El GUACAL Operating Instruction PDF

Operating instruction
Commission No. H10798 El Guacal
COMPACT DEGASSING PLANT
HOFGAS- Ready 3000 CDM
Comm.No.: H10798 El Guacal Page 1 / 105

Register
1 General.................................................................................................................................. 4
Overview of revisions .......................................................................................................................... 4
Introduction.......................................................................................................................................... 5
Other valid documentation .................................................................................................................. 5
Customer Service ................................................................................................................................ 6
Copyright ............................................................................................................................................. 6
2 About landfill gas systems .................................................................................................. 9
General description ............................................................................................................................. 9
3 Safety Specifications and Responsibility ......................................................................... 12
Symbols in this documentation.......................................................................................................... 12
Qualification of the employees .......................................................................................................... 13
General safety aspects...................................................................................................................... 14
Potential endangerments by gases and exhaust gases .................................................................... 15
Eex-zone concept.............................................................................................................................. 20
Safety measures ............................................................................................................................... 21
Potential endangerments by gas processing plants .......................................................................... 22
Protection for personal ...................................................................................................................... 23
4 Product Description ........................................................................................................... 24
Technical specification of the plant ................................................................................................... 24
P&I-diagram / dimension drawing / legend........................................................................................ 31
5 Transport / Storage / Erection / Disassembling ............................................................... 27
General information ........................................................................................................................... 27
Required equipment .......................................................................................................................... 28
Loading/Transportation / Unloading .................................................................................................. 29
Assembly instruction ......................................................................................................................... 31
Adjustment before putting into operating .......................................................................................... 44
Calibration of the Gas Analysing System .......................................................................................... 46
6 Operation of the plant ........................................................................................................ 47
Safety at the operation of the plant ................................................................................................... 47
Putting into Operation ........................................................................................................................ 48
Operating panel ................................................................................................................................. 54
Function buttons ................................................................................................................................ 54
Panel descriptions and set points of Plant control A101 ................................................................... 55
Memograph ....................................................................................................................................... 66
7 Function description .......................................................................................................... 71
Starting procedure ............................................................................................................................. 71
Operating phase ................................................................................................................................ 72
Switching off ...................................................................................................................................... 72
Temperature regulation ..................................................................................................................... 73
Start position of the air flap................................................................................................................ 75
Pressure regulation ........................................................................................................................... 75
8 Electrical description ......................................................................................................... 78
Circuit diagram of the plant and the flare .......................................................................................... 78
Circuit diagram of the gas Analysis System CH4 / O2 / CO2 ............................................................. 78
Circuit diagram of the fluegas Analysis System CH4 / O2 ................................................................. 78
Circuit diagram of the KUHSE System .............................................................................................. 78
Frequency Inverter parameters ......................................................................................................... 79
9 Repairs ................................................................................................................................ 80
Trouble shooting................................................................................................................................ 80
Fault analysis..................................................................................................................................... 82
Disruptive incident ............................................................................................................................. 87
Shutting down .................................................................................................................................... 88
Storage / conservation ...................................................................................................................... 88
10 CDM ..................................................................................................................................... 89

Register
Concept for data monitoring and storage .......................................................................................... 89
CDM Instrumentation & Tolerances .................................................................................................. 92
Equipment Certificates ...................................................................................................................... 93
Validation of CDM instrumentation .................................................................................................... 94
Maintenance of CDM instrumentation ............................................................................................... 95
11 Maintenance ....................................................................................................................... 96
General maintenance instructions ..................................................................................................... 96
Maintenance plan .............................................................................................................................. 98
Proof of maintenance ...................................................................................................................... 101
Spare parts list ................................................................................................................................ 102
12 Appendix ........................................................................................................................... 105
Supplier components list ................................................................................................................. 105
Attached components manuals to HOFGAS-Ready 300 CDM flare ............................................ 105

General Overview of revisions
General
Overview of revisions
File name: H10798 Operating instructions
Table 1: Overview of revisions
Version Date Name Chapter Changes
new 2011-01-26 Beutler Marc
Swiss Gas Combustion Technology

Plant engineering and environmental systems
Hofstetter Umwelttechnik AG
Münchringenstr. 12
CH-3324 Hindelbank
Switzerland
Contact person: Beutler Marc
Phone +41 (0) 34 411 86 40
Fax +41 (0) 34 411 86 10
[email protected]
www.hofstetter-uwt.ch
©

General Introduction
Introduction
The main purpose of a Landfill gas plant is to collect, safely deliver and properly burn off as much
of the gas produced by the Landfill gas, as possible. The production of gas in waste is a
continuous biological process, the intensity of which cannot be influenced or controlled.
Safety and protection against explosions

must therefore be uppermost guaranteed.
The necessary monitoring is guaranteed by an efficient safety technique of the complete plant
In order to ensure trouble free and safe operation of the plant, it must be professionally installed,
commissioned and operated, as well as carefully maintained in accordance with these Operating
Instructions.
The mains supply of the plant, as well as between electrical control between the control cabinet
and the individual plant components may only be carried out by a licensed electrician and in
accordance with local specifications.
Only persons who are well acquainted with the installation, commissioning, operation and
maintenance and have the necessary qualifications may work on the plant.
Should the information in these Operating Instructions not be clear or insufficient, the
manufacturer (representative) will be only too pleased to give you further information.
Other valid documentation

The Operating Instructions consist of 1 file, containing 12 chapters. The Appendix list is included in
chapter 12.
Abbreviations used in the operating instructions are explained in the following list:
UEL ➝ Upper explosion limit
LEL ➝ Lower explosion limit
HOFGAS- Efficiency ➝ Flare for Landfillgas with a methane content of

between 30..55 Vol %, with autonomic control
(High temperature flare) Combustion temperature 1000 °C, regulated via the
combustion optimisation by means of an air throttle
SUVA ➝ Swiss Accident Insurance Association
PTB ➝ Physikalisch-Technische-Bundesanstalt

General Customer Service
Symbol:
➝ Indication of a source of danger
Customer Service
Additional information and assistance for special applications are available from:
Münchringenstrasse 12
CH-3324 Hindelbank
Tel.: + 41 34 411 86 86
Fax: + 41 34 411 86 10
E-Mail [email protected]
Internet www.hofstetter-uwt.ch
Copyright
We reserve all rights in this document and in the information contained therein. Reproduction, use
or disclosure to third parties without express authority is strictly forbidden. © Hofstetter
Umwelttechnik AG 2011.

General
Konformitätserklärung
CE Declaration of Conformity
Déclaration de Conformité européenne
Declaraciòn de Conformidad CE
Gemäss Anhang II, Part 1, Section A der EG- Maschinenrichtlinie 2006/42/EG

In accordance with Annex II A of the EC Machine Directive 2006/42/EC
Selon la directive européenne 2006/42/CEE, annexe II A, relative aux machines
Según Anexo II A de la Directiva 2006/42/CE relativa a las máquinas
Hersteller:
Manufacturer, producteur, productor
3324 Hindelbank
Dokumentationsbevollmächtigter Philipp Schaad
Mandatory of documentation, mandataire de la notice d'instructions, Senior project engineer
representante autorizado del manual de instrucciones
3324 Hindelbank
Hiermit erklären wir, dass folgendes Produkt

We hereby declare that the following product, garantissons que la version livrée des machines mentionnées ci-dessous, por la presente
declaramos que el siguiente producto
Bezeichnung: Entgasungsanlage
Designation, désignation, denominación
Typ: HOFGAS- Ready 3000 CDM

Type, type, tipo
Geräte Nr.: H10798

Unit no, N° de l’appareil, núm. aparatos
Baujahr: 2011
Construction year, année de fabrication, año de fabricación
In der gelieferten Ausführung folgenden Bestimmungen entspricht:

Complies with the following provisions in it delivered version, satisfait aux exigences suivantes, de la versión suministada responde a
las siguientes disposiciones
2006/42/EG EG – Maschinenrichtlinie
EC Machine Directive 2006/42/EC, Directive européenne 2006/42/CEE relative aux machines,
Directiva 2006/42/CE relativa a las máquinas
Folgende harmonisierten EU-Normen wurden angewendet:

The following harmonises EU standards were applied, Les normes d’harmonisation européennes suivantes ont été appliquées,
Se han aplicado las siguientes normas UE armonizadas

General
EN 60204-1 Sicherheit von Maschinen – Elektrische Ausrüstung von Maschinen

Safety of machinery – Electrical equipment of machines, Sécurité des machines – Equipement
électrique des machines
EN 12100-1 Sicherheit von Maschinen – Grundbegriffe, allgemeine
EN 12100-2 Gestaltungsleitsätze
Safety of machinery – Basic concepts, general principles for design, Sécurité des machines –
notions fondamentales, principes généraux de conception
94/9/EG(ATEX95) EG-Richtlinien zum Explosionsschutz
99/92/EG (ATEX 137) EC Directive ATEX 94/9/EC, 99/92/EC, Directive ATEX 94/9/CE, 99/92/CE, Directiva ATEX
94/9/CE, 99/92/CE
Bei einer nicht abgestimmten Änderung der Maschine verliert diese Erklärung ihre
Gültigkeit.
In case of a not coordinated modification of the machine, this declaration of conformity is not valid anymore.
Lors d'une modification non coordonnée de la machine cette déclaration de conformité perd sa validité.
En caso de una modificación no coordinada de la máquina, esta declaración de la conformidad es inválida.
Ort / Datum Hindelbank, 26.01.2011

Place / date, lieu / date, localitad / fecha
Unterschrift mit Angaben zum Unterzeichner i.V. Marc Beutler

Signature / details of signatory, signature / Project Manager
fonction, firma / mención del firmante

About landfill gas General description
systems
About landfill gas systems
General description
Landfill gases are combustible gases which must, in accordance with the Clean Air Act, be
rendered harmless. This can be done in different ways. We differentiate between Landfill gas
flaring off in a high temperature flare and Landfill gas utilisation in a high temperature furnace or a
Landfill gas engine.
In order to fulfil this task, the Landfill gas must be pumped out of the Landfill gas with a gas pump.
In order to abide by the stringent demands required by ex-proof stipulations, the whole plant must
be sufficiently dimensioned in order to incorporate safety technique equipment.
For example the gas composition must be continuously monitored, in order to prevent the build up
of explosive gas mixtures in the system. Or flares are equipped with burner controls EC-type-
tested and certified, in order to ensure a defined firing process.
Main components of the Landfill gases:

Methane – concentration range: 30 up to max. 55 Vol. %
Carbon dioxide - concentration range: 20 up to 40 Vol. %
Oxygen – concentration range: 0 up to 6 Vol. %
Nitrogen: 0 up to 48 Vol. %
Water vapour max.: approx. 1 Vol. %
Trace elements
Gas analysis should be taken of corrosive trace elements (i.e. hydrogen sulphide) and halogenated
hydrocarbon (present at the same time as water vapour, gas condensate and oxygen in Landfill
gas).
Critical concentrations relative to corrosion (not binding guideline values)

• Halogenated hydrocarbon in Landfill gas ⇒ 50 mg Chlor/Nm3
• Hydrogen Sulphide in Landfill gas ⇒ 100 mg/Nm3

Should the concentrations exceed these limits, then we would recommend taking special
measures, which should be discussed with the manufacturer.
Further demands relative to Landfill gas quality:

• Dust free (to be considered during on-site planning)
• Condensate free Landfill gas (to be considered during on-site planning)

systems
Basic equipment of pump and flare station
The basic equipment of the Hofstetter pump and flare station incorporates all elements to comply
with regulations and safety specifications for the delivery and combustion of Landfill gas.
• All gas contacting parts rust-free or galvanised steel
• All gas contacting parts pressure proof up to 2,5 bar
• Landfill gas proof blower
• Flare for low emission combustion of Landfill gas
• Plant control with all necessary elements for observation of Eex-proof
The Landfill gas is extracted from the Landfill gas by using a blower to create a sub-atmospheric
pressure (negative pressure). The processed gas is then conveyed either to the flare or the
utiliser, for low emission, controlled combustion.
The additionally installed gas analysis system continuously monitors the composition of the Landfill
gas and shuts down the plant before an explosive mixture can form in the system.
Gas processing pump station
The extracted Landfill gas is fed over a suction line to the condensate tank which is included in the
gas cooling system. Next the wet saturated Landfill gas is finely dewatered in the condensate
separator so that it can be burnt off either in the flare burner or in the utilisation without the build
up of condensate. The condensate which is collected here is fed back to the lagoon.
Landfill gas blower
The blower produces the above mentioned negative pressure in the Landfill gas. In view of the
pressure increase of the blower the Landfill gas is conveyed through the pipeline system of the
flare or the utiliser. According to required stipulations, the blower, which represents a source of
ignition, is fitted with downstream flame arresters.
As a further protective measure a flame arrester can be fitted upstream and downstream of the
blower, which prevents in case of explosion, the flame spreading in the system.
The blower is started with a star delta connection. The blower can be switched on and off by
means of a manual switch at the electrical control.
The description of the methods of operation and their functions can be found in chapter „operation
of the plant.“

systems
Flare
The flare burns off the processed Landfill gas at approx. 1000°C. In the main harmful nitrogen
oxide is degraded in this stage. Various safety devices, such as quick closing gate valves, over
temperature monitoring, flame monitoring, etc. guarantee a safe combustion of the gas at all
times.
Gas analysis system
Landfill gas consists mainly of methane (CH4), carbon dioxide (CO2), nitrogen (N2) as well as
Oxygen (O2). It also contains very small quantities of hydrogen sulphide, carbon hydride and
traces of halogenated hydrocarbon. At a particular ratio of the oxygen-(O2) and methane (CH4)
content, the gas mixture becomes explosive. To ensure that this can never occur, in spite of the
safety measures, the plant is equipped with an analysis system:
This analysing system is connected via the measuring gas sampling filter and sampling pipeline, to
the Landfill gas system. There is one measuring gas sampling point on the top of the condensate
tank.
The methane and oxygen content in the Landfill gas is measured using two analysers. If the limit
value of the O2 or CH4 content is exceeded or fallen short of, the plant shuts down. Thereby it is
ensured that no Landfill gas explosive mixtures are conveyed through the plant. In order to prevent
the occurrence of an explosive atmosphere through a defect measuring gas pipeline in the
analysis cabinet itself, it is permanently ventilated by the cabinet fan. The air current is monitored
and if the fan is defect, the measuring gas supply as well as the complete plant is shut down.
Also the CO2 content of the gas is analyzed.
Plant control pump station
The plant control incorporates all necessary switching and display elements for monitoring and
control of the pump and flare station. This unit displays warning and alarm signals. All necessary
analogue and digital signals are transmitted to the terminal in the control cabinet. A detailed
description of the control can be found in chapter „Operation of the plant“.
The KUHSE-System allows to monitor the operation of the plant.

Safety Specifications
and Responsibility
Safety Specifications and Responsibility
The safety references in this chapter are to be read before the start-up of the
gas utilization plant. With misapplications heavy injuries can enter.
Symbols in this documentation
To the better distinction endangerment risks are certain by following alarm symbols and signal
words:
Alarm symbols and

Impact
Signal words
Reference on a dangerous situation, which, if it is not

Danger avoided, leads to death or to heavy injuries.
personal injury
Reference to a dangerous situation, which, if it is not

Warning avoided, can lead possibly to death or to heavy injuries.
Reference to a dangerous situation, which, if it is not

Precaution avoided, leads possibly to middle or light injuries.
material
damage
Reference to a situation, those, if it is not avoided, possibly

Attention to damages of construction units, the plant and/or its
functions or a thing in its environment leads.

Safety Specifications Qualification of the employees
and Responsibility
Qualification of the employees
Persons working in dangerous areas must:
1. Know the dangers and be able to recognise dangerous areas.

2. Learn the safety preventive measures and use in every situation
3. Be equipped with suitable and reliable equipment
Experience and Knowledge of the following activities are a must:
Activities Staff Experiences Knowledge

Multiyear experience
regarding transport Proof of load safety device
and storekeeping of instructions; Transport and
Transportation and Staff Hofstetter,
structural steel storage references of
storage Shipping company
members and if Hofstetter; Safe handling
necessary power conveyances
supply units
Fundamental safety and health
Multiyear experience regulations, in particular for
Errection and as a mechanic of gas gas processing plants, Gas
Installation processing plants and and burn technology,
Mechanic,
mechanical Measuring and automatic
Installateur, if
Maintenance engineering parts control, Safe handling
necessary as an
multiyear experience conveyances and tools;
electrical specialist
Shutting off and as Installateur, if pronounced technical
disassembling necessary as an understanding;
lectrical specialist with electrical installations:
Electrical specialist
Multiyear experience in Fundamental safety and health
industrial companies regulations, in particular for
Operation Operator
with gas processing gas processing plants,
plants instruction job and product
Multiyear experience
Staff disposal within the range of the Specialist for cycle and refuse
Disposal
enterprises regional disposal of economy
wastes

Safety Specifications General safety aspects
and Responsibility
General safety aspects

Responsibility for plant operation and maintenance work
Specifications for the construction and operation of Landfill gas plants have been derived from
different stipulations. At the present time no technical standards exist or are being drawn up
especially for Landfill gas.
The following principles are however today generally acknowledged:

• Landfill gas recovery and Landfill gas utilisation plants are categorised by the authorities as
plants requiring control.
• The responsibility of this lies with the plant operator. He must ensure that the plant is being
operated and maintained in accordance with the current safety requirements
• Everyone concerned with Landfill gas must realise that there are hidden dangers. It is therefore
important that the plant is operated and maintained only by suitably trained, reliable personnel.
• Persons, who operate and maintain a gas plant, must be given the necessary specialised
training and be acquainted with the relevant regulations for prevention of accidents as well as
directives and general technical regulations.
• They must be able to judge the condition of a Landfill gas plant.
• We should strive for training of skilled labour and their further education. Manufacturers of
Landfill gas plants dispose of a wide range of specialist know-how and experience. They also
carry out courses for Landfill gas personnel regularly.
• The operation instructions must always be available on location of plant and the responsible
personnel acquainted with same.
• Operating specifications, including maintenance plan, are supplied by the manufacturer. Other
regulations in respect of gas collection system, gas pipeline etc. as well as regulations for the
prevention of accidents must be set up according to local conditions.
• We should strive for training of skilled labour and their further education. Manufacturers of gas
plants dispose of a wide range of specialist know-how and experience. They also carry out
courses for personnel regularly.

Safety Specifications Potential endangerments by gases
and Responsibility and exhaust gases
Potential endangerments by gases and exhaust gases
Short description of safety technique

Landfill gas is a combustible gas mixture (CH4, CO2, N2, O2, etc.). The combustible matter in
Landfill gas is methane that forms an explosive mixture with air in concentrations between 5 - 12
Vol. %. For safety reasons, usually the upper and lower explosion limit for pure methane in air is
adopted: UEL= 15 Vol. %, LEL = 5 Vol. % CH4. There is a permanent danger of air being sucked
into the system when extracting Landfill gas, resulting in building up an explosive mixture.
The following diagram illustrates the mixture concentration and the three conditions, which can
ensue through the intake of air in native Landfill gas (line A-O).
Explosive range when Landfill gas is mixed with air

0
100%
10
100%
Methane content CH4
20
90 90
Inert gas content in Landfill gas
10
(2
30 CO2, N2
80 ,0
8
80
/7
,9
2)
20
(4 40
70 , 17
/1
70
5,
83
30 )
(6
, 25
50
60 /2
3,
60
40 75
55 (8 ) A
,3
5/ 60
50 31
,6
50
50 5)
(1
0,
4/ 70
40 39
,6
)
40
60
(1
2,
5/
47 80
30 70
,5
) 30
(1
4,
6/
55 90
20 ,4
) 20
UEL 15 14
100%
10
LEL 5
0 10 20 30 40 45 50 60 70 80 90 100%
Inert gas content (CO2, N2) in Landfill gas/air mixture vol.%
A = Average composition of native Landfill gas

UEL = Upper Explosion Limit
LEL = Lower Explosion Limit

A source of ignition can bring about an explosion of the explosive atmosphere. An explosion is
combustion which develops rapidly (oxidative reaction). The generation of the flame front can
reach a speed of 500 m/sec. Thereby the subsequent rise in pressure (explosion over pressure) is
approximately 5 to 6 bar.
In unfavourable cases (long, unsecured piping) the explosion can turn into a detonation.
Here the flame front reaches a speed of over 1500 m/sec and an over pressure exceeding 50 bar!
C ombustion cha mbe r S ta rt of pipe Tra ns- De tona tion to prote cta ble
s ourc e of e xplosion is tion fus e pla nt pa rts
igntione a re a
De fla gra tion uns table s tationary

(Explosion) Detona tion
DN
e xplo s ive
mixture
L
v [m/s] p [bar]
2000 v det 100
v def1
1000 p def1 p det 50
0 0
L = (m)
for pipeline DN100 (L/D = 100)
v = speed of flame front
p = pressure build up through volume expansion k:\analys e\allg \08 0395d 1.d rw
of burnt off mixture (compression front)
Therefore it is necessary, when taking into consideration possible sources of ignition, to take,
three main groups of safety technical precautions when operating Landfill gas plants.
1. Preventive measures in order to prevent or limit the formation of a dangerous, explosive

atmosphere, known as primary explosion protection E1.
2. Preventive measures in order to prevent ignition of the dangerous explosive atmosphere;
known as secondary explosion protection E2.
3. Constructive measures, in order to limit casualties during an explosion, known as constructive
explosion protection E3.

Sources of ignition
Sources of ignition are flare, gas pump and electrical equipment and measuring units connected
into the gas flow. The gas pump can activate ignition when friction is caused by solid matter
sucked into the system causing sparks.
The Landfill gas itself does not produce explosive gas atmospheres. However, explosive
atmospheres can be produced by:
• Intake of air through the surface of the Landfill gas
• Leaky pipelines
• Fractured pipelines
• Shearing off of gas collectors (gas well heads)
• Dehydration of hydraulic seals
• Insufficient ventilation of the pipeline before putting into operation
• Re-entering of air after failure of the gas pump

Prevention of accidents
Maintenance, control and repair work of gas recovery plants are not limited to machinery. Often
dangerous areas must be worked upon.
These are:
• Dewatering shafts
• Leachate shafts
• Control and revision shafts
• Reservoirs
• etc......
In these areas it must be reckoned with that there are low concentrations of Landfill gas.
The main dangers are:
• Oxygen deficiency (danger of suffocation)
• Toxicity (sickness, poisoning)
• Danger of explosion
The biggest danger is because the gas concentration is usually so small that it is not observed by
the human sense organs.
A number of preventive measures are generally binding, in order to limit the danger to personnel.
Fundamentally
Persons working in dangerous areas must:
1. Know the dangers and be able to recognise dangerous areas.

2. Learn the safety preventive measures and use in every situation
3. Be equipped with and use suitable and reliable equipment

Important safety preventive measures
1. It is forbidden to climb into a shaft, even one of insignificant depth, without taking necessary
safety preventive measures.
2. The works management must give permission or organise all work undertaken in shafts, and
well as periodically checking same.
3. The shaft must be ventilated over a longer period of time (several hours) before entering.
4. Control explosive gas concentration LEL in the complete depth of the shaft.
When the LEL > 100% (> 5 Vol. % CH4) then an explosion can occur through mechanical,
electrical or static sparking.
The danger of explosion is banished, when the CH4 concentration is lower than 20% of the
LEL (5 % Vol. CH4 x 20% = 1 Vol.% CH4).
The inspection requires forced ventilation.
5. Using a portable ventilator, the shaft should be continuously forced ventilated before and
during the maintenance work. Even if absolutely no CH4 concentration is detectable, we
would recommend forced ventilation; as other substances hazardous to health could be
present!
6. A safety belt must be worn when working in a shaft, so that in an emergency the workman
can be pulled out. If the shaft is deep or has a difficult descent, then a safety rope is
absolutely necessary.
7. Two strong men should act as guards at the entry of the shaft, in order to intervene in case of
emergency. This guard can be reduced to one person, if a derrick with lifting gear is available.
The person must have continuous visual contact with the workman in the shaft.
8. Leave the shaft immediately by signs of nausea. The person in charge must be informed.
9. Shafts giving problems should be reported to the person responsible, so that the necessary
precautions can be taken.
10. The plant operator is responsible to ensure that the personnel are instructed in the use of
safety regulations and security appliances. Utilisation and function of the security appliances
should be tested in use regularly.
11. The above said precautions do not replace or change possible other effective regulations.

Safety Specifications Eex-zone concept
and Responsibility
Safety equipment for maintenance personal
The following is recommended as practicable and efficient equipment for the prevention of „gas
accidents.
1. Reliable, portable methane measuring device possibly combined with O2 measuring, with scale
for the LEL and eventually with scale for micro range. As a rule such units are ex-proof and can
be used as a continuous measuring warning unit. They must frequently be calibrated (before
each use!). Calibration gas bottles belong to the equipment!
2. Portable ventilation device with electric operated blower (eventually 24 V) suction filter, 10m
hose. A storage battery or generator can be used for locations without electricity. Ensure that
the exhaust gas from the generator group is not picked up by the blower!
3. Rescue belt with rope, approved by applicable standards.
4. Portable derrick with roping down and lifting gear. One individual should be able to operate the
unit easily.
5. Ex-proof torch.
6. Fresh air breathing apparatus (air mask) with approx. 10 m air tube. Such equipment does not
require much room in the "tackle box", but can be used at short notice or is very useful in an
emergency.
Equipment is only reliable when it is in perfect condition and when personnel know
how to use it in practise. Training in the use of the equipment is imperative for
effective accident prevention!
Eex-zone concept
On-site requirements
• Outdoor installations
Natural ventilation, no Eex-zone around installations
• Pump station indoors

controlled by room air surveillance Eex-zone 2 in 0.5m radius around possible openings
in piping (valves, flanges, blower sealings)
• Pump station indoors

no control by room air surveillance Eex-zone 2

Safety Specifications Safety measures
and Responsibility
Safety measures
Preventive measures in order to restrict or prevent the build-up of an explosive

atmosphere - primary explosion protection E1:
By periodically checking the methane and oxygen content in the gas, it can be ensured that no
explosive atmospheres are produced over a longer period of time. The permanent monitoring of
gas mixtures with an analyser is recommend for closed Landfill gass with gas pipelines laid under
the ground and absolutely necessary for operating Landfill gass.
The plant must be operated with a gas mixture whose CH4 concentration is > 30 Vol. % and O2
concentration is < 3 Vol. %. If these values are fallen short of (alarm barrier), respective exceeded,
then the reason must be detected immediately and being eliminated. If the limit value of 25 Vol. %
CH4 and maximum 6 Vol. % O2 is attained, then the plant must be automatically shut down and
locked. It may not be started up again until the reason for the rise in O2 has been definitely
eliminated.
Preventive measures in order to restrict ignition of the explosive atmospheres -

secondary explosion protection E2:
• The construction of the pump and flare station is designed in accordance with the explosion
protection guidelines (in Germany Eex-RL).
• All measuring and monitoring units connected into the gas flow as well as other electrical
material are intrinsically safe.
• Before putting the plant into operation for the first time as well as after a long standstill or repair
work, measurements must be taken to ensure that no explosive atmospheres are present in the
suction pipeline.
Preventive measures in order to limit casualties during an explosion - constructive

explosive protection E3:
• A flame arrester upstream of the flare, prevents back-firing into the compressor.
• If the Landfill gas is utilised, then a quick closing gate valve has to be fitted immediately after
the T-branch, so that in case of fault the gas utilisation pipeline closes.
These preventive measures considerably eliminate danger for people working in the vicinity of the
plant.
Additional safety measures

In spite of all technical precautions, there is always a small threat of danger through an explosive
atmosphere, oxygen deficiency or noxious gases. If a gas warning unit responds, protective
measures must be taken.
The following protective measures should be taken into consideration.

• Remove persons from the endangered area
• Eliminate the source of ignition in danger area
• Eliminate dangerous gas concentrations through additional ventilation measures
• Inert the working area with nitrogen
The extent of the necessary protective measures to be taken depends on the situation.

Safety Specifications Potential endangerments by gas
and Responsibility processing plants
Potential endangerments by gas processing plants

Danger due to explosive gases
The following endangerments can occur with the enterprise at any time and cause heavy injuries
or damages to property:
• Main dangers for persons are: Oxygen deficiency - danger of suffocation Toxicity - nausea,
corrosions, poisonings
• Dangers of explosion
• Failure of important functions of the gas processing plant
• Endangerment of the environment by leakage
• Therefore always protective clothing carry to prevent „protection equipment for personnel"
Danger due to hot
• Hot components must be safe before contacts.

• Wear Protective clothing, eye protector and protective gloves, to prevent skin contact, in
particular eye contact.
• Before all work on the gas processing plant: Take a cooling time of at least 120 min. and
wear protective gloves
Danger due to mechanical systems
• During all transportation, assembling and disassembly work can be squeezing and cuts.
• Wear protective clothing and protective gloves, in order to prevent cuts.
Danger due to electrical systems

Endangerments by electricity exclude. Instructions of the manufacturer of the electrical equipment
for regular inspection and maintenance consider.
Danger due to other equipment

See Appendix with the manuals of the other equipments.

Safety Specifications Protection for personal
and Responsibility
Warning Symbol
On the product are different warning symbols:
Warning symbol
Symbol Danger Part
Danger by voltage Electrical Cabinet
Hot surface Flare
Protection for personal
With all work on the gas processing plant „personal protection equipment “and/or protection
equipment for gas systems are to be carried.
Personal protection equipment
Personal protection equipment

Symbol Meaning Describtion
Safety helmet protects the head e.g.

Safety helmet
before falling down articles.
Safety shoes protect the feet before falling

Safety shoes down articles and/or before entering of
high-standing nails.
Protection of the ears protects at close

Protection of the ears range of the machine before the noise
arising there
Protective gloves e.g. protect the hands

Protective gloves before dangerous delivery media, before
mechanical effects.
Protective goggles protects eyes with

Protective goggles spraying particles as well as dangerous
delivery media.
Protective clothing protects the skin
against spraying particles and dangerous
Protective work dress
delivery media as well as against easy
mechanical endangerments.
breath and face mask protects before
dangerous delivery media, which can
Brath- and face mask
arrive over the respiratory system into the
body (e.g. Gases) .

Product Description Technical specification of the plant
Product Description
Technical specification of the plant
Pos. Pce. Description
2.1 1 Compact degassing plant HOFGAS- Ready 3'000 CDM.

3
Gas flow rate of the blowers max. 3'000 Nm /h
3
Gas flow per each blower max. 1'500 Nm /h
min. 300 Nm3/h
Gas flow rate of the flare max. 3'000 Nm3/h
min. 300 Nm3/h
Turn down ratio flare 1 : 10
Gas temperature at inlet of the plant max. 35 °C
Blower pressure rise max. 230 mbar
Suction pressure at inlet of the plant max. -100 mbar
Burner capacity max. 15'000 kW
min. 1'500 kW
Flow measurement turn down ratio 1:6
Methane concentration 30..50 % by vol.
Oxygen concentration 0..6 % by vol.
Combustion temperature 1'000..1’200 °C
Flue gas temperature 1'000..1’200 °C
Residence time ≥ 0,3 s
Flange connection PN6 DN250
Expected sound pressure level at full load ≤ 69 dB(A)
in 15m distance and 2m height
Nominal power rating of the motor 2 x 37 kW
System of protection (standard) IP54
Electricity supply 3x220V/120V 60Hz
Fuse protection 600 A (slow)
Basic equipment
Skid:
- Hot dip galvanised skid
Suction side:
- Piping in hot dip galvanised steel
- Connection flange DN250 PN6
- Isolation and regulating butterfly valve with hand lever
- Connection device for anemometer, AEV1"-15mm
- Manometer set -160..0 mbar with isolation valve
- Thermometer set 0..100°C
- Dewatering unit in hot dip galvanised steel with:
- Level monitoring EEx
- Connection for condensate extraction pipe with isolation valve
- Flame arrester, according to EN standards (ATEX) housing of
carbon steel and element of stainless steel

Radial gas blower:

- Base frame with foundation pads, pre painted and coated
- Isolation and regulating butterfly valve with hand lever
- Blower unit, suitable for landfill gas with foundation pads
- Electric motor Eexd IIBT4 motor for VFD control
- V-belt transmission
- Gas inlet and outlet flanges with pipe compensators
- Temperature monitoring of the blower, EEx execution
Pressure side:
- Piping in hot dip galvanised steel
- Connection flange
- Non return valve
- Regulating butterfly valve continuously adjustable
Flare: (Hofstetter)
HOFGAS- Efficiency 3000 with concealed high temperature
combustion
- Installed beside the Ready skid onto a concrete
- Supporting structure made of hot dip galvanised steel
- Combustion chamber made of stainless steel, inside with high
temperature resistant insulation of ceramic fibres
- Flue gas measuring connection DN80/90°, 80% from t he top, 2pcs
- Injector burner
- 2x Combustion air intake by natural draught principle with electric
actuated louver
- 2x Ignition burner
- 2x Ignition burner piping with ball valve, slam shut valve and
pressure regulator with Manometer
- 2x Electrical ignition device with ignition transformer
- 2x UV probe for flame monitoring, EC-type-tested and certified
- Thermocouple for the continuous monitoring of the combustion
temperature and indication at operating panel
- Start pressure switch
- Piping made of hot dip galvanised steel
- Isolation and regulating butterfly valve continuously adjustable
- 2x Electrical slam shut valve, EC-type-tested and certified
- 2x Flame arrester according to EN standards (ATEX) housing of
carbon steel and element of stainless steel
- Burner nozzle pressure monitoring for the control of combustion
Electrical control cabinet: (Hofstetter)
- Skid mounted electrical control cabinet with all necessary control and
safety elements
Components:
- Cabinet with door and swivel frame, in weather proof execution
- PLC Mitsubishi with program on Eeprom
- Operating panel Beijer E 200 mounted on the swivel frame, with
control keys, LCD monochrome display (4 lines x 20 characters) for
the indication of the operating conditions and of the parameters
(language: English)
- Burner control unit for the automatic ignition and flame monitoring
- EEx separators elements
Features:

- Automatic regulation of the combustion temperature

- Ignition repetition
- Safety turn off by overload of the blower
- Safety turn off by overheating of the blower
- Safety turn off by overheating of the burner
- Safety turn off by high level in dewatering unit
- Hours meter blower
- Hours meter flare
Switches:
- Main switch, accessible externally
- Start/Stop blower
- Start/Stop/External flare
- Purging facility
Signal lamps:
- Main alarm lamp mounted externally
Signals: According to CDM Memograph and KUHSE list!
- DI External emergency stop (safety interlock circuit)
*DO = digital output signal, DI = digital input signal, AO = analogue output signal
Engineering, documentation:
- Mechanical and electrical engineering including:
- Project management
- Detail project planning and design
- P&I Diagram with legend
- Layout drawing
- Wiring diagram
- Functional description
- Operating and maintenance instructions in English
- Technical documentation in English
2.2 1 Suction pressure control (electrical)
- 2x VFD's 37 kW for each blower
- needed reduction pieces
- pressure sensor –250..0mbar, piezoresistive, EEx execution
- connected to the PLC of the control system
software control
ROI of less then 1/2 year in comparison with a direct drive
technology
2.3 1 Regulation range 1 : 10
- 2-stage burner
- Gas distribution manifold and electric actuated butterfly valve
- Connected to the PLC of the control system
2.4 1 Translation into Spanish
- Operating and maintenance instructions (English and Spanish)
- Control panel (English)
2.5 1 Preparation for transportation
2.6 1 Uninterruptible Power Supply system UPS, to assure the tension supply of
the control tension of 24V (via power pack) of the PLC, the panel, data
storage (Memograph etc.) and of the gas analysis cabinet.
This system is recommended when the supply network has tension
fluctuations higher then ±5%.
With:

- UPS 3’000VA for 120V 60Hz power supply

- Fuse unit
- Installation in the plant control cabinet
- Wiring diagram
- Engineering, documentation
2.7 1 - Safety ladder alongside the combustion chamber, with single rail
fallguard system, catch carriage, connection hook, safety harness
and fastening brackets on the combustion chamber
2.8 1 Wear and tear parts kit
- 1 UV bulb
- 1 set of ignition electrodes with
holder
- 1 thermocouple type S
- 1 thermocouple type N
- 1 V-belt
- 1 lever grease gun
- 1 Lithoplex LM3 grease
2.9 1 Spare parts kit
- 1 UV eye
- 2 connectors for the electrodes
- 1 ignition transformer
- 1 automatic burner control unit
- 1 louver actuator
- 1 pressure sensor
- 1 pressure switch
- 1 set spark plug cable
- 2 industrial miniature relays
2.12 1 KUHSE system connected hard wired (as in La Pradera):
- KUHSE-Telecontrol unit
- Card framen for 68K-Control system, 42 TE
- 24 V DC, CPU card, fiber-optic cable card
- Data storage card for 32 Trends, writing in minutes with more then
10 days storage and protocol of more then 3 days
- LED indicators
- GSM-Modem card, antenna, Always-On_function
- Digital input card with 30 inputs for 3 operation and failure notice
- Digital output card with 30 outputs, including 4 relais
- Analog card with 12 analog signals 4..20mA with 2 Pt100 signals
- Fiber-optic connection to fiber-optic card of the TeleControl unit.
2.13 1 Installation and implementation of the KHUSE-Telecontrol unit in the
main control cabinet to connect analog signals 4..20mA and digital
signals, consisting of;
- Enlargement of the control cabinet
- galvanized separators, passive
- Electrical wires and labor
- Installation of the KHUSE unit
- Planning and extension of the electrical diagram
2.14 1 - CO2 transmitter sensor GAE
measuring range: 0..100 Vol.% CO2 / measuring principle: infrared
- AO Analogue output signal 4..20mA for CO2 measuring range

CDM Monitoring
2.15 1 Flow measuring, differential pressure flow meter (E & H)
- EEx execution
- analogue output signal 4..20mA
- indication of gas flow in Nm3/h
- measuring range 0 - 3'150 Nm3/h
- Flow computer
- connected to the control system, indication of the value on the PLC
operating panel.
The flow meter will be calibrated according to following gas composition
(on a wet basis)
CH4 = 50 % by vol O2 = 2 % by vol

CO2 = 35 % by vol p = 100mbar
N2 = 13 % by vol t = 75°C
2.16 1 Gas analysis system HOFGAS- Assay (NUK)
- CH4 transmitter sensor GAE
measuring range: 0..100 Vol.% CH4 / measuring principle: infrared
- O2 transmitter sensor GAE
measuring range: 0..25 Vol.% O2 / measuring principle: electrochemical
- Wall cabinet in weather proof execution (W 600 x H 800 x D 400 mm),
rain protection, cabinet heating/fan with thermostat, fan with in and
outlet grid, connection for measuring gas, condensate discharge and
calibration gas piping
- Flame arresters, solenoid valve, manual valve for calibration gas,
measuring gas cooler with condensate extraction pump for condensate
discharge pipe, measuring gas filter, measuring gas pump with bypass
needle valve, flow meter with flow control, water stop filter, air flow
monitoring cabinet ventilation NVE with self hold
- Electric control connected to the PLC with:
Gas flow control with alarm delay, alarm identification with analogue
output signal 4..20 mA on terminals, current and flow alarm as
common alarm on potential free terminals, Key switch (calibration /
revision / measuring) monitoring switch (zero gas/calibration gas),
monitoring flow alarm and current alarm, output relay calibration,
switch off measuring gas pump and solenoid valve at main alarm
- Measuring gas line with nozzle and pre filter, return line for
condensate, with insulation and heating, measuring gas discharge
piping to the atmosphere
Output from PLC:
- AO Analogue output signal 4..20mA for CH4 measuring range
- AO Analogue output signal 4..20mA for O2 measuring range
2.17 1 Data logger Memo-Graph (E & H)
- Measurement principle:
Electronic recording, plot and archiving analogue and digital input
signals. Data storage is done in an internal memory (power failure
secure SD technology).
Long term archiving is done in the PC, whereby the data can be
transferred to the PC by either SD card, serial interface
(RS232/485), USB, or using a Ethernet connection.

Using the delivered PC software the units can be set up, read out
and the measured data can be archived and displayed on screen
- 16 universal channels (AI)
- 14 digital inputs (DI)
- 6 relays
- Display modes:
Multi-coloured LCD display 7"
Curves/plot sequences, curves in zones, columns/barograph, digital
display, events list (alarm set pints/power failure), condition display,
historical display as curves with digital measured value display, date
and time, signal analysis (min./max/average/quantities, times)
coloured channel identification and individual text measurement
point tag name
- Data storage:
Selectable memory cycle per group. Cyclic copy's of measured data are
archived to SD memory card (512MB). Permanent storage of all unit
set-up parameters on a internal storage AND on the SD memory card.
(e.g. 12 analog inputs saved per minute generate 1824 days recording
duration).
- The Memograph will be secured with an additional fuse in the power
supply
1 Mathematics module to Memo-Graph(E & H)
- 8 additional, calculated channels, can be cascaded
- Mathematical calculation of analogue channels, basic mathematics
functions, constants, integration (quantity totalisation from analogue
inputs) and mathematical functions
1 Telealarm system to Memo Graph(E & H)
- Transmission software
- Alarm to mobile phone in case of alarm on the SPS / Memo-Graph
2.18 1 Power consumption meter (Emu)
Measuring and monitoring of the electricity consumption of the plant,
with:
- Multimeter module for measuring and monitoring of electrical
values, for 220V 60Hz, with LCD panel
- Integration in the plant control cabinet
- Connection to the data registration unit of the plant, programming
- Engineering, wiring diagram, documentation
- DO Digital impulse signal
2.19 1 Flue gas analysis (NUK / Emerson)system for monitoring the volumetric
fraction of unburned methane and residual oxygen in the exhaust gas of
the high temperature flare.
Analysis system includes:
- CH4 analyzer, NDIR type, measuring range 0...2 vol.%; accuracy: ≤ 1%
of the span Binos 100 (model 2010)
- O2 analyzer, Binos 100 (model 2010), chemical cell, measuring range
0...21 vol.%
- Wall cabinet in weather proof execution (W 800 x H 1500 x D 500
mm), rain protection, cabinet heating/fan with thermostat, fan with in
and outlet grid, connection for measuring gas, condensate discharge
and calibration gas piping
- Condensate preseparator with condensate extraction pump

- Gas conditioning system with cooler to 5°C with co ndensate extraction

pump, solenoid valve, five-way-valve for calibration gas, measuring
gas filter, measuring gas pump, flow meter with flow control, water
filter
- Humidity control unit
- Control unit with flow alarm measuring gas, humidity alarm, switch of
measuring gas pump and valve, calibration, key-button, lamps for
humidity alarm and flow alarm
- Flow alarm, humidity alarm and calibration signal as potential free
change-over contacts on terminals
- Weather-protection roof 1400 x 700, mounted on the analysis
cabinet
Output from PLC:
- AO Analogue output signal 4..20mA for unburned CH4
- AO Analogue output signal 4..20mA for residual O2
1 Fluegas probe, resistant up to 1’200°C, removable a nd gas sampling line
made of stainless steel, removable, with sampling coupling at the lover
end for control of combustion quality, fastening brackets on the
combustion chamber
1 Support structure for mounting the analysis cabinet, made in hot dip
galvanized steel, for installation on the concrete plate beside the flare
2.20 1 Thermocouple Typ N for the continuous monitoring of the fluegas
temperature and indication at operating panel
2.21 1 One spare PLC Mitsubishi for H10116 & H10117 of Green Gas
Three Eeprom with the program, one for each plant:
- H10116 GGG Medellin Curva de Rodas Ready 2x1500-3000 CDM
- H10117 GGG Medellin La Carillera Ready 2x1000-2000 CDM
- H10798 Green Gas El Guacal Ready 3000 CDM

Product Description P&I-diagram / dimension drawing /
legend
P&I-diagram / dimension drawing / legend

Transport / Storage / General information
Erection /
Disassembling
Transport / Storage / Erection / Disassembling

General information
Present installation manual shall be used for the installation of the Ready 3000 CDM plant'. Follow
strictly the installation instructions below.
Warning signs (see below) will prevent the source of danger during installation of the flare skid.
In case of question please contact the local Hofstetter representative or Hofstetter Umwelttechnik
AG in Switzerland.
Health and Safety:

Apply and ensure that the local health and safety rules for crane work and
fork lift operation is strictly applied.
Saftey shoes, protective helmet, work dress and protective gloves wear:
+ + +

Transport / Storage / Required equipment
Erection /
Disassembling
Required equipment
Following equipment is used for installation:
The equipment used for installation may vary from the recommended equipment
below, as long the local health and safety rules are strictly applied!
Equipment list:
Pos. No of pce. Description Picture

1 2 Crane for unloading the all parts
from the Open top Containers
and installation of the flare
2 1 Working platform to reach a
height of 7 meters and a load
capacity of 200kg.
3 2 Chain suspension with 2 chains

with contraction device.
4 1 Drilling machine for installation

of the Hilti concrete anchors with
concrete driller
5 1 Complete tool box with:

- Spanner up to 36mm
- Required tools for electrical
and flange connections

Transport / Storage / Loading/Transportation / Unloading
Erection /
Disassembling
Loading/Transportation / Unloading
Only use lifting gear and load handling equipment (e.g. lifting straps) which are
suitable for the weight to be lifted. Max. load information can be found on the
type plate of the lifting gear. It is strongly recommended to use only the eye
bolts when lifting the meter by itself.
During transport and storage operations, make sure that:
• the plant is firmly secured at all times

• Humidity and ambient temperature are within specified limits.
• If the device is to be stored outside for more than one day, sealing surfaces of the flanges
and must be protected from corrosion, e.g. with Anticorit spray. The same measure shall
be taken if the meter is to be stored in dry condition, but for more than a week.
Loading/Transportation
• The loading and fixing on in the container is

with transport aid for the combustion chamber
according to Hofstetter UWT guidelines.
• Just lift and fix the combustion chamber by
using the designated eyebolts.

Transport / Storage / Loading/Transportation / Unloading
Erection /
Disassembling
Unloading the base frame
• Use 2 two (2) crane to unload the base frame
with the plant mounted.
• Just lift the plant by using the designated
eyebolts installed on the supporting structure
and the base frame!
Unloading the combustion chamber

• Use the fastening brackets to lift the
combustion chamber from the truck.
• Lift the combustion chamber and put it to a
prepared place with soft ground.
• If the transport aid are still mounted, remove
them from the combustion chamber.

Transport / Storage / Assembly instruction
Erection /
Disassembling
Assembly instruction
The flare unit must be erected outdoors and not in the
immediate vicinity of buildings. If the Landfill gas site is
not secure, the degassing plant should be protected
against trespassers by a fence.
Assembly of the plant
• The plant erection site should be levelled off and covered with a reinforced concrete base. Lift
the complete base frame supports by means of a hoist and place it with the anchorage at the
desired spot on the concrete base and level off if necessary.
1. Assembly of the skid

2. Assembly of the pipes direct to the skid
3. Assembly the pipe to the flare
4. Assembly the supporting structure
5. Assembly the pilot burner piping
6. Assembly the combustion chamber
1
3

Erection /
Disassembling
Assembyl of the blower skid
• For the fixation of the base frame, on

each side two Hilti anchors are needed.
The bolts (HSL-3-B) are included in the
delivery of Hofstetter UWT.
• Next pictures show how to fix the Hilti
bolts HSL-3-B.
• For the fixation of the pipes to the blower

skid Hilti anchors are needed type HSA
M12/25/45.
• For the fixation of the pipe to the flare
Hilti anchors are needed type HSA
M12/25/45.

Erection /
Disassembling
• Holes are provided in the base plate for

anchoring the unit. If the flare is placed
separately drill holes with a diameter of
28 mm to a depth of 190 mm for each of
the enclosed stud anchors.
• It is an advantage to clean the bore

holes with compressed air.
• Using a hammer, tap the anchor through

the part being fastened into the drilled
hole until the washer is in contact with
the fastened part. Do not expand anchor
by hand prior to installation.
• After applying the necessary starting

torque with a normal ring spanner, the
red bolt top shears off. The visible
green lead seal indicates that the
necessary initial tension is achieved and
the anchor carries the permissible load
(around 160Nm).

Erection /
Disassembling
Installation of the supporting structure
2 units U-bars
• First of all remove segments

out of transportation rack
• Assembling of the two (2)
supporting structure like on
figure left.
• Please look of the right
position of it.
• Install the 2 (two) U-bars
NOTE: do NOT tight any

screws at this stage !

Erection /
Disassembling
Mounting of the piping inside and outside supporting structure
• Mount all piping inside
on bracket (according
to layout!!!) and fix with
screws and fixing with
the 10 pcs of bowls.
• Put the whole
supporting structure
onto the pipes.
Fixing of the supporting structure
Fix the supporting structure

to the concrete foundation,
using Hilti bolts HSL-3-B
M20/30 as shown above.
Mounting of the pilot burner piping

Install the pilot burner
piping before installation of
the combustion chamber!

Erection /
Disassembling
Assembly of the injectors
• Remark: The injectors have to installed

before the combustion chamber.
Otherwise, the injectors cannot be
installed anymore.
• Take care that the air flap does not

go damaged during installation!
• For each nozzle you have to install a

injector.
• Therefore you need screws and nuts.
Tool size for the nuts/screws: 13

For each injector you need
3x Screws M8 20mm
3x Nuts M8
• Each screw you have to grease with the

“Metaflux Lubricating metal” which is
also a part of the delivery. If you don’t
use this, later deassembly could
become very difficult!
• After installation of the injectors, assure

that all the injectors are mounted
vertically!

Erection /
Disassembling
Assembly & mounting of the combustion
2 units combustion
chamber segment type 1
2 pcs DN80 flanges
1 unit combustion chamber

segment type 2
1 unit combustion chamber

segment type 3

Erection /
Disassembling
Remove the segments out of

the Rack, begin with the outer
segment:
Place the first segment as

show beside!
It’s recommended to use a
soft base with additional
rectangular blocks of wood
Rectangular Soft base

block of wood

Erection /
Disassembling
Attach two fragments of the

combustion chamber as
illustrated in the drawing.
Mount the two fragments

together with the destined
screws
When the two parts of the

combustion chamber are
screwed together, use a
second crane for lifting and
moving

Erection /
Disassembling
Put the two fragments back

to the ground as described in
the drawing on the right.
Lift the half combustion

chambre to a vertical
position.
Use two cranes to avoid

scratches while lifting.
If this part is in vertical position,

detach the second crane

Erection /
Disassembling
Connect the half combustion

chamber on the support
structure.
Restart for mounting the

second half of the combustion
chamber
NOTE:
Tight all screws of the flanges
when all 4 segments are in its
positions.

Erection /
Disassembling
Connection of the dewatering line
• The connection to the condensate output

1”.
Installation of the 2x ignition burner
• Install the ignition burner by the

ignition burner flange on the
combustion chamber.
• The adjustment of the ignition
electrode and the air gap for the
ignition burner is described below.
• Install the connection-hose (Not
visible in the drawing beside.
• Install the protection casing of the
ignition burner.

Erection /
Disassembling
Installation of ignition burner

1. Take the ignition burner and install it
to the combustion chamber as
shown on the left side.
2. Install the flexible steel hose the
ignition burner. Do not forget to
install the seal! (white PTFE-washer,
fixed by the ignition electrodes for
transport)
3. Install the UV-sensor
4. Adjust the ignition electrodes as
described on page 94 of Ref/1/.
5. Connect the ignition cables to the
electrodes. It does not matter which
cable is connected to which
electrode.
6. Install the protection cover to the
ignition burner.
hose
Insulation UV-sensor

Transport / Storage / Adjustment before putting into
Erection / operating
Disassembling
Adjustment before putting into operating
Before putting the plant into operation the following adjustments must be checked or carried out.
IMPORTANT!
All values given in these operating instructions are basic
setting values or values taken from experience and must
be adapted to the respective operating conditions.
Adjustment of the flare

Ignition electrodes
CAUTION!
Ignition voltage 10 kV. Before touching high voltage
parts, definitely ensure that the mains are switched off.
For optimum ignition, the electrodes must be

adjusted according to the following sketch.
3 -4 m m
• gap too large ➜ no spark

• gap too small ➜ weak spark
• no gap ➜ short circuit and damage to ignition transformers
See also “Ignition burner” (Appendix)
Take care not to damage the ceramic sleeves of the ignition while adjusting the gap by only
moderately tightening the clamp screws.

Transport / Storage / Adjustment before putting into
Erection / operating
Disassembling
Placing the thermocouple
Holder for thermocouple

• Install the thermocouple with the foreseen
support in the middle position of the
15 combustion chamber
• Before introducing the thermocouple, a slit
Find max. and
must be cut in the isolation of the burning
stable Temperature chamber. The thermocouples should be
Find max. and mounted deep enough, that they can measure
stable temperature
the max. temperatures.
Insulation of the
combustion chamber
Direct coupled damper motor GIB 335.1E

• The coupled motor is directly mounted onto the damper axle by means of a special clamp.
• The motor is protected against overload.
• The angle of rotation is mechanically limited to 90 °.
• When damper or motor end position is attained, the motor stops automatically.
• The gears can be manually disengaged by simply pressing down the spring loaded button on
the motor cover. Whilst this button is pressed down, the damper blades can be adjusted by
hand.
• A position indication (potentiometer) is integrated, the actual position can be checked on the
Panel: MEASURE / Flap Pos.
• The limit air flap position (open, close) can be adjusted on the panel.

Transport / Storage / Calibration of the Gas Analysing
Erection / System
Disassembling
Calibration of the Gas Analysing System
IMPORTANT!
Please use the NUK Operating instruction in the Appendix.
The given values for the composition of the calibration gas mixture, concerns
recommendations for the usage with Landfill gas.
IMPORTANT!
When using the calibration gas mixture, ensure that the
maximum pressure of 300 hPa is not exceeded. A higher
pressure can destroy the measuring system.
Gas pump
Check Pretension of the V-belts before putting in operation as shown in the operating manual of
the supplier.

Operation of the plant
Safety at the operation of the plant

During the operation of the plant, be aware of the following danger:
DANGER
The following safety references have to be read before starting the operation of the
plant. If there are misapplications, heavy injuries can enter. Guarantee qualification
of the service personnel!
Dangers due to gases

• Stop immediately when leakages of equipment are present and repair the
defect components.
Dangers due to electrical systems

• Instructions of the manufacturer of the electrical equipment for regular
inspection and maintenance are to be considered.
CAUTION
Burn by affecting hot surfaces
• Avoid contact with hot surfaces
Saftey shoes, work dress, protective gloves, protective of the ears, protective
mask if necesseary :
+ + + +

Operation of the plant Putting into Operation
Putting into Operation
1Q1
Operating and display elements on the control cabinet
+B1
1Q1 Switch: Main / Emergency stop 0 - 1
The switch serves to cut off the electricity supply of the whole plant. Immediate shut
down

38A1 42A1
13S1
+B2
Operating and display elements on the control cabinet
42A1 Display: Operating panel
38A1 Display: Memograph
13S1 Emergency STOP

STOPs the plant
36H2 common alarm lamp

Lamp flashes: Indicates that there is an alarm on the control panel switches off the
plant.

36H1 common warning lamp

Lamp flashes: Indicates that there is a warning on the control panel
12S1 reset alarm

Reset the alarm
35H1 gas blower 1 in operation

Shows with a lamp, if the blower is in operation
35H3 gas blower 2 in operation
Shows with a lamp, if the blower is in operation
35H2 alarm gas blower 1

An error on the blower has been occurred.
35H4 alarm gas blower 1
An error on the blower has been occurred.
27H7 flare in operation

Shows with a lamp, if the flare is in operation.
27H2 alarm flare
An error on the flare has been occurred.
26S1S1 flare ON-OFF

Starts the flare, when the starting conditions are given.
27S1 restart flare after pmin

After the min. pressure, push restart the flare to continue
11S2 suction pressure regulation HAND-AUTO

The pressure regulation can be done by automatic mode or with the potentiometer by
Hand.
26S2 Flare purge

Possibility to purge the system.

When starting up for the first time, the gas pipeline network must be evacuated, without switching
on the gas pump. For this purpose the Landfill gas(s) specific butterfly valve(s) is/are opened. Due
to the static pre-pressure in the suction pipeline, the Landfill gas flows into the pipeline system of
the flare. The plant is correctly evacuated, if gas can be detected at the access points, (i.e. at the
measuring sleeves upstream of the flare; Screw in the sleeves again after evacuation!) and a more
constant CH4-minimum of 30 Vol. % can be measured.
When putting into operation, the combustion chamber must be heated up slowly. At low load and
air throttle completely opened (pull out relay for „close air throttle“ in flare control cabinet) the plant
must run:
• in 2 hours up to 500°C
• then 1 hour rest on 500°C
• then in 3 hours up to the max. allowed operating temperature 1200°C
• 1 hour rest on this operating temperature
From this time, there are no more restrictions (plug in again relay for “close air throttle“), but the
plant should be operated continuously, as the life of various plant components is considerably
reduced by repeatedly switching on and off the plant.
Readiness for start up

The flare is ready to start when the following conditions have been fulfilled:
• The electricity supply of 230V +/-5%, 50Hz, 10 AT is available.
• The Main Switch is switched in position 1.
• Check all relevant safety functions.
• No fault is present (red LED ALARMS not active).
Starting the analysis system

1. The main switch at the analysis control is switched on
2. The measuring gas pipe is connected
Starting the gas pump

Conditions necessary to start gas pump.
1. No alarm must be signalled, i.e. the collective alarm lamps or the red lamps are burning.
Starting the gas pump

Turn the switch ‘gas pump’ to position ‘I’
IMPORTANT!
Gas Pump:
Check the direction of rotation!

Tightness of the pipes, flanges and connections
During the gas pump test, the Tightness test of all gas connections (with Soap - Spray) can be
checked.
IMPORTANT!
All connections have to be free from leakage!
Purge facility of the flare

• Purge the pipeline system if O2 concentration is smaller than 6% and the CH4 concentration is
higher than 25%. Open the manual valve on the suction and pressure side. Landfill gas flows
through the pipeline system.
• The flare is switched off
• The flare temperature is below 250 °C
• Blower is running Start pressure is available
Thereafter the slam shut valve opens (1…120s) and the air flap of the flare opens completely.
• As a safety measure the ignition system is deactivated.
• As a safety measure, a delay will occur (2...10 min.) between the end of purging and before
start up for normal operation.
Starting conditions
The flare starts up as soon as the following conditions are enabled:
• The switch 'Flare' is turned to 1 and:
The gas pressure is higher than the value set on the start-pressure switch (approx. 50 mbar).
• The switch 'Flare' is turned to "Ext" and:
The external start signal is enabled. The potential free contact external release Flare Remote 0-
1 must be closed and:
• The gas pressure is higher than the value set on the start-pressure switch (approx. 50 mbar).

Combustion
Combustion of the Landfill gas should take place in the flare series HOFGAS -Efficiency in
excess air at a temperature set value of about 1000°C. The quality of the combustion can be
judged roughly by the following features:
• Poor combustion with insufficient excess air Flame noise hardly discernible, CO- and odour
formation. Flame is yellowish and is possibly
visible outside of the flame hood
• Ideal combustion with sufficient excess air Flame noise distinctly audible, stable flame
(proper adjustment) formation, optimal temperature, no or a
minimum of CO formation, no odour formation
• Too much excess air, results in a low flame Very noisy, unsteady flame, flickers and
temperature extinguishes in extreme cases (fault cut-off)
Stop the flare

The flare has to be stopped in these ways.
1. The switch ‘flare’ is turned to position ‘0’ or “Ext”.
2. Turn the switch ‘gas pump’ to position ‘0’

Operation of the plant Operating panel
Operating panel
Function buttons
ALARM MAIN MEASURE CONFIG
ALARM In case of any alarm, the alarmscreen automatically appears with the
corresponding message. The red LED "Alarm" is blinking
The last alarm appears first, further eventual alarms can be viewed with the
UP/DOWN-keys.
The alarms can be acknowledged with the "Reset"-key if they are not active any
more.
The LED "Alarm" is lit permanently if the alarm is acknowledged, but the alarm is
still active.
As long as there are further alarms, the red LED is on.
MAIN Overview of the state of the flare
MEASURE Actual measuring values
CONFIG After entering the password the standard factory settings for various parameters
can be changed.
WARNING! Don't change settings without asking the supplier! Otherwise any
claims on warranty will be refused!
RESET Push button to reset the command in case of an alarm

If the reason for the alarm persists, the Alarm-LED will change from blinking to red
light. This button is also used as lamp-test.
As long as an alarm is active, it keeps a '-' sign in front of the text.

The other buttons on the panel serve as entering devices in the CONFIG-Menu.

Operation of the plant Panel descriptions and set points of
Plant control A101
Panel descriptions and set points of Plant control A101
Panel
Main picture
After the start-up or by pressing the “MAIN” button, you can see the following picture on the
display (scrolling with the ▲ ▼ buttons):
Blower 1+2 ON P- / OFF / 1 ON / 2 ON / 1+2 ON / 1 ON P- / 2 ON P-

Flare ON / OFF / OFF (P_MIN) / STARTING... / PURGING...
Temp. Control / Air Lack / Aut. Restart
1010 °C Stage 1 / Stage 2
Setpoint 1020 °C / Flare temp. Setpoint depending on the actual burner pressure
Actual xxxx °C / actual flare temperature
SucP Setp from Panel / Kuhse
SucP Setpact 80 mbar / actual suction pressure setpoint
SucP Set 80 mbar P SucP / suction pressure setpoint from panel
Act xxx mbar / actual suction pressure
SlvBl_on 80 % / Speed limit of master Blower -> start slave blower
T_ SlvBl_on 10 s / Time delay start slave blower
SlvBl_off 80 % / Speed limit of master Blower -> stop slave blower
T_ SlvBl_off 10 s / Time delay stop slave blower
Measure
Press the “MEASURE” button on the OP. The following picture appears (scrolling with the ▲ ▼
buttons):
CH4 xx.x Vol% / actual CH4 content of the raw gas

O2 xx.x Vol% / actual O2 content of the raw gas
SucP_Gas -xxx mbar / actual suction pressure
P_Noz_ST1 xxx mbar / actual nozzle pressure of flare step 1
P_Noz_ST2 xxx mbar / actual nozzle pressure of flare step 2
T_Flare xxxx °C / actual combustion temperature
Flap Pos. xx ° / actual flap position
I_Blower 1 xxx A / actual current of the blower 1
I_Blower 2 xxx A / actual current of the blower 2
Oh_Blw1 xxxxxx h / operating hours of blower 1
Oh_Blw2 xxxxxx h / operating hours of blower 2
Oh_Flare xxxxxx h / operating hours of the flare

Plant control A101
Password entry
input the password

press the ENTER button
Config
Press the “CONFIG” button on the OP. The following picture appears:
CONFIG MENU
>SucPressReg
>Flare
>Plant
>Time delays
>Alarm delays
>Analysis
>Analogue values
Select submenu:
go with the ▲▼ buttons to the submenu point
Suction pressure regulating
SUC.PRESS REGULATING
KP 250 % / Proportional factor
TI 2.0 s / Reset time
TD 1.00 s / Derivative action time
Sampletime 0.100 s / Time lag of the derivative action
Y_Min 20.0 % / Minimum blower speed
Y_Max 100.0 % / Maximum blower speed
Y_Start 30.0 % / Start speed
Y_PID xxx.x % / Actual internal controller value
P_suc Set -50.0 mbar / Suction pressure setpoint

P_suc Act -xx.x mbar / actual suction pressure

Plant control A101
Flare
FLARE
>Flare Temperature
>Air Flap
>Burner Pressure
>2-Stages
>Start Trails
Select submenu:
go with the ▲▼ buttons to the submenu point
Flare temperature
FLARE TEMPERATURE / PARAMETERS FOR FLARE TEMP. REGULATION

P_mbar / Nozzle pressures
2 10 32
60 / Setpoints at the above mentioned nozzle pressures
T_SP °C
1000 1020 1070
1100 / Prealarm min. temperature
T_min 800 °C / Alarm max. temperature (Overload protection)
T_max 1200 °C / CONTROLLER
CONTROL SETTINGS
P 200 / Proportional factor
I 20.0 s / Reset time
D 0.0 s / Derivative action time
SamplTime 1.000 s / Sample time
SwitchDiff 0.7 % / Switch difference
PulseTime 0.5 s / Pulse time
Auto1/Manual0 1 / Open/close air flap manually
0/open1/close2 0 / Open/close air flap manually
Flap Pos xx ° / Actual flap position
T Set 1020 °C / Setpoint depending on the actual burner pressure
T Act xxxx °C / Actual temperature
Y_PID / Open / Close
Samples 10 / Number of measurements of burner pressure
SampleRate 1000 ms / Time between the measurements
Hc 5.00 kWh/Nm³ / Heat value of the gas
Chp 0.47 / Ratio between nozzles of the stages 1 and 2

Plant control A101
Air flap position
AIR FLAP POSITION / AIR FLAP SETTINGS

SetpCurve xx ° / Actual calculated value for flap pos. after ignition (calculated from curve)
Actual xx ° / Actual flap position
Ignition 30 ° / Ignition position (higher values for high CH4 or flow)
MaxPos 85 ° / Limit open
MinPos 5 ° / Limit close
AIR FLAP CURVE / AIR POSITION AFTER IGNITION
P mbar 10 60 / Straight line defined by 2 points, x-axis
Pos° 30 80 / Straight line defined by 2 points, y-axis
Deviation 5 % / Admitted deviation from straight line
AIR FLAP CURVE LOW
P mbar 10 60 / Straight line defined by 2 points, x-axis, 2-stage burner
Pos° 10 50 / Straight line defined by 2 points, y-axis, 2-stage burner
Burner pressure
BURNER PRESSURE / BURNER PRESSURE

P_max xx mbar / Overload protection: Alarm when higher
P_min xx mbar / Burnback protection: Switch off flare when lower (without
AIR LACK alarm)
/ AIR LACK PROTECTION
Delta_P 5 mbar / When pressure rises xx mbar
Delta_T 5 s in xx seconds
Delta_Pos 10 ° air flap opens zz degrees
2-Stages
2 STAGE BURNER / 2 STAGE BURNER

Stage 1>2 50 mbar / Release stage 2 at xx mbar
Stage 2>1 6 mbar / Switch back to stage 1 at yy mbar
Delay 5.000 s / Delay time for stage switching
AirLack 2>1 50.000 s / Deactivate air lack protection when switch back to stage 1

Plant control A101
Start trails
START TRAILS / START TRAILS

Start N° 1 / No. of start trails before alarm
Plant
PLANT
SucPressMax -150.0 mbar / Overload protection: Alarm when lower
RestrtFlare 5.0 mbar / Difference between suc. press and setpoint to restart flare
StartPlantfrom Panel / Kuhse
StartBlwfrom Panel / Kuhse
StartFlarefrom Panel / Kuhse
SucPSetpfrom Panel / Kuhse
Time delays
TIME DELAYS / INTERNAL DELAY TIMES AND SETTINGS

Contr Start 120.000 s / Delay time of the temperature control at startup
Contr Air Lack 20.000 s / Delay time of the temp.control after air lack mode
AutoManFallBack 10.000 s / Maximum running time if controls are by passed manually
AirFlapMove 6 h / Air lack emergency: Air flap opens every xx hours
FlapPosMove 1 ° for xx degrees
Burner Relais 10 s / Safety time of the used burner control automat
PURGE TIMES
Purge time 15.000 s / Purge time
Purge delay 120.000 s / Delay flare start after purge
Alarm delays
ALARM DELAYS / INTERNAL ALARM AND PREALARM DELAYS

T_max Delay 60.000 s / Delay time for over temperature alarm
T_min Delay 300.000 s / Delay time for minimum temperature prealarm
P_max Delay 60.000 s / Delay time for maximum pressure alarm
P_min Delay 2.000 s / Delay time before stopping the flare because of min. pressure

Plant control A101
Analysis
ANALYSIS
CH4_Alarm 25.0 Vol% / Explosion protection: Alarm when higher
CH4_PreAl 30.0 Vol% / Explosion protection: Prealarm when higher
O2_Alarm 3.0 Vol% / Explosion protection: Alarm when lower
O2_PreAl 6.0 Vol% / Explosion protection: Prealarm when lower

Plant control A101
Analogue values
ANALOGUE VALUES
GainAI0 0.312500 / Scaling for analogue input AI0 – Gain
OffsAI0 -312.500000 / Scaling for analogue input AI0 – Offset
OffsAI4 0.000000 / Scaling for analogue input AI4 – Offset
OffsAI11 -425.000000 / Scaling for analogue input A11 – Offset

Plant control A101
Alarms
When an alarm is active, the common alarm or common warning lamp light up.
Press the “alarm” button on the E1022.
No. Comment Function Check/Correct

1 PLC BATTERY LOW The charging condition of the PLC replace the battery
battery is to low
2 ALARM ANALYSIS RAW Common alarm of the raw gas see the operating manual of
GAS analysing system the raw gas analysing system
3 ALARM CH4 The CH4 content in the raw gas is check the gas system
lower than parameter
« CH4_Alarm »
4 ALARM O2 The O2 content in the raw gas is check the gas system
higher than parameter
« O2_Alarm »
5 FAULT BLOWER 1 The inverter –5U1 has an error see the error message on the
inverter display
see operating manual Hitachi
SJ700
6 FAULT BLOWER 2 The inverter –8U1 has an error see the error message on the
inverter display
see operating manual Hitachi
SJ700
7 SUCTION PRESSURE MAX. The suction pressure in front of the the obturators in front of the
blower is lower than parameter « blower are open?
SucPressMax » check the pressure sensor
PSAL 11.5 (-22B1)
9 TEMPERATURE MAX. The temperature behind the blower the obturators in front of and
BLOWER 1 1 is to high behind the blower are open?
check the temperature switch
TSAH 41.6 (-23S2)
10 TEMPERATURE MAX. The temperature behind the blower the obturators in front of and
BLOWER 2 2 is to high behind the blower are open?
check the temperature switch
TSAH 42.6 (-23S3)
11 ALARM ANALYSIS FLUEGAS Common alarm of the flue gas see the operating manual of
analysing system the flue gas analysing system
12 EMERGENCY STOP An emergency stop button was pull the emergency stop
pushed button

Plant control A101

15 CONDENSATE LEVEL MAX The condensate level in the check condensate drain
condensate trap is too high - check the level sensor
LSAH21.3 (-23S1)
16 FAIL CONTR.VOLT. 24V/1L+ The function test of the control check circuit breaker -3F4
voltage 24VDC 1L+ failed check wiring
17 FAIL UPS LINE The input voltage of the UPS is not check power supply
available check fuse -2F1
18 UPS BATTERY NOT O.K. The charge status of the UPS charge battery
battery is too low check UPS power supply
19 FAILURE UPS The UPS has an error see operating manual UPS
EATON
22 EQUIPMENT FAILURE The blower is running, but the flare Start the flare
is not running for 10 minutes
24 CH4 SIGNAL FAIL The CH4 raw gas analogue signal check the CH4 gas analyser
is lower than 3mA in the raw gas analysing
system
check the external cabling
25 O2 SIGNAL FAIL The O2 raw gas analogue signal is check the O2 gas analyser in
lower than 3mA the raw gas analysing system
28 BURNER PRESS. SIGNAL The nozzle pressure analogue check the pressure sensors
FAIL signal is lower than 3mA PISHL 81.6 (-22B2) and
PISHL 81.39 (-22B3)
29 FLARE TEMP. SIGNAL FAIL The combustion temperature check the thermocouple
analogue signal is lower than 3mA element TICAH 81.60
check the signal converter -
33A2
30 TEMPERATURE MAX FLARE The temperature is higher than too much gas ?
parameter « T_max » is the CH4 value to high ?
check the air flap and motor
31 FAULT BURNER CONTROL The flare had too many restarts. check UV-sensors RSAL
More than parameter « Start No. » 81.23 and RSAL 81.53
check electric ignitions IT
81.16 and IT 81.46
check gas valves V81.4 and
V 81.34

Plant control A101

32 BURNER PRESS. MAX The burner pressure is higher than overload flare ?
parameter « P_max »
33 PREALARM CH4 The CH4 content in the raw gas is check the gas system
lower than parameter «
CH4_Prealarm »
34 PREALARM O2 The O2 content in the raw gas is check the gas system
higher than parameter «
O2_Prealarm »
35 CABINET TEMPERATURE The temperature in control cabinet check fan -4M1
HIGH is higher than 50°C check filter of the fan and
outlet filter
36 CALIBRATION ANA. The raw gas analysing system is in
RAWGAS calibration mode
37 CALIBRATION ANA. The flue gas analysing system is in
FLUEGAS calibration mode
38 TEMPERATURE MIN FLARE The temperature is lower than too little gas ?
parameter is the CH4 value to low ?
« T_min » check the air flap and motor

Plant control A101
How to set the parameters
Parameters of the 3-point automatic controllers
The behaviour of a regulation depends on different parameters. Therefore, just an only parameter
should be changed at the same time.
- P Proportional proportion
- Main part of the regulator (regulation reinforcement)
- High value quick
- Low value slow
- I Integral proportion
- Slope / speed
- High value slow
- Low value quick
- D Differential proportion
- Increases the absorption
- Makes the regulation quick
- High value quick
- Low value slow
- SamplTime
- Down time while resetting of the control value (do not change this parameter!)
- SwitchDiff
- Within this range, there is no adjustment
- PulseTime
- Switch-on time of the control output (may affect overshooting)
A deviation in temperature can not be measured as quickly as a deviation in pressure. Therefore,

the temperature regulation (louver) works slower than the pressure regulation (regulation valve).
The following table shows all standard parameters for both regulations:
Control parameter Temperature regulation Pressure regulation

P (-) 200 5
I (100ms) 20.0 0.5
D (100ms) 0.0 3.0
SamplTime (100ms) 1.0 0.5
SwitchDiff (%) 0.7 0.2
PulseTime (100ms) 0.5 0.2

Operation of the plant Memograph
Memograph
This is a simple Instruction only. There are also other ways to manage the configuration data or
measured values. Please consult the Manual from E&H for detailed information.
Export measured values from the Memograph RSG40 Series

You will need a USB-Stick (Recommandation: at least 256MB)
Data can be transferred to the installed PC

software in one of the following ways:
• Using USB, RS232/485 or Ethernet.
Easiest way on the side is with USB-Stick.
Go to Memograph and connect your USB-

Stick on the front panel.
Then press “EXTRAS”
1: USB A socket "host" e.g. for USB memory stick

2: USB B socket "function" e.g. to connect to PC or
laptop
3: LED at SD slot. Yellow LED lit when the device
writes to the SD card or reads it.
4: Slot for SD card
5: Navigator
Select in this window

“Copy memory completely”
Save the complete measured value memory

onto USB Stick card?
YES
If the storing was sucessful, you get a

Message “USB stick has been updated”
OK
Remove the USB stick selecting

“Remove Safety”
You will be asked if you really want to remove
the USB stick
YES

Before removing the USB stick, you will be

asked if you like to store the internal memory
data to the USB stick.
YES
Wait with removing the USB stick until you
get the message.
• Standard is *.rpd File, for reading in ReadWin.

• For Viewing data direct in a spreadsheet (e.g. MS-Excel®) follow these steps:
Select "Open format (*.csv)" (comma separated values) as the save mode in the unit under
" Main menu Setup System Ext. memory -> Save as"
Export Setup (configuration) data from the Memograph RSG40 Series
Go to Memograph and connect your USB-Stick

on the front panel.
Then press “EXTRAS”
1: USB A socket "host" e.g. for USB memory stick

2: USB B socket "function" e.g. to connect to PC or laptop
3: LED at SD slot. Yellow LED lit when the device writes to
the SD card or reads it.
4: Slot for SD card
5: Navigator
Select
“Save Setup”
You will be asked if you really want to save

the setup file to the USB stick
YES
After a sucessful storing you get the message
“Set up saved”
Remove the USB stick selecting
“Remove Safety”
You will be asked if you really want to remove
the USB stick
YES
Before removing the USB stick, you will be
asked if you like to store the internal memory
data to the USB stick.
NO
Wait with removing the USB stick until you get
the message.

Basic Instruction for using Readwin

(if you already have installed the program on the PC)
Start Readwin on the PC
(Programm is delivered with the Memograph)
First time use of Readwin on a PC only:

(if you already configured Readwin with your plant unit, go direct to Import data)
Press this Icon (Display/change unit setup/add

new unit)
Do a left mouse click to this folder

Then use drop down menu “Unit group/plant”
Add New Group
Add New Uni

Put in the details of this plant
choose Interface:
“parameter file from data source”
Choose path of the source data

(usb stick/ *.rpd File)
Open Continue OK.
Close the window

Save setup
YES
Close the next window also

Import Data
In the main screen, press Icon “read out

measured values using PC card drive.
Select the path where the data can be found
(USB stick / rec_data), press ok than in the new
windows button “start”
You will be asked to delete or keep the data on

the USB-Stick.
Now you are back in the main screen of
Readwin
Display Measured Values
In the main screen, press Icon “display

measured values
From data base.
Select the unit in the according group by left
double click on the unit.
Choose the time range to display (too much
data generates a confusing display).
Choose the values you like to display using (too

much data generates a confusing display).
Diagram of the selected value.

In the bottom on the left you can display the

single data (base of the curve), pressing left
mouse click on “Test (Tabular)
Export this chart by right mouse click on the

chart Save into a xls-File
Open Microsoft Excel and open the file.
It’s also possible to export the plot into the

clipboard. Use the the folder “Display”
Snapshot (clipboard).
Open Word and paste (Ctrl V) the plot.

Function description Starting procedure
Function description
Starting procedure
The start up of the flare has the following procedure:
1. Message on Panel: MAIN / Flare STARTING...
The air throttle will be set to the ignition position (Panel: CONFIG / Air Flap Position / Ignition)
(max. 150 sec).
2. The automatic burner control activates the sparking voltage with the transformer, if the air
throttle is in the ignition position and the UV-sond doesn’t see a flame.
3. The automatic burner control opens the quick closing valve of the ignition gas line.
4. The UV-sensor detects the flame and gives a signal to the automatic control burner.
If the flame isn’t detected, a fault signal comes from the automatic burner control. Restart trials
will follow, the number of starts is 1, the BCU has itself already 4 trials
5. (Panel: CONFIG / Start trials / Start N°.)
6. As soon as the flame has been burning for a given retention time, the automatic burner control
opens the main gas valve.
7. After another retention time, the automatic burner control cuts off the sparking voltage.
8. The air throttle opens up to a calculated position depending on the burner pressure.
The calculation follows the equation of a straight line defined by two points. The coordinates of
the two points can be varied (Panel: CONFIG / Air Flap Position / Air Flap Curve / P mbar,
Pos°)
9. Message on Panel: MAIN / Flare ON / Temp.control
When the calculated position is reached and the temperature is higher than the min.
temperature (Panel: CONFIG / Flare temperature / T_min) or after 2 minutes, the combustion
temperature regulation is activated, the flare tries to reach the temperature setpoint
(Panel: CONFIG / Flare temperature / Setpoint).

Function description Operating phase
Operating phase
In the operating phase the following functions are in action:
• Message on Panel: MAIN / Flare ON.
• The combustion temperature regulation is active (Panel: MAIN / Flare ON / Temp.control).
• In case that the flare fails during the operation, there will be automatic restart trials (4) by the
BCU
• Combustion air deficiency protection:
Panel: MAIN / Flare ON / Air lack
If the burner pressure is increasing x mbars (Panel: CONFIG / Burner pressure / Air Lack /
Delta_P) within y seconds (Panel: CONFIG / Burner pressure / Air Lack / Delta_t) the air flap is
opening z degrees (Panel: CONFIG / Burner pressure / Air Lack / Delta_Pos). The higher the
pressure raise, the more the air flap will be opened.
When the pressure-depending position is reached, the temperature regulation is activated
again with 20 seconds delay.
• Overtemperature protection:
If the temperature goes higher than the maximum temperature (Panel: CONFIG / Flare
temperature / T_max) the air throttle is opening.
– If the temperature will not fall below T_max within 1 minute the flare is stopped (Alarm).
– If the temperature is falling below T_max in less than 1 minute, the temperature regulation
is activated again.
Switching off
The flare stops if the following facts are enabled:
• The electricity supply to the flare control is switched off
• The Main Switch is switched off to position 0.
• A fault is present (red LED ALARM is active).
• The gas pressure is lower than the minimum pressure (approx. 2-4mbar) (Panel: CONFIG /
Burner Pressure / P_min).
• The switch "Flare" is turned to 0
• The switch "Flare" is turned to Ext and the operating signal is disabled by the overriding control
plant.

Function description Temperature regulation
Temperature regulation
General
A proper combustion does not necessarily need a constant temperature of e.g. 1200°C. The
temperature depends on the
• Gas quality (50..70... % methane)
• Gas quantity (min...max flow)
• Combustion air quantity (see KnowHow 05 under www.hofstetter-uwt.ch )
If the gas quality and the flow are high, a good combustion requires a higher combustion
temperature, and vice versa.
However, the PLC allows the temperature to be adapted according to the above mentioned
factors.
Principle of the regulation

The regulator is opening and closing the air flap depending on the combustion temperature.
actual temperature > setpoint air flap opening
actual temperature < setpoint air flap closing
The characteristics of the 3-point regulator can be changed over the operating panel:
Panel: CONFIG / Flare Temp / Control Settings / P

Panel: CONFIG / Flare Temp / Control Settings / I
Panel: CONFIG / Flare Temp / Control Settings / D
Panel: CONFIG / Flare Temp / Control Settings / SamplTime
Panel: CONFIG / Flare Temp / Control Settings / SwitchDiff
Panel: CONFIG / Flare Temp / Control Settings / PulseTime
The burner pressure represents the gas flow. Therefore, each pressure requires its own
combustion temperature. The theoretical values are approached by 3 linear equations.
Combustion
temperature
(°C) Burner pressure
(Gas flow)

Function description Temperature regulation
The 4 couples of values can be entered as following:
Panel: CONFIG / Flare Temp / p mbar (e.g. 2 10 32 60)

Panel: CONFIG / Flare Temp / T SP °C (e.g. 1000 1 020 1070 1100)
Each resulting temperature is treated as the actual setpoint (T) and is shown on the panel. To
avoid a too dynamic setpoint, the burner pressure is given by 2 parameters:
The number of measurements of the burner pressure (Samples) and the time of the
measurements (SampleRate)
Panel: CONFIG / Flare Temp / Control settings / Samples (e.g. 10)

Panel: CONFIG / Flare Temp / Control settings / SampleRate (e.g. 200 ms)
In case of a 1:10 burner, the ratio between the nozzles of the stages 1 and 2 needs to be defined.
So, the sudden change in pressure from stage 1 to 2 (or vice versa) is considered in the
calculation of the temperature setpoint.
Panel: CONFIG / Flare Temp / Control settings / Cbp (e.g. 0.5)
Further, the entire curve of the temperature can be increased or decreased depending on the gas
quality. The following graph shows the dependence of the temperature on the heat value.
30
Change of the
temperature 3 5
setpoint (°C) Heat value Hc
(kWh/Nm3)
-50
Panel: CONFIG / Flare Temp / Control settings / Hc (e.g. 5 kWh/Nm3)

Function description Start position of the air flap
Start position of the air flap
IMPORTANT!
Changing the standard parameter must only
done by skilled worker.
The standard value for the start position of the air flap is 40°.
Pressure regulation
Operating condition after start
a) Pressure regulation reach the temperature between Tmin & Tmax (normal case)
Temperature (°C)
Temperature
control
Tmax
Tset
Tmin
Zeit (t)
30°
f(pburner)
90°
Air flap-pos. (°)

Ignition Reached the pressure
dependent position
1. Air flap goes on startposition

2. Ignition phase
3. Air flap goes on pressure dependent position
4. Temperature-control active

Function description Pressure regulation
The standard value parameter for the air flap curve.
AIR FLAP POSITION AIR FLAP Setttings

SetpCurve xx ° Acutal calculated value for flap pos. After ignition
Actual xx ° Acutal flap position
Ignition 30 ° Ignition position
AIR FLAP CURVE FLAP POSITION after Ignition
P mbar 10 60 Straight line defined by 2 points, x-axis
Pos° 30 80 Straight line defined by 2-points, y-axis
Deviation 5 % Admitted deviation from straight line
b) Pressure regulation reach the temperature below Tmin
Temperature Temperature
(°C) control
2 minutes
Tmax
Tset
Tmin
Temperature
control
time (t)
30°
f(pburner)
90°
Ignition Reached the

Air flap-pos. (°) pressure
dependent
position
Too much air cooling the temperature down. Change the standard value parameter, therefore the
airflap open less.
The position of minimum load mustn‘t be lower than the limit switche of the air flap

Function description Pressure regulation
c) Pressure regulation reach the temperature over Tmax
Temperature Temperature
(°C) control
Tmax
Tset
Tmin
max.1
minute
time (t)
30°
f(pburner
Ignition pburner reach

Air flap-pos. dependent
(°) position
Too less air cooling the temperature down. Change the standard value parameter, therefore the
airflap open more.
The position of full load mustn‘t be higher than the limit switches of the air flap.

Electrical description Circuit diagram of the plant and the
flare
Electrical description
Circuit diagram of the plant and the flare
Circuit diagram of the gas Analysis System CH4 / O2 / CO2
Circuit diagram of the fluegas Analysis System CH4 / O2
Circuit diagram of the KUHSE System

Electrical description Frequency Inverter parameters
Frequency Inverter parameters
Changed parameters vs. standard parameters
Parameter Function Settings

b037 Display mode 00
(Freigabe Parameter !)
F002 Acceleration time setting 90
F003 Deceleration time setting 90
A004 Maximum frequency 60
A061 Maximum working frequency 60
A011 Input active range start frequency 15
A012 Input active range end frequency 60
b092 Cooling fan control 01
b098 Themistor for thermal protection 01
C014 Terminal 4 active state 01
C021 Terminal 11 function 00
C022 Terminal 12 function 05
C032 Terminal 12 active state 01
C102 Reset Signal 00
C029 Analogue output AMI 00
C028 Analogue output AM 01

Repairs Trouble shooting
Repairs
Basically, repairs to Landfill gas plants may only be carried out by competent, trained personnel,
i.e.
a) Landfill gas specially trained personnel
b) by the Landfill gas plant manufacturer
c) by the manufacturer of the individual units
If there is any confusion, or you are unsure, please contact the manufacturer.
Trouble shooting
Procedure to eliminate a fault

1. Determine the fault by means of the text on the operating panel
2. Eliminate the fault
3. Acknowledge the fault with ‘reset’ key on the panel
The failure messages on the panel are self-explaining and offer up to 3 of the most possible failure
reasons.

Repairs Trouble shooting
Most frequent failure examples:
Failure Trouble Shooting
Flare does not ignite Control the ignition electrode
WARNING!
Voltage 10’000V; turn off at mains!
The distance between the electrode points should be approx. 3
mm. If necessary exchange defect electrodes.
Flare does not work in spite of pre-pressure • Control UV-sensor for external damage
(min. 15 mbar) and a sufficient CH4-content of • Clean the UV-sensor with a clean cloth,
between 30..55 Vol. %. (flame extinguishes free of dust and grease. Grease, even
after ignition) when invisible, can absorb the UV-rays up
to 95%.
• Control that the UV-sensor is functioning
correctly.
Cover the sensor with a hand so that the
flame is no longer visible. Either an ignition
cut follows, or the flame extinguishes. After
elapse of the safety time of the automatic
burner (5s) a new start attempt must follow.
• Control the motor of the quick closing valve.
The valve must audibly open during ignition
• Carry out function control
Flare still does not start Carry out Putting into Operation and Function
Control.

Repairs Fault analysis
Fault analysis

Fault Analysis
System: Sparky M 300 Ambience cond.: outdoors © Hofstetter Umwelttechnik AG
Pos. Search Components Function Failure Aspect of Failure Available Failure effect Effect
No. mode damage, recognition measures to the system Remarks
possible cause
1. PI 11.3 Manometer Suction pressure Wrong reading Condensate, Wrong display, Replacement unit None Only reading, no
measuring measuring range impossible for exchange other function
exceeded pointer position
2. PIR Pressure transmitter Suction pressure No measuring Condensate, Wrong Replacement unit Stop the system Alarm, Stop the
11.5 measuring signal, zero electrical defect measuring for exchange flare if too much
offset value underpressure
3. TI 11.4 Thermometer Gas temperature Wrong reading Condensate, Wrong display, Replacement unit None Only reading, no
measuring measuring range impossible for exchange other function
exceeded pointer position

possible cause
4. TSL Thermostate switch Outside temperature Does not Bimetal strip defect, Heated parts Clean contact, Cut-off complete Repair
101.1 monitoring with switch corrosion can freeze exchange unit plant, sequence immediately
connection of heater (measuring gas error
bands pipeline)
5. TSAH Thermostat switch, Temp. monitoring Does not capillary tube The gas pump Exchange unit Plant part is not Repair
41.6 over-temperature gas pump switch defect, Corrosion does not switch operative immediately
42.6 blower off at over-
temperature
6. K Manual butterfly Manual shut-off In open mode defect seal Gas flows exchange seal Landfill gas in repair
xx.x valve device in the gas -defect, closes through in spite system despite immediately
pipeline, open / only partly of closed valve closed valve
close
7. X Flame arrester Prevents flame back None or not Contamination of Deficient gas Clean disk Insufficient gas Repair
41.2 firing in ex-case enough gas safety disk flow for utilisation immediately
42.2 flow
81.9
81.39
8. X 41.3 Pipe compensator Vibration absorption outside leak Broken corrugated Gas smell, air Replace Plant part is not Repair
41.5 in pipeline hose, due to intake compensator operative immediately
42.3 overload
42.5

possible cause
9. V Motor butterfly valve opens slow / closes In open mode Seal defect, Not possible to Exchange seal, if Unstable gas Repair
81.4 quick defect, closes corrosion, drive control, also not necessary replace pressure, immediately
81.34 only partly, or defect possible to valve, replace possible
in closed move valve by drive breakdown of
mode defect, hand utiliser
opens only
partly.
10. X Heating band Trace heating of Short circuiting Insulation defect Measuring Replace heat band Insufficient Repair when
141.3 measuring gas/dewatering dewatering, no convenient
gas/dewatering pipeline freeze measuring gas
pipeline up flow
11. P Gas pump Delivery of Landfill Outside Corrosion, Gas smell, Repair casing, if No gas supply Shut down plant
41.4 gas leakage, contamination in overload of necessary clean until repaired
42.4 blocked Landfill gas pump’s motor pump

possible cause
Pressure switch Control pressure Does not Corrosion, flare does not If necessary clean fault flare Exchange
12. PSH
start monitoring before switch overloading start contact, exchange immediately
81.1
flare unit
Pressure transmitter Control pressure Does not Corrosion, flare doesn't shut If necessary clean Possible Exchange
13. PISHL
monitoring before switch overloading down when contact, exchange damages to the immediately
81.9
flare pressure low unit burner
81.39
Magnetic valve, opens quick / closes In open mode Corrosion, Gas flows Clean valve, if Safety technique. Shut down plant
14. V 81.13
currentless quick -defect, closes contamination through in spite necessary replace shut off of gas until repaired
81.43
connected only partly of closed valve corroded parts flow not
guaranteed.
15. V 81.12 Pressure controller Gas flow pressure Does not Contamination, Considerably Clean control, if Poss. shut down Repair
81.42 control regulate corrosion, defect fluctuation in gas necessary replace of utilise due to immediately
pressure membrane pressure
fluctuations
16. A Ignition electrode set sparks to ignite the Ignition defect Ignition In spite of Replace ignition Back pressure If necessary shut
81.17 burner transformer attempts to start transformer, adjust not stable, poss. down plant until
81.47 defect, electrodes flare does not electrode spacing, no gas utilisation repaired
very warm start up. if necessary
replace electrodes
17. RSAL UV-monitoring UV-Monitoring of the Flame is not UV-bulb defect, In spite of Replace UV-bulb. Burner operation Shut down plant
81.23 complete burner flame detected Dirty attempts to start Clean UV-sensor not possible until repaired
81.53 flare does not
start up.
18. TICAH Thermocouple Flare temperature No measuring Electrical defect, No flare Possible Flare temperature Immediate
81.60 measuring / signal sensor fracture temperature replacement unit control does not exchange
81.61 regulation reading, poor work, poor
combustion

Repairs Disruptive incident
Disruptive incident
Please fill in by disruptive incident and send it to Hofstetter Umwelttechnik AG
Hofstetter Umwelttechnik AG +41 34 411 86 11

Münchringenstrasse 12 Fax +41 34 411 86 10
CH-3324 Hindelbank [email protected]
Schweiz www.hofstetter-uwt.ch
FAX-No.
FROM
DATE
Project: Product: HOFGAS- Ref. #:

Date of incident occurred :
L
Number of incident :
Plant is in operation Yes No Position of the H4
Gas utilisation Yes No Thermocouple H3
H2
Operating hour :
H1
Date / kind of last maintenance : Depth L = ............ mm
Insulation
Height = ............
CH4 content % O2 content %

Gas flow Nm3/h
Description incident (if possible with photo)

Shutting down
Shutting down
Stop the unit
In order to shut down the whole plant properly, the following procedure is recommended.
1. Switch off the gas pump and the flare with the switches “Gas pump 0-I“ and “Flare 0-I“.
2. Switch off the main switch of the flare control.
3. Switch off the main switch on the control cabinet and make safe against third parties
accidentally switching on, i.e. with a padlock on the main switch.
When working on electrical components of the plant, we recommend removing the main fuse to
prevent third parties accidentally switching on.
Storage / conservation
If the plant is laid still for a longer period of time, we would recommend servicing and cleaning of
the individual components in accordance with the manufacturers' instructions.
According to installation site, consideration should be taken of the climatic conditions (heat/frost).
A new start definitely requires a new Putting into Operation and Function Controls.

CDM Concept for data monitoring
and storage
CDM
Concept for data monitoring and storage
(according to the regulation of UNFCCC)
The monitoring methodology is based on direct measurement of the amount of Landfill gas
captured and destroyed at the flare platform and the electricity generating/thermal energy unit(s)
to determine the quantities as shown in Figure 1. The monitoring plan provides for continuous
measurement of the quantity and quality of Landfill gas flared. The main variables that need to be
determined are the quantity of methane actually captured MDproject,y, quantity of methane flared
(MDflared,y), the quantity of methane used to generate electricity (MDelectricity,y)/thermal energy
(MDthermal,y), and the quantity of methane generated (MDtotal,y).
FE
F
Flare
CH4 P F T F
Landfill Power
plant
F
Boiler
Measurements:
CH4 = Fraction of CH4
T = Temperature
P = Pressure
F = Flow of Landfill gas (m3)
FE = Flare efficiency

and storage
To determine these variables, the following parameters have to be monitored:
• The amount of Landfill gas generated (in m³, using a continuous flow meter), where the total
quantity (Landfill gas total,y) as well as the quantities fed to the flare (Landfill gas flare,y), to the
power plant
(Landfill gas electricity,y) and to the boiler (Landfill gas thermal,y) are measured continuously. In
the case where
LANDFILL GAS is just flared, one flow meter can be used provided that the meter used is
calibrated
periodically by an officially accredited entity.
• The fraction of methane in the Landfill gas (wCH4,y) should be measured with a continuous
analyzer or, alternatively, with periodical measurements, at a 95% confidence level , using
calibrated portable gas meters and taking a statistically valid number of samples and
accordingly the amount of land fill gas from LANDFILL GAS total,y, LANDFILL GAS flare,y,
Landfill gas electricity,y, and Landfill gas thermal,y shall be monitored in the same frequency. The
continuous methane analyser should be the preferred option because the methane content of
Landfill gas captured can vary by more than UNFCCC/CCNUCC CDM – Executive Board
ACM0001
Sectoral Scope: 13 28 July 2006 8 20% during a single day due to gas capture network conditions
(dilution with air at wellheads, leakage on pipes, etc.).
• The flare efficiency (FE), measured as the fraction of time in which the gas is combusted in
the flare multiplied by the efficiency of the flaring process. For this purpose, the methane
content of the flare emissions should be analysed at least quarterly, and where necessary more
frequent, to determine the fraction of methane destroyed within the flare.
• Temperature (T) and pressure (p) of the Landfill gas are required to determine the density of
methane in the Landfill gas.
• The quantities fossil fuels required to operate the Landfill gas project, including the pumping
equipment for the collection system and energy required to transport heat, should be
monitored. In projects where Landfill gas gas is captured in the baseline to either meet the
regulation
or for safety reason, fossil fuel used in the baseline too should be recorded.
• The quantity of electricity imported, in the baseline and the project situation, to meet the
requirements of the project activity, if any.
• The quantity of electricity exported out of the project boundary, generated from Landfill gas, if
any.
• Relevant regulations for Landfill gas project activities shall be monitored and updated at renewal
of
each credit period. Changes to regulation should be converted to the amount of methane that
would have been destroyed/combusted during the year in the absence of the project activity
(MDreg,y). Project participants should explain how regulations are translated into that amount
of gas.
• The operating hours of the energy plant and the boiler.

and storage
Data Monitoring / Recording on the Memograph
Signal name Signals Input

available Memograph
CH4 AO AI
O2 AO AI
CO2 AO AI
Analyzer in Operation DO DI
Analyzer in Calibration DO DI
Flow Nominal AO AI
Flow Counter DO DI
Flow Temperature AO AI
Flow pressure abs AO AI
T-Combustion AO AI
Flare ON/OFF DO DI
Consumption kVA DO DI
Fluegas CH4 unburnt AO AI
Fluegas O2 resid. AO AI
Fluegas Analyzer in Operation DO DI
Fluegas Analyzer in Calibration DO DI
Collective Alarm DO DI
Gas pump 1 ON DO DI
Gas pump 2 ON DO DI
Faulty Gas pump 1 or 2 DO DI
- AO = Analogical Output signal, on terminals, can be stored on Memograph, indicated as AI)

- DO = Digital Output signals, on terminals, can also be stored on Memograph, indicated as DI)

CDM CDM Instrumentation &
Tolerances
CDM Instrumentation & Tolerances
Measurement Symbol Range System Supplier Meas. freq. Det. Limit

Fluegas temperature TICR 0..1200 °C PtRh10-Pt JUMO continously
FI with P+T Differential Endress &

Gas flow 0-3'150 Nm3/h continously
compensation Pressure Hauser
Endress &
Gas flow pressure PI(C,R) 0..2,000 bar abs piezoelectric continously
Hauser
Gas flow Endress &
TI(C,R) -0..100°C PT100 continously
temperature Hauser
Landfill gas Analyser CH4 0..100 vol% NDIR NUK continously
CO2 0..100 vol% NDIR. NUK continously
O2 0..25 vol% electrochem. NUK continously
Fluegas Analyser CH4 0..2 vol% NDIR NUK continously

O2 0..21 vol% chemical NUK continously
Measurement Symbol Accuracy Repeatability Calibration Remarks

local
FI with P+T recalibration by to be calibrated based on UNFCCC
Gas flow max +/- 1.5 % < 0.1%
compensation E+H guidelines
every 3 years
Landfill gas Analyser CH4 +/- 1.0 % < 0.5% operator Zero and two point calibration with:
CO2 +/- 1.0 % < 0.5% All 4 weeks - ambient air
O2 +/- 2.0 % < 1.0% locally - cal. gas mix. CH4+CO2+N2
Fluegas Analyser CH4 +/- 2.0 % < 0.5% operator Zero and two point calibration with:
- ambient air
O2 +/- 2.0 % < 1.0% locally
- cal. gas mix. CH4, N2
Fluegas temperature TICR +/- 1.5 °C EN Standard ---

CDM Equipment Certificates
Equipment Certificates

CDM Validation of CDM
instrumentation
Validation of CDM instrumentation
The validation of the used sensors and instrumentation requires several measurement
equipments:
- Reference Pressure Sensor or a reference pressure which can be attached

- Reference Temperature sensor or reference temperature analyser [0..100°C]
- Reference Temperature sensor or reference temperature analyser [0..1200°C]
Pressure Indicators / Sensors: Can be validated using a reference Manometer on the same
position or
Can be validated using a reference sensor on the same
position or
Can be validated using a reference pressure which will be
attached to the sensor directly
Temperature measurement (Gas): Can be validated using a reference temperature indicator on

the same position or
Can be validated using a reference temperature analyser on
the same position [0..100°C]
Temperature measurement (Flare): Can be validated using a reference temperature analyser on

the same position [0..1200°C]
Flow measurement: Can be validated using a reference differential sensor on the

same position or
Can be validated using a reference sensor on the same
position

CDM Maintenance of CDM
instrumentation
Maintenance of CDM instrumentation
Thermocouple
The thermocouple measures the combustion temperature. For this component, no maintenance
has to be done. Only a visual check every half year should be realized. Check, if there are any
damages (cracks) on the protection tube. If yes, the thermocouple has to be replaced.
The component should be replaced latest after one year of use to ensure a correct temperature
measuring.
The correct function of this component is fundamental, because:
The measured temperature is a audit trail for CDM Projects that the flare is running
Gas flow analyser

Like all precision instruments flow meter is vulnerable to abuse and operating conditions outside
its specifications and limits. It is prudent therefore to periodically check the security and running
condition of the meter. It is essential that this be done if a significant over pressure has occurred, if
the installation has been subjected to abnormal vibration or if the gas should become excessively
contaminated.
Recalibration
Hofstetter advises to recalibrate the flowmeter every three years. This should be realized by a
representative of Endress + Hauser. See contact information in the Appendix or on the webpage
of Endress + Hauser to find a calibration center close to your location.
Landfill gas Analyser

The gas analysing system NGA5 - CH4-CO2-O2 is a modular construction and designed for
continuous operation. The measuring gas to be analysed, is taken direct from the Landfill gas
pipeline and fed via the internal measuring gas processor to the measuring instruments.
The recalibration of this analyser should be realized every week, using a reference gas as
described in the manual of the manufacturer.
There are other maintenance issues to be done (like exchanging the filter, hoses, a.s.o.).
Please read manufacturers manual in the Appendix to assure correct operation.
Flue Gas Analyser

The gas analysing system CH4-O2 is a modular construction and designed for stationary,
continuous operation. The measuring gas to be analysed, is taken direct from the flare and fed via
the internal measuring gas processor to the measuring instrument. The analysed measuring gas is
led back to atmosphere.
The recalibration of this analyser should be realized every week, using a reference gas as
described in the manual of the manufacturer (see Appendix).
There are other maintenance issues to be done (like exchanging the filter, hoses, a.s.o.).
Please read manufacturers manual in the Appendix to assure correct operation.
For all maintenance issues it is essential, that the manual of the

manufacturer will be considered (see appendix).
The manuals of the manufacturers are the main documentation for all
maintenance issues and maintenance intervalls.

Maintenance General maintenance
instructions
Maintenance
General maintenance instructions
As previously mentioned, a high availability of a Landfill gas plant can only be achieved when
servicing of all components is carried out regularly. including gas collection, gas pipelines and
dewatering devices.
The term "Service“ covers the following activities::
Control • Visual control, (also acoustic control) for external and internal damage
• Deformation through subsidence or other outside influences
• Collection of water in pipeline system
• Check the plant parts for possible leaks (gas emission, influx of air in
gas collection and pipeline network)
• Check for gas emissions on the surface of the Landfill gas
• The water level of the hydraulic seal of the dewatering devices
Maintenance • General servicing such as cleaning, greasing
• Carry out function controls
• Replace wear and tear parts. The most important parts must be
kept in stock! The plant manufacture will define and offer these
parts.
Corrective • Detect and replace faulty parts
maintenance • Carry out repairs
Optimisation • Gauge, readjust
• Optimise control loop
• Optimise suction quantity
Operation reliability • Control and calibrate measuring system
• Determine safety limit, control setting, re-adjust
• Check safety technique
• Judge plant condition, including gas collection, pipe network and
dewatering devices
Reporting • Make a measuring report and report of the plant condition.
• Log the work carried out noting deficiencies and particular incidents

Maintenance General maintenance
instructions
To ensure readiness for operation and in support of the Landfill gas personnel, we would
recommend concluding a Maintenance Contract.
The scope of activity of the maintenance personnel is considerable. Plus the fact that modern
Landfill gas plants are extensively automatic. The wide range of measuring equipment and control
loops offer a high safety of operation; require though, a considerable know-how.
The ideal "Landfill gas plant “technical support"
has knowledge of • Gas and combustion technique

• Mechanics
• Electro technique
• Measuring and control technique
is • Reliable
• Responsible
is prepared to • Further education
• Identify himself with Landfill gas plants and is acquainted with
all functions.

Maintenance Maintenance plan
Maintenance plan
Pump station
The plant operator is responsible for ensuring that the plant is

kept in a clean and safe operational condition.
Dewatering system
suction sided condensate pipe
Control visually, functioning of the dewatering system X
Gas collection
Check pipeline network and well heads for:
• Deep points, water pockets X
• Crushing, cracks and damage X
• Excess tension X
Check function of the dewatering system x
Check function of the regulating valve, plugs and insertion device x
for anemometer
Measure gas flow, pressure, CH4-content and temperature and
log results! as necessary
If the gas collection is not working to requirement, adjust
accordingly.
Blower
General control of noise, silent running X

Check V-belt tension x
Record operating hours, lubrication if necessery! X

Maintenance
Flare
Carry out general control X
Carry out flare control check x
Carry out temperature limit selector control x
Control ignition electrodes (adjustment) x
Replace ignition electrode x
Caution! High voltage 10’000V, turn off main switch!
Clean UV glass x
Replace UV lamp x
Clean flame arrester (compressed air, steam unit) x
Check and clean the motor valve x
Check the condition of the air throttle x
Check the thermocouple and if necessary replace x
Check condition of ceramic insulation x
Control
Lamp control x
Recording of operating hours x
Monitoring of the complete functional procedure x
File fault report x
General
Keep operational record x

Clean and maintain x

Maintenance
Follow strictly the attached operation and maintenance instructions for

the above mentioned components
Gas analyzer
Ref#/ NUK documentation
Flow meter
Ref#/ E+H documentation
Gas pump
Ref#/ Continental documentation
KUHSE system
Ref#/ KUHSE documentation

Maintenance Proof of maintenance
Proof of maintenance
The plant operator makes a report in which all maintenance work with name of the executor and
date.
Deficiency and method of elimination are to be entered in the check list.
The plant operator is responsible for correct entry!
Example of a check list

Check list plant part ................................. Calendar Week 36/09
Check point per maintenance plan Date Name
Condition Control date
Ignition electrode space too large set to 6 mm 9.3.2009 Smith
UV-glass dirty cleaned 9.3.2009 Smith
Flame optimisation nothing found 9.3.2009 Brown
Dewatering clogged cleaned 9.3.2009 Smith
Gas collection nothing found 9.3.2009 Smith
... ... ... ... ...
... ... ... ... ...
... ... ... ... ...
Incidentals:
Checked by:
10.03.09 Jones

Maintenance Spare parts list
Spare parts list

Please give always the following information when ordering spare parts.
Refer to the Legend to P&I-diagram for defining the spare part.
e.g.
1. Plant type HOFGAS Ready 3000

CDM
2. Fabrication No. of the plant _________________
3. Plant model _________________

➜ This information can be found on the
type plate
4. Designation of spare parts _________________
5. Article No. _________________
6. Type of spare part _________________
7. Further description or send us the defect part
➜ this information can be found in the spare

parts list, the legend in the appropriate
register, or direct from the spare part

Maintenance Spare parts list
Orders for spare parts should be sent to the manufacturer or representative in your country.
Please fill out this formular and send it to:
Fax. No.: +41 34 411 86 10
Münchringenstr. 12
CH-3324 Hindelbank
Switzerland
Phone +41 (0) 34 411 86 11
www.hofstetter-uwt.ch
Delivery adress Billing adress
Name Name
...................................................... ......................................................
Company Company
...................................................... ......................................................
Street Street
...................................................... ......................................................
E-mail E-mail
...................................................... ......................................................
...................................................... ......................................................
Place, Date Signature, Firm stamp

Spare parts list
Recommendation: To achieve the best possible availability of the plant, it is advisable to stock the
following spare parts:
Art. No. Description Quantity
Flare
004239 Ignition electrode 2
004231 Ignition plug 2

008230 UV-Sensor 1
011299 Thermocouple type “S” 1
- Thermocouple type “N” 1
- Pressure switch 1
Compact plant
- lever grease gun with Retinax LX2 grease 1
- set V-Belt 1
Analysis system
- gas sampling pump 1
spare hoses for condensate pump 2
measuring gas filter inlets 5
water stop, membrane filter 1
filter mats for ventilation fan 5

Appendix Supplier components list
Appendix
Supplier components list
Attached components manuals to HOFGAS
-Ready 300 CDM flare
Ref# CD-Rom
Supplier Component Part

Continental Gas pump
Danfoss Thermostat to Gas pump
Endress + Hauser AG CDM Monitoring
Eaton UPS
EMU Energy meter
G-Bee Aenometer set
Hilti AG Bolts Hilti
Hitachi Frequency converter
InterApp valves
Jumo flue gas
Jumo Thermocouple
Jumo Thermometer
Kromschroeder Compensator
Kromschroeder Flame detector
Kromschroeder Automatic burner control BCU
Kromschroeder Ignition electrodes
Kromschroeder Pressure regulation
Kromschroeder Pressure switch
Kromschroeder Ignition trafo
Kromschroeder UV sensor
Kromschroeder Valves VAS VK
KUHSE Data Monitoring
Mitsubishi PLC
NUK Gas analyzer
NUK Control Cabinet
Phoenix contact Contacts clamps
Raychem Heating band
PROTEGO Flame arrester
Pepperl + Fuchs Level switch
Schmidlin Combustion air flap
Siemens Combustion Air flap actuator
TRAFAG Temperature switch
WIKA Gas pressure sensor IS-20
WIKA Gas pressure sensor S-10
WIKA Manometer
WISAG Heater band

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Operating instruction

Commission No. H10798 El Guacal

COMPACT DEGASSING PLANT

HOFGAS- Ready 3000 CDM

Comm.No.: H10798 El Guacal Page 1 / 105

Comm.No.: H10798 El Guacal Page 2 / 105

Comm.No.: H10798 El Guacal Page 3 / 105

File name: H10798 Operating instructions

Table 1: Overview of revisions

Version Date Name Chapter Changes

new 2011-01-26 Beutler Marc

Swiss Gas Combustion Technology

Comm.No.: H10798 El Guacal Page 4 / 105

Safety and protection against explosions

Other valid documentation

UEL ➝ Upper explosion limit

LEL ➝ Lower explosion limit

HOFGAS- Efficiency ➝ Flare for Landfillgas with a methane content of

SUVA ➝ Swiss Accident Insurance Association

Comm.No.: H10798 El Guacal Page 5 / 105

➝ Indication of a source of danger

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Gemäss Anhang II, Part 1, Section A der EG- Maschinenrichtlinie 2006/42/EG

Hiermit erklären wir, dass folgendes Produkt

Typ: HOFGAS- Ready 3000 CDM

Geräte Nr.: H10798

In der gelieferten Ausführung folgenden Bestimmungen entspricht:

Folgende harmonisierten EU-Normen wurden angewendet:

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EN 60204-1 Sicherheit von Maschinen – Elektrische Ausrüstung von Maschinen

Ort / Datum Hindelbank, 26.01.2011

Unterschrift mit Angaben zum Unterzeichner i.V. Marc Beutler

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About landfill gas systems

Main components of the Landfill gases:

Carbon dioxide - concentration range: 20 up to 40 Vol. %

Oxygen – concentration range: 0 up to 6 Vol. %

Water vapour max.: approx. 1 Vol. %

Critical concentrations relative to corrosion (not binding guideline values)

• Hydrogen Sulphide in Landfill gas ⇒ 100 mg/Nm3

Further demands relative to Landfill gas quality:

• Condensate free Landfill gas (to be considered during on-site planning)

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Basic equipment of pump and flare station

Gas processing pump station

Landfill gas blower

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Gas analysis system

Also the CO2 content of the gas is analyzed.

Plant control pump station

The KUHSE-System allows to monitor the operation of the plant.

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Safety Specifications and Responsibility

Symbols in this documentation

Alarm symbols and

Reference on a dangerous situation, which, if it is not

Reference to a dangerous situation, which, if it is not

Reference to a dangerous situation, which, if it is not

Reference to a situation, those, if it is not avoided, possibly