UNIDO Biogas Workshop, 17th of June, Vienna

The importance of safety standards, risk

assessment and operators training for a
successful biogas market development

Clemens Findeisen
Consultant Development Cooperation
German Biogas Association
Content

• German Biogas Association

• Trainings in the area of safety on biogas plants
• Hazards on biogas plants
• Risk evaluation and precautions
• Safety guidelines and documentation

2
 Structure of the German Biogas Association

Steering Committee Headquarters in Freising

Member of the European Biogas Association

7 members, elected for a 4-year-period 23 employees, organised in 10
departments

Board of Trustees Berlin Office

over 400 honorary experts

Elected honorary spokesmen of regional groups, working groups and 5 employees

advisory boards
Regional offices (North,
Advisory Boards, Working Groups South, East, West and

(EBA)
Advisory boards of plant operators, companies, the legal profession, Editorial Office Biogas
funders; Working groups for the areas permissions, safety, feeding-in Journal
of biogas, environment, heat, waste and fertiliser law
5 employees

23 Regional groups in Germany

4,800 Members Companies and manufacturers

Operators of biogas plants
Interested private individuals Corporate finance
Providers of feedstock
Public authorities
Research Institutions Planners, advisers, laboratories
Lawyers
 German Biogas Association - Objectives
Objectives :
• Promotion of the biogas sector
• Promotion of a sustainable energy
supply
• Definition of legal framework for
reliable and long-term investments
• Creation of adequate technical rules
and standards
• Promotion of R & D
• Exchange of information
• Members service
Lobbying on federal state, federal
and EU level in the following
fields:
• Renewable Energy Act (EEG)
• Energy management
• Regulatory approval
• Environmental law
• Laws on agricultural issues
• Tax law
• …
4
 International Agenda
of the German Biogas Association
• International Affairs Department
• Supporting members with information about the international biogas
markets
• Biogas Convention and Trade Fair
• Supporting Biogas Associations and Biogas Trainings worldwide
• Cooperation with international organizations –
promoting Biogas in Developing- and emerging countries
Some GIZ energy Programms with biogas components
o Brazil: Diffusion of climate friendly Biogas Technologies (BMZ, 2013–2017)

o Turkey: Efficient and Climate-friendly Use of Animal waste (BMU, 2010–2014)

o China: Optimization of Efficient Biomass Utilization (BMZ, 2009–2013)

o Mexiko: Energetic use of urban muncipal waste (BMZ, 2014-2018)

o Kenia, Ghana, Mozambique, Tanzania : PEP Renewable Energy Subsahara-Africa (BMWi, 2013–2016)

o Kenya, Ghana: Resource Recovery – Made in NRW (Government Nordhein-Westfalen, 2014 -2015)

o Indonesia, Thailand, Vietnam, Philippines, Myanmar: PEP Renewable Energy South-East Asia (BMWi, 2012–2015)

o Caribbean Community: Support to institutional structures for the promotion of renewable energies and energy efficiency (BMZ, 2012 – 2016)

o Indonesia: Promotion of Least Cost Renewables in Indonesia, (BMZ, 2012 -2015)

o Serbia: Development of a sustainable Bioenergy market (BMZ, 2013-2017)

o South-Africa: South African-German Energy Programme – SAGEN (BMZ, 2011-2014)

o Vietnam, South Africa, Ghana, Colombia, Peru: Wir holen die Welt nach Bayern und bringen Bayern in die Welt (Bavarian Ministry of Economic Affairs )

o Central America: Promotion of Renewable Energies and Energy Efficiency in Central America (BMZ, 2010–2014)

o Costa Rica: Support of Costa Ricas strategy of carbon neutrality as a model for low-carbon development (BMU, 2011-2015)

o Powering Agriculture - Sustainable Energy for Food: Regional (BMZ, 2013-2015)

o Energising Development - ENDEV: Regional (Multistakeholder)

o India: Emission-neutral Rural Energy Supply Programme (BMZ, 2009–2014)

o Vietnam: Support for the establishment of a renewable energy agency (BMU, 2010–2014)
Página 6
biogas.org german-biogas-industry.com

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 Number of biogas plants & installed electric capacity
9.000 4.500
Number of biogas plants in Germany
Installed electric capacity in Megawatt [MW] 8.005
8.000 7.8507.944 4.000
7.515 4.054
4 GW Biogas capacity installed el. Power (5% ! of total PC) 7.175 3.859
7.000 3.500
3.543
3.352
Number of biogas plants

5.905
6.000 3.000

Installed electric capacity

3.097

4.984
5.000 2.500

2.291
3.891
4.000 3.711 2.000
3.500
1.893
3.000 2.680 1.500

1.377
2.050 1.271
2.000 1.750 1.100 1.000
1.600
1.300
1.050
1.000 850 650 500
617
450
274 370
139 159 186
0 0

© Fachverband Biogas e.V. / German Biogas Association

Years

8
Content

• German Biogas Association

• Trainings in the area of safety on biogas

plants
• Hazards on biogas plants
• Risk evaluation and precautions
• Safety guidelines and documentation

9
10
 Safety –
Establishment of Regulations and Standards –
Training standards for operators, etc.
Sustainable Image of Biogas!

11
Ministries involved in the biogas plant safety in Germany

Federal Ministry for the Federal Ministry of Federal Ministry for Federal Ministry
1. Environment, Nature
Conservation, Building
Labour and Social Economic Affairs of Food and
Affairs and Energy Agriculture
and Nuclear Safety

plant environment Ordinance on Industrial Health

2. safety protection and Safety
(explosion safety)
energy supply

3. UBA KAS LAI AISV BG´S GAA LASI AGS,A Energie-

z.B. DVGW
BS aufsicht

-immission control
Ordinance on Industrial - Energy crops/
- water protection Energy Economy Law
Safety and Health; German sustainabilty,
- waste law (EnWG); Gas Network
Occupational Safety and - Regional value
- Technical Instructions on Access Ordinance
Health Act; Ordinance on - agricultural laws
Air Quality Control / (GasNZV); Technical
Hazardous Substances, - greenhouse-gas
Technical Instructions on Standards of the
Ordinance on Biological reduction
4. Noise Protection:
Agents;
DVGW (German
Technical and
- …..
BImSchG; WHG, Explosion Protection Scientific Association
KreislaufWG, (94/9/EG, 99/92/EG, BGR for Gas and Water):
KrWAbfG/AbfKlärV 104, 11.PSGV) G 260, G262, VP265,
EEWärmeG; UVPG Machinery Directive G462, G415, G1030,
DÜMV; TierNebG; 06/42/EG; Biogas Safety G469
StörfallV Rules
Biogas Training Network

Since October 2013

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Curricula of the 2 days operators qualifications
training in Germany

• Legal Framework of plant construction and operation

• Risk assessment
• Explosion protection
• Documentation
• Mandatory obligations for the plant operator
• Damage and accident management
• Safety relevant checks and maintenance
• Best-practice-example (on-site check and evaluation)
• Multiple-choice exam

14
Content

• German Biogas Association

• Trainings in the area of safety on biogas plants

• Hazards on biogas plants

• Risk evaluation and precautions
• Safety guidelines and documentation

15
 Hazards on biogas plants

general distinction of hazards:

- health hazards

- environmental hazards

http://www.syswe.de/de/landwirtschaft/biogasanlagen-
leckage/gaskamera/bildergalerie.html

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 Hazards on biogas plants

Fire hazards

Heat Hazardous substances

1 2

Noise Mechanical hazards

Electrical hazards Crash or falling down

Source 1: http://pixabay.com/de/photos/icon/

Source 2: http://www.safetysign.com/products/p2407/warning-
electrical-hazards-label

Source: http://www.unece.org/trans/danger/publi/ghs/pictograms.html
Gas hazards
17
 Hazards on biogas plants

Distribution of accidents according to the hazards

• In 2012:
About 7,500
radiation noise
biogas plants no information
chemical heat 1% 1% 1%
in Germany hazards 4%
7%

• About 270
accidents with
86%
injured people

mechanical
hazards
Source: SVLFG = German Agricultural Occupational Health and Safety Agency

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 Hazards on biogas plants

Accident on a biogas plant with 4 dead people in

2005
 One day before the accident dairy and animal waste products
were delivered to the biogas plant.
 This mixture was stored in a 100m³ mixing tank and had a very
low pH-value (hydrolysis).
 At the day of the accident a dutch lorry driver delivered
chopped hog (60°C, sulfide, pH-value 8,5).
 In the mixing tank both components were merged => chemical
reaction with the release of a extremly high concentrated H2S-
gas cloud.
 Due to the opened mixing tank and the integrated mixer the
deadly gas could spread throughout the closed hall.
 Estimated amount of H2S: 10.000 ppm
Rhadereistedt
 immediate death…

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 Hazards on biogas plants

Mechanical hazards:

- Moving parts of machinery

- Dangerous surfaces

20
 Hazards on biogas plants

Mechanical hazards:

Moving parts –
watch your clothes!

21
Hazards on biogas plants

Mechanical hazards:

Falling:
• Into tanks
• From construction area
• From silo
• From ladder
• …

22
 Hazards on biogas plants

Gas hazards – dangerous components of biogas

Carbon dioxide (CO2)

 CO2: colorless, odorless, heavier than air
 MAC1 5000 ppm = 0,5 %; dangerous area
above 8 Vol. %
 danger of suffocation

Methane (CH4)
 methan ist colourless, odorless and lighter than air
 danger of suffocation
 explosive range 4,4 % - 16,5 %

Oxygen (O2)
 O2-concentration below 18 Vol.-% is dangerous
1 23
maximum allowable concentration
 Hazards on biogas plants

Gas hazards – dangerous components of biogas

Ammonia (NH3)
 ammonia is colourless, pungent smelling and lighter than air
 danger of fire 15 % - 30 %
 MAC1 20 ppm = 0,002 %
 30 - 40 ppm = irritation of mucous membranes, respiratory tract
and eyes
 1000 ppm = 0,1 % = difficulty in breathing, unconsciousness

Hydrogen Sulfide (H2S) :

 H2S is colourless, smelling like rotten eggs
 heavier than air, strong blood and nerve poison
 MAC1 10 ppm = 0,001 %
 50 ppm 0,005 % = irritation of the respiratory tract
 200 ppm 0,02 % = paralyzed sense of smell
 700 ppm 0,07 % = respiratory arrest (death)
1 24
maximum allowable concentration
 Hazards on biogas plants

Explosion hazards – „Explosion Triangle“

Biogas Air (oxygen)

explosive range: > 11,6 Vol.-%
6 - 22 Vol.-%

Igniction
Ignition temperature:
700 °C

25
 Explosion / deflagration due to gasleakage

- 2 seriously injured
- approximately 400,000 €
property damage
26
Content

• German Biogas Association

• Trainings in the area of safety on biogas plants
• Hazards on biogas plants

• Risk evaluation and precautions

• Safety guidelines and documentation

27
Risk evaluation and precautions

Risk Assessment

 The focus for the issue of a risk assessment is to protect and to

reduce the exposure to risk and hazards of employees.

 The employer must determine, evaluate, and minimize the

hazards and must consider the acquired knowledge by

- the design and selection of work tools

- as well as the design of workplaces
- work and production processes
- work procedures
- and interactions of all of the above

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 Risk evaluation and precautions

Explosion hazards

• Explosion hazards must be determined and assessed. In particular, it

must be determined where potentially explosive atmospheres can
occur.

Potentially explosive areas have to be classified into Ex-

zones = Ex-Zone-Document is necessary in Germany for all
biogas plants!

• Potentially explosive areas must be identified by appropriate signage.

• In areas where explosive gas/air mixtures can occur and which

are classified as Ex-Zone only special and officially accepted devices
and tools are allowed to be used.
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 Risk evaluation and precautions

Ex-Zones

Zone 0
DANGER explosive atmosphere is present continuously, for long periods or
frequently. E.g.: overflow protection, Zone 0 in the pipe and in the area
near the overflow

Zone 1 (radius 1 m)
explosive atmosphere is likely to occur occasionally, in normal
DANGER operation conditions. E.g. immediate vicinity of manholes into the gas
storage tank or on the gas-retaining side of the fermentation tank, and
in the vicinity of blow-off systems, pressure relief valves

Zone 2 (radius 1-3 m)

explosive atmosphere is not likely to occur in normal operation
conditions, but if it does occur, it will be for a short period only. E.g.
DANGER
manholes and the interior of the digester, in the vicinity of aeration and
ventilation openings of gas storages

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Content

• German Biogas Association

• Trainings in the area of safety on biogas plants
• Hazards on biogas plants
• Risk evaluation and precautions

• Safety guidelines and documentation

31
 Safety Guidelines and Documentation

Operating instructions and instruction manuals

 The manufacturers introduce products into the market with operating

instructions.
 The operating instructions from the component manufacturers must be
collected and stored safely from the plant operator.
 For the operation of different resources, equipment, etc., the operator
has to provide an instruction manual which includes operating
instructions, as well as information about hazards that result from the
installation conditions.
 In addition, special operating states such as startup and shutdown of
the system need a specific instruction.
 The employees must be instructed regularly about safe operation, e.g.,
using the instruction manual.

32
 Safety Guidelines and Documentation

Requirement to label: P 06 No Admittance

P 02 fire , smoking etc. are Without Authorization
prohibited

W 21 explosive atmosphere W 03 poisonous substances warning sign

W 01 warning
M 03 earprotection M 09 use safety M 04 use W 16 flammable
harness respiratory biohazard substances
protection warning sign
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 Safety Guidelines and Documentation

Operating instruction for a biogas system in normal operation - 1

In general:

 During filling and emptying, pay attention to pressure fluctuations and ensure
good accessibility to the operating equipment.

 Avoid ignition sources

 Do not work on your own! (always at least 2 persons)

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 Safety Guidelines and Documentation

Operating instruction for a biogas system in normal operation - 2

Daily:

 Record the gas meter reading and operating hours of the motor.
 Check the motor oil level.
 In the control room, at the control box, check whether the malfunction lights are
illuminated.
 Check the water pressure in the heating system.
 Check the air-dosing pump of the desulphurization system for operability.
 The airflow injected for desulphurization must be matched to the current gas
production rate (max. 6% vol.).
 Monitor the digester temperature.
 Select the agitation intervals so that no layer of scum/sediment layer develops.
 For all inlets and outlets, assure that the liquid manure/substrate flow is
maintained according to the process regulations.
 Check the fill levels in the digester and end storage.
 Check the membrane connectors (e.g., attachment hose at the membrane gas
storage).

35
 Safety Guidelines and Documentation

Operating instruction for a biogas system in normal operation - 3

Weekly:
 Check the fill level of the sealing liquids in the overpressure and under-pressure protectors
and condensate separator; if necessary, in the case of a danger of frost, check the antifreeze
agent (if the weather warrants, daily checks are also required).
 Check the submerged propeller function; observe whether vibrations are present.
 Visually inspect the motor and the lines.
 Check the gas magnet valve for function and contamination.
 Check the intermediate space of the self-closing gas shutoff valve for tightness.

Monthly:
 Actuate all scrapers a few times so that they are not stuck.
 Possibly remove the oil deposits in the CHP unit and clean the oil catch basin.

Twice a year:
 Check the ventilation and exhaust in the machine room of the CHP unit.
 Inspect the electrical systems for damage.
 Check the under-pressure monitor of the gas system for function.
 Check the function of the gas sensors, fire detector (if present).

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 Safety Guidelines and Documentation

Operating instruction for a biogas system in normal operation - 4

Annually:
 Check the gas-carrying system parts for damage, tightness, and corrosion.
 Calibrate the gas sensor with suitable test gas.

Every 2 years:
 Check the fire extinguishers.

Pits and shafts:

Before entering and during presence in the pits and ducts, it must be guaranteed that there is no
hazard of poisoning, as well that there is sufficient breathable air. Operating equipment must be
reliably secured so they don’t switch on (lock out procedures). Ensure that there is sufficient
ventilation. In the case of insufficient ventilation, there is a danger of asphyxiation, fire, and
explosion.

37
 Conclusion

• Biogas is as an all-rounder and a key in the energy mix

• Biogas plants are complex process plants with several hazards

• Operating staff and owner need professional skills and Know-how.
Importance of national operators training and periodic retraining!!!
• Well-qualified plant designers and manufacturers are required.
• Problem in Germany: too many rules (over-regulation and the
disproportionate burden to the operators and manufacturers)
• Problem in some developing- and emerging countries: no or lacking
regulation
• ISO (International Standard Organisation) TC 255: developing and
promoting standardisation in Biogas industry

• Lot of experience and know-how in Germany. Partnerships!

Keep it safe, efficient and simple!

38
Thank you for your attention!

16.-18.02. 2016 BIOGAS ConfEx – Conference / Nürnberg

15.-17.11. 2016 BIOGAS ConfEx – Conference / Hannover
parallel to EnergyDecentral

• Biogas Basics!

• Know-How Transfer!

• International Panel on
Development & Emerging Countries!

• Best practise on Waste digestion and „exotic“

substrates!
www.biogas.org
39
 Clemens Findeisen

Consultant
Development Cooperation
German Biogas Association

Telefon: 0049 (0) 1763 / 17 88 290

Email: clemens.findeisen@biogas.org
Internet: www.biogas.org

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