Energy for Agriculture (E4A) Quality Management System (QMS) General Quality Manual September 2015 E N E R G Y F O R A G R I C U L T U R E
Energy for Agriculture (E4A)
Quality Management System (QMS)General Quality Manual
September 2015
ENERGY FOR AGRICULTURE
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TABLE OF CONTENTS
TABLE OF CONTENTS ................................................................................................. 2
PURPOSE OF THIS MANUAL ...................................................................................... 3
1. INTRODUCTION .................................................................................................... 4
1.1 Classification of Biodigesters ........................................................................... 4
1.2 Selection of Type of Biodigester ....................................................................... 8
1.3 Components of ZamDigester ........................................................................... 9
Organisation Structure of E4A .................................................................................. 9
2. CONCEPT OF QUALITY IN BIODIGESTER PROJECT ............................................. 11
2.1 Backgorund ................................................................................................. 11
2.2 General Approach and Strategy of Quality Management System (QMS) .............. 12
2.3 Quality Control Process ................................................................................. 21
3. ROLES AND RESPONSIBILITIES OF STAKEHOLDERS .......................................... 25
3.1 Role of Biodigester Owners............................................................................ 25
3.2 Role of RBSU Technicians .............................................................................. 26
3.3 Role of NBSU ............................................................................................... 27
3.4 Role of Biogas Construction Enterprise/Installer/Mason ..................................... 28
ANNEX-1: QUALITY STANDARDS FOR ZAMDIGESTER-2015 ..................................... 30
ANNEX-2: TOLERANCES .......................................................................................... 36
ANNEX-3: FORMS AND FORMATS FOR QC ................................................................ 37
ANNEX-4: QUALITY CONTROL TOOLS AND EQUIPMENT .......................................... 54
ANNEX-5: QUALITY CHECK OF BIODIGESTERS AND KNOWLEDGE OF USERS........... 57
ANNEX-6: MONITORING PARAMETERS FOR ZAMDIGESTER ..................................... 58
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PURPOSE OF THIS MANUAL
Non-functioning and poorly functioning biodigesters cause not only capital waste but also do a
lot of harms and damages to the reputation of biodigester technology and eventually to the
desired future expansion of biodigester project. The satisfied biodigester users usually
become the main and effective promotional tools and extension media for the dissemination
of the technology and vice-versa. And hence, to safeguard the interest of the users,
implementing agencies, and donors; it is important that the biodigesters function to the
desired level. This is only possible when the biodigesters are selected, constructed and
operated as per the set quality standards. To ensure the quality of biodigesters, it is
important that effective and stringent quality control mechanisms are formulated and
enforced efficiently. The quality on training and capacity building; promotion and extension
activities; construction, operation and maintenance of biodigesters have to be a major
concern. As the rate of installation of biodigester will be increasing in the country year by
year, more careful attention has to be paid to ensure the quality of the final product. This
increases calls for more effective quality management system in place. This quality manual is
a document containing the quality policy, quality objectives, quality control process and
description of the quality management system to be practiced under the framework of Energy
for Agriculture (E4A) project.
The notion of quality is of utmost important for E4A project as it aims at creating a solid
foundation in the country for the subsequent projects in the future. There is need to ensure
each and every biodigester installed functions as anticipated. Non-functioning biodigester will
pose negative effect at different levels as follows:
At Client’s level: Sub-standard quality of product leading to unsatisfied clients,
gossip/negative image, loss of investment, and waste of land and initiative.
At Mason’s/constructor’s level: Bad reputation, loosing of job, no growth and loss of
investment.
At Project’s level: Waste of resources, loss of momentum, slowdown of distribution, set
back of the project, drop out of donors, and ultimate failure of the project.
This Quality manual explains the requirements to ensure that the quality standard are
enforced and complied with. It specifies requirements for Quality Management Systems
(QMS) by which E4A;
a. Develops and implements a policy and corresponding objectives which take into account
statutory and regulatory/legal and other requirements to which E4A subscribes.
b. Demonstrates its ability to consistently provide product and services that satisfies
customers/stakeholders, and
c. Enhance customer/stakeholders satisfaction through the effective application of the
systems, including processes for continual improvement of the systems and the assurance
of conformity to customer requirements.
This manual will help biogas engineers, quality inspectors, monitoring and evaluation officers
and biogas technicians to carry out the task of quality control effectively and efficiently.
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1. INTRODUCTION
1.1 CLASSIFICATION OF BIODIGESTERS
There are different designs of household biodigesters being disseminated in different parts of
the globe today. Broadly, they can be classified based upon type of digester, type of feeding,
and methods of construction as described below:
a. Based upon type of gas holder
i. Floating Gas Holder
In 1956 the floating drum biodigester, popularly known as KVIC (Khadi and Village Industries
Commission) Gobar Gas plant, was introduced in India.
In this design, the digester chamber is made of
brick/stone masonry in cement mortar. A mild steel
drum is placed on top of the digester to store the biogas
produced in the digester. Thus, there are two separate
structures for gas production and collection.
The advantage of the floating drum design is the
constant gas pressure, which is equal to the gasholder’s
weight divided by its surface. This means that lamps,
stoves and other appliances don’t need any further
adjustments once they have been correctly set to a certain pressure rating. Another
advantage is that the risen level the gasholder indicates quantity of the available gas. With
the introduction of fixed dome Chinese model plant, the floating drum plants became obsolete
because of comparatively high investment and maintenance cost.
Advantages Disadvantages
• Constant gas pressure
• Suitable for larger plants
• Easy to understand
• Shallow digging work required and
therefore suitable for areas with high
water tables
• Can be transported to other areas,
suitable for roaming population
• Low initial investment cost
• Very vulnerable for damages by
playing children, stray cattle, etc.
• Frequent repairs and protection
measures are necessary;
• Low gas pressure, unsuitable for gas
lamps;
• Limited lifetime of the plastic,
especially when exposed to sunlight,
<2 years;
• Sensitive to ambient temperature
variations
• Requires a large surface area
• Expensive to build
• Cannot be built in remote areas,
nearby metal workshops are
necessary
• Regular (annual) maintenance
required
• Fairly sensitive to temperature
changes, less suitable in mountainous
regions
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ii. Fixed Gas holder
The fixed dome also known as Chinese model biodigester was
developed and built in China as early as 1936. It consists of an
underground brick/stone masonry compartment (fermentation
chamber) with a dome on the top for gas storage. In this design,
the fermentation chamber and gas holder are combined as one
unit. This design eliminates the use of costlier mild steel gas
holder which is susceptible to corrosion. The life of fixed dome
type plant is longer (over 20 years) compared to the floating drum
design. The original Chinese model is usually complete made out
of concrete and constructed with the help of moulds. Based on the
principles of fixed dome model from China many different designs
have been made in other countries.
Advantages Disadvantages
• Underground structure, stable
temperature, space saving
• On the spot construction with locally
available materials
• Durable, no moving parts, with little
maintenance.
• Fluctuating gas pressure
• Expensive construction cost in some
countries (cement)
• Artisan skill levels required
iii. Balloon Type
This type of biodigesters use plastic membrane of different types to store biogas produced in
digester. These types of digesters are low-cost, easy to install, and easy to transport into
remote areas, while yielding sufficient gas for both cooking and lighting needs. However, the
life-span of plastic bag digesters is relatively shorter depending upon the type of plastic
membrane used, provisions of covering/roofing, provision of fencing, and effectiveness of
operation and maintenance activities.
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b. Based upon type of Feeding
i. Continuous Feeding
The rural household digesters are fed once a day with the proper mix of dung and water/urine
and the fresh input displaces the same volume of digested bioslurry from the digester. Every
day a certain quantity of fresh input is fed into the digester which is expected to remain in the
digester for a prescribed retention time and produces gas over this length of time before being
discharged.
ii. Batch Feeding
In this process the whole digester is filled once with raw materials for gas production along with
some starting (seed) material. This is allowed to ferment and produce gas over a certain length
of time and when gas yields become very low the digester is emptied of all the sludge which can
be supplied as manure. In this system gas production begins at a low level and goes on
increasing only to drop down again after reaching the peak. Because of variable gas production
level, high cost and periodic emptying and filling of digesters, this process has not become
popular. Examples of these digesters are small size garbage plant and crop-residues plant.
iii. Semi-batch /continuous Feeding
A combination of batch-fed and continuous fed digestion is known semi-batch or semi-
continuous digestion. Such a digestion system is used where the waste like garbage etc., which
are available on daily or weekly basis but cannot be reduced to make slurry. In the semi-batch
system, the animal manure can be added on a daily basis after the initial loading is done with
garbage, agricultural waste, leaves, crop residence and water hyacinth etc.
c. Based upon methods of installation
Likewise, based upon the methods of installation biodigesters could be classified as (i) Pre-
fabricated model and (ii) constructed in site model.
d. Based upon ownership of Biodigesters
Based upon the ownership of biodigesters, they can be classified as (i) domestic biodigesters
and (ii) institutional biodigesters and (iii) community biodigesters.
The following are some of the models being used in different parts of the world.
Flooding drum models (India) Floating drum Model (Nepal) Janatha Fixed Dome (India)
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KT 1 Fixed Dome, Vietnam Chinese Fixed Dome Plastic Bag digester
GGC Model Deenbandhu Fixed Dome, India
CAMARTEC and Modified CAMARTEC Biodigesters – Tanzania and Uganda
Vacvina Digester, Vietnam Bangladesh IDCOL Model
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Steel Digester – Indonesia Prefab fiber reinforced – China
1.2 SELECTION OF TYPE OF BIODIGESTER
To successfully achieve anticipated objectives of biogas project, it is imperative that the best
suited model/design of biodigester is selected for the wide-scale dissemination. Varieties of
models/designs of biodigesters are being used in different countries in the world with successful
track records. Based upon the performance of the existing plants and experiences from other
biogas countries, attempts should be made to select the best model for the wide-scale
dissemination of the biogas technology in the country.
The following factors have been considered to evaluate the suitability of biodigesters in Zambia
assuming that the adaptability of any biodigesters in a given context depends mainly upon
these factors.
a. Climatic and geo-physical parameters: Ambient temperature, geo-physical conditions of the
soil and condition of ground water-table
b. Technological Parameters: Structural strength against different load conditions (structural
durability), methods of construction/supervision time and effort in quality control, methods
of operation and maintenance, applicability/adoptability of the design in different
geographical context for mass dissemination, prospects for sharing of technical information
and know-how.
c. Affordability of potential farmers to install biodigester: availability of construction materials;
availability of human resources (skilled and unskilled) at the local level, cost of installation,
operation and maintenance, transportation facilities.
d. Purpose of the use of the products from biodigester: use of gas for cooking, lighting and/or
operating a dual-fuel engine; use of slurry as organic fertilizer.
e. Performance of existing models, if any, in the local and/or regional conditions: existing
physical status and functioning, user's level of satisfaction.
f. Quality and quantity of available feeding materials: type of feeding materials (cattle dung,
human excreta etc.), availability of water for mixing, no. of cattle per household
Based upon above mentioned criteria, the fixed-dome double spherical model of biodigester
maned as ZamDigester has been developed for wide scale dissemination of the technology in
Zambia.
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1.3 COMPONENTS OF ZAMDIGESTER
The major components of ZamDigester are: inlet (mixing chamber and water/urine collection
chamber), digester (digestion chamber), gas holder (storage chamber), outlet (displacement
chamber), gas conveyance and application system (pipes and appliances) and slurry compost
pit(s). The mix of dung and water (mixed in inlet or mixing chamber) passes through the inlet
pipe to the digester. The mixer produces gas through digestion process in the digester and the
produced gas is stored in the gas holder (top of dome). The digested slurry passes out from
digester to outlet tank (displacement chamber) and flows out to the compost pits through
overflow opening in the outlet tank. The gas is then supplied to the kitchen through the pipe
line.
The ZamDigester generally consists in detail of:
1. Inlet (Mixing Tank)
2. Inlet Pipe(s) separate for cattle
dung/pig manure and latrine
3. Digester
4. Gas Holder (dome)
5. Manhole
6. Outlet (Displacement Chamber)
and overflow opening
7. Main Gas Pipe and Turret
8. Main Gas Valve
9. Pipeline
10. Water Outlet (Water Trap or Drain)
11. Gas Tap
12. Gas Stove with rubber hose pipe
13. Compost pit(s)
ORGANISATION STRUCTURE OF E4A
E4A project aims at installing 3,375 biodigesters in farming households in years’ time starting
from May 2015, providing them access to clean energy, increased employment and income, and
improved living condition through the productive use of products – biogas and bioslurry,
through:
• Development, strengthening and facilitating a commercially viable and market oriented
biogas sector in Zambia (Supply and Demand side management as well as facilitating
creation of enabling policy environment
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• Provision of Technical Assistance to transfer know-how, experience and technical
information available from successful implementation of other biogas programs
• Maximizing the benefits of the operated biodigester for productive uses, in particular the
optimum use of biogas and bio-slurry
The structure of E4A comprises of two major units, the implementation unit (National Biogas
Support Unit - NBSU and Regional Biogas Support Unit - RBSU) and Technical Support Team
(SNV Advisory team) as mentioned below:
Biogas Support Units (NBSU and RBSU)
• NBSU Coordinator
• Chief Biogas Engineer (CBO)
• Promotion and M&E Officer (PM&EO)
• Finance and Admin Officer (Part-time)
• Secretary/Admin Assistant
• Regional Biogas Technicians
SNV Advisory
• Country Director (Part-time)
• Project Manager
• Senior Project Officer
• Finance/Project Accounting
• Procurement and Contracting (Part-time)
The flowing diagram illustrates the project functions and respective actors:
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As shown in the diagramme, the major responsibility of quality assurance rests on the users
themselves, masons from construction companies, technical staff members of National and
Regional Biogas Support Units.
2. CONCEPT OF QUALITY IN BIODIGESTER PROJECT
2.1 BACKGORUND
‘Quality is not an act; it is a habit’ – Aristotle
In general, quality is the degree of compliance of a process or its outcome with a predetermined
set of criteria, which are presumed essential to the ultimate value it provides. Quality is doing
the right things in right way. A product or process that is reliable, and that performs its
intended function is said to be a quality product. Quality is the extent to which products,
services, and processes, are free from defects, constraints, and items which do not add value
for customers. The quality of a product or service refers to the perception of the degree to
which the product or service meets the customer's expectations. In technical usage, quality can
have two meanings:
a. The characteristics of a product or service that bear on its ability to satisfy stated or implied
needs.
b. The product or services should be free of deficiencies.
In the case of Energy for Agriculture (E4A) project, the quality is basically related to the
following aspects of project implementation:
a. Quality of the design of biodigester: The biodigester should be cost-effective; users’
friendly; easy to construct, operate and maintain.
b. Quality of training and capacity building activities: Correct training need assessment;
proper selection of training participants, proper selection of facilitators, suitable training
contents, session plans and scheduling; appropriate training methods; effective practical
sessions; effective evaluation of training; timely follow-up of the evaluation findings.
c. Quality of promotion and extension works: Potential customers are fully aware and
understand all the benefits and costs. They are provided with factual data and information
and are be aware of their roles and responsibilities for quality control.
d. Quality of the construction (including selection of construction materials and appliances):
Strict adherence of set quality standards on site selection, selection of construction materials
and appliances and construction.
e. Quality of the operation and maintenance by the users and technical backstopping from
the installer: Effective training to users’, provision of users’ manual, timely follow-up visits
by the installer.
f. Quality of after-sale-services on behalf of the installers: Strict adherence of terms and
condition of after-sale-service provisions including timely actions to the complaints from
users, routine visits and problem-solving.
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g. Quality of financial and administrative procedures and practices: Proper utilisation of
fund; timely disbursement of credit and/or subsidy amount, if any; proper book-keeping;
less-lengthy procedures; fast, friendly and useful customer services.
If the biodigester is able to do what is anticipated by the project personnel and what the user
wants it to do, then it is a quality plant. In other words, if the final product fulfils the anticipated
requirements, it can be referred as a quality plant. Hence, quality is the performance excellence
of biodigester as viewed by all stakeholders. Thus, if the installed biodigester:
has the right dimensions, configuration and features,
does what it's supposed to do,
is reliable and durable,
is delivered on-time, and
is well-supported;
then it is quality biodigester.
2.2 GENERAL APPROACH AND STRATEGY OF QUALITY MANAGEMENT
SYSTEM (QMS)
The general aim of the Quality Management System (QMS) is to ensure that the overarching
objectives of the E4A are met in the best possible way with the available resources. The basic
objective of QMS in E4A is to ensure that the installed biodigesters meet the set quality
standards and they function optimally without any major problems for the anticipated duration
of time. Effective QMS not only helps in ensuring the compliance of quality standards but also
provides learning opportunity for the project personnel.
While enforcing QMS, E4A will make sure that the following four basic principles are considered:
a. Reliability of the information collected
b. Uniformity (consistency) of the information collected and analyzed
c. Impartiality (neutrality) while collecting information
d. Transparency when dealing
Quality Control visits are integral part QMS. The objective of the quality control is to encourage
stakeholders to comply with the set quality standards. Quality Control is all the means by which
the frequency of defects in a biodigester is reduced. It includes quality planning, quality
measuring and quality analysis. While conducting QC visits, E4A will ensure that the concerned
project personnel are aware of:
a. Purpose of quality control visits
b. Frequency of visits
c. Reporting and documentation methods
d. Corrective actions
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Quality Management in Biodigester Projects refers to the systematic monitoring and evaluation
of the various aspects of the project, services, or product (biodigesters) to ensure that
standards of quality are being met. It attempts to avoid, or at least minimize, issues that led to
defects in the first place.
The quality management strategy rests on four widely accepted premises of biogas project
dissemination:
a. It is usually exponentially cheaper to deal with defects when they’re caught early than it is
to fix them later
b. The higher the level of quality assurance (coverage, frequency, effectiveness), the easier it
is to catch defects early
c. It is important to apply techniques to highlight defects in the requirements specification
(“building the wrong thing”) as well as in the implementation (“building it wrong”), and to
address not only functional requirements but also other areas of quality like maintainability,
scalability and performance, usability and accessibility, security and more.
d. Quality management task becomes more effective, if it is outsourced to a capable institution
in the long run.
The following table illustrates in brief the short and long-term strategy for quality assurance
under the framework of E4A.
Project
Functions
Short-term Strategy Long-term Strategy
Promotion
and
marketing
Develop Information, Education
and Communication (IEC)
materials, organize community
meetings and capacitate
masons/biogas companies to
promotion and marketing.
NBSU/RBSU takes the lead role in
doing so.
Strengthen the capacity of Biogas
Construction Companies/
enterprises to take overall
responsibility of the task of
promotion and marketing.
Training and
Capacity
Building
The NBSU through SNV TA,
conduct technical training to build
capacity of stakeholders including
local artisans and project staff-
members.
Capacitate local institutions/
vocational training centres, training
organizations to conduct training
and capacity building activities
Two key principles of Quality Management System
are:
The biodigesters should be suitable for the
intended purpose: fit for purpose
Mistakes/defects should be eliminated: right
first time
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Project
Functions
Short-tern Strategy Long-term Strategy
Construction
and after-
sale-services
NBSU/RBSU with TA from SNV
enhances skill of local artisans
and mobilise them to form
biodigester construction
companies.
Focus on private sector (biogas
construction enterprises)
development and
institutionalization of construction
and after-sale-services
Quality
Control
Technical staff from NBSU/RBSU
will take the lead role. SNV will
build their capacities to carry out
quality control activities.
NBSU/RBSU will be fully capacitated
to take the overall responsibility.
NBSU will build capacity of
government, semi government or
other suitable organizations and
out-source the task of quality
control to them.
The following sections describe the general strategy in detail.
Strategy-1: The task of Quality Control is associated with all project functions
Quality Control (QC) will refer to the operational techniques and the activities used to fulfil and
verify requirements of quality within the framework of E4A. QC is the planned process of
identifying established technical specifications for the project and exercising influence through
the collection of specific (usually highly technical and standardized) data. The basis for decision
on any necessary corrective action is provided by analyzing the data and comparing it to system
specifications/requirements. At E4A, it implies all those planned or systematic actions necessary
to provide adequate confidence that the biodigester is of the type and quality needed and
expected by the stakeholders.
In E4A, quality control is involved in developing systems to ensure biodigesters are designed
and constructed to meet or exceed users’ requirements. As with cost control, the most
important decisions regarding the quality of a biodigester are made during the design and
planning stages rather than during construction. It is during these preliminary stages that
component configurations, material specifications and functional performance are decided.
Quality control during construction consists largely of insuring conformance to this original
design and planning decisions.
The following figure illustrates the general functions required for any national project on
domestic biogas within the framework of E4A. The concept of quality is associated with each
and every function.
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Program Functions
Quality Concept
Promotion and Marketing
Training and Capacity Building
Construction and After-sale-services
Operation and Maintenance
Financing
Extension, Research and Development
Program Management and
Administration
Quality of promotional tools and techniques
Quality of information dissemination
Correct selection of unique selling point
Correct selection of audiences
Training need assessment Correct selection of participants Correct selection of facilitators/trainers Correct selection of training venue, training
methods and tools Certification, accreditation and registration Provisions of refresher training
Convenient, effective and efficient subsidy and credit
channelling mechanisms
Selection of correct design Selection of right client Selection of suitable site for construction Selection of quality construction materials and
appliances Provision of guarantee Provision of Users’ training and instruction manual Provision of compulsory routine monitoring visits Effective enforcement and compliance of quality
standards
Provision of pre and post construction training to users
Availability of spare parts Provision of compulsory visits of
installers on call Provision of warranty system System to collect complains from users
Provision of Users’ training on bio-slurry use Provision of Bioslurry use Manual Provision of routine Biogas Users’ Survey Identification of R&D needs based upon filed
findings Effective on-site use of research findings
Provision of Quality Control of the Quality Control Initiatives
Provisions of Technical Audits Selection of right partners Effective networking with local and external
stakeholders Effective service delivery mechanism Provisions of regular coordination, follow up and
sharing meetings Participatory program management system Effective documentation of lessons learnt and
timely sharing of information Effective advocacy, lobbying and networking for
policy formulations
Quality control is increasingly important concern during biogas project implementation. Defects
or failures in constructed biodigesters can result in costs. Even with minor defects, re-
construction may be required and facility operations impaired. Increased costs and delays are
the results. The structured QC system is therefore important for the following main reasons:
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a. To maximize performance, reliability and lifetime of every biodigester
b. To maximize the value for money for Biogas customers, E4A donors and Government of
Zambia
c. To maximize the potential livelihood benefits to customers and communities
d. To minimize the risk of accidents or damage to users or property
e. To maintain the reputation, credibility and value of the Biogas Project in Zambia
Strategy-2: Strong Focus on Capacity Building of Relevant Stakeholders
The overall aim of quality management in the long run will be to build the capacity of NBSU and
RBSU staff members to carry out the tasks of quality assurance. They will internalize the
process of quality control and feel ownership of the process. For this to happen, they will be
provided with appropriate capacity building initiatives related to quality assurance. Once they
are provided with such capacity building package, they will be given responsibilities to carry out
quality control activities.
Capacity building of constructors/masons, vocational training institutes, government line
agencies and other stakeholders involved in biodigester sector is crucial for effective quality
control. Knowledge and skills of biodigester technicians and masons are vital in ensuring the
quality of construction, operation and maintenance. QC activities therefore will begin from the
very onset of these training projects.
Quality control will be considered to be a ‘bottom-up’ activity. Rather than imposing it from the
top, the actors in the lower tire will realize the importance and provide effort to ensure the
quality. The constructors/mason and the biogas households will be encouraged and capacitated
to play a major role in ensuring the overall quality of biodigester and hence, they will be
provided with effective training packages on quality management.
To ensure effectiveness of the training programme, it is important that:
a. right persons are selected for the training
b. right trainers are selected to facilitate the training sessions
c. training contents, session plans and scheduling are suitable to meet the training objectives
d. the training methods are suitable for the particular audiences in particular learning
environment
e. the practical demonstration and on-the-job training sessions are effective
f. the evaluation of training is carried out effectively and the findings are used to improve
similar training in the future
g. timely follow-up is made to evaluate the application of learning from the training in the
workplace
The users in biogas households will be provided with at least the following two types of training:
a. Pre-construction training to familiarize them with benefits of biodigesters, installation
modality, incentives and support services being provided to them by the project, general
quality standards and their roles and responsibilities on quality control.
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b. Post-construction training to strengthen their knowledge and skills on effective operation,
routine repair and maintenance activities, provisions of after-sale-services and complaints
mechanisms.
Strategy-3: Formulation and Enforcement of Quality Standards
Quality standard is a framework for achieving a recognized level of excellence within the
project. These are stipulations of measurable physical properties or characteristics, which
materials, equipment or constructed items must have as a minimum. Achievement of a quality
standards demonstrates that the project activities have met the requirements laid out by a
quality control authority. In general, quality standards are the benchmarks of levels of service
or design specification.
Standards, as a rule or principle, are used as a basis for judgment or comparison – whether the
installed biodigester fulfills the basic requirements. These are statistics that measure changes or
deviations and provides impetus to analyze whether any deviation will have detrimental effects
on functioning. It helps in identifying the level of accuracy in complying the set criteria.
To facilitate effective monitoring for ensuring quality, standards have been developed under the
framework of E4A. The quality standards are basically related to the following aspects:
a. Quality standards related to location and size of biodigesters
b. Quality standards related to the design of biodigesters
c. Quality standards related to construction of structural parts and installation of pipes, fittings
are appliances.
d. Quality standards for the operation and maintenance of biodigesters (after-sale-services on
behalf of the installers and routine O&M on behalf of users)
The details on standards for ZamDigester have been given in Annex-1. These include, the
standards, their specifications including the tolerances (the ‘what’ part), and category as well as
potential consequences, if these standards are not met (the ‘why’ part).
These standards have been categorized under three different groups keeping in view their
importance. The critical standards are those which need to be followed strictly and no
compromise should be allowed. Failure to comply with these standards will have serious adverse
effect on the end product and on the project as a whole. The major standards are very
important for the smooth functioning of the biodigesters and failure to comply these standards
results in serious problems with the functioning. The minor standards are also important for
the successful operation of biodigester however, these can sometimes be manipulated based
upon the site conditions. Still care should be provided to adhere with these standards.
Various surveys on Quality of Biodigester Construction have confirmed that failure to achieve
appropriate Quality of Construction is a problem. The pressure to reduce the initial costs of
construction and supervision were found to have had an adverse effect on quality, as could be
predicted. Within the conventional processes for the construction contract, the installers, who
are keen to get the job of installation of biodigesters, can do so by offering low prices, but at
the risk of not being able to produce construction work which fulfills the specification or meets
sustainable standards. Likewise, technical supervisors are often under pressure to reduce the
cost of construction supervision. Inadequate supervision leads to sub-standard quality of
construction. Lack of quality in construction of biodigester is often manifested in poor or non-
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sustainable workmanship, and unsafe structures, and in delays, cost overruns and disputes in
construction contracts.
E4A believes that construction of biodigester should be sustainable, and to this end, it is the
policy of E4A that each actor in the construction process should be committed to satisfying its
obligations in respect to achieving Quality of Construction.
Construction is not value-free and hence the approach that organizations take in solving
problems is influenced strongly by the values and beliefs they hold. Values and beliefs drive
attitude and behavior, and thus outcomes. If improved quality management and quality of
construction is desired, then it will be necessary for quality management and quality of
construction to be embodied within the values and belief system of the client body. If this is not
the case, all the good intentions of the suppliers of services, goods and processes further down
the project cycle will have limited impact.
E4A will allow to have a certain tolerance limits for every quality standards based upon their
importance. Tolerance is the degree to which the set quality standard can vary or deviate
without jeopardizing the functioning of the biodigester. In E4A case, tolerance is the permissible
limit of variation in the physical dimensions of biodigester. Dimensions of biodigester may vary
within certain practical limits without significantly affecting functioning of the final product.
Tolerances are specified to allow reasonable leeway for imperfections and inherent variability
without compromising performance. Tolerances are fixed based upon the anticipated degree of
precisions to ensure effective operation of biodigesters. Most of the quality standards developed
for the construction of biodigester allow certain tolerances. The maximum tolerance limits are
given in Annex-2.
Strategy-4: Provision of Reward and Penalty Mechanisms
The disadvantage or painful consequences resulting from an action or condition that is against
the set quality standards are referred to as ‘penalty’ whereas something given or received in
Hence, both the supervisors as well as constructors (installers) should realize the
following facts to ensure good quality of biodigesters:
a. To recognize the importance of quality of construction.
b. To adopt quality management systems.
c. To provide procedures for corrective action when quality control and /or
acceptance criteria are not met.
d. To provide feedback to concerned persons/authorities for improvement of
quality of construction.
e. To recruit, train and assign a skilled work force.
f. To take measures to ensure that the persons involved in construction and
supervision are qualified, and/or accredited as required.
19
recompense for full compliance of the quality standards is a ‘reward’. Penalties are imposed
when the quality of works and the final products are of inferior quality than the anticipated
whilst rewards are awarded when the product fully meets or even exceeds the expected level of
quality.
The quality control system in E4A proposes reward provision to encourage those doing
exceptional works. The following reward mechanism will be practiced:
a. Installer(s) who construct biodigesters with minimum or no defects will be awarded as ‘best
installer(s) of the year’. The best installer will be provided with certain incentives and
rewards.
b. The best installer will be rewarded with technical, financial and institutional supports to
establish/strengthen a biodigester construction company.
c. The RBSU technicians who do outstanding job will be awarded as ‘best technician(s) of the
year’ and awarded with certain incentives. The best technician(s) will be given opportunity
for exposure visits or participation in any national/international training/workshop/seminar
on biodigester technology.
Likewise, the following ‘penalty mechanisms’ will be practiced to ensure the quality while
constructing and supervising the construction of biodigesters:
a. Poor quality work, the defaults, will surface in the database through the QC reports and
through QC on QC reports. The installer/mason(s) and technicians will be warned on such
defects based upon the severity of the defects. Repeated offenders against the quality
standards will be removed from the project and the defects will be corrected by utilizing the
functionality incentive not paid to the mason.
b. If certain mistakes are commonly made in a throughout all sites, this will be addressed at
the new technical training and at annual refresher trainings for masons and supervisors.
c. If RBSU technical persons fail in their role of quality inspectors, the technicians will be
provided with a warning. Technicians who, after a first warning, commit the same mistakes
again will be removed from the project;
d. On a monthly basis the RBSU have to report on the complaints they have received from the
users and the action they have taken. If a user claims that he/she has registered a
complaint and this is not responded by the local RBSU technicians, NBSU will investigate and
possible actions will be taken.
e. The installer(s)/companies will be categorized in three categories, such as (a) best
performing (b) satisfactorily performing and (c) poorly performing, based upon responses
from the users and operational conditions of biodigesters they install. The poorly performing
installers will be warned to improve their performance within a certain timeframe. If their
performance rating still falls under ‘poorly performing’ such installers will not be entertained
under the framework of the project for certain period of time.
Strategy-5: Operationalization of Database
E4A will install database-oriented software in order to keep track of the construction of
biodigesters both quantitatively and qualitatively. This software will be used to monitor the
biodigester dissemination progress, monitor the construction process, control the quality of the
construction, keep track of the trained professional involved in the construction and monitor
their after sale service and finally keep track of some financial data. E4A will ensure that: (a)
each biodigester has a unique serial number engraved in a permanent nameplate. The
identification numbers are listed in the database; and (b) the GPS coordinates of the location of
20
each biogas digester is recorded in the database. The software will be designed to be easy to
use even for non-experienced computer users by providing simple and intuitive data entry
forms.
Each completed biodigester will be given a unique code number after the completion of
construction works while filling the ‘Construction Completion Form’ besides other attributes such
as GPS location, address etc. All the information along with unique code number will be
managed in a computerized database. The following coding system will be practices:
Year of Construction – Province Code – Company/Mason Code - Plant Number
Provinces will be coded with suitable notions (usually three letters, such as LUS for Lusaka).
Likewise the name of company/mason is also coded accordingly with suitable coding (for
example LBC for Lusaka Biogas Construction Company). The coding for the first ZamDigester
constructed by Lusaka Biogas Construction Company in 2015 in Lusaka province will therefore
be:
13-LUS-LBC-0001.
The following roles in terms of database operation will be given care:
a. RBSU in the provinces (fields)
Follows the progress of the project in his/her province.
Enters data for his/her province.
Views the data from his/her province.
Provides feedback to biogas installer/masons.
Transmits the RBSU data to the NBSU.
b. NBSU Chief Biogas Engineer in Centre
Views and updates the data from all provinces.
Eventually gathers the provincial data.
Prints reports.
Provides feedbacks to RBSU.
c. E4A Financial Administrator
Checks the subsidy payments (for early 750 biodigesters)
Checks the payment of functionality incentives to masons
Provides feedbacks to NBSU.
d. E4A M&E Officer
Creates new accounts
21
Administers the Dbase.
Provides feedbacks to concerned personnel.
The following points will be taken care of while designing and operating central database:
a. The Software will be developed using MS Access 2003 – relational or extended relational
database system
b. The Software will be easy to use and will remind the user of the forms on which the data is
collected.
c. The Software will support several concurrent users accessing the same data.
Strategy-6: Outsourcing of Customer Support Service
E4A will carry out the required quality management tasks in the field through its trained
technical officers at NBSU and RBSU. The task of customer support service will be out-sourced
to capable private sector organization. The selection of such institutions will be done from open
bidding process guided by the Terms of Reference which is given in Annex-3.
The following flow-diagram illustrates the process of out-sourcing the task of Customer Support
Centre to local organization. E4A will make sure that the capacity of the local organization is
built to internalize the whole process of QM tasks.
2.3 QUALITY CONTROL PROCESS
As mentioned earlier ‘quality control’ will be the integral part of all the project functions. The
general rule will be (i) under-construction controls first by the technical persons of
company/installer (100% of the biodigester), then by the RBSU quality inspectors (sampling
according to skill and experience of mason and available resources – at least 50% in the initial
phase of the project); (ii) construction completion inspection by RBSU quality inspectors, on
100% of constructed plants (iii) monitoring of compliance of after-sale obligations (on at least
50% of the biodigester in the initial phase of the project) and (iv) quality control of quality
control activities by NBSU technical persons on randomly sampled biodigesters (10 to 20%
depending upon resources availability).
All the inspection findings are then entered into a Dbase; evaluated and monthly feedback
provided to respective stakeholders. Company grading, incentives and penalty, need of training,
revision of manuals etc. are done based upon database output.
The following diagram details the QC process:
22
Potential Farmer Approaches
Installer
Feasibility Study done (From 2a)
If feasible,
Drawing, cost and quantity estimation consulted with the farmer. Construction Contract
Signed (Form – 3)
If not feasible
Inform the farmer why not
feasible
Construction
Quality Control visit by Installer – 100% of the biogas plant (Form-4)
Quality Control visit by project quality
inspectors - 10-25% of the biogas plant
(Form-4)
Feebback provided
Construction Completed and Completion Report
Submitted (Form-5)
Form-5, acceptd
Guarantee Card Issued, Subsidy
payment recommended
Initial Feeding of plant
recomended
Acceptance Visit (Validation
of Form – 5)
Form-5, not accepted
Acceptance visit done by quality inspectors from project – 100% plants visited
Installer instructed to correct the
defaults
Operational Stage
Users receives operation and maintenance
training
Users receives instruction (O & M)
manual
Installer provides After-sale-service as per Guarantee terms
and conditions
QC Inspectors monitors the compliance of
guarantee provisions (Form – 7)
Performance monitoring including Do-No-Harm Assessment is done at least once in 6 months
(Form -6)
List of Potential Farmers is prepared (Form-1)
Baseline Information
collected (Form – 2b)
All data (Form-1 to Form-7) are
entered into a computer database
Reports prepared and acted upon
If found complied with,
guarantee terms and condition,
gurantee fee relaeased
23
Quality Control Visits are the main tools to monitor the quality of works being carried out at
the field level. The diagram below shows the scope of quality control visits:
The following diagram illustrates proposed timeline of such QC visits.
The diagram illustrates the visits generally necessary during the process of the installation of
biodigesters. Among these, RBSU technician should visit the site together with BCC technician
for the first and second visits. NBSU technical officers will visit some of the randomly sampled
sites for site verification. The fourth (general inspection) could be optional depending upon the
need. Besides these visits, at least two visits will be made or two telephone call will be made to
monitor the quality of after-sale-services within a year from the date of plant operation.
The 'Plant Completion Report', will also include proper measurement of different vital
components of biodigester such as diameter of digester, pressure height, diameter and height
of outlet tank etc (as given in Annex-4). This form should be filled before the initial feeding of
the plant. RBSU technicians will be trained to fill this form for all the new plants. NBSU
technicians will randomly sample some of the filled forms (at least 25%) at the site and validate
it instantly. Subsidy could be released immediately after the approval of 'Plant Completion
Report'.
The scope of work during the QC visit includes assisting and checking the construction and
providing feedback to mason. The purpose is also to make sure that the masons are qualified
enough to carry out their activities. General process for QC visits will be as follows:
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a. The mason/installer/BCC submits the details on under-construction as well as completed
biodigesters to the RBSU Technician.
b. The RBSU technician selects the biodigesters to be inspected from the list of under-
construction and completed plants on the basis of random sampling
c. Field visit schedule is prepared
d. Site verifications are carried out using the standard formats
e. The filled forms are signed by three parties (concerned mason, owner and the RBSU
technician)
f. The data and information are entered into computer database
g. Necessary feedback and suggestions is given to the installer/mason through the field
technician based upon the analysis of the data and information
h. The installer/mason follows/acts upon the feedback and suggestions immediately
i. NBSU Technical Officers select some plants on random sampling basis (under-construction,
construction-competed and operational) and carries out validation of data and information
collected by field technicians.
Sampling of Biodigesters for QC is done carefully to represent the number of biodigester
installed. Quality control in biodigester construction typically involves insuring compliance with
minimum standards of material and workmanship in order to insure the performance of the
facility according to the design. For the purpose of insuring compliance, random samples and
statistical methods are commonly used as the basis for accepting or rejecting work completed.
Rejection is based on non-conformance or violation of the relevant design specifications.
Quality control visits by RBSU and NBSU to under-construction and completed biodigesters are
very important to check the compliance of the quality standards by the masons. Visits to all the
biodigester will not be possible because of the resource constraints. Therefore, random
sampling or stratified random sampling methods (stratifications made based upon responsible
supervisors or masons, provinces, districts, types and/or sizes of biodigesters etc.) will be used
to select the biodigesters for quality control visits. The sampling will be done by district
technicians.
The following general formula could be used for deciding the sample size
n = sample size
N = Population (number of plants constructed)
e = level of desired precision or margin of error, expressed as a fraction of 1 (usually
5% to 10%)
For example, if 300 plants are being constructed in a province in a particular year, the district
technician will visit at least 171 plants not to exceed margin of error by 5%, 75 plants not to
2)(1 eN
Nn
25
exceed the error by 10% and 23 plants not to exceed the error by 20%. The greater the
precision anticipated, the larger will be the sample size.
Though the frequency of visit and sample size depends on the skills of masons, internal quality
management mechanism of the installer/company and available resources to carry out the
quality control visits, the following picture shows the minimum requirement to ensure quality of
biodigesters.
3. ROLES AND RESPONSIBILITIES OF STAKEHOLDERS
3.1 ROLE OF BIODIGESTER OWNERS
The biodigester owners are the most important stakeholders in quality control of biodigester
during construction as well as operation and maintenance phases. They are responsible to:
a. Participate in pre and post construction training sessions.
b. Prepare construction sites and collect materials according to the instruction of the
installer/mason and/or RBSU technician.
c. Set the construction schedule and deadlines in consultation with the RBSU and the
installer/mason.
d. Provide required unskilled labor for the digging work and to assist the masons during
construction as per the contract provision.
e. Constantly monitor the work of installer/mason.
f. Operate the plant as stipulated in the operation manual.
g. Carry out routine repair and maintenance works as per maintenance manual.
h. Report problems to the installer/mason and/or NBSU.
i. Respond to calls from Customer Service Centre and call them in case of any problem related
to operation of biodigester.
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j. Lodge complaints in RBSU/NBSU if the installer/mason does not respond to the call for
problem solving.
3.2 ROLE OF RBSU TECHNICIANS
RBSU technicians will be responsible for the protection of farmers against incompetent and/or
careless installer/BCC/masons. It is done through quality control during the construction on
randomly sampled plants and completion control of all plants. During these visits the
technicians will methodically inspect biodigesters using appropriate inspection forms. The
technician will ensure that no plant is handed over to the user if he/she is not completely
satisfied that the completed plant, including pipeline and appliances, will function as it is
supposed to. The above described control mechanism is also laid-down in the construction
contract signed by mason, RBSU technician and user.
The detail tasks of NBSU Technician are:
a. Select suitable households to register with the Project for technical and financial assistances
with the help of local masons/BCCs.
b. Help users select suitable designs, sizes, locations for biodigesters and required
construction materials as per the quality standards.
c. If required, assist users in obtaining a biodigester construction loan with a recognized
financial institution.
d. Help users purchase/prepare accessories and tools as per required technical standards for
the biodigesters.
e. Introduce trained and certified mason’s team/mason to the users for their selections and
construction agreements.
f. Help and provide document to users instructing construction supervising procedure,
including their roles during and after the construction works, in order to assure construction
and installation quality.
g. Supervise the work of local masons during construction and installation of biodigesters in
order to control construction quality. The biodigesters to be visited are selected randomly
from the list of under-construction biodigesters informed by the installer/masons. Data and
information are recorded in the standard Construction Monitoring Form (given in Annex).
Masons are instructed to correct any deviations from the standards. Any mason who
violates seriously the construction requirements are reported to NBSU for final actions such
as stopping mason’s jobs, revoking certificates, cancellation of construction contracts etc.
h. Fill database or submit the filled Construction Monitoring Form to NBSU for entering the
data and information into the database.
i. Instruct biodigester users to prepare feedstock as per quality requirements before operating
plants.
j. Visit all the completed plants for filling Construction Completion Report (also known as
Acceptance Report) (given in Annex). This visit is made after the completion of construction
works but before the initial feeding of the biodigester. Measurements of various key
components are taken and crossed checked with the standard. Test and Acceptance jobs
are carried out in cooperation with users and mason. The data and information is filled and
27
Construction Completion Report and is signed by the three parties (RBSU technician, mason
and the user). The biodigester code is mentioned in the Construction Completion Report for
project management. Biodigester owners are instructed to feed the biodigesters only if the
quality standards are met. Any rectification needed is carried out by the mason in an
agreed timeframe.
k. Submit the Construction Completion Reports from fields to RBSU for data entry or if access
is given enter the data and information into the database and register the biodigester into
project management file.
l. Instruct biodigester users on methods to apply feedstock and start up the biodigesters
according to technical requirements.
m. Supervise, follow up, support masons’ team, and solve complains from biodigester users if
required.
n. Carry out checking of existing physical status and functioning of biodigesters and the
warranty responsibilities at least once in six months during the warranty period of 2 years
in randomly sampled biogas households. Biodigester Performance Monitoring Form (given in
Annex) will be used during this visit. The information could also be collected through phone
calls if the users do not have any specific complain.
o. Report NBSU if the mason/masons’ team violates the term and conditions set out in
warranty provision.
3.3 ROLE OF NBSU
Given the limited resources (human and financial) and time, NBSU may not be in a position to
visit all under-construction or completed biodigesters to ensure the compliance of quality
standards by the installer/masons. The role of NBSU should be to build the capacity of RBSU
biogas technicians to internalize the quality control process. To ensure this to happen, NBSU
should:
a. Train RBSU technicians
b. Accompany RBSU technicians to the field to monitor their works at the field level and
provide necessary back-stopping services at site
c. Ensure that RBSU technicians are building capacity of masons and BCCs to effectively carry
out the quality control activities through transferring of their skills and knowledge
d. Carry out QC control visits to randomly sampled biodigesters to validate the data and
information collected and submitted by RBSU technician.
NBSU should realise that capacity building of local masons, BCC supervisor, RBSU technicians
and other stakeholders involved in biogas sector is crucial for the sustainability of the project.
Knowledge and skills of RBSU technicians and masons are vital in ensuring the quality of
construction, operation and maintenance. QC activities should commence from the very
beginning of these training projects. To ensure effective learning from training the following
issues should be considered:
a. Proper selection of training participants
28
b. Proper selection of facilitators
c. Suitable training contents, session plans and scheduling
d. Appropriate training methods
e. Effective practical sessions
f. Effective evaluation of training
g. Timely follow-up of the evaluation findings
The NBSU should facilitate the RBSUs to formulate selection criteria for the participants and
ensure that these criteria are adhered to. For example the selection criteria for masons could
be:
a. Formal education of at least up to 5th standard. Should be able to read technical drawings
and other instructions provided to them from time to time
b. At least 2 years of experience in construction works as a mason or plumber. Previous
experience in biodigester construction would be an added advantage.
c. Be a permanent resident of the province
d. Have good reputation in community – should be a trusted person
e. Good interpersonal and communication skill
f. Receptive to community’s need and willingness to support them
g. Age between 20 to 60 years
h. Good health
Likewise, NBSU should monitor the training project to evaluate the overall effectiveness of such
project.
3.4 ROLE OF BIOGAS CONSTRUCTION ENTERPRISE/INSTALLER/MASON
Biogas Construction Companies (BCCs)/installer and/or mason, who wish to corporate with the
E4A and benefit from the incentive scheme, will be required to seek recognition from the NBSU.
Such recognition is subject to a series of strict conditions such as:
a. Approval of standard design and sizes of biodigesters;
b. Trained, certified and registered masons for the construction of biodigesters;
c. Construction of biodigesters on the basis of detailed quality standards;
d. Provision of E4A approved quality biodigester appliances (pipes, valve, stove, water trap,
lamp);
e. Provision of proper user training and provision of a user instruction manual;
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f. Provision of one year guarantee on appliances and two years guarantee on the civil structure
of the biodigester, including an annual maintenance visit during the guarantee period;
g. Timely visit of a technician to the biodigester in case of a complaint from the user;
h. Proper administrative system in place.
The activities of the Installer/Mason depends to a large extent on his/her interest and
initiatives. The masons/ masons’ team assigned for the construction of biodigester will have the
following responsibilities:
a. Construct the biodigesters according to the E4A quality standards and details as stipulated
in construction manual.
b. Complete the construction works including fitting of pipes and appliances within a stipulated
timeframe.
c. Instruct the biodigester users on the proper feeding procedures of biodigesters and on the
proper use of biogas and bioslurry.
d. Provide warranty on the construction within 24 months period with effect from the data of
completion as mentioned in the completion report.
e. Repair and maintain biodigesters and solve any technical and operational problems in
accordance with the conditions described in the warranty certificate.
f. Visit the functional biodigesters at least twice a year during the warranty period to check the
plant and appliances even if no complaints are lodged by the users.
g. Involve in marketing, participate in pre-construction and post construction training to users
and initial feasibility visits to potential and interested farmers.
30
Annex-1: Quality Standards for ZamDigester-2015
Standards Specifications Why?
A. Biodigester Location and Size
1. Site Selection The site should allow easy construction
The site should allow easy operation, eg:
feeding with manure and water, opening
and closing main gas valve, and draining
water drain.
The site should ensure that the
biodigester is safe from damage by
vehicles or equipment
The site should not cause nuisance or
danger for people using the area
The site must have enough space to
construct the digester as shown in the
technical drawings
Major
A suitable site avoids accidents/
difficulties during construction. It also
facilitates easy operation and
maintenance of biodigester. The
benefits of biogas could be optimized if
it is constructed in proper sites.
2. Number of
biodigesters per
household
Only one plant per household unless
approved by E4A
Critical
To benefit as many households as
possible from the incentives and
supports from the government no
house should be provided with two
plants.
3. Proximity to
Kitchen
The biodigester must not be more than 50
meters from the kitchen (where gas will be
used).
Minor
Longer distance means more
investment in pipes. Long distance
increases the risk of gas leakage and
damaging of pipes. It also results in
the decrease of gas pressure which
could only be compensated with costly
larger pipes.
4. Proximity to
structures, trees
or equipment that
caused vibration
on earth
All parts of the digester should at a
reasonable distance from structures, trees or
any machines that creates vibrations on
ground.
Major
There will be risk of structure collapse
or damage during construction due to
excavation for digester. Heavy
vibrations increase the risk of cracks in
walls and dome of biodigester
endangering its functioning to a
greater extent.
5. Sizing of the
Digester
The size of biodigester should be determined
according to quantity of dung available (kg
per day). If the household has more dung
available than is needed, then the
biodigester size can be chosen by estimating
the average gas consumption: 0.33-0.4 m3
per person per day. If animals are not
always kept in a stable close to the
biodigester then the whole quantity of
produced dung may not be available for
feeding – must be estimated what
proportion can be collected.
Critical
Under-feeding or over-feeding of
biodigesters alters the hydraulic
retention time. If fed less, slurry
remains in the digester even after
releasing all the gas inherited by it
creating a dead volume in the plant. If
fed more, slurry comes out of the plant
before releasing all the biogas
inherited by it, causing deficiency of
gas; foul odour in the surrounding and
escape of pathogens without being
killed.
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Standards Specifications Why?
6. Initial Feeding of
the Digester:
The plant should be fed with required quality
of initial feeding with proper water-dung
ratio as described in O&M manual.
Critical
Users tend to feed the plant with more
water than recommended as a large
quantity of dung is needed for initial
feeding. More water will result in
settling of solid particles in the floor
creating dead volume. Users should be
instructed to collect dung for some
days or borrow from neighboring
households if possible.
B. Standards of Materials and appliances
7. Good quality
bricks/Districts
Best quality locally available
Properly Burnt (for bricks), straight,
regular size+shape
No cracks or broken parts
Able to bear pressure up to 120kg
Test 1: Hit 2 bricks together lightly to test
quality - they should make a clear metallic
sound
Test 2: Hold 2 bricks/Districts in a “T” shape
and drop them from waist height onto
ground. They should not break.
Before use, bricks must be soaked for a few
minutes in clean water (to ensure the mortar
sets properly)
Major
Bricks/Districts are the main structural
component of the biodigester design,
so poor quality could cause failure of
the walls or dome resulting in gas
leakage.
8. Good quality sand a) For concreting works coarse and granular
sand is needed while for plastering, fine
sand is needed.
b) The sand should be clean and contain less
than 3% impurities (do bottle test – see
below)
.
Bottle Test
Put about 10cm of sand into a clear
bottle and fill it with clean water
Shake the bottle well then leave standing
for 15-30 minutes so a layer of sand and a
layer of mud forms
if the layer of mud is more than 3mm
thick above the layer of sand (or 3% of sand
layer thickness), then the sand must be
washed before use (too much mud/silt)
Major
Sand is mixed with cement to use in
construction. The presence of silt and
clay in sand reduced the bonding
capacity of cement. The structure
becomes vulnerable to cracks, bulging
and wear &t tear.
9. Good quality
cement
Portland Cement of High Quality Brand
Fresh and free of lumps
Cement should always be stored off the
floor (raised on planks) and at least 20cm
away from walls
Major
Poor quality will make the construction
more difficult (poor consistency) and
reduce strength of the biodigester.
10. Good quality
aggregate
Clean (free of dust+ impurities)
Hard (not breakable between fingers)
Maximum 2cm (which is less than 25%
of the thickness of the structure being made,
eg: pit covers)
Major
These are used in casting the slab for
compensating tank. Soft, dirty and
too-large gravel will weaken the
concrete. As the thickness of slab will
be less than 7 cm, the size of
aggregate should not be more than ¼
of the thickness.
11. Good quality main
dome gas pipe
Galvanized, light quality iron
At least 60cm long
Diameter bigger than 15 mm
Joints properly sealed
Major
Strength of pipe and quality of
connections is very important to avoid
leaks.
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Standards Specifications Why?
12. Good quality main
gas valve
High quality (easy to operate, durable
and resistant to rusting)
Major
It should be opened and closed every
time the gas is used, so high quality
and durability is needed to reduce risk
of gas leakage.
13. Good quality pipes
and fittings
(socket, elbow,
tee and nipples.)
Galvanized Iron Pipe or PVC
Minimum 0.5 inch diameter or 0.75” if
over 60m length (or 30m if 2 burners used
at same time)
The fittings used in the pipeline of a
biodigesters are socket, elbow, tee and
nipples. These fitting should meet the
required quality standards.
Major
Pipes convey biogas from the plant to
kitchen. It is not always possible to
bury the pipes underground hence
they are prone to damage where
exposed. Minor damage could result in
heavy leakage of biogas.
14. Good quality
water drain
Approved by quality control authority.
Must be able to drain the accumulated
water inside the pipeline.
Major
Low quality water drains increases the
risk of gas leakage.
15. Good quality gas
tap
Easy to operate- not too tight or loose
Nylon washer should be greased properly
Major
Gas taps are used quite often and
hence are prone to wear and tear.
Minor defect may lead to gas leakage.
16. Good quality gas
stove
Approved by E4A
Single or double burner
Adjustable primary air intake
Evenly spread burner holes
Easy to use and repair
Major
High quality stove will ensure users’
satisfaction as such stoves are burn
with higher efficiency. Low quality
stoves will not only make the users
unsatisfied but also is prone to gas
leakage and accidents.
17. Good quality gas
Lamp
Approved by E4A Major
High quality lamps will ensure users’
satisfaction as such lamps will burn
with higher efficiency. Low quality
lamps will not only make the users
unsatisfied but also is prone to gas
leakage and accidents.
C. Construction Standards
18. Approved model
of biodigesters
ZamDigester model of plants as per the
design and drawing
Critical
ZamDigester models are approved
designs. Various capacity building
projects as well as cost and estimation
of biodigesters are carried out for
these models.
19. Only trained
masons carry out
the construction
work
The mason registered in E4A office after
successfully completing the required training
courses on biodigester construction
Critical
An untrained person does not know the
details of quality standards and
methods of construction. Relative
positioning of different components is
very important for the effective
functioning of any biodigester. Only
the trained persons know the
consequences of not following the
standard dimensions and quality
standards.
20. Biodigester
appropriately
placed under the
ground
The depth of digging as per drawing, ±10
cm.
In case of high water table or rocky
strata the depth can be changed with proper
justification AND proper stabilisation
measures are provided around the structure.
Major
If placed properly, the plant will not be
affected adversely by the external and
internal forces acting upon it. The
plant will be safe from external socks,
erosions and vandalisms. Moreover, if
plant are constructed at proper depth,
temperature inside the digester will be
maintained even during winter season.
33
Standards Specifications Why?
21. Proper Diameter
and height of
digester and gas
holder
The radius of the tank should not differ by
±3% of the standard dimension
The overall height should not differ by ±5
cm
Major
Correct diameter/depth ratio is very
important for the stability as well as
effective functioning of a biodigester. If
the diameter is more or less, the plant
will be bigger or smaller and the
relative volume of digester, dome and
compensating tank will be disturbed
adding risk to smooth operation.
22. Proper back-filling
in the outside of
the wall of
digester
The space between natural soil and the
digester wall is filled with soils and
compacted well.
Major
If the space is not filled, the force
excreted by the slurry inside the
digester will not be counterbalanced
which will cause cracks in the walls.
23. Proper plastering
inside the gas-
holder
Gas holder is treated with 5 layers of
plastering as indicated in the construction
manual. The finished surface is smooth and
free from cracks.
Critical
The gas holder is very sensitive part of
the biodigester. If it is not gas tight,
the produced gas will escape resulting
in shortage of biogas for use. Leaky
gas holder results in a total failure of
the biodigester.
24. Proper top-filling
over gas holder
The height of top-filling is at least equal to
40 cm from the top of the dome.
Major
The top-filling over gas holder acts as
counter-weight to balance the pressure
of biogas accumulated in the gas
holder. It avoids the risk of cracks in
gas holder. It also helps in stabilising
the temperature inside the digester.
25. Proper placing
and construction
of manhole
The manhole should be constructed exactly
opposite to the inlet pipe.
The height of the manhole should not differ
from ±5 cm from the standard.
The diameter of manhole should differ by ±5
cm from the standard
Major
Wrong placing of manhole will affect
the hydraulic retention time. If the
vertical level difference between the
top of round wall of the digester and
floor of compensating tank differs, the
volume of effective gas storage is
affected.
26. Proper Diameter
and height of
compensating
tank
The radius of the tank should not differ by
±3% of the standard dimension
Major
The size of compensating tank is
determined by the storage volume of
the gas holder. If the volume of
compensating tank is less than the
designed, the pressure required to
push the biogas from gas holder to the
point of application will be less.
27. Proper backfilling
against the walls
of compensating
tank
The outside of the outlet walls is properly
compacted with rammed soil to prevent soil
erosion.
Major
If the outer space is not filled, the
force excreted by the slurry inside the
compensating tank will not be
counterbalanced which will cause
cracks in the walls.
28. Proper cover of
compensating
tank
The compensating tank should be covered
with proper concrete slab. The thickness of
slab should not differ by ±1 cm from
standard.
A small opening should be placed in one of
the cover slabs for inspecting inside of the
compensating chamber.
Major
The RCC cover is important to avoid
people and animal falling inside the
compensating tank by accident. It also
avoids excessive evaporation of slurry
accumulated in the tank.
The opening in one of cover slabs
facilitates the inspection of inside of
compensating tank without removing
the heavy concrete slabs.
34
Standards Specifications Why?
29. Correct
positioning of the
inlet pipe(s)
The inlet pipe is placed to discharge exactly
at the hart line (imaginary line that joins
centre of digester, manhole and outlet tank).
The bottom edge of the inlet pipe should be
as per the drawing. If because of space
limitation, the inlet pipe could not be fit as
per standard, a small baffle wall has to be
constructed in the digester to avoid short-
circuiting of slurry.
Major
If the inlet pipe is not placed exactly
opposite to the outlet pipe, hydraulic
retention time will be shortened
meaning that the slurry will flow out to
the compensating tank quicker than
anticipated. As the slurry will flow to
outlet pipe from the nearest short
route, there will be risk of creation of a
dead volume in the digester. The baffle
wall will prevent the slurry to follow
the shortest route. Short circuiting of
slurry in a latrine attached plant will
invite health risks as the pathogens
could not be destroyed during the
digestion process.
30. Correct
positioning of
inlet tank or toilet
pan level
The bottom of inlet tank should be at least
15 cm higher level than that of overflow
opening in the compensating tank.
Major
If the bottom of the inlet tank or toilet
pan level is at lower level than
overflow opening in the compensating
tank, the digested slurry will flow
towards the inlet tank rather than
coming out from overflow opening.
31. Correct fitting of
main gas valve
No fittings in between elbow in the dome
gas pipe and the main valve. The joint is
properly sealed with Teflon tape and good
quality adhesive.
Critical
Any defects in fitting the main gas
valve will result in gas leakage.
32. No unnecessary
fittings in the
pipeline
Pipeline contains minimum joints as
required.
Major
The more the fittings in the pipeline,
the more the joints and the more the
chances of gas leakage.
33. Proper burial of
pipeline
The pipeline is buried to at least 30 cm
where possible. It is protected well with
clamps and covers where burial is not
possible.
Major
Exposed pipe is vulnerable to damage.
Exposure of PVC pipe to sunlight
makes it brittle and prone to breakage.
34. Water drain able
to drain the whole
quantity of
condensed water
and protected in
a well maintained
chamber
The profile of pipeline should be maintained
properly so that the whole quantity of
accumulated water is easily drained.
Water drain should be protected in a
chamber. The size of the chamber should be
such that it is easy to operate water drain
and rain water does not enter into it. The pit
should be provided with a good cover.
Major
If the condensed water that
accumulated in the lowest profile in the
pipeline is not drained periodically, it
Districts the flow of gas and disturbs
the functioning of appliances.
If not protected in small chamber, the
water drain is prone to clogging and
damages.
35. Correct fitting of
gas tap
The gas tap is placed in convenient place
and the joint is sealed with Teflon tape and
good adhesive.
Major
Improper fitting of gas taps will result
in gas leakages and difficulty in
operation.
36. Correct fitting of
gas stove
The connecting pipe from gas tap to the
stove is correctly fitted to avoid the gas
leakage and with enough length so the stove
can rest easily on a table or the ground.
Major
Improper fitting of gas taps will result
in gas leakages, difficulty in operation
and increased risk of accidents.
37. Correct fitting of
gas lamp
The gas lamp is located in safe and
convenient place. The lamp must be
installed at least 60cm below the ceiling to
avoid risk of fire. The joint must be sealed
with Teflon tape and good adhesive.
Major
Improper fitting of gas taps will result
in gas leakages, difficulty in operation
and increased risk of accidents.
35
Standards Specifications Why?
38. Correct fitting of
Gas Pressure
meter
U-shaped pressure gauge (manometer)
made up-of a transparent plastic or glass
tube and filled with coloured water or a
clock-type digital or analogue pressure
meter has to be installed in the conveyance
system, near the point of application of the
gas, to monitor the pressure of gas.
Whatever may be the type this device
should be the best among those available in
the local market and should meet set quality
standards, if any.
Major
The pressure gauge is fitted to monitor
the pressure of gas that flows to the
appliances. When the needle of the
pressure gauge indicates higher
pressure, then the gas tap should be
adjusted to allow less gas to flow to
the stove or lamp and vice versa.
Importantly, when the indicator shows
full pressure, gas has to be used;
otherwise there is chance of gas
leakage to the atmosphere, which
should not happen from the
environmental point of view. Likewise,
when the gas pressure is very low, one
has to stop using the gas to avoid
slurry in the pipeline. If the pressure is
less than 15 cm water column, it is not
preferable to use gas anymore.
39. Proper
construction of
slurry composting
pit
2 compost pits with the total volume of at
least equal to volume of the plant should be
constructed. The depth of the compost pits
must not exceed 1 metre and the distance
between the two compost pits must not be
more than 50 cm. The length and width at
the top must be more than of the bottom
and 10 cm mud has to be added on all sides
to raise the height from the ground level to
avoid rain water enter the compost pits.
Major
In addition to the major plant
nutrients, bioslurry also provides
micro-nutrients. It is beneficial for
improvement of the physical structure
of the soil, increased soil fertility,
increased water-holding capacity of the
soil and enhanced activity of the
micro-organisms in the soil.
D. Standards on O & M and After-sales-services
40. User’s instructed
on operation and
minor repair
works
At least one member from the user’s
household is provided with proper
orientation on operation and minor
maintenance of biodigester. User must be
able to satisfactorily answer at least 20 of
the 28 questions in the User Training
Knowledge Test (see below).
Major
Proper operation and maintenance
(O&M) of different components of a
biodigester is very important for its
efficient and long-term functioning.
The users have the major
responsibility of carrying out
operational and minor maintenance
activities as anticipated. It is therefore,
necessary to orient users on these
activities upon the completion of the
construction works.
41. User Manual Biogas User Manual is provided to the users Critical
It is not uncommon that users may
face some problems to operate
biodigesters. It may not be possible to
receive the help of technicians at all
times. This manual provides
information to the users on effective
operation and maintenance of
biodigesters. The manual will help the
users to identify problems and provide
solutions accordingly.
42. Warranty and
After-sale-service
provisions
Warranty Certificate for at least 2 year is
provided to the user with clear explanation
of conditions in presence of the
Installer/Mason, and user pays Warranty Fee
that is held in trust by E4A
Critical
The after-sale-services ensure having
well-functioning biodigesters with
satisfied and positive users, leading to
farmer-to-farmer motivation.
36
Standards Specifications Why?
43. Performance
monitoring of
Biodigester
The biodigester should be visited at least
once in six months by the project technical
persons to monitor overall performance
Major
It is compulsory that all the install
biodigesters function to the anticipated
level. Non-functional plant will have
negative effect on carbon trading and
overall future of the project.
Annex-2: Tolerances
SN Description Tolerances
1. Inner Diameter of digester ± 3%
2. Total inner height of digester ± 10 cm
3. Height from floor to bottom of inlet pipe ± 5cm
4. Height from floor to top of manhole (floor of outlet) ± 5cm
5. Height between top of round wall and floor of outlet tank ± 3cm
6. Diameter of outlet tank ± 3%
7. Height of outlet tank up to the bottom of over flow
opening ± 5cm
9. Thickness of slab ± 1cm
10. Height of inlet floor from the ground level ± 5 cm
12. Height of inspection chamber ± 5cm
13. Height of top filling over dome ± 5cm
37
Annex-3: Forms and Formats for QC
Energy for Agriculture (E4A): QUALITY CONTROL LOG BOOK
1. Biodigester
Code No.
Serial Number:………………………………. GPS Easting:………………. GPS Northing…………….…….
2. Householder Name:……………………………………. Telephone Number:…………………………….ID Card No. …………..
3. Address Village:…………………..…………….… District:……………………..…… Province:…………………..……….
4. Mason Name:………………………………………………. E4A Registration Number:……………………………..
5. Biodigester Size …........................m3
6. Construction Period Started: ..………………..………. Completed: …..…………………….…….
Quality Control Status
Form Title Completed By Checked
(name,date)
Data
Entered
(name,date)
2a Site Survey for Potential
Households
Signed:……………. Name:………………..…………..
Position:……………………Date:……………
2 b Baseline Survey Form Signed:……………. Name:…………………..………..
Position:……………………Date:……………
3 Construction Contract Signed:……………. Name:…………………..………..
Position:……………………Date:……………
4 Quality Inspection Form -
During Construction
Signed:……………. Name:……………..……………..
Position:……………………Date:……………
5 Quality Inspection Form -
Final Acceptance (Before
Filling)
Signed:……………. Name:……………………..……..
Position:……………………Date:……………
6 General Monitoring
Inspection Form
Signed:……………. Name:……………………………..
Position:……………………Date:……………
7 Warranty Certificate Signed:……………. Name:…………………..………..
Position:……………………Date:……………
8 Warranty Audit (Monitoring
before the maturation of
warranty period)
Signed:……………. Name:……………………………..
Position:……………………Date:……………
Timeline for Inspections:
38
Form - 01
Energy For Agriculture (E4A): LIST OF POTENTIAL CUSTOMERS
No. Full Name of
household head
Address Number of domestic animals
Province District Village Buffalo Cow Pig Poultry Other
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
21
22
23
24
25
26
39
Form-02(a)
Energy for Agriculture (E4A): Field Survey form for Potential
households
1. General Information Date of survey ....................................
Name of household head: ........................................................... Telephone No: ........................
Province:………………………….………. District:………………………………………. Village:………………………………………
Number of people in family: Adult: Children (age <10): Total:
2. Land information
Enough land area available for construction: Yes No
Flooding/Water inundation problems in wet season: Yes No
3. Water and Sanitation Information Sanitary Infrastructure (tick) Water source on use (tick) General sanitary Condition of (tick)
Simple Pit latrine River water Good Fair Bad
Improved latrine Lake/Pond Kitchen
No latrine Deep Tube well Latrine
Drainage system Shallow Tube well Water Source
Dug-wells Drainage System
Piped Water Tap Household
wastes disposal
Canal
4. Animal husbandry development activities Livestock Numbers
Adult Calf If open-grazed, for how many
hours/day?
Stall-fed Open-grazed Stall-fed Open-grazed
Cow/Oxen
Buffalo
Pigs
Poultry
Total quantity of dung/poultry litter production ………………………..kg/day
Distance between Cattle-shed/Kraal and kitchen: ……………………… m
5. Credit demand
Do you need loan to install biodigester: Yes No
If yes, what amount?..................................
Remarks: HH suitable for Construction Not-suitable for Construction
Recommended size of Biodigester: 4/ 6/ 9/ 14/ 21 cum
Survey officer
(Full name and signature)
Biogas Household head
(signature)
40
FORM-02(B
ENERGY FOR AGRICULTURE (E4A)
BASELINE SURVEY FORM
Instruction: Conduct this survey with each new customer, during construction-phase.
A. General Household Information
1a) Name of household Head:……………………….
b) Male Female
c) Main occupation:…………………………………
2. Address:
a) Village:…………… b) District: ………………
c) Province: ……………………………………
3a) Name of interviewer:
……………………………
b) Date: ……………………..
4. Condition of the house:
a) Building material: Stone Brick Wood Thatched Others..................................
b) Roofing material: Tile CGI Sheet Thatched Others.............................................
5.a) Total Number of people in household: 5.b) Number of people between 10 and 60 years old:
5.c) Number of children below 10 years old: 5.d) Number of people above 60 years old:
B. Income and Expenditure
6. Main source(s) of income (Rank from the most to the least important in numerical order, start from 1 which is the most important):
Farming/cultivation Livestock Business, specify:………………………… Government Service
Other service, specify………. Small trade Others, specify:............................................................
7. Household Income (estimate average): a. …………………………………….. per month
8. Total Household Expenditure (estimate average): a. …………………………………….. per month
9. Household Assets How many in the Household? Estimated Value?
Television a)…………………………….. b)………………..ZMW
Motorbike a)…………………………….. b)………………..ZMW
Car/jeep/bus a)…………………………….. b) ………………..ZMW
Stereo g)…………………………….. h)………………..ZMW
Tractor i)…………………………….. j) ………………..ZMW
Diesel Generator k)…………………………….. l) ………………..ZMW
Other: …………………………………………….. m)………………………….. n) ………………..ZMW
10. a) Do you have any agricultural land: Yes, Owning Yes, Renting No
b) If ‘Yes’, how many ha: Cultivated:………………..(ha) Other:………………..(ha)
B. Energy Use and Expenditure
Energy Type Main Use
(Cooking, Lighting)
Where from?
(Market, Forest)
Cost? ZMW per unit
(hours/day if free)
Quantity Used
in Dry
Season?
Quantity
Used in Wet
Season?
11. Firewood* (kg) a) b) c) d) e)
12. Charcoal* (kg) a) b) c) d) e)
13. LPG (kg) a) b) c) d) e)
14. Kerosene (litre) a) b) c) d) e)
15. Electricity (unit) a) b) c) d) e)
16. Diesel (litre) a) b) c) d) e)
17. Petrol (litre) a) b) c) d) e)
18. Other: …………… a) b) c) d) e)
19. Other……………… a) b) c) d) e)
* If collected from forest, mention whether twigs/branches are collected or a whole tree is fell down to prepare firewood/charcoal
41
C. Fertilizer Use and Expenditure
Fertilizer Type Main Use
Rice, Vegetables
etc
Where
from?
Market, etc
Cost?
ZMW per
Unit
(or hours/
day if free)
Quantity
Used in Dry
Season? (per year)
Quantity
Used in Wet
Season? (per year)
Distance
of use
from
Biodiges
ter (m)
20. Farm Yard Manure
(Animal Dung)
a) b) c) d) e) f)
21. Chemical Fertilizer
Type-1 (name &
composition)…………….
Type-2………………
Type-3…………….
a) b) c) d) e) f)
22. …………… a) b) c) d) e) f)
D. Health, Sanitation and Environmental Conditions
23) Has anyone in this household had a serious respiratory problem in the last 6 months? Yes No
24) Has anyone in this household had a serious eye infection or problem in the last 6 month? Yes No
25) How often the children in the households get diarrheal diseases?
Quite Often Some times in 3-4 months Very rare
26) How often does someone in the household get sick? ………………..times per month
27) How often is there a problem with bad smell from animal or household wastes? …………………….. times per month
28) Where is the cattle dung and household wastes dumped?
In wet pit or lagoon In semi wet areas In dry areas (this info is needed for Carbon Finance)
29) Where do you defecate?
In private latrine In open spaces surrounding the house In open spaces far from house
D. Household Tasks
Minutes per Day
(estimate average)
Who usually does this?
(eg: Husband, Mother,
Daughter, Son etc)
30. Collecting Firewood a) b)
31. Cooking Breakfast a) b)
32. Cooking Lunch a) b)
33. Cooking Dinner a) b)
34. Cooking Animal Feed a) b)
35. Cleaning cooking vessels a) b)
36. Collecting water a) b)
37. Collecting the feed/fodder and feeding
cattle
a) b)
38. Other Cooking: ………………………. a) b)
39. Do all the children above 6 in the
household go to school?
Yes all Only the boys Only the girls None
Thank you very much!
42
Form-03
ENERGY FOR AGRUCULTURE (E4A)
BIODIGESTER CONSTRUCTION CONTRACT Province:……………………. Plant serial no.:…………………….
1. Party A: E4A Supported Household.
Name of Household Head:………………………………………………………….;
Address:……………………………………………………………….……… Tel: .......................................
ID document type and number:…………………………………………………….
2. Party B: Regional Biogas Support Unit (RBSU)
Name of Officer:………………………………………………………………
Address:……………………………………………………..……………………………. Tel:……………………………………………………………………
3. Party C: Biodigester Construction Company or Enterprise (BCE)
Biodigester Mason Name:…………………………………………………………...
Address:……………………………………………………………………… Tel:......................................................
ID document type and number:…………………………………………………….
All parties agree to participate in the construction of a biodigester at the premises of Party A, upon the
following conditions:
Article 1. Scope of work
To construct a biodigester, according the quality standards set by the E4A, sized … m3 at the premises of Party A.
Article 2. Obligations
Party A: The Biogas Household
a. In consultation with Parties B and C, set a deadline for the start and completion of the work.
b. Select/Prepare the construction site and collect materials according the instructions of Party C.
c. Decide and agree the mode of labour or material contributions and pay the BCE/mason accordingly. If all the
construction materials and labours (skilled and non-skilled) is to be arranged by the BCE/mason arrange
payment accordingly. Provide adequate labour for the digging work and to assist the Mason during the
construction if it is to be managed by biogas household.
d. Pay for the construction work as agreed in Article 3.
e. Transfer all rights, credits, entitlements, benefits or allowances arising from or in connection with
any greenhouse gas emissions reductions arising from the operation of the biodigester (Emission
Reductions), and agree to take all necessary action required to ensure the transfer of those Emission
Reductions to the E4A.
Party B: The E4A RBSU
Conducts a survey at the premises of Party A with Party C to determine the conditions for biodigester construction
and advise Party A accordingly.
a. Provides Party A with an information sheet containing the required quantities as well as cost estimation of
construction materials, appliances, skilled and unskilled labour, and cost of warrantee and other fees.
b. Assures that the BCE/Mason recruited by Party C, is trained, experienced and certified in his/her profession.
c. Gives full essential technical support to Parties A and C whenever needed.
d. Monitors the quality of the construction works through sample construction inspections and provides on-the-spot
instructions to mason, if modifications/rectification needed.
e. Conducts a Plant Completion Inspection in all completed plants. If the plant is considered by the Supervisor to be
complete and fit to function without problems, it will be handed over to Party A. Party A will receive a signed and
stamped Completion report from Party B.
f. Guarantees the provision of functionality incentive to Party C as per set mode of payment.
g. Ensures that the users are trained on operation and maintenance of biodigester as well as on bioslurry
application.
h. Ensures that two-year warrantee certificate is issued by Party C to party A.
Party C: The BCE/Biogas Mason
a. Constructs the biodigester according to the E4A quality standards.
b. Completes the construction works, including pipefitting and appliances connection, within 20 calendar days. If
there is a delay due to reasons beyond the influence of the BCE/mason such as high ground water or rocky soil,
a new completion date will be determined in consultation with Party A and B.
c. If, due to illness or other personal reasons, unable to complete the work in time, contact Party B for consultation
on how to complete the assignment within the agreed period.
d. Instructs the biodigester user (Party A) on the proper feeding procedure of the biodigester and on the proper use
of the biodigester appliances.
e. Will work in a responsible manner and therewith minimize the risks of accidents.
43
f. No claims can be made by Party C to Parties A or B in relation to injuries sustained during the construction
process.
g. After completion, leaves the construction site in a fit to be seen state.
h. Provides warranty on the construction within a 24 months (two years) period since the completion date
mentioned on the completion report.
i. Repairs the biodigester if any technical problem occurs, in accordance with the warrantee conditions described in
the warrantee certificate.
j. Visits the biodigester at least once in six months during the 2 year warrantee period to check the plant and
appliances, even if no complaints are lodged by Party A.
Article 3. Cost of installation and Payment
The cost of installation of biodigester will be based upon the cost and quantity estimation supplied to Party A by Party
B. Party A can decide whether he/she will handover overall responsibility of collection/supply of construction
materials and un-skilled labors to the BCE/mason OR supply all or part of these.
The cost of construction materials such as, sand, gravel, cement, reinforcement rods, GI pipe, can be paid by Party A
directly to the supplier with whom he/she purchases them. Party A will also make sure these materials will be at the
construction site in time. Party C will advise Party A on the required quality and quantity of these materials. The cost
of the skilled labor, amounting to ZMW….........., will be paid directly by Party A to Party C upon completion of the
construction.
However the following items could be supplied by Party C to Party A. Party A will pay Party C the cost as follows:
Item: Number Cost per Item Total Cost
Pressure Gauge
Dome gas pipe
Biogas Stove
Biogas Lamp
Biogas Rice-cooker
Biogas Water-heater
……………………………
……………………………
Party A has to fulfill all financial obligations to Parties C upon completion of the construction including the pipefitting
and the installation of the appliances.
Article 4. Construction Starting and Completion Date
The construction will start on ………..(day)/……..…(month)/…………....(year) at the latest.
The construction will finish on ………..(day)/…………(month)/……….…..(year) at the latest.
Article 5. Unilateral Termination of construction contract and compensation:
Each party has rights to terminate the construction contract unilaterally and can request for compensation when the
other party offend contract provisions. However, there should valid reasons for such termination.
The offending party has to compensate all expenses which the other party had paid for the lost, unless otherwise
stated.
Article 6. Complain and dispute settlement:
All complains and disputes will be considered and settled by the three parties base on mutual interest. If the
concerned parties cannot reach final agreement then the matter will be brought before Civil Court for final decision.
This contract is made in 3 copies of the same value and become effective since the signing date.
Date:………….(day)/………….(month)/………………..(year)
Party A: Head of Household; Full name + signature --------------------------------------------------------------------
Party B: E4A/RBSU Representative Full name + signature --------------------------------------------------------------
Party C: BCE Representative Full name + signature ---------------------------------------------------------------------
44
Form-04
ENERGY FOR AGRICULTURE (E4A)
QUALITY INSPECTION FORM – UNDER CONSTRUCTION PLANT Date of Inspection:………… Plant Code No: ……….
1. General Details Auditing (QC on QC)
1. a) Name of Owner :…………………….………..…(b) Tel No:……………….(c) ID Card No……..
b) Address: Village.:……….….......… District:…………………….….…… Province:………………..…….
2. Date of Commencement of the Construction ………………………………(dd/mm/yy) Pass □ Fail □
3. Name of Mason………………………………………….. 4. Regd. Number of Mason:……………… Pass □ Fail □
5 No. of families using the biodigester? a)1 □ b) 2 □ b) 3 □ Pass □ Fail □
B. Biodigester Feeding
1. Biodigester Size ............................................m3 Pass □ Fail □
2. No. of Cattle/Buffalo
Adult……. Calf………. Total……….
3. No. of Pig
Adult…….Calf………. Total……
4. Poultry:
Total No.……….
Pass □ Fail □
5 Total dung production …………kg Pass □ Fail □
6 Is dung being collected for the initial feeding? a) Yes □ No □ Pass □ Fail □
7 Provision of toilet attachment a) Yes □ No □ Pass □ Fail □
C. Location of Biodigester Site Pass □ Fail □
1. Is Biodigester location suitable? a) Yes □ No □ b) Comment:…………………… Pass □ Fail □
2. Distance from: a) Kitchen: ..…m b) Animal Shed: ..…m c)Structure: ….……m
d)Tree: ……m e) Drinking Well:…..m f) Main road ....m
Pass □ Fail □
3. Flood/stagnant water problem a)Yes □ No □ Pass □ Fail □
D. Bricks / Blocks Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Shape Good □ Fair □ Bad □ Pass □ Fail □
2. Sound Good □ Fair □ Bad □ Pass □ Fail □
3. Drop test Good □ Fair □ Bad □ Pass □ Fail □
4. Are they the best locally available? Yes □ No □ Pass □ Fail □
E. Sand Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Bottle test ………..….% impurity Pass □ Fail □
F. Gravel Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Cleanliness Good □ Fair □ Bad □ Pass □ Fail □
2. Maximum size …….……. mm Pass □ Fail □
3. Shape Good □ Fair □ Bad □ Pass □ Fail □
G. Cement Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Quality of Cement Good □ Fair □ Bad □ Pass □ Fail □
2. Brand name …………………….. Pass □ Fail □
3. Lumps Yes □ No □ Pass □ Fail □
H. Emulsion Paint Pass □ Fail □ Action:………………………………….. Pass □ Fail □
4. Quality of Paint Good □ Fair □ Bad □ Pass □ Fail □
5. Brand name ……………………. □ Pass □ Fail □
H. MS Reinforcement rod Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Diameter ………. mm Pass □ Fail □
2. Condition of Rods (not too rusted
etc)
Good □ Fair □ Bad □ Pass □ Fail □
I. Construction Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Layout of plant made correctly? Yes □ No □ Pass □ Fail □
2. Diameter of digester a)………cm (Standard = ………cm) Pass □ Fail □
3. Depth of excavation a)………cm (Standard = ………cm) Pass □ Fail □
J. Overall Quality Pass □ Fail □ Pass □ Fail □
1. Quality of construction of digester and dome Good □ Bad □ Not Complete □ Pass □ Fail □
2. Quality of construction of outlet tank Good □ Bad □ Not Complete □ Pass □ Fail □
3. Quality of construction of inlet tank Pass □ Fail □
4. Overall Quality of Workmanship Good □ Fair □ Bad □ Pass □ Fail □
K. Financing (ask users) Pass □ Fail □ Pass □ Fail □
1 Do the users know the cost of biodigester and their contribution? Yes □ No □ Pass □ Fail □
2 Do the users know about the credit and subsidy mechanisms? Yes □ No □ Pass □ Fail □
L Items to be Fixed by Mason/Overall Comments
Signature of Inspector: Signature of QC
Inspector:
Signature of Mason: Comment:
Signature of the user:
45
Form-05
ENERGY FOR AGRICULTURE (E4A)
QUALITY INSPECTION FORM – FINAL ACCEPTANCE (BEFORE FILLING) Date of Inspection:……………..……… Plant Code No:……………………………………
A. Biodigester Details
1. Name and Address of Owner Name…………………………………ID Card No:……….
Village:…………………..……..District………………………………. Province………………………….
2. Name of Mason Name………………………………………………………..……………… Regd. No. …………………….
3. Biodigester Size .................................................m3
4. Construction Period a)Started: ..…………. b)Completed: .....………. c)Total Days: ………..
5. Reason if longer than 30 days …………………………………………………………………………………………………
6. Is there a toilet at the customer’s house? Yes □ No □
7. Is the toilet connected to the biodigester? a)Yes □ No □ b) Will connect later
8. Total quantity of Dung available for Feeding per day ………………… kg
To be filled by RBSU Supervisors Auditing(QC on QC)
B. General Construction Quality Pass □ Fail □ Action:…………………………………..
1. Site suitable for Biodigester Yes □ No □ Pass □ Fail □
2. Top filling over dome Good □ Fair □ Bad □ Pass □ Fail □
3. General quality of workmanship Good □ Fair □ Bad □ Pass □ Fail □
4. Total quantity of cement used …….. bags Pass □ Fail □
D. Inlet Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Type of inlet Mixing chamber □ Channel for flushing □ Pass □ Fail □
2. Finishing Good □ Fair □ Bad □ Pass □ Fail □
3. Inlet floor vs. bottom of overflow opening well above □ just above □ below □ Pass □ Fail □
E. Digester and gas holder Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Finishing of floor and walls Good □ Fair □ Bad □ Pass □ Fail □
2. Plastering inside the digester and gas holder Good □ Fair □ Bad □ Pass □ Fail □
Inlet pipe position in the digester Good □ Fair □ Bad □ Pass □ Fail □
F. Outlet Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Floor and wall finishing Good □ Fair □ Bad □ Pass □ Fail □
2. Backfilling against the wall Good □ Fair □ Bad □ Pass □ Fail □
G. Toilet (if connected) Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Position of Pan level vs. bottom of overflow opening well above □ just above □ below □ Pass □ Fail □
2. Pipe Provisions for future attachment Yes □ No □ Pass □ Fail □
3. Positioning of inlet pipe in the digester Good □ Fair □ Bad □ Pass □ Fail □
H. Pipes and Accessories Pass □ Fail □ Action:………………………………….. Pass □ Fail □
1. Quality of dome gas pipe Good □ Fair □ Bad □ Pass □ Fail □
2. Quality of main gas valve Good □ Fair □ Bad □ Pass □ Fail □
3. Type of gas pipe PVC □ Flexible plastic □ GI □ (dia Φ: …) Pass □ Fail □
4. Total length of gas pipe …..m
5. Quality of gas pipe Good □ Fair □ Bad □ Pass □ Fail □
6. Unnecessary fittings Yes □ No □ Pass □ Fail □
7. Depth of pipe trench ……… cm Not buried □ Pass □ Fail □
8. Sealing agent Good □ Fair □ Bad □ Pass □ Fail □
9. Quality of stove Good □ Fair □ Bad □ Pass □ Fail □
10. Number of burners 1 □ 2 □ 3 □ Pass □ Fail □
11. Location of stove Appropriate □ Not Appropriate □ Pass □ Fail □
12. Quality of connecting pipe Good □ Fair □ Bad □ Pass □ Fail □
13. Quality of gas tap Good □ Fair □ Bad □ Pass □ Fail □
14. No. of lamps 0 □ 1 □ 2 □ Pass □ Fail □
15. Quality of lamp Good □ Fair □ Bad □ Pass □ Fail □
16. Location of lamp Appropriate □ Not Appropriate □ Pass □ Fail □
17. Quality of gas pressure gauge Good □ Fair □ Bad □ Pass □ Fail □
18. Water drain at lowest point in pipeline? Yes □ No □ Pass □ Fail □
19. Water drain pit constructed correctly? Yes □ No □ Pass □ Fail □
20. Water drain pit cover ok, and in place? Yes □ No □ Pass □ Fail □
I. Gas Tightness and Water Tightness (if used) Pass □ Fail □ Action:………………………….
1. Gas Tightness (if done) Pass □ Fail □ Pass □ Fail □
2. Water Tightness (if done) Pass □ Fail □ Pass □ Fail □
J. Compost Pit
1 Compost pits constructed? None □ One □ Two □ Pass □ Fail □
46
2 Total volume of pits (approximate) ………………. Cum m
K. Financing
1. What was the actual total cost of your plant including your contributions? ZMW……….………………. Pass □ Fail □
2. Credit taken from Not taken □ Bank □ MFI □ Other:……… Pass □ Fail □
3. How long did it take to arrange the loan? a)……… days b) Not Applicable □ Pass □ Fail □
4. What is interest rate and repayment period of loan? a)…..…% per month b) Period………....months Pass □ Fail □
5. How much subsidy did you receive? No subsidy □ ZMW. …………
6. Did anyone get any training on how to use the biodigester? Yes □ No □ Pass □ Fail □
7. Have you received Biodigester O& M Manual? Yes □ No □ Pass □ Fail □
8. Have you received guarantee certificate? Yes □ No □ Pass □ Fail □
Final Measurement of Various Components (inspection to be made before filling the plant)
Passed Inspection – □ Approved for Dung Feeding □ Not Approved for Dung Feeding
Comments ................................................................................................................................................................................
....................................................................................................................................................................................................
Inspected by RBSU Officer Name:……………………………....……….Signature:….………………………. Date:……………..
Witnessed by the Mason Name:…………………………....………….Signature:….………………………. Date:……………..
Witnessed by the User Name:………………………....…………….Signature:….………………………. Date:……………..
SN Component Dimension QC on QC
Actual Standard Deviation Tolerances
1. Inner Diameter of digester: ± 3% Pass/fail
2. Total inner height of digester: ± 5cm Pass/fail
3. Height from floor of the digester to bottom of inlet
pipe ± 5cm
Pass/fail
4. Length and breadth of manhole floor: ± 2cm Pass/fail
5. Height of manhole (height of round wall): ±5cm Pass/fail
6. Height of manhole up to the floor of outlet: ± 5cm Pass/fail
7. Height of outlet up to the bottom of over flow opening ± 5cm Pass/fail
8. Height of overflow opening: ± 2cm Pass/fail
9. Thickness of slab: ± 1cm Pass/fail
10. Diameter of outlet tank: ± 3% Pass/fail
11. Height of outlet tank: ± 5cm Pass/fail
12. Height of inlet tank/chamber from the ground level: ± 5cm Pass/fail
13. Inner height of the inlet chamber: ± 5cm Pass/fail
14. Size of turret: ± 5cm Pass/fail
15. Height of turret: ± 5cm Pass/fail
16. Height of top filling over dome: ± 5 cm Pass/fail
17. Inner diameter of inlet ± 2cm Pass/fail
47
Form-06
Energy for Agriculture (E4A)
BIODIGESTER PERFORMANCE MONITORING FORM Inspection date:……………………
Household Details
1. 1 Biodigester Code ……………………..
2. 2 Name if User (a)Name:………………………………………..……… (b)Telephone Number:………………………
3. 3 Address (a)Village:……………………….. (b)District…………:…………… (c) Province:…………………
4. 4 Biodigester Size ............................m3
5. 5 Date of Visit .......................................................................
6. 6 User Visited ………………………………………………………………. (Name and position in house)
7. 7 Purpose of Visit (a)Regular QC Check □ (b)Problem Reported □
8. 8 User’s General Satisfaction (a)Very Happy □ (b) Quite happy but some problems □ (c)Disappointed □
9. 9 User’s view on current
performance? (a)No problems□ (b) Ok but some problems□ (c) Plant not functioning □
Problems Reported:…………………………………………………………………………………………
10
Information on Gas-use
(a) Use of Gas Stove
(b) Use of Gas Lamp
(c) Sufficiency of gas
………………… hours per day total
…………………. hours per day total
(a)More than Enough □ (b) Enough □ (c) Not Enough □
(i) If not enough, - how often do you not have enough gas?
(a) Daily □ (b) Sometimes in a week □ (c) sometimes in a month □
(ii) What you think is the reason for insufficient gas?
(a) Less feeding□ (b) Problem with plant□ (c) Longer hours of gas use □
(d)others .............. □
(iii) If more than enough, - How often do you have too much gas?
………………times/mth
- What do you do if there is too much gas?
Flare it □ Use it for something □ Let it escape □
11
Do you use the Bioslurry? a) Yes □ No □
b) If Yes, how is it?: (a) Better than FYM □ (b) Same as FYM □ (c) Inferior
than FYM □
b) If No, why not?:
………………………………………..………………………………………………………..
12 General Condition of Plant (a) Good Condition □ (b) Satisfactory Condition □ (c) Poor Condition □
Comments: …………………………………………………………………………………………………………
13
Any problems found by
inspector?
No, working fine □ Some small problems □ Major problems □
Problems Found:
……………………………………………………………………………………………………….
14 Repair Actions during Visit,
if any:
a………………………………………… b…………………………………………………..
c………………………………….
15 Condition of Plant after
Actions: (a)No problems□ (b)Ok but some problems □ (c)Problems remained same □ Problems Remaining:……………………………………………………………………………………………
16 Instructions given to the
User:
a………………………………………………………………………………….
b……………………………………………………………………….…………
17 Follow-up Actions Needed
(+ dates):
a………………………………………………………………………………….
b………………………………….…………………………………………………
Inspector User
…………………………………………
Name:…………………………… Date:……………
Position:…………………..
………………………………………….
Name:………………………………….. Date:……………
48
Form-07
ENERGY FOR AGRICULTURE (E4A)
BIODIGESTER MONITORING BEFORE THE MATURATION OF WARRANTY PERIOD
(This evaluation shall be filled about one week before the end of warranty period and should be done
on-site accurately and with high responsibility. Any points that do not comply with the real figure or
condition lead to cause penalty and compensate on own expenses.)
General Information: To be filled by the RBSU Supervisor
Date of Visit …….…/…………….…/…………………….
Name of Plant Owner .……………..……….
Biodigester Code ………………………….
Address Village……………………….. District………..………..….... Province………..……………
Name of Mason …………………………….
Biodigester Size: 4/ 6/ 9/ 14/ 21 cum
Plant Completed Date
End of warranty Period Date
…..…/………../………….
….…./…….../……….….
Visited by (Mason) ……………….……
Name of user(s) consulted 1.……………..….…………………………… 2. ……………….…………….…………..……
Number Animal
Feeding per day
Cow.......….…Buffalo........... Other…………………….
...............Kg
Plant Structure
Condition of Inlet/mixing tank
Condition of turret (inspection)
Condition of main gas valve
Condition of outlet tank
Condition of Water drain Chamber
Condition of Top filling
Good Fair Damaged
Good Fair Damaged
Good Fair Damaged
Good Fair Damaged
Good Fair Damaged
Enough Not enough No filling
Pipe System and Appliances
Leakage in pipe line
Condition of Pressure gauge
Usual pressure in:
- early morning
- Noon
- late evening
Yes No
Proper Not Proper
Close main valve for10-20 min. and check – ask the users
…………..…
………..……
……………..
No. of Gas Stoves
Functioning of Gas Stove(s)
No. of Lamps
Functioning of gas lamps
Functioning of water trap
Functioning of gas taps
1 / 2 /3
Fine□ Minor problems□ Major problems□
1 / 2 / 3 / 4 / 5
Fine□ Minor problems□ Major problems□
Fine□ Minor problems□ Major problems□
Fine□ Minor problems□ Major problems□
Use of Gas Stove
Use of Gas Lamp
Enough gas to cook/light
How often not enough gas
Reason for insufficient gas
How often too much gas
What the users do if too much gas
………………… hours per day total
…………………. hours per day total
Yes □ No □
Daily □ Sometimes in a week □ sometimes in a month □
Less feeding □ Problem with plant □ Longer hours of gas use □ others …… □
Very Often □ Sometimes □ Never □
Flare it □ Use it for something else □ Let it escape □
Slurry Management
No. of Slurry pit
Size of slurry pit
Compost hut
Condition of compost hut
Use of liquid slurry
Use of semi-liquid slurry
Use of compost
Overall Situation of slurry use
0/ 1/ 2/ 3
Enough Small Very Small
Constructed Not constructed
Good Fair Poor
Yes No
Yes No
Yes No
Properly Managed Fairly managed Poorly managed
Documentation present:
- User manual
- Slurry booklet
- Guarantee Card
- Other document………………
Yes No
Yes No
Yes No
Yes No
49
A-S-S and Repairing record:
1st visit: - Date
- Works done
- Cost of Repair works
2nd visit: - Date
- Works done
- Cost of Repair works
3rd visit : -Date
- Works done
- Cost of Repair works
description: (copy from the guarantee certificate backside)
…….../……./…………………………
1.……………………………………………2.…………………………………………3……………………...……………
Nu………………………………………....
…….../……./…………………………
1.……………………………………………2.…………………………………………3……………………...……………
Nu………………………………………....
…….../……./…………………………
1.……………………………………………2.…………………………………………3……………………...……………
Nu………………………………………....
Users Trained Yes No
User’s level of satisfaction Fully satisfied □ Partly satisfied □ Not-satisfied □
Reason for not satisfying
o ……………………………………
o ……………………………………
o ……………………………………
User’s view on current performance No problems □ Ok but some problems □ Plant not functioning □
Existing problems reported by the
user(s), if any
1. …………………………….……
2. …………………………………
3. …………………………………
Overall condition of plant
Good Fair Poor
Comments on Overall Condition
and functioning of the plant
…………………………………………
…………………………………………
…………………………………………
Recommendation for follow-up
action including the deadline
…………………………………………
…………………………………………
Recommendation for Release of Guarantee amount Yes No
Signature of RBSU Supervisor: …………………………………… Signature/Finger Print of Plant Owner: ……………………..….
Date: ……/……../20………………… Date: ……/……../20……………
50
Form - 08
ENERGY FOR AGRICULTURE (E4A)
ACTIVITY REPORTING FROM FIELD
Date: Month……/Quarter..........., 200.....
Items Activities Planned Activity Actual Progress Remarks
A Promotion and Marketing
A.1 Promotion activities
a Public Media
b Deliver brochures, leaflets, posts
A.2 Investigate potential customers
A.3 Promotion activities to customers
A.4 Registration for Biodigesters
B Construction and Maintenance
B.1 Construction of biodigester
B.2 Maintenance
C Training
C.1 Biogas technician
C.2 Biogas mason
a Biogas experienced mason
b Biogas fresh mason
C.3 Biogas user
C.4 Related officers
D Comprehensive application
extension
D.1 Model design
D.2 Biogas newsletter
Petition:
...................................................................................................................................................................
...................................................................................................................................................................
...................................................................................................................................................................
...........................................................................................................................................................
Date: …… month……20……
Prepared by…………………… Reviewed by:………………..
(Full name + signature) (Signature + stamp)
51
Form - 09
ENERGY FOR AGRICULTURE (E4A)
LIST OF BIODIGESTER USERS FOR SUBSIDY PAYMENT
Period: From …..…/…..…/20…………… to ……/……/20…………
SN Name Address ID No. Plant
code
Date of
acceptance Village District Province
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Date: ………. month……………20……….…
Prepared by…………………… Reviewed by:………………..
(Full name + signature) (Signature + stamp)
52
Form - 10
ENERGY FOR AGRICULTURE (E4A)
BIODIGESTER WARRANTY CERTIFICATE
Biodigester Size: .......... m3 Plant Code: .... – .... – .... / ......
Name of User: ........................................... Tel No.: ……………..……………………
Address: Village..................... District..................... Province…………….…………….
Date of Plant Acceptance: ........./ ......../20……. Warranty Expiry Date:……/…../20……
Warranty Performing BCE:………………………………………….… BCE Code: .... – .... – ....
Address: ............................................................... Telephone: ...............................
Name of BCE Representative: .................................. Position:................…………………....
Terms and Conditions:
1) Warranty period will be 24 months for structural components, such as inlet, digester, gas-holder, outlet, water-
drain pit; and 12 months for pipe-fittings and appliances such as biogas stove, lamp, water-drain, mixing device,
main valve and gas taps, effective from the date of acceptance.
2) BCE will visit the biodigester within three days after receiving complain from the user and carry out the needed
repair works to solve the existing problem(s).
3) BCE will visit the plant at least once in a year during the warranty period to monitor the condition of biodigester
even if there are no complaints lodged from the user.
4) BCE is responsible to bear the costs of repair and maintenance within the warranty period. However, if the
problem is caused because of negligence/mishandling from the users the cost of construction materials and/or
appliances as well as unskilled labors has to be paid by the users. BCE will only bear the cost of skilled labors to
carry out the repair works in this case.
5) BCE will not be responsible for any problem encountered because of the use of sub-standard quality of
construction materials and appliances on behalf of the users while carrying out repair works.
6) This warranty is not valid for any defects or damages as a result of natural disasters such as landslides, floods,
earthquake etc.
7) BCE will not be responsible for any defects or damages caused because of improper operation and maintenance
activities on behalf of the users which are not as per the instructions from BCE or User’s Manual.
8) Warranty will be null and void for any defects/problems caused by any sorts of repair activities carried out by the
users without informing BCE.
9) The representative of BCE visiting the plant under the framework of this warranty provision will fill the
information as anticipated in the table given in the backside of this warranty card.
10) The user has rights to contact Energy for Agriculture (E4A) to lodge complain if BCE does not fulfill the
commitment. E4A will take necessary action against the BCE, including non-payment of warranty amount.
Name of BCE Representative…………………………..
Signature:……………………………………………………….
Position:…………………………………………………………
Date: ……………………………………………………………
Name of Plant Owner:………………………………..
Signature:……………………………………………………
Date:……………………………….…………………………..
53
Details of works carried out
Date of visit Purpose of visit
(routine/called by user)
Repair activities carried out during
the visit
Name of technician
(Full name + signature)
54
Annex-4: Quality Control Tools and Equipment
Routine Monitoring Tools
(a) Measuring Tape – 5m long
(b) Pressure Meter (Digital or analogue)
(c) pH Meter
(d) Digital Thermometer
Used for measuring
different components
of biodigester.
To measure the pH
(acidity and
alkalinity) level of
the influent and
effluent.
To measure/monitor
temperature
(ambient and various
locations inside the
biodigester).
Used to measure gas
pressure and detect
leakages in the
biodigester and pipe
systems.
55
To locate the exact
locations of
biodigesters.
To assess the
performance of
filtration
system by
measuring the
percentage of
methane and
CO2 in biogas.
(e) GPS Receivers
(f) Plier
(g) Screw Driver
(h) Pipe Wrench
Specialised Monitoring Tools
(a) Biogas Analyser
56
To measure the
quantity of biogas
consumed by a
specific end use
applications such as
generators.
To facilitate
measurement of
different
components of
filled
biodigesters
To check leakages through
gas holders, pipelines and
appliances.
To collect
sample of
bioslurry
from
biodigesters
(b) Bioslurry Sampler
(c) Folding Pipe
(d) Foot Pump or Bicycle Pump
(e) Biogas Flow Meter
57
Annex-5: Quality Check of Biodigesters and knowledge of Users
Parameters Size of Biodigester
4 6 9 14 21
Dung Feeding in Kg 20-40 40-60 60-90 100-140 150-210
Gas production in litre
(35-40 litres of biogas per kg of
cattle dung)
700-1400 1400-2100 2100-3200 3500-4900 5300-7400
Single Burner Stove Burning time in
hours
3 to 4 5 to 6 8 to 9 12 to 15 18 to 20
Methane content > 50% > 50% > 50% > 50% > 50%
Maximum pressure at NTP in kPa 7 8 9 10 12
pH 6.5 – 7.5 6.5 – 7.5 6.5 – 7.5 6.5 – 7.5 6.5 – 7.5
Total Solid in influent 6-10% 6-10% 6-10% 6-10% 6-10%
User Training and knowledge Pass (min 20/28 correct) □ Fail □
Action:……………………….
1. How much dung must you feed into the plant each day? a)…………… b) Pass □ Fail □ Pass □ Fail □
2. How much water must you feed into the plant each
day?
a)…………… b) Pass □ Fail □ Pass □ Fail □
3. What determines the quantity of gas production? a)…………… b) Pass □ Fail □ Pass □ Fail □
4. When should you close the main gas valve? a)…………… b) Pass □ Fail □ Pass □ Fail □
5. How do you check for gas leaks? a)…………… b) Pass □ Fail □ Pass □ Fail □
6. What should you do if there is a problem with your
plant?
a)…………… b) Pass □ Fail □ Pass □ Fail □
7. How do you drain water from the gas pipes? a)…………… b) Pass □ Fail □ Pass □ Fail □
8. How often should you drain water from the gas pipes? a)…………… b) Pass □ Fail □ Pass □ Fail □
9. What must you always check and do at the outlet tank? a)…………… b) Pass □ Fail □ Pass □ Fail □
10. How do you light the stove? (ask user to do for you) a)…………… b) Pass □ Fail □ Pass □ Fail □
11. With the gas tap, how should you make the flame look
and sound?
a)…………… b) Pass □ Fail □ Pass □ Fail □
12. How can you ensure the efficient burning of the stove? a)…………… b) Pass □ Fail □ Pass □ Fail □
13. How do you light the lamp? (ask user to do for you) a)…………… b) Pass □ Fail □ Pass □ Fail □
14. How can you save gas so that you have longer time for
use?
a)…………… b) Pass □ Fail □ Pass □ Fail □
15. How do you use bioslurry? a)…………… b) Pass □ Fail □ Pass □ Fail □
16. How do you make good compost fertilizer using
bioslurry?
a)…………… b) Pass □ Fail □ Pass □ Fail □
17. What are some of the advantages of bioslurry over
conventional farm-yard manure?
a)…………… b) Pass □ Fail □ Pass □ Fail □
18. What are some of the safety precautions while using
biogas?
a)…………… b) Pass □ Fail □ Pass □ Fail □
19. How can you estimate the quantity of gas inside the gas
holder?
a)…………… b) Pass □ Fail □ Pass □ Fail □
20. What should you do if the digester is always full (more
gas than you need)?
a)…………… b) Pass □ Fail □ Pass □ Fail □
21. What is the use of the gas pressure meter? a)…………… b) Pass □ Fail □ Pass □ Fail □
22. How do you avoid the scum formation in the biogas
plant?
a)…………… b) Pass □ Fail □ Pass □ Fail □
23. If the gas stops because of a scum layer forming inside
the digester, how would you fix it?
a)…………… b) Pass □ Fail □ Pass □ Fail □
24. What should be taken care while emptying the biogas
plant?
a)…………… b) Pass □ Fail □ Pass □ Fail □
58
Annex-6: Monitoring Parameters for ZamDigester
SN Parameter Frequency Equipment Monitoring
1 Feeding of cattle-dung Daily at set times (end of
afternoon?)
Bucket, weighing scale Initially daily by local
technician, later perhaps
by hh
2 Feeding of water Daily at set times (end of
afternoon?)
Bucket Initially daily by local
technician, later perhaps
by hh
3 Mixing of dung and
water
Daily at set times (end of
afternoon?)
Visual Initially daily by local
technician
4 Biogas consumption Continuous Gas flow meter, Sulphur
filter
Initially daily by local
technician, later less
5 Digester temperature Daily at set times, fixed
position
Min-max thermometer
(or more advanced?)
Daily by local technician /
continuous
6 Ambient temperature Daily at set times, fixed
position
Min-max thermometer
(or more advanced?)
Daily by local technician /
continuous
7 pH Weekly at set point; before
feeding, in the digester, in
the outlet discharge point
pH meter, litmus paper Weekly by local technician
8a Max gas pressure Daily in the morning, before
first gas consumption
Pressure meter Daily by local technician,
later perhaps by hh
8b Max outlet slurry level Daily in the morning, before
first gas consumption
Measurement stick,
measuring tape
Daily by local technician,
together with pressure.
Later perhaps by hh
9a Min gas pressure Daily in the evening, after
last gas consumption
Pressure meter Daily by local technician,
together with pressure.
Later perhaps by hh
9b Min outlet slurry level Daily in the evening, after
last gas consumption
Measurement stick,
measuring tape
Daily by local technician,
together with pressure.
Later perhaps by hh
10 Biogas stove-use
hours
Daily Clock Initially daily by local
technician, later by hh.
11 Biogas lamp-use hours Daily Clock Initially daily by local
technician, later by hh.
12a Closing of main valve Daily in the evening, after
last gas consumption
Clock Initially daily by local
technician, later by hh.
12b Opening of main valve Daily in the morning, before
first gas consumption
Clock Initially daily by local
technician, later by hh.
13a TS and VS fresh dung Twice for each plant, after
process is stabilized (three
months operation)
Containers, oven,
weighing scale, simple
lab equipment
By research institute,
laboratory
13b TS and VS slurry in
outlet
Twice for each plant, after
process is stabilized (three
months operation)
Containers, oven,
weighing scale, simple
lab equipment
By research institute,
laboratory
14 Water tightness In sampled plant. Once
upon commissioning and
once at the end of the
testing period
Lots of water, measuring
tape. Details on Biogas
Technology Manual
By Project Technical
Officers
15 Gas tightness For each plant. Once upon
commissioning and once at
the end of the testing
period
Lots of water, measuring
tape, pressure gauge.
Details on Biogas
Technology Manual
By Project Technical
Officers
16 Sediment and scum
content
Each plant to be checked,
at the end of the testing
period
Buckets, visual, weighing
scale, camera, folding
rod
By Project Technical
Officers
17 Daily Biogas
Production
At least once in a month for
12 months
Measuring tape, visual By Project Technical
Officers in the beginning
and later by local
technicians
59
Lusaka Office:
SNV Netherlands Development Organisation7 Nkanchibaya Road, Rhodes Park
P. O. Box 31771, Lusaka, ZambiaT: +260 1 255174/175
F: +260 1 255176
Kasama Office:
SNV Netherlands Development OrganisationPlot 2623 Lunzuwa Road, Central TownP. O. Box 410576, Kasama, ZambiaT: +260 04 222988F: +260 21 222986
www.snvworld.org/zambia
This Quality Management Manual for fixed dome biodigester aimed at Quality Inspectors, Biodigester Technicians and M&E Officers is prepared by Prakash C. Ghimire for Energy for
Agriculture (E4A) project. Any query related to this manual could be addressed to [email protected].
This manual is solely for the internal use of Energy for Agriculture (E4A) project to facilitate quality management process and ensure the compliance of quality standards. Any information from this
document may be copied or reprinted, subject to the condition that it is properly credited and cited.