Presentation on

Operation & Maintenance

of Biogas Plant
Training on Biogas
For Participants from HoAREC
5-07-09

Presentation by: BSP-Nepal

 Operation
&
Maintenance of Biogas
Plant
 Functioning of a Biogas Plant

O Pressure Full Pressure

Functioning of Biogas Plant

Non Function/Problems plant

Components of a Biogas Plant
!!! Important !!!

 Proper construction only not sufficient,

proper use of Gas and Slurry to be
done
 User must know the basic functioning
characteristics to safeguard the
technology
Operation and Maintenance(1)

 This is one of the vital elements for

sustenance of the technology

 Proper Maintenance will ensures

satisfaction of the users
 Biogas Plant Design in Nepal (2)

 A Sectional View of Biogas Digester Showing

Feed Inlet, Gas Outlet and Slurry Overflow.
 Daily feeding
 For efficient and sustainability of the technology
feeding to be done as per the plant capacity

 Daily feeding in the ratio of 1:1 with homogeneous

mixing with mixer (Dung + Water) is vital

 Unwanted particles - Stone, Mud, Sand and heavy

straw - must be removed from the feeding
 Feeding amount / Types of materials / Temperature
must be well attended to
 Main Gas Valve

 This is a vital component of the biogas

plant
 Has to be closed whenever gas is not
in use
 Never try to assemble/dissemble
without trained Mason/Technician
 Never open/close in half position
 Lubricate only inner portion of valve
ball with oil
 Fully tighten it into the gas pipe
Mixture Machine
Dome Gas Pipe
Main Gas Valve
 Gas tap
 Gas tap open / close for stove flame
and heat control not for gas supply,
 Use oil for lubrication on the side of
tap rubber - O ring
 Clean the impurities in gas delivery
aperture of tap
 Do not use tools for opening or
closing the tap
 Gas leakage must be repaired
immediately
 Cracked rubber hose to be replaced
immediately
Gas Tap
Water Drain Device
 Gas Production
 Gas production depends upon feeding of
the plant and the temperature
 In winter season when the temperature
is low gas production will also be low
 This can be improved by proper top
filling (40 CM) of soil (heap composting)
 Never leave the concrete of the plant
bare or with little top filling
 By thumb rule 10kg dung feed plant
should run the biogas stove for an hour
Biogas Stove
 Water drain and drain pit
 Condensed water vapor accumulates in
gas supply pipe, which clogs the gas flow.
 Red flame or wheezing sound in the
pipeline indicates the water accumulated
in pipe line, Released water trough water
drain device
 Carefully lift the drain pit slab while
draining/Cover after draining the water
 Do not use tools for operation
 Outlet
 Proper operated biogas plant throws out
digested slurry via outlet overflow
 Slurry has to freely flow away and it can
not flow back into the outlet
 Rainwater should never be able to flow
into the outlet
 Dried slurry can block the overflow and
create a problem, hence needs to be
removed periodically
 Never leave an opened outlet pit
unattended
 If an outlet slab is cracked, it should be
replaced immediately
 Operation and Maintenance(2)
 Proper Feeding of Dung and Water in 1:1 ratio
 Frequently Cleaning of Overflow hole
 Operation of Main Gas Valve
 Operation of Water Drain device
 Operation of Gas tap
 Operation of Mixer device
 Top Filling/ Back filling
 Operation of Stove
 Operation of Gas lamp
 Problems Solving Techniques(1)
Problems Causes
1.Although there At the beginning, in newly filled
is enough gas in plant, there is an mixture of
the dome, gas different non-combustible gases,
does not burn. which do not burn.
Newly filled slurry do not produce
methane gas instantly.
Main gas valve may not be
opened.
The hole of gas tap and stove jet
hole might be obstructed
Water may have blocked the gas
flow.
Lack of methanogenic bacteria.
Remedies
Release all the stored gases from the
dome. By opening gas taps and
water drain plug. Repeat this process
until the gas burns easily.
Wait for about a week because, it
takes some time to produce
methane.
Open Main gas valve.
Clear all the ports in the gas tap,
stove jet and burner cap.
Open water drain and release all the
water from the pipe line.
Add slurry from old operating plant.
 Problems Solving Techniques(2)

Problems Causes Remedies

2 Gas Quantity of slurry is Feed recommended amount of

production decreased or dung and water daily.
suddenly increased suddenly
reduced or then recommended.
completely Ratio of dung and Mixture ratio should be corrected
stop. water suddenly as to the recommended ratio. (1
changes. kg dung :1 liter water)
Decreased in the leave the mixture in the sunlight
temperature inside for few hours before feeding
the digester. inside the plant.
Increase the top filling on dome
by more than 40 cm.
 Problems Solving Techniques(2)

Problems Causes Remedies

Gas Chemicals such as soap Avoid use of such contaminating

production water, detergent, phenyl chemicals and dung from under treatment
suddenly and dung from the under cattle.
reduced or treatment cattle may have Continue to feed the plant daily with
completely been mixed. recommended amount of fresh dung and
stop. water until methanogenic bacteria
develops fully.
Plant not having enough Manage enough sunlight on dome.
sunlight on dome.
Gas leakage in the pipe Check all the joints with soap foam,
joints. repair the leakage or call the company
Cracks in the rubber technicians as soon as possible.
hose due to poor quality. Replace with Neoprene rubber hose
only.
 Problems Solving Techniques(3)

Problems Causes Remedies

3 Flame is Pressure of the Let the pressure rise by giving
very weak combustible gas is weak. enough rest period.
or burns The hole of gas tap and Clear all the pores in the gas tap
little with stove jet hole might be and stove jet.
red flame. obstructed.
Water may have been Open the water drain and
collected in the pipe line. release all the water from the pipe
line.
 Problems Solving Techniques(3)
Problems Causes Remedies
3 Flame is Slurry may have entered Open the union of the main gas
very weak the pipe line. valve, fill the pipe line with water
or burns and open the water drain so that
little with the filled water isreleased through
red flame. the water drain. Continue this
process until the pipe line is free
from slurry. Same method should
be applied through the gas tap to
clean the other half of the pipe
line.
No slope, drain not Maintain necessary slope so that
placed at the lowest water in the pipe line accumulate
point or Incorrect sloping in the water drain from all side.
of the pipeline.
 Problems Solving Techniques(4)

Problems Causes Remedies

4 Gas burns Air hole and gas jet Position the air regulator
with weak and hole in the burner pipe ring so that the air hole is
long flame far my have been blocked. only half covered.
away from the Clean the jet hole as well
stove burner as air hole free from foreign
matters.
5 Hard to Carbon deposits may Frequently check the
operate gas have taken place. appliances for carbon
tap, main gas deposits. Clean and
valve and gas lubricate it weekly.
cock of the
lamp.
 Problems Solving Techniques(6)

Problems Causes Remedies

6 Slurry in Under fed plant. Feed the plant with recommended amount of dung
the pipe line and water.
In correct ratio of dung Maintain correct ratio of dung and water.
and water.
Leakage  Repair all leakage.
Harmful Chemical in  Avoid using chemical in the toilet.
the mixture.  Do not use dung from sick cattle.

Low temperature.  Maintain proper ( 40 cm ) top filling on dome.

 Manage adequate sunlight on dome.
 Warm the mixture by sunlight for few hours

before feeding.
Little rest period and  Provide adequate rest period and economically
excessive use of gas use gas.
 Problems Solving Techniques(6)

Problems Causes Remedies

PLANT a) smaller dome a) Adjust volume of outlet as

MEASUREMENT and/or bigger outlet required to maintain the
volume relation
GAS LEAKAGE a) Leakage before a) Repair it by proper
main valve sealing /tightening
b) Leakage from b) Observe it properly and if
dome found, empty plant & re-do
proper plastering/painting
inside the
 Problems Solving Techniques(6)
Problems Causes Remedies
OPERATION a) Failing to close a) Always close main valve
main valve when gas is not in use
b) Not observing b) Observe longer rest period
rest period during winter
c) Blockage of outlet c) Check it regularly and clear if
overflow obstructions observed in
overflow
TEMPERATURE a) Low gas a) Follow the methods to
( in winter) production due to improve gas production
low temperature
Reduced gas a) Bacteria killed by a) Avoid feeding toxic material;
production toxic materials if no gas production, empty
b) Reduced activity digester and re-feed
of bacteria b) Maintain favorable (optimum)
condition in the plant
 Questions and Observations on
Operation & Maintenance

Questions
 Proper Feeding of Dung and Water
 Frequently Cleaning of Overflow hole
 Operation of Main Gas Valve
 Operation of Water Drain device
 Operation of Gas tap
 Operation of Mixer device
 Top Filling/ Back filling
 Operation of Stove
 Operation of Gas lamp
 List problems in terms of frequency and difficulty in addressing