DRYER & COGEN PQS TRAINING PROGRAM · 4. Certificate of Completion • Operators that the Board...

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DRYER & COGEN PQS TRAINING PROGRAM

PURPOSE

The Dryer & Cogen PQS Training Program was established to guide staff through their journey of becoming a fully-trained Operator at the Encina Wastewater Pollution Control Facility (EWPCF).

GENERAL

It is the Encina Wastewater Authority’s (EWA’s) goal to provide training programs which increase the knowledge and skills of employees while enhancing opportunities for advancement within the organization. The Dryer & Cogen PQS provides Operators with uniform knowledge of the more complex treatment areas at the EWPCF, which require a higher skill level.

PROCEDURE

1. Enrollment • The PQS Coordinator will issue the Operator a Dryer & Cogen PQS start date and

Training Guide. • This PQS must be finished during the Operator’s rotation in the dryer building.

2. PQS Training Guide

• The Operator is responsible for the completion of the program. Each question in the Training Guide needs to be reviewed with their mentor or supervisor. If the mentor or supervisor feels the operator has a good understanding of the subject matter, they will sign the question as being completed.

• The Operator can personalize each section in the Training Guide with notes, acronyms, pictures, or anything which will help them understand the concept.

• The Operator is responsible for their Training Guide, which is necessary to document successful completion of the PQS and is a valuable tool for future reference.

• If the Operator is uncertain of where to find information relevant to the PQS questions, they should ask their mentor or supervisor for assistance.

• As each section is signed as completed, the Operator is to bring the Guide to the PQS Coordinator who will update their performance tracking status.

• Once the Training Guide is completed, the Operator is ready to advance to the Board Review.

3. Board Review • Operator Board Reviews will be conducted by the Heat Dryer and Cogeneration

Supervisors. • The Board Review will be approximately three hours in length.

DRYER & COGEN PROFESSIONAL QUALIFICATION STANDARDS

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• The Operator will be verbally questioned about the heat dryer and cogeneration facilities and procedures to determine their level of comprehension. The questions will be operational (troubleshooting and reaction methods), mechanical (type of equipment) and theoretical (how the process works).

• To pass the Board Review, an Operator must score 70% or higher. Both Supervisors must be in agreement on the recommendation for the Operator to pass.

• If a passing score is not obtained, the Operator will be given additional time to review the material before repeating the Board Review.

• Board Review results should be given to the PQS Coordinator for filing.

4. Certificate of Completion • Operators that pass the Board Review will receive a signed Certificate of Completion

from the Chief Plant Operator. • A copy of the Certificate of Completion will be given to the PQS Coordinator for filing. • Upon successful completion, the Operator may be eligible for promotion to an Operator

II (if appropriate).


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TABLE OF CONTENTS

1) COGENERATION SAFETY 4

2) COGENERATION OPERATIONS 7

3) HEAT DRYER SAFETY 13

4) HEAT DRYER OPERATIONS

a) POLYMER BLENDING 24

b) CENTRIFUGE 27

c) MIXER 31

d) RECYCLE BIN 33

e) FURNACE / DRUM 35

f) DRYER TRAIN 38

g) CONDENSER / VENTURI SCRUBBER 41

h) PELLET COOLER / TRANSPORTER 43

i) PRODUCT STORAGE SILO FACILITIES 46

j) FUGITIVE DUST COLLECTION 49

k) REGENERATIVE THERMAL OXIDIZER (RTO) 50

l) SCADA CONTROLS 52

m) PRODUCT QUALITY 56


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Cogeneration Safety

1. Why is it important to wear hearing protection in the engine room?

_____________________________________ (Signature and Date)

2. What is an appropriate course of action to take if there is a fire in the engine room?

_____________________________________ Signature and Date)

3. You are tasked with locking out an engine. Detail the steps to be taken and where you can find them.


4. What is the purpose of the rubber mats in front of the switchgear?


5. What is the minimum space required to be kept clear of objects in front of an electrical panel?



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6. You are told by your supervisor to secure the natural gas to the cogeneration building. Where is the isolation valve located?


7. You are told by your supervisor to secure the mixed gas to the cogeneration building. Where is the isolation valve located?


8. What would you do if you observed a contractor working in the engine room without proper safety gear?


9. Explain the steps you would take to mitigate an oil spill in the engine room?


10. Why is it important to have cleaning gear stored in a central location?



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11. How many fire extinguishers are assigned to Cogen and where are they located?


12. Explain the different types of fire extinguishers located in the cogeneration building and what they should be used for?



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Cogeneration Operations

1. Explain the energized path of both the MA and MB breakers.


2. What gases do the engines utilize for cylinder ignition?


3. Explain the aeration and agitation air MCC configurations.


4. How many Kilowatts can each engine produce and what are they rated for?


5. What functions do the generators serve?



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6. Explain how the Eclipse System works.


7. Discuss how the mixed gas blowers operate.


8. Explain engine resizing.


9. What agency governs engine emissions?


10. What is the purpose of the UPS system?

_____________________________________ (Signature and date)


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11. Why do we want to keep KW import less than 1,050 KW and total plant load under 2,250KW?


12. What is the BTU value of digester gas?


13. What is the BTU value of natural gas?


14. Why do we have a waste gas burner?


15. What hazards are present in the Cogeneration building?



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16. Explain the process of starting an engine.


17. Explain how to shut down an engine.


18. Explain the block heater system and how to operate it.


19. Explain how the tie breakers work.


20. Explain the heat loop system and the different heat exchangers.



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21. How do you fill and drain the main heat loop system?


22. What’s the purpose of the heat loop expansion tanks?


23. Practical exercise: demonstrate how to start and stop aeration air blowers.


24. Practical exercise: demonstrate going islanded.

_____________________________________ (Signature and date)

25. Practical exercise: demonstrate returning to the grid.


26. Practical exercise: demonstrate lock out / tag out of an engine.



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27. What is the purpose of load shed and how does it work?


28. What is EMP and why is it important?


29. What is the frequency by which SDG&E captures import data and how does this affect the process of separating and returning to the grid?


30. What is the APCD permitted daily and annual limit for natural gas and digester gas consumption for the four Cogeneration engines?


31. What is the APCD permitted annual limit for digester gas to the waste gas flare?



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Heat Dryer Safety 1. When dealing with digested sludge what are some of the hazards?


2. What PPE should you use when handling digested sludge?


3. What are the symptoms of skin exposure to centrifuge polymer?


4. If you see polymer spilled on the floor, what steps should you take to mitigate the problem?


5. What are the methods for cleaning up a polymer spill?



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6. How should polymer totes be stored?


7. What is the flash point of Camelina coating oil?

_____________________________________

(Signature and Date)

8. Under transport information in the SDS, is Camelina oil a dangerous product?


9. What are the hazards of liquid nitrogen?


10. What is the proper PPE to use when bleeding off the nitrogen tank?



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11. Where are the SDS sheets located for pellet coating oil?


12. When you hear the term bulk chemicals, what does that refer to?


13. Why is it necessary to “spot” the bulk chemical delivery driver during staging?


14. When the bulk chemical delivery driver is done staging and setting up to offload the product, what should you confirm the driver is wearing?


15. One of the most important steps in the bulk delivery process is to ask to see the SDS. Why?



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16. If the product delivery hose leaks at any time, what must you first do as the spotter?


17. If there is a mishap during a delivery and a spill occurs, you should first notify your supervisor or a manager and make a public announcement over the PA system. What should you do next?


18. If an employee gets doused by a chemical in the bulk storage area, what steps should you take to aid the victim?


19. If you see a chemical leaking from a pipe, is fixing it right away the proper thing to do? If not why?


20. Whose responsibility is it to keep a chemical spill contained?



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21. Before a biosolids hauler leaves the EWPCF, what should they be given in case an accident occurs resulting in a biosolids spill?


22. SOP 32 Biosolids Spill Response Plan is written for whom?


23. What do you do if you want to inspect the RTO media?


24. Is it okay to open the hatch with the RTO running? Explain


25. When working the heat dryer night shift, what piece of equipment should be part of your uniform?



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26. Practical exercise: demonstrate the three point contact for climbing onto and off of equipment?


27. When parking the trailer jockey, what needs to be done before walking away from the truck? Explain why.


28. Before backing up a trailer with the trailer jockey, what must you ensure is in place? Explain.


29. When driving forward with the tractor trailer, what must you ensure is in place?


30. What side of the truck is the blind side? Explain the hazards associated with the blind side.



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31. Can you walk under the trailer to get to the other side? Why or why not?


32. Before you fill a trailer, what must you do to ensure that loading of the vessel will be safe?


33. Explain what you should do if you hear an air leak with the tractor trailer?


34. If you experience dust while loading into a trailer, what should you do?


35. When cleaning the oil nozzles, what PPE should be utilized?



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36. What is happening when you hear a nitrogen purge? What calls for it to purge?


37. What are the concerns when a hard shutdown happens to the dryer?


38. What tends to accumulate on the walls of the recycle bin and why is it a concern?


39. What should you do with the recycle bin if the dryer goes down and is off for over two hours?


40. Why is the burst disc on the fugitive baghouses and bucket elevators important?



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41. Explain the hazards associated with a bucket elevator and what safety device is used.


42. Explain why a grounded vacuum is used to clean the dryer building.

_____________________________________ (Signature and Date) 43. After using the dust vacuum, what should you do and why?


44. Explain the requirements that must be met before using the scissor lift or the aerial lift.


45. Where are the vacuum attachments stored?

_____________________________________



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46. How do you clean the hand rails in the dryer building?


47. Once per day, what must you do with stored totes?

_____________________________________ (Signature and Date) 48. Before recycle bin seeding operations, what must the operator check with the seed totes before the

forklift picks them up for use?


49. When the tote bags are emptied, what must be done with the empty bags?


50. What are three types of fire hazards associated with heat drying operations?



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51. What are four possible mechanisms for self-heating of pellets?


52. What are four methods of preventing a dust explosion?



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Polymer Blending

1. When should you last batch the centrifuge polymer system and why is it important?


2. During heat dryer shutdowns, why is it important to flush the polymer lines?


3. Practical exercise: demonstrate a proper polymer drawdown.


4. Practical exercise: demonstrate the steps you would take in response to a low water pressure alarm.


5. Practical exercise: demonstrate how to use the polymer system with a polymer tote.



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6. What is the purpose of having age tanks and why are they important?


7. What is the purpose of the recirculation pump for the bulk polymer tanks and why is it important?


8. What is the purpose of dilution water and when is it used?


9. Practical exercise: demonstrate how to rotate feeder/blenders.


10. While operating the dryer, you hear an audible alarm from the polymer blending system. What are some possible conditions for an audible alarm and what is your first course of action when responding?



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11. Practical exercise: demonstrate how to make a change in polymer solution using the feeder/blender.

_____________________________________ (Signature and Date) 12. Practical exercise: calculate the age time for the current polymer feed rate.



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Centrifuge

1. Explain how a centrifuge works.


2. When should you CIP a centrifuge and why is it important?


3. What is centrate and where does it go from the centrifuge?


4. Why do we have flush water in the centrate line and what is the appropriate amount of flow?


5. Practical exercise: demonstrate how to use all injection points for the centrifuge polymer.



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6. Explain the difference between “load mode” and “differential mode” on the centrifuges.


7. You notice that the centrate going to DAFT #1 is very foamy. What could be causing this?


8. Before starting a centrifuge, what are all the things you should check?


9. During the startup of the centrifuge the load rapidly increases. What could be happening and what steps can you take?


10. If during shutdown you receive a “flush flow alarm”, what happened and how do you fix it?



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11. Explain the purpose of the dump valves.


12. Define bridging. What are some indications it may be occurring?


13. Explain the purpose of the lube pump.


14. Practical exercise: demonstrate how to pump out a cake bin to DAFT #1.


15. The cake pump pressure is increasing even though the lube pump shows running. What should you do?



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16. You receive a low load alarm for the cake pump. What could be happening and what should you do?


17. How do you rotate cake bins?


18. Practical exercise: demonstrate how to lock out and tag a centrifuge.



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Mixer

1. Identify the internal components of the mixer and explain how they work.


2. When operating the dryer you receive a “High Load” alarm on the mixer. What conditions could trigger this alarm and what should you do?


3. Describe the consistency of proper mixed material.


4. Explain what the dry/wet ratio is and why it is important.


5. Explain what problems may occur if the mixed material sent to the dryer is too wet. What if it is too dry?



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6. Describe how the mixer door interlocks work.



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Recycle Bin

1. What is the appropriate operating level range for the recycle bin and why is this important?


2. When operating the dryer, you notice the level in the recycle bin has been slowly increasing throughout the day. What is most likely happening and how can you fix it?


3. What can you do if the recycle bin temperature is getting too high?


4. What steps do you take to seed the recycle bin?


5. What steps do you take to empty the recycle bin?



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6. If there are high levels of CO in the recycle bin, what must you do?



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Furnace / Drum

1. Practical exercise: demonstrate how to start the furnace flame.


2. You receive a “BMP Burner Flame Failure” alarm. How do you reset this alarm?


3. Explain the air/fuel ratio in the furnace and how it affects the operation of the heat dryer.


4. You notice that the furnace is struggling to maintain a negative pressure. What could be causing this and how can you fix it?


5. Without receiving any alarms you notice that your wet feed group has shut off. What can cause this and how do you restart it?



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6. What is the minimum outlet temperature necessary to make Class A pellets? _____________________________________ (Signature and Date)

7. What can you do if you receive a “High Drum Load” alarm and what can cause this alarm?


8. Where are the quench and false load valves located within the furnace/dryer? Explain their purpose.


9. Drum outlet temperature is an indicator of the final product dryness. If the dryer outlet temperature is consistently unstable, what are the two possible causes for this?


10. What is the maximum permissible oxygen concentration in the heat dryer while it is in operation and why is this important?



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11. You notice a large amount of water being discharged from the furnace drain while the dryer is in operation. Explain where this water is coming from and what action should be taken.

_____________________________________ (Signature and Date) 12. Practical exercise: demonstrate how to switch the furnace supply fuel from natural gas to a blend of

natural and digester gas. _____________________________________ (Signature and Date)


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Dryer Train

1. Explain the solids and process air loops.


2. How does the shaker work and where does the discharge from each chute go?


3. What adjustments can be made on the crusher and how does it affect the overall process?


4. Explain the diverter valve and what causes it to open and close.


5. You receive a “High O2” alarm on the dryer. What will happen if it continues to rise and what can you do to lower the O2 concentration?



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6. Explain the purpose of the Main I.D. Fan and how adjusting it affects the dryer train.


7. Explain how a rotary air lock valve works.


8. What is the evaporative capacity of the dryer and what affects its efficiency?


9. The dryer system can be divided into six process areas. What are they?


10. Why must the dryer system always be operated with a negative pressure?



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11. Explain how material is conveyed by a screw conveyor and by a bucket elevator.



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Condenser / Venturi

1. Explain the internal components of the condenser and how it works.


2. What can you do if you receive a “High Return Air Temperature” alarm?


3. You notice the venturi fan is at 100% and the furnace is not maintaining negative pressure. What is happening and what can you do to solve it?


4. What is the purpose of the cyclones in the venturi and how do they work?


5. What is the proper water flow to the condenser and venturi? How do changes in flow affect the overall dryer performance?



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6. Practical exercise: demonstrate how to set the proper water flow for the condenser and venturi. _____________________________________ (Signature and Date)


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Pellet Cooler / Transporter

1. How does the pellet cooler work?

_____________________________________


2. You receive a “High Level” alarm for the pellet cooler. What do you do?

_____________________________________


3. You receive a “Fill Cycle Too Long” alarm. What do you do?

_____________________________________


4. Practical exercise: demonstrate how to purge the pellet cooler. Explain why and when to do this.

_____________________________________


5. Practical exercise: demonstrate how to initiate a manual transport from the pellet cooler.

_____________________________________



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6. You receive a zero speed fault on the final bucket elevator that will not reset. What has caused this and what should you do now?


7. Why is it important to begin with an empty silo and remove the first few transports from the storage silo after dryer start up?


8. What is the proper water flow to the pellet cooler? How do changes in flow affect the pellet?


9. Specify the order of the valve sequencing required to fill and purge the pellet transporter.


10. Describe the internal components of the pellet cooler and how it works to cool incoming pellets.



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11. What is the optimum temperature for pellets exiting the pellet cooler? What is too high a temperature and why?


12. What are the pros and cons of pneumatic conveyance systems compared with belt and screw conveyors?



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Product Storage Silo Facilities

1. Practical exercise: demonstrate how to “bleed nitrogen” to a silo.


2. You receive a zero speed fault on the screw conveyor while off-loading pellets. What are some of the possible causes and how do you reset this alarm?


3. What is the max temperature in the silo that can be off-loaded into tote sacks?


4. Explain the placement of the temperature probes in the silos and what information they provide.


5. Explain how the baghouse works and why it is important?



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6. What is the maximum temperature pellets can be stored in the silo before operator intervention is required? What is the maximum temperature the silo was designed to withstand?


7. What are the four process safety systems associated with the storage silos?


8. What is the purpose of coating granular biosolids and why is it important?


9. What steps must be performed before a trailer is loaded?


10. While loading a trailer, you notice a large amount of dust escaping the chute. What may be the problem and what action do you take to correct it?



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11. How often should the coating nozzles be inspected and how would you verify the coating oil system is working correctly?



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Fugitive Dust Collector

1. Where does the Fugitive Dust Collector (FDC) pull dust from?


2. Why is it important to regularly verify flow for the FDC sample points?


3. You feel no vacuum at one of the FDC sample points. What is wrong and what can you do to fix it?


4. While operating the dryer, you receive a high differential alarm for the baghouse. Why is this important and what should you do?


5. While performing your daily rounds, you hear the baghouse fan shut off with no audible alarm. What may be happening and what should you do?



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Regenerative Thermal Oxidizer (RTO)

1. Practical exercise: demonstrate how to initiate an Auto Start on the RTO.


2. What is the minimum operating temperature of the RTO and why is this important?


3. Before being able to Auto-Start the dryer, what steps must you complete with the RTO?


4. After a media flush, what is the best way to start the RTO and why is it important?


5. You notice that the exhaust fan is running at 60Hz. What can this mean and should you be concerned?



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6. Explain the path of airflow through the RTO, including the purge cycle.



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SCADA Controls

1. You notice very small pellets in the mixer. Why is this problematic and what steps can you take to remedy this?


2. Explain the correlation between the recycle material metering screw speed, the dry/wet ratio and the cake pump speed?


3. Practical exercise: demonstrate how adjusting the air/fuel ratio affects the dryer train.


4. Practical exercise: demonstrate how adjusting the dry/wet ratio affects the mix.


5. Practical exercise: demonstrate how to use the automated valves to purge nitrogen to the silos and recycle bin.



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6. What are the different color codes associated with the dryer equipment (dark blue, light blue, green, red, and yellow)?


7. After completing the Pre-Start Inspection Checksheet, list the steps taken to start up the Drum Drying System (DDS).


8. After Auto Start of the DDS is complete, how do you initiate Flame On?


9. If the flame does not ignite after initiation, what are some problems that could exist?


10. What should the set points on the Wet Feed Control be at start up?



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11. The DDS is up and running. List the set points the system looks for in order to call on the Wet Feed Group?

_____________________________________


12. After ignition, how long does it take for the natural gas control valve to fully start to modulate? _____________________________________ (Signature and Date)

13. The Wet Feed Group has just been called on, but the cake pump did not start with the rest of the equipment. Why?


14. You just received a “Low% O2 “alarm in the DDS. List some of the causes and what you would do to correct the alarm condition.


15. Practical exercise: demonstrate how to trend the drum inlet and outlet temperatures for the previous 24hrs.



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16. You notice the furnace pressure is occasionally reading a positive value. List some reasons for this problem and how you can correct them.



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Product Quality

1. What are SGN and UI? Why are they important?


2. Practical exercise: demonstrate how to run a sieve analysis on Pure Green product.


3. Calculate the wet feed cake rate for the current dryer operation.


4. Calculate the pellet production rate for the current dryer operation.


5. Calculate the current water evaporation rate.



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6. What is the minimum capture rate the centrifuges are operated at and why is this important?


7. Complete the following decision diagram.

2 Hour Product %TS Test

%TS > __ No Further

action required

Check Mixer %TS

YES

%TS > __ NO

NO

%TS > __ %TS < __

________ dry/wet ratio

________ dry/wet ratio

NO

YES YES

NO

YES

Resample Product %TS

after 1hr

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DRYER & COGEN PQS TRAINING PROGRAM · 4. Certificate of Completion • Operators that the Board...

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