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

OWNERS MANUAL

Ankur Scientific Energy Technologies Pvt. Ltd.,

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

Dear Customer,

FOREWORD

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 Scientific Energy Technologies Pvt. Ltd.,

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

CONTENTS
SR. NO TITLE PAGE

1.0

2.0

3.0

Introduction 1.1 What is Biomass Gasification? 1.2 Why Biomass Gasification? 1.3 Thermal Applications 1.4 Electrical Applications Technical Specifications for GAS-250 Plant 2.1 Gasifier System 2.2 Power Generating Set 2.3 Important Operating Parameters Gasifier System Description 3.1 Brief Description 3.2 Feeding System/Feed Shell 3.3 Hopper 3.4 Reactor 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
IMPORTANT OPERATING PARAMETERS

6 6 6 7 7 8 8 9 11 12 12 12 13 13 14

4.0

21

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 Installations and Commissioning 5.1 Installations and Commissioning of Gasifier 5.2 Installation and Commissioning of Gasifier and Engine Cooling Tower 5.3 Erection and Commissioning of PLC Panel 1. Gasifier PLC Panel 2. Engine Breaker PLC Panel 5.4 Installation & Commissioning of WWTS 5.5 Connection of all Water Pumps and Pipes for Gasifier System, Gasifier Cooling Tower, WWTS and Intermediate Settling Tank. 5.6 Engine GENSET Installation and Commissioning Recommendation Operating Procedures 6.1 Biomass Feed Cycle 6.2 Hopper Unloading Procedure 6.3 Start-up Procedure 6.4 Running Instructions 6.5 Shut-Down Sequence
4

29

32 32 34 36 53 54 55 56 56 57 58 59 60

5.0

6.0

7.0 8.0 9.0 10.0

Specifications of Auxiliaries Filter Media Preparation Dos and Donts Maintenance Schedule 10.1 Gasifier Maintenance Schedule 10.2 Engine Maintenance Schedule Trouble Shooting 11.1 Gasifier Trouble Shooting 11.2 Engine Trouble Shooting Safety Precautions Annexure and Enclosures

62 64 65 66 66 67 70 70 71 77 78

11.0 12.0 13.0

1.0 1.1

INTRODUCTION 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. Page 6 of 78

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 Mode of Operation Gasifier Type Rated Gas Flow Average Gas Calorific Value Gasification Temperature Fuel Feeding Ash Removal Start-up Biomass Fuel Type Biomass Fuel Specifications Permissible moisture content in biomass Rated hourly consumption Ash Discharge Typical Conversion efficiency of gasifier Typical gas composition Gas parameters at the inlet into engines ANKUR WBG-400 Cold & Ultra Clean Gas Downdraft 1000 Nm3/hr 1,100 Kcal/Nm3 1050 1100 0C Automatic: On-line mode, depending on the signal given by the wood level sensor. Automatic Dry Ash discharge from the gasifier through water cooled screw conveyor Through Promiser and Wet Blower Wood Chips Minimum : 15 x 15 x 10 mm Maximum: 25 x 25 x 10 mm Permissible fines less than 5%. 5 to 20% (wet basis) 300 350 kg Up to 7 % > 75% CO - 19 3% H2 -18 2% CO2 - 8 3% CH4 Up to 3% N2 - 50%

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 : 12C Water Outlet Temperature : 7C Promiser Process Water Cooling Tower Capacity : 10 TR Water Flow Rate : 5 m3/hr Inlet Water Temperature : 37C Outlet Water Temperature : 32C Promiser Clean Water and Engine Capacity : 150 TR Cooling Tower Water Flow Rate : 90 m3/hr Inlet Water Temperature : 37C Outlet Water Temperature : 32C

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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 Sound level at 1m distance Length Height Weight Gas connection Exhaust pipe Engine make and model Generator make and model RPM Voltage/Frequency Cylinder displacement Volume No. of cylinders and mode Total Displacement Generating Set Power Cal. Value of Wood gas Max. inlet temperature cooling water Max. outlet temperature cooling water

UNIT dB(A) Mm Mm Mm Mm Mm

VALUE 105 4500 2500 7500 150 2 X 125 Cummins GTA 1710G Stamford HC 4F (380KVA) 1500 400/ 50 Hz 2.33 12 CYLINDER 28 250 1000-1100 kcal / Nm 35 40 C

1/Min V/Hz Ltr. Ltr. kW

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PERFORMANCE DATA Thermal energy input Consumption Wood gas Thermal energy in cooling water Thermal energy in exhaust gas Thermal efficiency Electrical capacity Electrical efficiency El. Characteristic = el. eff. / th. eff. Cos phi DESIGN LAYOUT DATA Exhaust gas volume flow rate Exhaust gas mass flow rate moist Exhaust gas mass flow rate dry Exhaust gas temperature at engine Exhaust gas release temperature without heat exchanger Exhaust gas release temperature with heat exchanger Combustion air volume Lubrication oil consumption Cooling water temperatures ( inlet , outlet ) Cooling water flow rate Exhaust Emission values ( NOx < 500 mg, CO < 1000 mg) GAS SPECIFICATIONS Carbon Monoxide CO Hydrogen H2 Methane Nitrogen Oxygen Others Tar content Particles content Relative Humidity Pressure at entry to Engine Pressure variation

% load kW M / hour kW kW % kW %

100 850 731 320 270 69.4 250 29.4 0.424

75 685 589 276 208 70.7 187.5 27.4 0.388 VALUE 2150 2580 2400 430 400 115

50 510 439 210 167 73.9 125 24.5 0.332

UNIT Nm / Hr Kg/ Hr Kg / Hr. C C C Nm / Hr Kg / Hr. C M / Hr

1180 0.4 Inlet 60C80C/Outlet 78C 90C 40 Within limits MIN 15 15 1.5 48 0.0 6 2 2 80 100 mmwc 50 MAX 21 18 3 54 0.5 8 10 10 90 600 mmwc 15

UNIT Vol % Vol % Vol % Vol % Vol % Vol % Mg / m Mg / m % mbar %

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2.3 Important Operating Parameters Gas Flow Measurement * Indicative Nozzle Pressure Drop (PN) at : rated flow Nozzle Pressure Drop (PN) at lowest : permissible rating

35 mm of H2O 25 mm of H2O

Gasifier Pressure Drop * - Indicative Gasifier Pressure Drop (PG) at : rated flow - Permissible PG limits at rated flow : Maximum Minimum :

150 mm of H2O 200 mm of H2O 400 - 500C < 45 C < 20-25 C 50 - 100 C 150mmwc Alarm when Wood level is Low 80 psi 95 C maximum (Engine Trip)

Outlet Gas temperature Promiser Gas Temperature Cold Gas Temperature Hopper Temperature Pressure Drop in Filter Line 1 and Line 2 Wood Level Sensor 1 & 2 Lube Oil Pressure Engine Coolant Temperature High

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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. AST063W400P-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 companys 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 57kg/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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into the gasifier, the top door is closed and the bottom door is opened. Theres 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, combustion. Pneumatic/ into pyrolysis It manual & has air zone. Hopper

nozzles for induction of air combustion 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. Theres 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. Promiser 2. Cyclone 2 1

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

1 2

and the separation box. This can be adjusted to set the PN within specified limit.

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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. should be corrected by If the direction is not correct, then the same interchanging any of the 2 phases. Never allow water to flow in the wet blower before starting it and until it achieves full Keep the blower drain valve open before starting the blower and keep it open until the Water in the blower should be adjusted with a valve provided at the water inlet, such that speed. system is in operation (if provided). 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
1. Heat Exchanger 2. Gas inlet 3. Chilled water Inlet 4. Warm water Outlet

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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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 1

Temperature is 12C and Water Outlet Temperature is 7C. The water inlet is 2 NB and water outlet is 2 NB. The make-up water line is 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.

2 4

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

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

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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 P 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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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, PFF must never be below 30-35 mm at rated condition (as per specified PN or PG) Mix the top layer of saw dust daily and observe the pressure drop. When P 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. installation of the cartridge Proper filters 1 3 2 4

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

totally eliminates any direct gas flow Passages and is extremely critical for proper function of pleated filter.

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Initial pressure drop P 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 P 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.

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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. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Sensor
Wood Level Sensor 1 & 2 Hopper temperature Set 150oC Hot gas temperature. set 500 oC Cold gas temperature set 50 oC Pressure transducer (Delta PN) Pressure transducer (Delta PG) Pressure transducer (Filter Line-1) Pressure transducer (Filter Line -2) Low Lube oil pressure Engine water temp. High Engine Over Speed Chilled Gas Temp. High Set Point 25 oC

Action
Feeding cycle auto start, System shut down with tripping and indication System shut down with indication & Data Recording Indication System shut down with indication System shut down Controlling & system shut down Controlling & system shut down Controlling & system shut down System shut down with indication. System shut down with indication. System shut down with indication. System shut down with indication.

Remarks
Through: PLC with Scada Through PLC with Scada Through PLC with Scada Through PLC with Scada Through PLC with Scada 0-250 mmwc Through PLC with Scada 0-500 mmwc Through PLC with Scada 0-250 mmwc Through PLC with Scada 0-250 mmwc Through PLC with Scada Through PLC with Scada Through PLC with Scada Through PLC with Scada

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2. HMI INDICATIONS: Sr. Parameter No. 1 Engine KW 2 3 (a) 3 (b) 4 5 6 7 8

Engine KWh Hour meter for Gasifier Hour meter for Engine Grid Voltage Generator Voltage Generator Current Power Factor Frequency

Action
Indication in HMI & Breaker Panel Meter Unit counting Indication in HMI & Breaker Panel Meter Hour counting Indication in HMI Hour counting Indication in HMI Indication in Breaker Panel Indication in Breaker Panel Meter Indication in Breaker Panel Meter Indication in Breaker Panel Meter Indication in Breaker Panel Meter

Remarks
Through PLC with Scada Through PLC with Scada Through PLC with Scada Through PLC with Scada

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 Page 22 of 78

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. Page 25 of 78

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 150C 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 doesnt open for 30 min., Shutdown occurs. Page 26 of 78

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

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9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Skip Charger Motor Faulty Fine Filter Line-1 Faulty Fine Filter Line-2 Faulty Dry Air Blower Motor Hot Air Blower Motor Vibratory Sieve Motor Cold Gas Temp. High Outlet Gas Temp. High Empty Wood Danger Wood Engine Cooling Tower Pump Faulty Engine Coolant Pump Faulty Engine Cooling Tower Fan Engine Oil Pump Faulty Chilled gas temperature high Gasifier Cooling Tower Fan Faulty 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 doesnt 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 AST063W400P-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 nutbolts 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
1. 2. 3. 4. 5. 6. 7. 8. 9.

INSTALLATION AND COMMISSIONING OF GASIFIER AND ENGINE COOLING TOWER Check the inner dimension of the basin. It should match with the dimensions specified by Ankur Scientific. Place the base channel. Fix all four arms with nuts and bolts. Grout/anchor the base channel on basin walls. Fix vertical angles in pockets. Fix top frame. Fix vertical Tee members. Fix middle angle and support members. Fix headers. 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 Check the WBT. If cold water temperature is WBT +4 C, problem is seasonal, cooling will get corrected automatically. Check the water spray pattern of nozzles. If jet umbrella is small or weak, flow might be less than required. Execute following Range is same but cold water a. Clean foot valve, bends etc. b. See for air pressure pocket zone in piping due to improper positioning temperature is high. (more than of valves in pipeline. c. Clean Nozzles. This can be done in running conditions also. required) d. If needed, check water flow. 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 Drift is more 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 MCBs and MPCBs 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. Page 36 of 78

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: Voltage, Ampere and Frequency Meter Grid Phase Sequence Indicator Generator Phase Sequence Indicator

Synchronizing Relay

KWH, KW and PF Meter

Air Circuit Breaker

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Mechanical ON

Switching Position Indicator

Charging Lever

Stored Energy Spring Mechanism Charge Indicator

Ready to close 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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Gas valve

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.

RPM and Hour indicator

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.

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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 storedenergy 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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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 1 1 wastewater treatment plant is 2 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 4 sand of size 2-3 mm. One charcoal filter 1. Charcoal Filter 2. Sand Filter shall always remain 3. Ball Valves 4. Trolley 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.

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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 Page 56 of 78

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:

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. 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. 2. Disconnect all the electrical and pneumatic connections to double door feed shell assembly. Disconnect the electrical and connection 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 pneumatic to the

Pneumatic Air Nozzle

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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. 7. Move the chain pulley block to the clear unloading position and land the hopper on the floor. 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 & PRECOMMISSIONING 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 (Pn). Light the igniting torch and ignite through gasifier air nozzles one after the other. Maintain 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. Page 58 of 78

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 32-33C 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 3233 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. Page 59 of 78

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 PN 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. Page 60 of 78

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 HP RPM Voltage VIBRATOR MOTOR SPARE HP RPM Voltage MOTOR FOR COMB ROTOR HP RPM Voltage GEAR BOX FOR COMB ROTOR Size Type Reduction Ratio GEAR BOX (Active Fine Filter) Size Type Reduction Ratio MOTOR (Active Fine Filter) 1 HP RPM Voltage MOTOR (Active Fine Filter) 2 HP RPM Voltage GEAR BOX (Active Fine Filter) 2 Size Type Reduction Ratio

ELCEN MAKE Sr. No. 86531 1.0 1420 415 ELCEN MAKE Sr. No. 84237 1.0 1400 415 SIEMENS MAKE Sr. No. 0705 180500 0.75 1410 415 ELECON MAKE Sr. No. 351574 2.25/50 INCH NUVD 3000:1 ELECON MAKE Sr. No. 397071 1-3/4/30 INCH SNUVD 3000 : 1 SIEMENS MAKE Sr. No. 0611 141045 0.75 1400 415 SIEMENS MAKE Sr. No. 0611 2022544 0.75 1400 415 ELECON MAKE Sr. No. 397070 1-3/4/30 INCH SNUVD 3000 : 1 Page 62 of 78

SCREW CONVEYOR GEAR BOX Type Ratio Torque SCREW CONVEYOR MOTOR- 1 (FOR DRY ASH REMOVAL SYSTEM) HP RPM Voltage WET BLOWER MOTOR (DIRECT DELIVERED TO UNITED ENGG.) HP RPM Voltage DRY BLOWER MOTOR (DIRECT DELIVERED TO UNITED ENGG.) HP RPM Voltage FEED SHELL VIBRATOR MOTOR HP RPM Voltage SCRUBBER PUMP HP RPM Voltage ENGINE COOLING TOWER PUMP 2 Nos. HP RPM Voltage GASIFIER COOLING TOWER PUMP HP RPM Voltage

BONFIGLIOLI MAKE 19.35 94 Nm

Sr. No. L 11334280031

AS 25 P19.35 P80 B5 B3,

CG MAKE Sr. No. IML0708 1 1415 415 SIEMENS MAKE Sr. No. SDF 0911-2174914 7.5 2905 415 SIEMENS Make Sr. No. 0906-2139322 5 2900 415 ELCEN MAKE Sr. No. 86528 0.5 1370 415 KIRLOSKAR MAKE, MODEL KDS-822++ 7.5 2900 415 KIRLOSKAR MAKE, MODEL KDS-520+ 5 2900 415 KIRLOSKAR MAKE, MODEL- KDS-520+ 7.5 2900 415

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WASTE WATER TREATMENT PLANT PUMP Transfer to Intermediate Settling Tank KIRLOSKAR MAKE, MODEL- SP 1HM HP RPM Voltage From Intermediate Settling Tank to WWTP HP RPM Voltage Alum Solution Dosing Flow Rate Phase Voltage AFTER COOLER H.E. PUMP HP RPM Voltage 2 2900 415 KIRLOSKAR MAKE, MODEL GMC 1.522+ 1.5 2900 415 INDO SUB MAKE, 150 LPH Single 230 KIRLOSKAR MAKE MODEL- GMC 1.522+ 1.5 2900 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 DOS AND DONTS:

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 10.1

MAINTENANCE SCHEDULE Gasifier Maintenance Schedule: DAILY EVERY 150 HOURS EVERY 400 HOURS EVERY 600 HOURS Check tips of Air nozzles & replace the tips if found damaged. Check Gasifier Control Panel and clean with portable air blower. Tighten loose connections, if any. Check hot gas pipeline and Scrubber assembly for choking & clean it if required. Clean and replace the pleated filter. If required change the pleated filter. EVERY 1000 HOURS Open the gasifier & check the throat of the combustion cone, repair if necessary. Flush oil from all the gearboxes of gasifier, check all oil seals & bearings. Replace if required. Check the flexible pipes, and if found damaged/dirty, replace it.

Check Manometer Check Hopper feed door water levels. rubber sealing cord and replace if required Check & make up Check Air Nozzle plugs water level in cooling /pneumatic air nozzle closure pond gasket & replace if required.

Check Hopper-Reactor flange sealing rope and replace if required. Check the blower impeller & casing thru the window provided for the same. If any deposits found, clean it. Check Hopper- Check the Gas valve Check oil seal & oil level of all Reactor flange bolts. operation & replace its gland the gearboxes. sealing rope if required. Check lube oil in the Check all the nut-bolts of all Check the wet blower shaft engine where the drives seal, pumps gland seal & all applicable motor love-joy coupling (if applicable), replace if required. Remove ash from cyclone wherever applicable. Drain out condensate water wherever applicable.

Whenever, gasifier is open for maintenance, check reactor by filling water in Reactor for comb rotor shaft gland seal leakage or any weld leakage. Check fasteners of all flanged Clean the pneumatic doors of Change the filter media & fill Change the gasifier cooling pond joints, clamps of flexible ash/fine particulates up to marked level. water, if required. hoses. accumulation. Check cleaning ports at the The swing valve at the flare Check and clean all the valves. bottom of the reactor for should be cleaned and its charcoal /ash accumulation movement should be free. clean it if required.

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10.2 Engine Maintenance Schedule 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 Check each operation as performed 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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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. 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. Page 68 of 78

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 11.1

TROUBLE SHOOTING: Gasifier Trouble Shooting Symptom Reason Choked charcoal bed Action 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 Stop the comb rotor in manual mode for 5 to 10 minutes and observe increase in PG. If it increases, allow it to reach to recommended value and change the comb rotor back to Auto mode.

Very high PG

Very low PG

Charcoal bed depleted.

Backfires Nozzles

through

Leakage through the screw conveyor dry ash collection doors. Air Choked charcoal bed or excessive air entering into the Gasifier other than through Air Nozzles

Check & clean the dry ash collection doors.

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

Very low pressure drop across Fine Filters i.e. PFF High gas temperature at Scrubber Pump faulty or Check Scrubber Pump and clean the scrubber outlet choked Spray Nozzle Spray Nozzle

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. 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. Not covered with filter Fill the filter media up to specified media up to specified level. level.

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11.2 Engine Trouble Shooting Engine Will Not Crank (Please refer Engine manual for more details) CAUSE Crankshaft rotation restricted. OK No voltage to starter solenoid. OK Check battery voltage to solenoid. CORRECTION Bar the engine to check for rotational resistance.

Starting motor operating but not cranking engine. OK Starting circuit connections loose or corroded. OK Key switch malfunction. OK Solenoid orOK starting motor restriction. Engine Crank But Will Not Start (Fuel System) CAUSE No fuel pressure at filter and gas quality is not good. OK Ignition firing circuit grounded. OK

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

Clean and tighten connection.

Check key switch line circuit for open circuits or loose connections

Replace starting motor.

CORRECTION Check main line gas pressure and gasifier.

Check ignition switch. instrument panel ground.

Check

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Ignition generator.

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

OK Check ignition alignment. timing marks

Ignition Coils (Transformers) OK Spark Plug. OK Spark plug adapter. OK Ignition Timing.

Inspect for cracks, moisture, broken connections. Check primary & secondary resistance. Check for type, gap, damage, electrodes & ceramic insulators. Check for water in cylinder. Check spark plug adapter for water leakage at O-ring and for cracked adapter

Check and correct ignition timing.

Engine Runs Rough or Misfires CAUSE Ignition System failure. OK Intake or exhaust valves adjusted wrong. OK Compression in cylinders is low. OK Camshaft out of time. one or more CORRECTION Refer to Ignition System Trouble Shooting, HT cable, HT coil, Connector and spark plug.

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

Perform a compression check and repair as needed

Check/correct alignment. Page 72 of 78

gear

train

timing

OK Camshaft or tappets damaged. Engine Noise Excessive CAUSE Drive belt squeal, insufficient tension or abnormal high loading. OK Intake air or exhaust leaks. OK Valve lash excessive. OK Turbocharger noise. OK Gear train noise. OK Pre-Ignition or detonation. OK External voltage supply. OK Oil specifications incorrect. Check oil specifications. Change to correct specifications if required. Verify that there are no external voltage supply paths to the On-Off switch. Refer to "Engine runs rough and or misfires". Visually inspect and measure gear backlash. Replace gears as required. Adjust valves. Make sure push rods are not bent or rocker levers worn. Inspect camshaft and tappets. CORRECTION Check belt tension and inspect drive belts. Make sure water pump, fan hub, and alternator turn freely.

Check for intake or exhaust leaks.

Check turbocharger impeller and turbine wheel for housing contact.

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Engine Vibration Excessive CAUSE Engine not running smoothly. OK Engine low idle speed set too low. OK Engine mounts loose or broken. OK Fan damaged malfunctioning. OK Fan hub malfunctioning. OK Alternator bearing worn or damaged. OK Vibration damper malfunctioning. OK Flywheel housing misaligned. OK Drive line components worn unbalanced, or out of alignment. Check / repair according manufactures procedures. to Check / correct flywheel alignment. Inspect / replace the vibration damper. Check / replace alternator. Inspect / replace fan hub. or accessories Check / replace component. the vibrating Re-adjust low idle speed. CORRECTION Refer to troubleshooting logic for "Rough Running or Misfiring".

Check / replace engine mounts.

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Governor Instability / Speed Variation CAUSE Engine Misfiring & vibrating. OK Check Ignition System Timing is incorrect. OK Inadequate gas flow. OK Gas pressure is too low or too high. OK Air cleaner restriction is excessive. OK Inadequate mixture valve and gas valve travel. OK Throttle shaft and body are in a bind. OK Throttle lever & linkage ball Ends are binding. OK Engine oscillation. OK If engine not taking load. Check gas valve and linkage. Check throttle shaft and body for binding and correct. Check ball ends for binding and correct. Check air intake restriction and change air cleaner element if required. Check mixture valve and gas valve and adjust. 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. CORRECTION Check Ignition System. Check fuel system.

Adjust gas blower valve and check auto control gas valve.

Check gas quality, gas pressure, Auto control gas valve and check ignition system. Page 75 of 78

The following maintenance / component replacement activities are extremely critical for reliable Engine operation.
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 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 Every 1000 Hrs Every 3000 Hrs

For Preventive Maintenance, the following Spares should always be kept in stock: Sr. No. 1. 2. 3. 4. 5. Description MICO make spark plug W5DC or Champion make spark plug RL 15B Ignition Transformer (3873589) HT Cable Spark plug connector (3874262) Tube Connector (3873426) Qty. 24 Nos. 12 Nos. 06 Nos. 01 Set 12 Nos. 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 Plan Layout Gasifier Foundation P & ID Diagram 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 AST063-W400P-SD-P 000 (Rev 1) AST063-W400P-PL-P 001 (Rev 0) AST063-W400P-GF-P 003 (Rev 0) AST063-W400-PID

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