FERTILIZER, LANDFILL- AND BIOGAS system... · • Risk of death and acute severe poisoning by hydrogen sulfide (H2S): Caution: H2S paralyzes the olfactory nerve, higher concentrations

1 O P E R A T I N G I N S T R U C T I O N S

H A Z A R D O U S M A T E R I A L I D E N T I F I C A T I O N

FERTILIZER, LANDFILL- AND BIOGAS Methane (CH4), Hydrogen Sulfide (H2S), Carbon Dioxide (CO2), Ammonia (NH3)

H A Z A R D S T O P E O P L E A N D E N V I R O N M E N T

WORKPLACE / RANGE: biogas plants, Manure pits, slurry channels, gas and slurry deposits, condensate pits, sedimentation pits, percolate, etc.

ACTIVITIES: agitation, flushing, pump, pumping, removal of percolate or the substrate, repair and maintenance work and stay in percolate or substrate workspaces

The gases are released in particular by moving substrate. This can result, in hazardous gas concentrations which hold over longer time.

• Risk of death and acute severe poisoning by hydrogen sulfide (H2S): Caution: H2S paralyzes the

olfactory nerve, higher concentrations are no longer perceived • Asphyxiation by carbon dioxide (CO2), and lack of oxygen (O2) • Risk of explosion from methane (CH4) • Health hazards of ammonia (NH3)

WARNING: Hydrogen sulfide and carbon dioxide are heavier than air. Therefore, a measurement should be taken always at the lowest point on which gas can accumulate to perform.

S A F E T Y P R E C A U T I O N S A N D R E G U L A T I O N S

• Never enter the fermenter, in deposits, pits or shafts , sedimentation pits, percolate , etc..

without protective equipment and without proper ventilation measures

• Respiratory protection: Entering existing biogas atmosphere only with self-contained breathing protective equipment, eg fresh air intake hose unit and rescue and emergency equipment permitted (see work instruction "Working in biogas-exposed closed areas")

• When working with percolate or substrate any ignition sources are to be avoided .

• Gas jet devices off

• Smoking and open flames are prohibited

• No light sample

• No welding and cutting work carried out , sparks, welding beads can also fall into more distant pits

( If such work absolutely is necessary , then ensure for good ventilation with a blower. Pits must be covered )

• Avoid all other possible sources of ignition .

• Eating , drinking or smoking is not allowed. Avoid inhalation of vapours ! Do not stand in a biogas cloud – protect eyes and skin from contact with biogas ! Store your work clothes it separately from normal clothes!

• Observe employment restrictions !

• Wear personal protective equipment (depending on activity): Antistatic protective clothing (eg cotton), hand protection (select on hazardous substances) Helmet, full eye protection, footwear with non-slip soles and steel toe cap, explosion-proof lamp, respiratory protection, use no spark-ignition tools, the manual gas meter (hand held meter) and the mobile gas detector should be used where appropriate.

Note: • The self-contained breathing protective equipment • The manual gas meter (hand held meter) • The mobile gas detector

The inspection / maintenance of the equipment needs to be checked in the documentation and must be documented in the operating log. Before using the equipment, a functional test should be carried out. It should be noted that the devices are fully charged / connected. It is necessary to carry out an inspection of the external condition and the display behavior of the devices. The equipment must be (re)calibrated if necessary.

W H A T T O D O I N C A S E O F D A N G E R Fire

department 112

• To rescue accident victims, only entry into pits, tanks, etc. with self-contained breathing protective equipment, rescue and emergency equipment.

• Provide adequate fresh air • Send out warning, evacuate and Isolate fire area if possible, rescue injured persons. • Inform supervisor. • If without risks, close leak or shut off the gas supply. Wear the damage inspection/repair always self-

contained breathing protective equipment. • Product is combustible. Initial fire: Use Portable Fire Extinguishers. In case of fire do not use the PFE before

the leak is closed, since the risk of creating an explosive cloud is very likely! In case of fire dangerous vapors (eg carbon monoxide)! In case of fire in the area, cool the containers with water spray! Bursting and explosion risk when heated!

• Stick to the company emergency protocol and inform the fire department .

F I R S T A I D

Emergency 112

FOR EACH FIRST-AID MEASURE: Pay attention to self-protection and medical treatment. Immediate life-saving measures, such as 'recovery position', 'cardiopulmonary resuscitation', 'Shock treatment' must be carried out depending on the situation. Cover wounds sterile. For body rest, protect against heat loss. CALL AN AMBULANCE, inform about a possible injury / poisoning due to hydrogen sulfide. INHALATION: Move person from the danger area. Supply fresh air by breathing in fresh air or ventilation. Airway devices use (self-protection).

In case of failure, biogas (volume flow rates of less than 20 m³ / h) may be discharged through a vent line into the environment.



PERCOLATE (FERMENTING LIQUIDS) H A Z A R D S T O P E O P L E A N D E N V I R O N M E N T

WORKPLACE / RANGE: BIOGAS PLANTS, PITS, PUMPS, DIGESTER, PERCOLATE, SEDIMENTATION PIT, ETC. ACTIVITIES: agitation, flushing, pumps, pumping, removal of percolate or the substrate, repair and maintenance work and stay in areas where percolate is available. • Percolate is enriched with organic matter and the liquid may cause irritation on prolonged contact with skin. Contact with mucous membranes should be avoided by appropriate protective measures. In the percolate are microorganisms that can form biogas from the organic ingredients without oxygen . Therefore always ensure when working with percolate for a sufficient supply of fresh air. The effluent percolate can also include organic acids to a degree that the percolate can be sour. Percolate is not suitable for consumption. • Percolate can have high COD / BOD values. Therefore, leakage of larger amounts of percolate is to be prevented. CAUTION: When ejecting and removing percolate during repairs and maintenance, hazardous gas concentrations may occur.

• Suffocation by carbon dioxide (CO2), and lack of oxygen (O2)

• Risk of explosion due methane (CH4)

• Health hazards caused by ammonia (NH4)

• Risk of death by hydrogen sulfide (H2S)

• Exposure to biological working substances


• Do not eat, drink, or smoke while working with percolate. Keep street clothing separately from work clothes.

• Observe employment restrictions!

• After the work it is necessary to wash your hands and disinfect.

• Wear personal protective equipment such as hand protection (type determined by hazardous substance) and a complete eye protection.


department 112

• Send out warning, evacuate and Isolate fire area if possible, rescue injured persons. • Inform supervisor. • If without risk, eliminate source of danger • Entry into tanks, shafts or pits to rescue injured persons is only permitted if the entering person is

wearing a self-contained breathing mask and one other person secures the Entrant with a rope, which is firmly anchored outside the danger zone.

F I R S T A I D

Emergency 112

FOR EACH MEASURE, FIRST AID: Pay attention to self-protection, adequate fresh air ventilation, medical treatment. Immediate life-saving measures, such as the recovery position, "CPR", "eye-wash", "shock treatment" must be performed depending on the situation. Cover wounds sterile. For body rest, protect against heat loss.

CALL AN AMBULANCE, inform about a possible injury / poisoning due to percolate and / or biogas.

PROPER DISPOSAL Percolate is performed in a circuit in the biogas plant. Excess water usually does not apply. By

spreading and / or disposal of percolate the legal regulations must be taken into account, including:

• Waste Management Law

• Fertilizers Law

• Water Management Regulation

• Fertilizer Regulation • Fertilizer application Regulation



BIOLOGICAL MATERIALS OF RISK GROUP 2


• The bio-waste in the dry fermentation plant can contain microorganisms of risk group 2 according to § 3 and §

4 (1) Residues of this biological materials can also stick on the machine technology, vehicles, wheel loaders, trash containers and other items that are used to process the waste.

• Biological materials of risk group 2 (eg, viruses, bacteria, fungi, parasites) can cause infections and diseases to people and pose a threat due to inhalation. Also an allergenic and toxic potential can not be excluded.

• For activities on the biogas plant biological material can be absorbed into the body by: - Inhalation - swallowing - contact through the skin (or existing or skin damage caused by injury).


• Wear suitable protective clothing at least breathing protection (dust mask class P2).

• Formation of dust should be avoided. In case of inadequate ventilation wear breathing protection..

• At work do not eat (not even chew gum), drinking or smoking.

• Before entering the rest rooms work shoes, gloves and overalls are taking off in the black area of the changing rooms and replace it with clean, non-contaminated clothing.

• PAY ATTENTION TO HYGIENE! After completion of the work soiled clothing and personal protective equipment (PPE) should be taken off and store it separately from clean, uncontaminated clothes.

• HAND HYGIENE NOTE

(hand washing and disinfection)! • NOTE separation of black and white areas and keep them clean!

• Appropriate vaccinations and medical examinations are to be provided as part of occupational health and occupational health checkups.

• Groups of visitors should be instructed to potential hazards. You are allowed to move only accompanied by a qualified and authorized person on the Anaerobic digestion facility!

• ACCESS RESTRICTION:

adolescents, pregnant women and people with weakened immune systems may not be permitted to the

Anaerobic digestion facility.


department 112

• When microbial contaminated biological material in your mouth, spit it out immediately and flush thoroughly with water. In no case swallow!

• Wash out open wounds, bleed them as dry as possible and spray with disinfectant.

• In case of dust particles / splashes in the eyes, immediately wash them out with plenty of fresh water.

• In case of intensive contact immediately consult a doctor (eg, by ingestion, inhalation, skin penetration by injury).

F I R S T A I D

Emergency 112

IMMEDIATELY INFORM THE FIRST AIDER AND THE SHIFT SUPERVISOR THE ACCIDENT:

• Ensure about Medical First Aid. • Unconscious casualties: detection of breathing and recovery position. • Immediately inform responsible doctor and inform with a reference to possible poisoning or ingestion of

biological material of risk group 2



Old and fresh oils (Lubricating, hydraulic, engine, gear, machine oils, etc..)


ACTIVITIES: draining, filling, transfer operations for vehicles, CHP, pumps, agitators, compressors, fans, etc.

• Oils are flammable. Vapors that are released due very strong heating and aerosols, can form an explosive mixtures with air. There is a risk of ignition oil-soaked clothing. Cause fire in contact with combustible materials.

• Frequent or prolonged contact with the products, including through oil-soaked clothing, can cause skin diseases such as inflammation, rashes and oil acne.

• Irritation of the eyes, the nose and throat caused by oil mist is possible. • Ingestion of large quantities may cause nausea and diarrhea. • Leaking oils are hazardous to water and harmful to aquatic organisms.


• Oils storage and filling only collecting trays; avoid splashing. • Do not overfill oil drums by using collecting trays and do not use them for collecting other

materials.

• Keep away sources of ignition, do not smoke, avoid open flames!

• Do not store together with oxidizing or self-igniting products.

• Avoid formation of oil vapours and -misting.

• Keep containers closed and protect from heat building up.

• Keep drenched cloths in non-combustible, closed containers.

• Replace cloths regularly. Smudged cloths Do not put in the pockets of working clothes.

• Filled containers need to be marked. Replace damaged labels. Never use or order vessels that can be confused with food containers. Do not consume any food in the range of old or fresh oil containers.

• Hand protection: Chemical-resistant for longer handling gloves (eg nitrile) • Avoid contact with eyes, skin and clothing.

• Change out soaked clothing immediately for fresh clothing

• Wash hands after handling and apply nourishing cream.

• To use skin cleaning of solvents, paint thinner, gasoline or similar.

W H A T T O D O I N C A S E O F D A N G E R

Fire department

112

• Do not empty into drains or waterways. In case of a leakage immediately absorb with mineral material (acid absorbent, diatomaceous earth, sand) and put this in a waste container.

• Airvent the area. • Oils are flammable. Suitable Extinguishing Media: Foam, carbon dioxide, dry powder. Or fight or

extinguish with water fog. Do not use water jet. Caution: Toxic fumes! • In case of fire is bursting of closed heated container, leaving oil storage in case of danger. • Escape route: see marking of escape routes and emergency exits • Caution: slip hazard because of greasy soil due to leakage / spilled material!

F I R S T A I D

Emergency

112

AFTER CONTACT WITH SKIN:

With contact the skin can become irritated and inflamed. Wash thoroughly with soap and water, remove contaminated clothing before.

AFTER CONTACT WITH EYES:

Flush under running water for at least ten minutes with open eyelids, consult an eye doctor.

AFTER SWALLOWING:

Do not induce vomiting, consult a doctor.

AFTER INHALATION:

Inhalation of vapours may cause dizziness, headache and loss of consciousness. Move the

victim to fresh air. Medical advice is necessary.

AFTER BURNING:

Cool affected skin with plenty of water. Use sterile dressing. Call a doctor.

NOTIFY FIRST AIDER ON SITE OR RESCUE SERVICE.

PROPER DISPOSAL

• When empty return drums to the supplier.

• Waste oils must not be added to the sewer or to the trash. • Residual substances may not come into contact with foreign substances (eg solvents). • For proper disposal or processing, the collection should take place separately in non-combustible,

resistant, sealable and labelled oil containers. • Keep waste container and empty container closed. • Disposal of waste oils should be in compliance with local regulations and the appropriate waste

code or supplied for reprocessing.

5 O P E R A T I N G

I N S T R U C T I O N S


Ethylene glycol Other designations: ethanediol, glycol

HAZARDS TO PEOPLE AND ENVIRONMENT

ACTIVITIES: gas storage, work on the safety valves with liquid template (filling, refilling and emptying operations, maintenance of the safety valves)

• Coolant is environmentally hazardous and hazardous for water. • Harmful if swallowed and by inhalation. • Repeated skin contact may result in adverse health

SAFETY PRECAUTIONS AND REGULATIONS • Avoid spilling, leaking.

• Keep away from fire, heat and open flame. • Keep away while eating or drinking. • Avoid skin and eye contact, use gloves as coolant be absorbed through the skin. • Should not be released into the soil, water or sewer system. • Refilling only above a sealed floor or collection container. • Wear protective equipment (eye protection, gloves) when handling

(gloves: Cat III Tricotril (moss green))

• Do not keep soaked in your cloting • Provide sufficient ventilation.


department 112

• Immediately change clothes when heavily soiled. • In case of fire: Clear with foam, dry powder, carbon dioxide or water spray. • Absorb spilled liquids with absorbent material (sand, earth) and dispose according to local

authority guidelines. Do not empty into drains.

F I R S T A I D

Emergency

112

AFTER CONTACT WITH SKIN: With contact the skin can become irritated and inflamed. Wash thoroughly with soap and water, remove contaminated clothing before.

AFTER CONTACT WITH EYES: Flush under running water for at least ten minutes with open eyelids, consult an eye doctor.

AFTER SWALLOWING: Immediately flush with water and drink a lot of water after flushing, consult a doctor.

PROPER DISPOSAL

• Small amounts may be diluted with plenty of water and washed away. Absorb spillage with inert absorbent material (sand, earth) and dispose of it as household waste.

• Used antifreeze has to be collected and handed over to a recycler

1 W O R K I N G I N S T R U C T I O N

A R E A O F A P P L I C A T I O N

Opening the Fermenter


• Before opening the doors the fermenter should be checked on a possible biogas atmosphere.

• Gases are mainly released by moving substrates. Hazardous gas concentrations can arise, which are kept for a long time (f.e. forming of mist).

• Life-endangering hydrogen sulphide (H2S); Caution: H2S paralyzes the olfactory organ, higher concentrations are no longer perceived.

• Danger of asphyxiation due to carbon dioxide (CO2) and lack of oxygen (O2).

• Danger of explosion due to Methane (CH4).

• Health hazards due to Ammonia (NH3)

TO BE OBSERVED: Hydrogen sulphide and carbon dioxide are heavier than breathing air. Therefore a measurement is always to be taken at the lowest point where gas can accumulate.


FOR OPENING OF THE DOORS THE FOLLOWING STEPS ARE NECESSARY:

• Execution of the Shut-down program (see operating manual). • After ending of the automatic post-ventilation (methane concentration: < 1 Vol.-% in the dry

fermenter), check the methane content in the same dry fermenter (at the measuring connections in the multiplexer) with the portable measuring device.

• Align the measured values of the automatic measurement and the manual measurement and

document these in the logbook. • Open the fermenter first when both measuring devices indicate a methane concentration < 1

Vol.-% and an oxygen concentration > 18%. • Normally the release for door opening will not be given automatically by the PLS. The

measured values of the manual measurement should be entered into the PLS first. The automatic release for door opening only then occurs when the manual input value as well as the automatic measurement show a methane concentration < 1 Vol.-%.

• WARNING:

In other cases (methane: >= 0,7 Vol.-% or oxygen: < 18 Vol.-%) the door can only be opened via a manual release (for procedure see instruction manual: “opening the fermenter”). In this case the presence of a potentially explosive atmosphere must be reckoned with.

• The required safety precautions for handling Biogas are to be observed. A test measurement

should be done with the manual measuring device. • The operator should make sure that the fermenter can be opened without danger. The

operator is responsible for this.

TO BE OBSERVED:

• Attention must be paid to bystanders during opening and closing of the doors as well was during driving movements of the wheel loader.

• During the opening and closing process of the fermenter doors no persons or objects should be in the door area. A safety distance of 10 m around the door area must be kept.

• To prevent a new methane production in the dry fermenter, it should be opened immediately after the measurement of the methane concentration < 1 Vol.-% by both measuring devices. A time frame of 20 minutes is set in the PLS during which the dry fermenter can be opened, after these 20 minutes the release will be deactivated and the shut-down resp. measuring procedure will have to be repeated.

• Working in the dry fermenter is only allowed when the worker is carrying the portable gas

detector. In case of an alarm by the portable gas detector the dry fermenter should be abandoned, the door should be closed and post-ventilation should be repeated.

• Food, drinks, cigarettes and cold symptoms are not allowed during works in the fermenter.

Avoid inhalation of vapours! Do not stay inside a biogas-cloud, also protect eyes and skin from coming into contact with biogas! Keep street clothes separated from work clothes! Wash or dry-clean dirty work clothes and working materials.

• Observe employment restrictions!

• Automatic programs are to be executed and monitored by instructed persons only! • Radlader niemals im Fermenter abstellen und verlassen! Es besteht Erstickungsgefahr!

• Never switch off the wheel loader and leave it behind in the fermenter! There is a risk of

asphyxiation! TO BE OBSERVED: • the automatic (methane) gas measurement • the manual gas measuring device (hand-held device) and • the portable gas detector

are to be maintained and inspected as indicated in the technical documentation. Maintenance of the devices should be documented in the logbook. Before using the devices these must be subjected to functional testing.

Attention should be paid to the fact that the devices are completely charged/connected properly. A check should be carried out on the external condition and the display behaviour of the devices. If necessary, the devices should be calibrated.

Wear personal protection equipment, works in the fermenter should only be carried out after it has been determined that no gas is present, the portable gas detector must be carried at all times during works in the fermenter. An atmosphere of safety should be verified continously.

B E H A V I O U R I N C A S E O F D A N G E R

Fire department

112

• If necessary, move the wheel loader out of the fermenter and shut it down.

• Rescue injured people, clear and barricade the danger zone.

• Inform superiors.

• If possible without risks, close the leakage or block the gas supply.

• Always wear self-contained breathing apparatus during damage repair.

• Product is flammable. Developing fire: apply portable fire extinguishers. In case of fire do not

extinguish before the leak has been closed, because there is a risk of an explosion endangered cloud! A fire causes hazardous fumes (f.e. carbon monoxide)! Use water spray to cool the containers in case of fire in the direct surroundings! Risk of bursting and explosion when heated!

• Observe the emergency plan and alert the fire department.

F I R S T A I D

Emergency

call 112

• WITH EACH FIRST AID MEASURE: pay attention to self-protection, medical treatment. Lifesaving emergency measures, such as “recovery position”, “cardiopulmonary resuscitation”, “anti-shock measures” should be performed depending on the situation. Cover wounds with sterile dressings. Ensure body rest and protect against heat-loss.

• AFTER INHALATION:

remove victims from the hazard zone. Supply fresh air by breathing fresh air or artificial respiration. Use breathing aids (self-protection).

D I S P O S A L • In case of failure, biogas (flow rates <20 m3/h) can be released into the environment via an

air outlet pipe. • The manufacturer’s stipulated disposal instructions are to be observed.


A R E A O F A P P L I C A T I O N Maintenance and repair works on machinery,

aggregates and fittings


• Maintenance and repair works are to be done only by trained personnel and with the client’s order.

• For all maintenance and repair works the manufacturer’s operating instructions and

the applicable safety and accident prevention regulations are to be observed.

• Maintenance and repair works are to be executed according to the inspection and maintenance plan provided in the documentation.

• Improper maintenance and repair works can lead to a risk of personal injury. • Life-endangering hydrogen sulphide (H2S); Caution: H2S paralyzes the olfactory organ,

higher concentrations are no longer perceived.

• Danger of asphyxiation due to carbon dioxide (CO2) and lack of oxygen (O2).

• Danger of explosion due to Methane (CH4).

• Health hazards due to Ammonia (NH3).


• The manufacturer’s safety regulations and maintenance instructions of the individual machines, aggregates and fittings must be observed.

• The maintenance instructions can be found in the documentation of the biogas plant.

• When working on machinery, aggregates and fittings, which work with/utilize the hazardous substance biogas, it should be guaranteed and checked that there is no gas. The operating instructions for “biogas” are to be observed.

• The inspections should be documented in the logbook.

• When working on machinery, aggregates and fittings, which work with/utilize the medium process water / percolate, immediate skin contact/contact with mucous membranes should be avoided.

• When working on machinery, aggregates and fittings, which work with/utilize the medium biogas, appropriate ducts should be connected and the ducts should be ventilated or inertized if necessary so no biogas can escape during maintenance. The operating instructions “Works at the openings of biogas-exposed containers” should be observed.

• Personal protective equipment (PPE) as indicated by the manufacturer in the safety precautions and instruction manual should be worn!


Fire department 112

• Clear and barricade the danger zone, inform superiors. • If possible without risk, eliminate the source(s) of danger. • Biogas is flammable. Developing fire: apply portable fire extinguishers. In case of

fire do not extinguish before the leak has been closed, because there is a risk of an explosion endangered cloud! A fire causes hazardous fumes (f.e. carbon monoxide)! Use water spray to cool the containers in case of fire in the direct surroundings! Risk of bursting and explosion when heated!

• Observe the emergency, escape and rescue plans and alert the fire department.

F I R S T A I D

Emergency call 112



remove victims from the hazard zone. Supply fresh air by breathing fresh air or artificial respiration. Use breathing aids (self-protection). Dose strength, type of application and further treatment to be arranged by the company doctor!

D I S P O S A L • Waste materials should be collected and disposed of in a professional manner.

3 W O R K I N G I N S T R U C T I O N :


Works at the openings of biogas-exposed containers


WORKPLACE / -AREA: biogas plant, gas storage, condensate pits, grit chamber, percolate storage tanks, biogas-exposed containers general, etc.


• Danger of asphyxiation due to carbon dioxide (CO2) and lack of oxygen (O2). • Danger of explosion due to Methane (CH4). • Health hazards due to Ammonia (NH3).

TO BE OBSERVED:

Hydrogen sulphide and carbon dioxide are heavier than breathing air. Therefore a measurement is always to be taken at the lowest point where gas can accumulate.


BEFORE OPENING THE BIOGAS-EXPOSED CONTAINERS:

• Make sure that the person working on the container is protected from falling into the container (rope equipment)

• Avoid sources of ignition and open flames • Open tank cover • Use fall protection equipment in the container opening • Check for a potentially explosive atmosphere • When checking the upper limit for an explosive atmosphere is max. 50% of UEL CH4 • Check for hydrogen sulphide (H2S) in the atmosphere / clearance of the atmosphere • Occupational exposure limit value hydrogen sulphide (H2S): 5 ppm / 7,1 mg/m3

WORKS ON THE OPEN CONTAINER / SECURING THE WORKER AT THE CONTAINER OPENING:

• Sufficient air exchange by ventilation measures to be ensured. • The portable gas detector to be carried during the works. • The worker at the container opening is to be secured by a climbing harness. • A second worker should be at a safe distance (min. distance to the shaft: 5 m) and needs to

secure the worker at the container opening. • In case the worker at the container opening is incapacitated, the second worker at a safe

distance needs to pull the incapacitated worker from the danger zone. • First aid measures (see below) should be performed immediately. • When suffering from physical impairments (coughing, nausea, headache, shortness of

breath, vomiting, etc.), the worker at the container opening should immediately remove himself from the shaft and move to a safe zone (min. distance to the shaft: 5 m, see first aid measurements in the text below).

TO BE OBSERVED: • the manual gas measuring device (hand-held device) and • the portable gas detector


Attention should be paid to the fact that the devices are completely charged/connected

properly. A check should be carried out on the external condition and the display behaviour of the devices. If necessary, the devices should be calibrated.

Wear personal protection equipment: anti-static protective clothing (f.e. cotton) if necessary, protective gloves (depending on hazardous substances), protective helmet, full protection of eyes, footwear with anti-slide soles and steel nose, explosion-proof lamps if necessary, non-sparking tools, portable gas detector.


Fire departm

ent 112

CLEAR AND BARRICADE THE DANGER ZONE, INFORM SUPERIORS.

• If possible without risk, eliminate the source(s) of danger. • Biogas is flammable. Developing fire: apply portable fire extinguishers. In case of fire do not

extinguish before the leak has been closed, because there is a risk of an explosion endangered cloud! A fire causes hazardous fumes (f.e. carbon monoxide)! Use water spray to cool the containers in case of fire in the direct surroundings! Risk of bursting and explosion when heated!

• Observe the emergency, escape and rescue plans and alert the fire department.

F I R S T A I D

Emergency call 112



remove victims from the hazard zone. Supply fresh air by breathing fresh air or artificial respiration. Use breathing aids (self-protection). Dose strength, type of application and further treatment to be arranged by the company doctor!




Works in biogas exposed containers


WORKPLACE / -AREA: biogas plant, gas storage, condensate pits, grit chamber, percolate storage tanks, biogas-exposed containers general, etc.


• Danger of asphyxiation due to carbon dioxide (CO2) and lack of oxygen (O2). • Danger of explosion due to Methane (CH4). • Health hazards due to Ammonia (NH3).

TO BE OBSERVED:

Hydrogen sulphide and carbon dioxide are heavier than breathing air. Therefore a measurement is always to be taken at the lowest point where gas can accumulate.


BEFORE OPENING THE BIOGAS-EXPOSED CONTAINERS:

• Make sure that the person working on the container is protected from falling into the container (rope equipment)

• Avoid sources of ignition and open flames • Open tank cover • Use fall protection equipment in the container opening • Check for a potentially explosive atmosphere • When checking the upper limit for an explosive atmosphere is max. 50% of UEL CH4 • Check for hydrogen sulphide (H2S) in the atmosphere / clearance of the atmosphere • Occupational exposure limit value hydrogen sulphide (H2S): 5 ppm / 7,1 mg/m3

BEFORE ENTERING THE BIOGAS-EXPOSED CONTAINER:

• Sufficiently ventilate the container and clear the atmosphere • Empty the container • Make sure that no percolate or biogas is lead to the shaft (close valves and flaps) • Avoid sources of ignition and open flames • Open tank cover (open shaft cover resp. manhole or open double-diaphragm cover) • Check for a potentially explosive atmosphere and occupational exposure limits (u. A.

O2 > 18%) • When checking the upper limit for an explosive atmosphere is max. 50% of UEL

WORKS IN BIOGAS-IMPACTED CONTAINER AND SECURING OF THE WORKER:

• Works in the container may only be executed with total breathing protection with external air supply (self-contained breathing apparatus) by qualified persons.

• The compressor of the breathing air supply must be set up outside the danger zone (outside hazardous areas such as explosion-endangered areas etc.).

• It must be ensured that the breathing air supply is not impaired (f.e. bending the breathing air hose, covering or clogging of the air supply openings, power failure, etc.).

• The portable gas detector and the hand-held gas measuring device must be carried during the works.

• All workers should wear personal protective equipments (see below).

• Workers at the container opening are to be secured by climbing harnesses. • In case of a rescue of a worker in the container, the worker should be pulled out

of the container by using the climbing harness. • There should always at least be one other worker standing guard at the opening

of the container. • If there are no breathing devices available, the container should only be entered

after constant and sufficient active ventilation by a blower (located outside the danger zone).

• Constant monitoring of the methane explosion limit is required. • Before entering the container and during the works in the container the atmosphere in

the container should be continuously inspected on hazardous gas concentrations like hydrogen sulphide, carbon dioxide, ammonia and sufficient oxygen content with the hand-held gas measuring device.

• Signs of hydrogen sulphine poisoning are coughing, nausea, headache, shortness of breath, vomiting, etc.).

• When one of the workers is showing these symptoms, the worker in the container should be rescued.

• All workers have the range to leave the container opening and find a safe area (at least 5 m away from the container opening).

• In case the warning device has not detected any hazardous gas concentrations, this needs to be checked again.

• The container must be closed. • The works can only be continued when self-contained breathing apparatus is available. • Furthermore all other measures mentioned above are to be carried to secure the

worker in the container (gas detector to measure the lowest explosion limit and gas measuring device to measure hazardous gas concentrations. A non-hazardous atmosphere must be verified continuously).

TO BE OBSERVED:

• the self-contained breathing device • the manual gas measuring device (hand-held device) and • the portable gas detector


Attention should be paid to the fact that the devices are completely charged/connected properly. A check should be carried out on the external condition and the display behaviour of the devices. If necessary, the devices should be calibrated.

Wear personal protection equipment: anti-static protective clothing (f.e. cotton), protective gloves (depending on hazardous substances), protective helmet, full protection of eyes, footwear with anti-slide soles and steel nose, explosion-proof lamps if necessary, non-sparking tools, self-contained breathing device, manual gas measuring device and portable gas detector.


Fire department

112

• Clear and barricade the danger zone, inform superiors. • If possible without risk, eliminate the source(s) of danger. • Biogas is flammable. Developing fire: apply portable fire extinguishers. In case of

fire do not extinguish before the leak has been closed, because there is a risk of an explosion endangered cloud! A fire causes hazardous fumes (f.e. carbon monoxide)! Use water spray to cool the containers in case of fire in the direct surroundings! Risk of bursting and explosion when heated!

• Observe the emergency, escape and rescue plans and alert the fire department. F I R S T A I D

112

• WITH EACH FIRST AID MEASURE: pay attention to self-protection, medical treatment. Lifesaving emergency measures, such as “recovery position”, “cardiopulmonary resuscitation”, “anti-shock measures” should be performed depending on the situation. Cover wounds with sterile dressings. Ensure body rest and protect against heat-loss. Contact a physician (referring to a possible hydrogen sulphide poisoning).

• AFTER INHALATION: remove victims from the hazard zone. Supply fresh air by breathing fresh air or artificial respiration. Use breathing aids (self-protection). Dose strength, type of application and further treatment to be arranged by the company doctor!




Works on live electrical plants and operating equipment


Electrical hazards:

• Electrical shocks can lead to cramping, ventricular fibrillation, cardiac arrest and internal burns.

• Burn hazard because of arcing issues caused by short circuits or earth faults. • Work at a height and stepleaders may expose workers to particularly severe risks to their

health and safety, notably to the risks of falls from a height and other serious occupational accidents.

• Brandgefahr durch unzulässige Erwärmung der elektrischen Betriebsmittel.


Works on live electrical plants may only be started when the following 5 SAFETY REGULATIONS are properly observed.

The works may only be executed by qualified electricians or under their direction or supervision.

1. Switch off power a. View the circuit diagrams and gather information on the

construction and switches. b. Only deal with safety-relevant facilities after consultation with the

person responsible for this. c. Create visible isolating gaps. d. One must wait for the discharge time with condensers.

2. Secure against restarting a. Mechanically block the button (f.e. by using locks) b. Remove the fuse holders c. Apply prohibition sign VS 1 according to DIN 40008-2

3. Validate that the power is off a. Only use voltage detectors which are suitable for the voltage available b. Test the functionality of the voltage detectors c. Validate that the power at the workplace is off

4. Earthing and short-circuiting

a. Earthing and short-circuiting is required at plants with nominal voltages over 1 kV.

b. The earthing and short-circuiting equipment must be dimensioned according to the occurring short circuit.

c. Always connect the installation with the grounding outlet first.

5. Cover or block adjacent live parts and elements a. Live parts must be protected from accidental contact by sufficiently

tightened and reliably mounted cover

• Wear facial protection and insulating safety shoes • Insulate the site • Only use insulated tools • Only use ladders and scaffolding according to specification


Fire department

112

• Check if it is necessary to shut off the power for secure troubleshooting. If yes, then switch off the plant, secure it against restarting, validate that the power is off and only then solve the problem.

• Inform superiors

F I R S T A I D

• Switch off the plant, safe the injured • Notify first-aiders • Administer first aid • Cool burns with water, if there is no breathing or pulse, immediately perform

cardiopulmonary resuscitation. • If there is no risk on respiratory failure or circulatory arrest, the victim should be

place in recovery position. • Report the accident: emergency call 112 • Inform superiors

M A I N T E N A N C E / D I S P O S A L

• Electrical systems and equipments are to be checked after construction, modification and maintenance.

• Maintenance only in accordance with the manufacturer’s instructions. • Check personal protection equipment, tools and other means for any defects

before use.



ADEQUATE BEHAVIOUR AND MEASURES

IN CASE OF AN ACCIDENT

WORK/PLANT SITUATION:

In case of an accident or damage (f.e. as a result of gas alarm, fire alarm) the plant will be automatically switched into a safe state resp. should be switched into a safe state by operating personnel.

In case of an accident or damage there may only be authorised personnel on site (f.e. qualified operating personnel, fire brigade), who are familiar with the procedures, potential hazards as well as the safety concept (incl. explosion-protection document) of the plant.

It is imperative to wear the required personal protection equipment (f.e. safety shoes, breathing apparatus) and the gas detector!


• In case of an accident or damage, but also in general, there is a complete smoking ban

on the entire installation site!

• Handling open flame, ignitable equipment (f.e. mobile phones) and sparking tools in

the alarm zone is prohibited!

• As a basic principle for safety the plant is only to be entered with a second person in

case of an accident or damage.

• Before the start of inspection activities and measures to eliminate the disturbance or

damage as well as during subsequent working arrangements the occurrence of a

potentially explosive atmosphere should be excluded by permanent supervision! Areas

in which there is controlled production of biogas should be secured and may not be

entered.

• Every accident or damage case is to be documented in the logbook!

• Save the injured in case of a personal injury and apply first aid measures. Should this be

impossible, then appropriate assistance should be called upon (fire departments,

doctor on call).

ALL MEASURES TAKEN SHOULD TAKE PLACE IN DUE CONSIDERATION OF SELF-PROTECTION


MEASURES TO BE TAKEN IN CASE OF AN ACCIDENT OR DAMAGE:

• Immediately inform the plant owner or his representative.

• Check if the plant was switched into a safe state properly.

• If this is not the case, then the plant should be switched into a safe state by pushing the emergency stop button in the electrical room.

• Locate the alarm zone by analysing the warnings generated by the gas warning system in the electrical room.

• Prepare an inspection round and check the personal equipment (calibrate gas detectors outside of the alarm zone).

• Before entering the alarm zone make sure there is sufficient fresh air supply and/or provide adequate ventilation measures.

• Identify the cause of failure in the alarm zone and evaluate the extent of the damage and secure the alarm zone.

• Inform the plant owner or his representative about the existing damage extent and the possible cause.

• Further instructions of the plant owner or his representative must be followed (if necessary obtain technical assistance from the company Waste Treatment Technologies B.V.).

• Provide appropriate measures or adequate compensation measures to deal with the cause in consultation with the plant owner or his representative (f.e. close off the area concerned in case of pipeline leaks; depressurize the entire fermenter in case of leaking door seals).

• Check if the provided measures have the desired effect.

• Check safety-related plant components for proper functioning.

• Operational and occupational safety recovery at the plant.

• Obtain clearance from the plant owner or his representative to restart the biogas plant.

• Vor dem Wiederhochfahren der Anlage ist ein Kontrollrundgang der Anlage unter Einsatz des Gasspürmessgeräts durchzuführen.

• Put the plant back in normal operation.

• Perform the daily inspection round according to the inspection and control plan. Thereby increased attention should be paid to the overpressure valves, the gas flaring system, the door seals and the check for leaks at gas-carrying ducts.

• The accident, the extent of the accident, measures/compensation measures taken, found abnormalities/irregularities and all notified persons should be documented in the logbook in writing, stating the date and time as well as the operational staff.

• Initiate further damage repair measures (f.e. restoration works by specialized companies).



ADEQUATE BEHAVIOUR AND MEASURES IN CASE OF POWER FAILURE

WORK/PLANT SITUATION:

In case of power failure the plant will be automatically switched into a safe state, power to the PLS will be maintained up until 15 minutes over a UPS, other electrical components are switched off.

In case of power failure there may only be authorised personnel on site (f.e. qualified operating personnel, who are familiar with the procedures, potential hazards as well as the safety concept (incl. explosion-protection document) of the plant.

It is imperative to wear the required personal protection equipment (f.e. safety shoes, breathing apparatus) and the gas detector!


• Caution, gas outlet: increased attention should be paid to the overpressure valves, because biogas will leak here in case of a failure in the (public) power supply.

• In case of power failure the on-call service will be informed by an SMS, a maximum response time of 2 hours should be observed.

• In case of power failure, but also in general, there is a complete smoking ban on the entire installation site!

• Before restarting the plant the occurrence of a potentially explosive atmosphere should be excluded by permanent supervision with the help of the gas detector!

• Every power failure should be documented in the logbook!

• Save the injured in case of a personal injury and apply first aid measures. Should this be impossible, then appropriate assistance should be called upon (fire departments, doctor on call).

ALL MEASURES TAKEN SHOULD TAKE PLACE IN DUE CONSIDERATION OF SELF-PROTECTION.


MEASURES TO BE TAKEN IN CASE OF POWER FAILURE:

1. Immediately inform the plant owner or his representative.

2. Check if the plant was switched into a safe state properly.

3. If this is not the case, then the plant should be switched into a safe state by pushing the emergency stop button in the electrical room

4. The UPS will provide power to the PLS for approx. another 30 minutes. If power comes back on within this time, the plant can be restarted again by acknowledging the message in the PLS in the electrical room.

5. When power is restored after more than 30 minutes, the plant should be checked for a potentially explosive atmosphere.

6. In case of power failure or plant shut-down the compressed air reservoir will contain sufficient compressed air to drive all the double-acting valves into the safe position and to maintain the door seal pressure for a certain period.

7. Prepare an inspection round and check the personal equipment (calibrate gas detectors outside of the alarm zone).

8. Perform the daily inspection round and exclude the occurrence of a hazardous atmosphere in the areas around the overpressure valves.

9. If this is not possible, it means that more errors have occurred, see working instructions: “Adequate behaviour and measures in case of an accident”.

10. As long as the plant is completely switched off during a longer power failure, after the UPS power supply has stopped, the main switch will be automatically switched off. When power is restored this main switch must be switched manually by the operating personnel after the plant has been cleared.

11. During a longer power failure (> 2 hours) the double membrane gas storage will break down and there will be a risk that with strong winds and heavy rain at the same time the membrane will be damaged. Therefore in this case the support air blower should be switched on again with an emergency power supply device.

12. During a very long power failure (> 24 hours) it is possible that the compressed air in the compressed air reservoir will be consumed and the door seal pressure will drop. Therefore it is essential to either equip the plant with an emergency power supply (f.e. connect an emergency power unit to the trafo) or systematically put the plant out of operation (turn off heating system, dry fermenter, release remaining biogas via pressure relief valve in the percolate storage tank).

13. Further instructions of the plant owner or his representative must be followed (if necessary obtain technical assistance from the company Waste Treatment Technologies B.V.).

14. Provide appropriate measures or adequate compensation measures to deal with the cause in consultation with the plant owner or his representative.

15. Operational and occupational safety recovery at the plant.

16. Obtain clearance from the plant owner or his representative to restart the biogas plant.

Maintenance only in compliance with the manufacturer's instructions.

8 W O R K I N G I N S T R U C T I O N S

A P P L I C A B I L I T Y

GAS TIGHTNESS TEST

R I S K S T O H U M A N S A N D T H E E N V I R O N M E N T

RISKS DUE TO EXPLOSIVE ATMOSPHERE:

• Fuel gas together with air form a highly explosive mixture. In the event of air being inlet into the downstream system device or fuel gas into the air-filled filter housing, there is an immediate danger of explosion as a result.

• If there are leakages, an explosive atmosphere may build up in the biogas system. • Ensure that no unauthorised personnel find themselves in danger zones.

P R O T E C T I V E M E A S U R E S A N D C O D E O F C O N D U C T

• Regular gas tightness tests are necessary to prove the technical gas tightness of the components (see maintenance plan).

• The gas tightness test is to be documented in the operating logbook.

PIPELINES:

1. Separate pipeline section from biogas system with valves or blanks. 2. Flush pipeline section with air. Interrupt the flush as soon as the measured CH4 concentration falls

below a value of 1% on a sustained basis. 3. Close off pipeline section with valves or blanks. 4. Pressurise pipeline with compressed air (approx. 2.5 bar). 5. Observe pressure over a longer period (30 min per m3 of pipeline volume, minimum 30 min) and

document in a log. 6. The pressure test has been successful if the pressure does not drop more than 50 mbar within the

observation period. 7. Next flush the pipeline with biogas (observe explosion protection) and start up again.

SEDIMENTATION PIT:

1. The sedimentation pit should be checked for tightness during normal operation; the operating pressure is around 2 – 5 mbar.

2. Spray all visible concrete surfaces (top edge, wall to pipe basement and electrical equipment room, wall to pump shaft) with foaming agent.

3. Check manhole cover and pipeline gaps in particular. 4. If a leak is established, the sedimentation pit should be shut down (see operating instructions) and

the leak should be fixed.

GAS STORAGE ON FERMENTER ROOF:

1. The gas storage should be filled with biogas up to the maximum fill level and an overpressure of approx. 2.5 mbar.

2. The feeding and discharging pipelines should be closed manually (in the DCS). 3. The flexible connection pieces including flange connections, screw joints and welds should be

sprayed with foaming agent. 4. The biogas overpressure should not drop more than 0.5 mbar within an observation period of at

least 30 minutes.

5. If a leak is established, the gas storage should be emptied and the leak should be fixed.

DOUBLE DIAPHRAGM STORAGE:

1. The double diaphragm storage should be checked for tightness during operation; the operating pressure is around 1 – 4 mbar.

2. The clamp connection of the diaphragm to the top of the container should be sprayed with foaming agent. The apron must also be lifted up.

3. The air between the inner diaphragm and the outer diaphragm should be checked regularly for methane content and the air above the measuring pipe should be analysed with the hand-held measuring device. The methane content may not exceed a concentration of 1%.

DRY FERMENTER:

1. The dry fermenter tightness should be checked regularly with foaming agent. 2. The tightness test is performed during normal operation; the operating pressure is around 2 – 5

mbar. 3. The door side (incl. door) and the rear side (incl. flange connections) should be checked in particular.

ACTIVATED CARBON FILTER:

See activated carbon filter operating instructions.

C O N D U C T I N C A S E O F E M E R G E N C Y

Emergency number

112

• Warn persons in the area not involved and ask them to leave the area surrounding the system immediately.

• Switch off gas treatment system. • If necessary, switch off upstream and downstream system components properly. • Determine source of hazard and fix properly.

M A I N T E N A N C E A N D D I S P O S A L

11 W O R K I N G I N S T R U C T I O N S


SEDIMENTATION PIT R I S K S T O H U M A N S A N D T H E E N V I R O N M E N T

WORKPLACE / AREA: Sedimentation pit

The sedimentation pit is always pressurised with gas; there is a health hazard and an explosion hazard from biogas:

• Danger to life from hydrogen sulphide (H2S): Caution: H2S paralyses the olfactory nerves; higher concentrations are no longer noticed

• Danger of suffocation from carbon dioxide (CO2) and a lack of oxygen (O2) • Explosion hazard from methane (CH4) • Health hazard from ammonia (NH3) • Biogas leakage at the exhaust opening

Observe biogas operating instructions.

WARNING: Hydrogen sulphide and carbon dioxide are denser than air. Therefore a measurement should always be taken at the lowest point at which gas can collect.


• The mobile gas detector should be carried along for operations.

BEFORE OPENING THE SEDIMENTATION PIT:

• Close feeding water pipes. • Close gas balance line (in the pipe basement) and secure again with lock. • Unlock and open venting pipe. • Connect and switch on the mobile air fan with hose to the air inlet. • Unlock and open air inlet. • Measure the exhaust composition with a mobile gas detector at the measuring pipe on the

exhaust pipe. • Open manhole cover once released.

WORK ON OR IN THE SEDIMENTATION PIT:

• Continue conduct as in operating instructions: "Working on opening containers exposed to biogas."

• If the sedimentation pit is being emptied: switch off sedimentation pit pumps. • When entering the sedimentation pit observe the operating instructions: "Working on

containers exposed to biogas."

BEFORE CLOSING THE SEDIMENTATION PIT:

• Fill sedimentation pit with industrial water up to upper edge of the dam.

CLOSING THE SEDIMENTATION PIT:

• Close and lock manhole cover. • Switch off and disconnect mobile air fan. • Close air inlet and exhaust openings and secure with lock. • Open gas balance line and once opened relock again. • Switch on sedimentation pit pumps. • Open feeding water pipes.

AFTER CLOSING THE SEDIMENTATION PIT:

• Check tightness of manhole cover by spraying with a foaming agent.

NOTE: • The manual gas detector (hand-held measuring device) and • The mobile gas detector

should be maintained and checked as stated in the device documentation. Maintenance of the devices should be documented in the operating logbook. Before using the devices, they should undergo a function test. Ensure that the devices are completely charged and connected properly. Carry out an inspection of the external condition and display function of the devices. The devices have to be calibrated if necessary.

Wear personal protective equipment: antistatic protective clothing (e.g. cotton), hand protection (tailored to hazardous substances), protective helmet, full eye protection, footwear with non-slip soles and steel caps, as required, ex-protected lamps, non-sparking tools, mobile gas detector

C O N D U C T I N C A S E O F E M E R G E N C Y Fire brigade

112

• Clear and close off danger zone, inform superiors. • Eliminate source of danger if possible without risk. • Biogas is combustible. Developing fire: use portable fire extinguisher. In case of fire, do not

extinguish before the leak is sealed because there is a risk of an explosive cloud developing! In case of fire, hazardous vapours are formed (e.g. carbon monoxide)! In case of fire, cool containers in the area with water spray! Danger of bursting and exploding if heated!

• Follow alarm, escape and rescue plans. Alert fire brigade.

F I R S T A I D

Emergency

number 112

FOR ANY FIRST AID MEASURE: Ensure self-protection, medical treatment. Immediate lifesaving actions such as "recovery position", "CPR", "anti-shock measures" must be carried out according to the situation. Cover wounds with sterile material. Ensure physical rest. Protect against heat loss. Inform a doctor (refer to possible hydrogen sulphide poisoning).

AFTER INHALATION:

Move the casualty out of the danger zone. Provide fresh air supply via inhalation of fresh air or ventilation. Use respiratory equipment (self-protection). Dosage, type of application and other treatment to be arranged by company doctor!

D I S P O S A L • Waste substances must be collected and disposed of in a professional manner.



Overpressure/underpressure safety devices

R I S K S T O H U M A N S A N D T H E E N V I R O N M E N T

Risks due to explosive atmosphere:

• Atex zone 2 applies in the area 3m around the safety devices. In the case of insufficient fill levels in the safety devices or in situations of overpressure, biogas is released into the atmosphere; an explosive atmosphere may result.

Health hazard (biogas):

• Biogas may be released in the area around the safety devices. Observe biogas operating instructions.


• The overpressure/underpressure safety devices should be checked daily. • The liquid fill levels must always be within the stated green range; adjust fill level if necessary.

In the case of frost:

• The overpressure/underpressure safety devices should be filled with at least 30% glycol. • Check fill levels as above. • Underpressure safety devices should be checked manually for stability. • The concentration of glycol, particularly in the underpressure safety device, may drop if

condensation forms (colour of liquid becomes lighter), therefore the underpressure safety device should be filled regularly with new antifreeze.

• The antifreeze filling is to be documented in the operating logbook. C O N D U C T I N C A S E O F E M E R G E N C Y

Emergency number

112

• If the safety device has frozen, the affected container must be taken out of operation.

M A I N T E N A N C E / D I S P O S A L

• Maintenance only in compliance with the manufacturer's instructions.

FERTILIZER, LANDFILL- AND BIOGAS system... · • Risk of death and acute severe poisoning by hydrogen sulfide (H2S): Caution: H2S paralyzes the olfactory nerve, higher concentrations

Documents