The biogas generator set room is a station that utilized biogas that generated from biogas tank

farm plant for electricity generation purposes by using low concentration biogas (<100 ppm) as

fuel to operate biogas engine. As biogas engine is running it rotates the alternator of the biogasgenerator set (genset) to generate electricity and supply for daily mill usage such as mill !uarters

mill water treatment plant mill effluent plant mill polishing plant estate !uarters etc.

• There are total of " biogas genset a#ailable at $adang %abah &alm 'il ill ($%&') biogas

generator set room which of them has a rated output power capacity of 00k*A. +owe#er

according to the genset manufacturer recommendation they recommend each of those genset is

recommend to run a total of ,0- of its maimum capacity which e!ui#alent of /00*A.

• The total *A that able to supply by $%&' biogas generator set room that recommended by

genset manufacturer are 1.*A or 100 k*A.

• 2asically $%&' biogas generator set room can be di#ided into 3 parts or partitions as shown

as below4

i. 2iogas 5enerator %et 6oom (semi7open space)ii. 2iogas 5enset +ardware %tore

iii. 2iogas 5enerator %et 8ontrol &anel 6oom

i#. %witchgear 6oom

#. 2iogas &lant 'ffice

#i. 8ooling Tower and 8ooling 9ater 8irculation &ump %hed

• The %afety :!uipment ; &ersonal &rotecti#e :!uipment (&&:) that are compulsory to be worn

are4i. %afety +elmet

ii. %afety shoes

iii. $ate hand glo#es

i#. :ar &lugs

#. :ar ug#i. $eather +and 5lo#es

BIOGAS GENERATOR SET ROOM DIVISION

1. 2iogas 5enerator %et 6oom 8ondition4

i. :nsure that the surroundings and biogas generator set control room always in clean

conditions and has ade!uate lighting.

ii. :nsure there is sufficient water supply or sufficient water reser#e for cooling tower daily

normal operations.

iii. :nsure that e#ery tool and chemicals such as lubricating oil and hand tools are arranged

in an orderly manner with appropriate labels and is easy accessible.i#. :nsure that chemicals ha#e clear and easily understood labels.

#. :nsure that operators ; workers do not smoke within biogas generator set room.

#i. :nsure that operators ; workers wear &&: all the time when they are working at the site.#ii. :nsure that there is no leakages from the biogas generator set body or concrete tank of

cooling tower or pipelines that a#ailable at biogas generator set room.

#iii. :nsure that there are no water or oil spills on the biogas generator set room floor to a#oid

slippery floor.

PREPARED BY: TAN YIT ZEN LAST UPDATED: 1st June 201




i. :nsure that there is no sign of biogas leakages from the biogas supply pipelines biogas

generator set.

. :nsure that the small cooling water containers for each particular biogas generator set

always ha#e sufficient water within it by looking on the its le#el indicator.

. 2efore starting work operations4

i. :nsure that all e!uipment pumps piping to be used are in good conditions and well7

maintained.

ii. :nsure that all chemical such as lubricating oil to be used are sufficient.

iii. :nsure that all the spare parts for biogas generator set is sufficient and a#ailable so that

operator or engine dri#er able to replace or do maintenance if biogas generator set went

faulty suddenly.

i#. :nsure that operators ; engine dri#ers carry out their tasks in serious and sincere manner.

#. All operators ; engine dri#ers ha#e to follow and eecute e#ery instruction in a correct

and appropriate manner.

#i. All operators ; engine dri#ers ha#e to ensure their own &&:s are always in well7

maintained and good conditions.

". After work operations4

i. 9astes or scheduled waste such as used lubricating oil ha#e to be collected and stored to

the place it supposed to be thrown and kept.

ii. :#ery hand tools that used for biogas generator set maintenance ha#e to be cleaned as

thoroughly as possible to etend the lifespan of those hand tools.

iii. After each time finished handling chemicals hand must be washed with soap and water

thoroughly to a#oid poisoning.

BIOGAS GENERATOR SET ROOM E!UIPMENTS

B"#$%s Gene&%t#& Set

A' St%&t"n$ U( B"#$%s Gene&%t#& Set )Genset*

1' Be+#&e St%&t"n$ ,#&- O(e&%t"#ns:

i. :nsure that 2iogas %witchboard o. " are energized and electricity supply from mill

engine room and the electricity current supply is stable has a standard #oltage reading of

/1 *.

ii. :nsure all of the inlet and outlet #al#es of the particular cooling water circulation pump

that wish to operate at that time are fully opened.iii. :nsure that the main power supply for cooling tower and cooling water circulation pumps

are switched on.

i#. :nsure that the main power supply of biogas engine blower is switched on and ensurethat the blower is set to =A>T'? mode by checking the setting at the &$8 touch screen

panel.

#. :nsure that the water condensate within biogas engine piping nock 'ff pots moisture

and sediment trap located at the outlet piping of double membrane holder are fully

discharged.

#i. :nsure that all of the necessary #al#es such as4

a) @nlet and outlet #al#es of biogas engine blower are fully opened





b) 'utlet #al#e located at the outlet piping of the double membrane air pocket is

fully opened

c) *al#es along the biogas engine supply pipeline is fully opened

d) 2y7pass #al#e between biogas flare supply pipeline and biogas engine supply

pipeline are fully closed

e) 2y7pass #al#e of chiller to nock 'ff (.'.) pot are fully shut

f) @nlet and outlet #al#es of biogas chiller ; dryer is fully openedg) *al#e located at the outlet piping of nd .'. pot which connected with biogas

engine supply header is fully opened

2' ,.en St%&t"n$ U( B"#$%s Gene&%t#& Set )Genset* %n/ Run B"#$%s Gene&%t#& Set "n Is%n/

M#/e

i. %tart the biogas chiller ; dryer by pushing its main circuit breaker (82) on 2iogas

%witchboard o." (2%").

ii. %tart the particular cooling tower by pressing the green button (start button) on 2iogas

%witchboard o. " (2%").

iii. %tart the particular cooling water circulation pump by pressing the green button (start

button) on 2iogas %witchboard o. " (2%").i#. ick start the biogas engine blower by pressing %TA6T? button on the &$8 touch screen

panel.

#. 'bser#e the pressure #alue within the biogas engine supply pipeline to ensure that the

pressure within the pipeline always maintain at a range of 0 B "00 mbar.

#i. 'perator walk back to biogas generator set control room to switch ='? some of the

control switch on the biogas generator set control panel such as4

a) %witch ='? C8 &ower

b) %witch ='? %olenoid *al#e %witch

c) %witch ='? odule &ower %witch (@ntelli5en 8omap 8ontroller)

#ii. 'perator will go to the biogas hardware store to get the A8 ; C8 mobile electric starter

and push the de#ice from biogas hardware store towards the particular biogas generator

set that wish to start up at that particular moment.#iii. 8onnect the both positi#e (D) and negati#e (7) terminal cables from biogas generator set

towards the anode and cathode of the A8 ;C8 mobile electric starter by using spanner.

i. 8onnect the " phase power plug that a#ailable at biogas generator set room to the " phase

power socket located at the back part of the A8 ; C8 mobile electric starter.

. %witch on the main power supply switch to supply " phase electric supply to A8 ; C8

mobile electric starter.

i. 8heck the condition of the biogas generator set by check whether the go#ernor of the

genset is energized or not.

ii. Turn the start key of genset to check to test the functionary of the biogas main supply

#al#e of the genset.

iii. &ump the engine oil from oil pan of the biogas generator set to cylinder head of the

genset by using manual hand pump until some oil pressure detected on the engine control

panel.

i#. &ump the engine oil by using C8 electric pump until the reading of the oil press of the

genset shown E0.100 &a.

#. %traight away crank the genset by turning the start key of the biogas genset and press

start button to acti#ate the electric starter of the biogas genset to start up the biogas

engine.





#i. AdFust the inlet #al#e of cooling water towards biogas genset and obser#e the oil

temperature of the biogas engine until the reading shown E/0o8.

#ii. 8hange the operation mode of the biogas generator set from =@C$:? to =6AT@5? mode

to speed up the biogas engine until its standard rated rotating rotation per minute (6&)

which is 1000 rpm.

#iii. &ress the =%tart? button on the @ntelli5en and when the controller panel start its cranking

countdown !uickly turn the signal input switch from ='GG? to ='?

i. AdFust the #oltage of generator set to be e!ui#alent to the #oltage of busbar by using

#oltage trimmer tuning switch.

. @nform mill engine dri#ers to switch off all of the related 82 for mill water treatment

plant mill effluent plant polishing plant mill domestic housing area and estate domestic

housing area.

i. &ress the Auto %ynchronization button to start the synchronization process of biogas

generator set into mill power generation network system.

ii. 6ight after that particular biogas generator set managed to synchronize with mill power

generation grid line inform the mill engine dri#er to trip the circuit breaker of 2iogas

%witchboard o.1 (2%1) #ia walkie talkie.

iii. 6epeat %tep (#) till (i) to kick start another biogas generator set to get ready for the biogas generator set to take loads from those particular station or places from mill engine

room.

i#. 6ight after second biogas generator set has synchronized into the power generation

network system inform mill engine dri#er to slowly add loads to biogas generator set

room by switching on all of those 82 one by one.

' A+te& O(e&%t"#n:

i. 2iogas engine dri#er will obser#e all of the monitoring parameters a#ailable at the engine

control panel and biogas generator set control panel hourly and record all those parameter

#alues into the engine room record book.ii. %witch off the " phase main power supply to the A8 ; C8 mobile electric starter.

iii. Cisconnect the positi#e and negati#e terminal cables from biogas generator set from the

cathode and anode of the A8 ; C8 mobile electric starter.

i#. 2iogas engine dri#ers ha#e to always keep communicate with mill engine dri#er to adFust

the #oltage of the supply electricity from biogas generator set towards mill engine room.

#. 2iogas engine dri#ers ha#e to always keep communicate with biogas tank farm plant

operator to obser#e the biogas content within the double membrane air pocket.

#i. 2iogas engine dri#er shall obser#e the water le#el within of the cooling water

containers and replenish the water within the cooling water containers if the water le#el

of the water containers keep decreasing.

' Ste(s t# 3e t%-en /u&"n$ %n e4e&$en56:i. @f e#er the power factor and the fre!uency of one of the biogas generator set has

abnormal fluctuation biogas engine dri#ers shall determine which one of the biogas

genset is less stable at that time if the total k9 of loads that took by both biogas genset

</0k9 biogas engine dri#er shall disconnect the synchronization of the less stable

biogas genset from the power generation network system.

ii. @f e#er the biogas content within the double membrane air pocket is less than 10- biogas

engine dri#er shall inform mill engine dri#er about that phenomenon so that mill engine





dri#er able to kick start additional diesel generator set to take up total consumption k9

loads that took by biogas generator set meanwhile biogas engine dri#er standby to shut

down all of the biogas generator set due to insufficient fuel.

iii. 6eport emergencies to Technical :ecuti#es ; Assistant ill anager as soon as possible.

B' S.utt"n$ D#7n B"#$%s Gene&%t#& Set )Genset*

1' Be+#&e St%&t"n$ ,#&- O(e&%t"#ns:

i. :nsure that which biogas generator set is going to shut down for that particular time.

ii. :nsure that the total power consumption at that particular hour ; time is less /0k9

where single biogas genset will be able to sustain total power consumption after shutting

down another unit of biogas generator set.

iii. :nsure that biogas engine dri#er already inform mill engine dri#ers to standby Fust in

case emergency happened and caused the whole biogas generator room tripped.

i#. :nsure that the power factor and fre!uency #alues of both biogas generator sets are in

stable state.

2' ,.en S.utt"n$ D#7n B"#$%s Gene&%t#& Set )Genset*:i. 2iogas engine dri#ers disconnect the particular biogas generator set by pressing the same

button that used to synchronize biogas generator set into mill power generation network

system.

ii. After the biogas undergo soft unloading the power consumption loads that carried by it

towards another biogas generator set and disconnected from the power generation

system biogas engine dri#er shall change the operation mode of the biogas generator set

from =6AT@5? into =@C$:? mode.

iii. &ress the red %T'& button on the @ntelli5en 8ontroller panel and slowly switch off the

signal input switch to cut off the signal transmission into the biogas generator set control

panel controller.i#. 9hile the controller is undergo cooling counter down biogas engine dri#er shall

immediately go to the biogas generator set site slowly close inlet #al#e of biogas mainsupply pipeline towards that particular biogas generator set.

#. 9ait until the speed of the biogas engine reducing until the whole biogas generator set

totally stopped biogas engine dri#er re7enter to biogas generator set control room to

switch off the following control switch4

a) C8 &ower switch

b) %olenoid *al#e %witch

c) odule &ower %witch (@ntelli5en 8omap 8ontroller)

' A+te& O(e&%t"#n:

i. :nsure the inlet #al#e of the main biogas supply pipeline is closed tightly.

ii. :nsure that the biogas generator set that being shut is totally in stationary condition.

iii. :nsure that the control panel of that particular biogas generator set is no longer

synchronized with mill power generation network system.

' Ste(s t# 3e t%-en /u&"n$ %n e4e&$en56:

i. @f e#er the power factor or fre!uency #alue of current running biogas generator set keep

fluctuating abnormally biogas engine dri#er shall liaise with mill engine dri#er to start up

one of the mill diesel generator set as standby unit to take o#er the power consumption

that loaded by the biogas generator set.





ii. 6eport emergencies to Technical :ecuti#es ; Assistant ill anager as soon as possible.

C##"n$ T#7e& %n/ C##"n$ ,%te& C"&5u%t"#n Pu4(

1' Be+#&e St%&t"n$ ,#&- O(e&%t"#ni. :nsure that all of the inlet and outlet #al#es of the particular cooling water circulation

pump are fully opened.

ii. %witch on the main power supply for both cooling tower and cooling water circulation

pump that wish to operate on that particular moment.

iii. :nsure that the inlet and outlet #al#e on the biogas generator set is fully opened.

2' Du&"n$ St%&t"n$ U( B#t. C##"n$ T#7e& %n/ C##"n$ ,%te& C"&5u%t"#n Pu4(

i. &ress the green button (start button) for both cooling tower and cooling water circulation

pump that wish to operate at that particular moment.

ii. 'bser#e the flow of water towards biogas generator set and towards cooling tower in

order to ensure the hot water is constantly flow from biogas generator set towards to

cooling tower to cool down.

' A+te& 7#&- #(e&%t"#n

i. :nsure that the water temperature that detected at the inlet and outlet of the biogas

generator set always below 30o8.

' Ste(s t# 3e t%-en /u&"n$ %n e4e&$en56

i. 6eport emergencies to Technical :ecuti#es ; Assistant ill anager as soon as possible.


stop of biogas generator set room

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