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All content, including technical writing,SOPs, graphic design, photography, layout,
and Process and InstrumentDiagrams created by Bob J. Kaplan
Norflux
Landfill Gas Plant
Authors Note - L7-I Bob Kaplan can produce 3D, Isometric, Plan View, or Exploded Drawings of Equipment and Buildings
Practices and Procedures Manual
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NorfluxNote Norflux is a fictitious company created only for use in this document.
L7-i.com Landfill Gas Plant
Standard Operating Procedures
SOP-LFGP-01
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NorfluxPower Generation
NORFLUX LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: BJ K-Trial3.2
REV: May 21, 2003 PREAMBLE Page i
Important Document Information
The contents of this document do not represent any existing facility.
This material may NOT be used without the written permission of the author Bob J . Kaplan
These pages have two main purposes, first, to present an example that can beused as a template for up-and-coming Training Manual Writers and second, togive prospective clients of Bob Kaplan an example of his work on a mid-rangedocumentation project (see project scale level notes on web page).
This manual is an example of a mid-complexity project that stopped short ofincluding section quizzes and a certification exam. For that reason it might moreproperly be considered as an advanced SOP manual rather than a full-blowntraining manual.
The process and instrument diagrams included in the appendix are an advancedoption and were created as a separate project.
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NorfluxPower Generation
NORFLUX LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: BJ K-Trial3.2
REV: May 21, 2003 PREAMBLE Page ii
These procedures are reviewed annually each November.
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NorfluxPower Generation
NORFLUX LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: BJ K-Trial3.2
REV: May 21, 2003 PREAMBLE Page iii
SOP Change Submission Sheet
Page # Change Request
123456789
SOP Change Control Sheet
Date Description Page Approval
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NorfluxPower Generation
NORFLUX LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: BJ K-Trial3.2
REV: May 21, 2003 PREAMBLE Page iv
SOP Locations
Three hard copies of this SOP manual are officially maintained. They are located as follows:
L7-i.com Landfill Gas Plant Office / Control Room L7-i.com Landfill Gas Plant File Area Generating Station Services Managers Office
Approval must be obtained before removing a copy from its assigned location. The documentmust be returned within seven days. The copy located in the Landfill Gas Plant Office & ControlRoom area must NEVER be removed.
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NorfluxPower Generation
NORFLUX LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: BJ K-Trial3.2
REV: May 21, 2003 PREAMBLE Page v
Initial Sign off and Validations
Reviewed By Bob Kaplan Date: May 08, 2008
Approved By Bob Kaplan Date: May 24, 2008
Operations Approval No Date: N/A
Title: Landfill Gas Plant Standard Operating Procedures
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 1
1.0 IntroductionThe following procedures are a guide for startup, shutdown, and routine operation of the L7-i.comLandfill Gas Plant. They are intended to help insure the safe and efficient execution of theseactivities. Changing conditions may dictate the alteration of certain steps; however, theprocedures as described in this document have stood the test of time in that they maximize safetyand minimize downtime.
Stylized Process and Instrument Diagram
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 2
Creators Note to Potential Customers and/or Employers
Note This page is not part of the Training Manual SOP.
The previous sketch, labeled Stylized Process and Instrument Diagram, is a synthesis of fiveseparate Process and Instrument Diagrams (P&ID).
This note has been included here to bring up important points regarding the utility of such asketch as well as the skills required to produce it.
The diagram, as well as the P&IDs it is based on, was produced from scratch by following andidentifying lines and equipment out in the field. The original image file is a vector graphic ratherthan a bitmapped graphic, which means that it can be enlarged to any size and printed withoutpixilation or any other loss of clarity. Such a sketch is perfect for mounting on a control room wallfor quick reference.
The drawing is the perfect backbone for use in a computer based training application. It can beanimated to show key process flows during different procedures. It was created using Corel Drawand can be saved in most other vector based graphics programs file format (AutoCAD, forexample).
This diagram has been singled out as it demonstrates the advantage of having someone like BobKaplan producing your training material. Bob is a Power Engineer with varied experience as aProcess Operator, Graphics Artist, Technical Writer, Internet Technician, and more. Skills fromeach of these fields were necessary to produce the desired outcome a functional and easy tofollow graphical summary of the entire process. The following is a rough breakdown of the skillsets.
Power Engineering skills were used to draw the P&IDs properly
Process Operator experience provides the experience to choose the appropriate content,ensuring that only the most important components were included to reduce clutter. Thismakes the sketch not only an excellent training aid, but also an invaluable reference toolfor use during process upsets and emergencies.
Technical Writer experience determined that the value of the sketch in helping to explainthe process was high enough to justify the additional time and expense used to create it.
Graphics Artist experience was needed to determine the most effective color scheme andplacement of components in the sketch - it also made sure that the proper drawingprogram was selected and that it was used in a quick and efficient manner.
Internet Technician experience was needed to determine the most effective way todeploy the sketch on a website or web based training program.
It is rare to find one person with all of the skill sets necessary to complete a USEABLE training
manual for industries such as Pulp and Paper, Oil and Gas, Petrochemical, and otherManufacturing sectors. It is rarer yet to find someone who also has significant experience increating software help files; user manuals; emergency procedures; computer based trainingmodules; business process analysis and documentation; QC manuals; FAQs; plant-site energydistribution analysis and documentation; web pages; and web applications. It is rare, but notimpossible; Bob Kaplan has all of this experience and more. Having all of these skills applied toyour training project ensures that you receive the best value and a quality outcome.
Bob Kaplan also has significant experience creating documentation in a team environment asboth team leader and as a valuable participant. Contact Bob at [email protected]
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 3
1.1 Process Overview
1.1.0 Main Process
Summary
Blowers, located in the Landfill Gas Plant (LFGP), apply suction to a network of methane richwells located throughout the L7-i.com Landfill. The blowers discharge into the initial gaspurification section that provides cool, dry and H2S free feed at low pressure to the main gascompressor(s). The compressor discharges into a 12-tray bubble cap contactor tower thatproduces high pressure dehydrated gas into the main sales line. The current end-use of the gasis to supplement natural gas usage at Norfluxs L7-i.com Generating Station.
Simplified Process Flow Diagram
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 4
Details of Main ProcessThe anaerobic decomposition of the organic waste component of the garbage buried in the landfillproduces Landfill gas - abbreviated as LFG. The gas is primarily composed of methane andcarbon dioxide; however, a small yet significant percentage of highly toxic compounds such ashydrogen sulphide and BTEX are also present. In the absence of a collection system, LFG canhave a significant negative impact on the environment by creating toxic conditions, offensiveodors, and causing stress to local vegetation. The gas also poses a significant explosive hazard.Not only does it make sense to properly dispose of the gas through incineration, but it alsobecomes a significant asset when its disposal generates electricity. It should be noted thatMethane gas is 21 times more potent than Carbon Dioxide as a greenhouse gas so it is importantto eliminate this contributer to global warming through the process of combustion.
LFG is collected in the L7-i.com landfill by a network of perforated wells and piping connected toa 14 main plant inlet line. A vacuum pressure of negative 1-2 psig (7-18 kPag) is applied to theinlet line, which in turn creates a constant suction on the entire collection system. Centrifugalblowers, located inside the plant, create the vacuum.
The LFG, saturated with water, discharges from the wells at temperatures typically around 60-90F (16-32C). As the water saturated gas flows towards the plant, it cools below its dew point,causing the water to condense throughout the collection system. Several strategically placedcondensate drains on the field flow-lines discharge most of the water back into the landfill refuse.
The remaining free water, as well as particulates composed of clay, soil, and fine refuse, areentrained with the LFG as it flows into the main plant inlet. In addition, other chemicals, in bothliquid and gaseous form enter the plant with the LFG. Portions of these additional chemicals arepotentially toxic, including hydrogen sulfide (H2S), and a combination of benzene, toluene, ethylbenzene, and xylene (BTEX).
CAUTION:
Every effort should be made to ensure that personnel do not come into direct contact with thesechemicals without adequate personal protective equipment. Potential pathways of exposureinclude inhalation, ingestion, and skin contact. Take appropriate safety precautions when thepossibility of contact exists.
Various plant safety related issues, practices, and procedures are beyond the scope of thisdocument. Refer to appropriate safety literature and always use safe trade practices.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 5
From the inlet line, LFG flows into the vertical hydro cyclone recirculating Inlet Separator (V-100).By design, V-100 removes almost all entrained water at inlet conditions and 80% of particulatesgreater than 10 micron in size. The vessel is equipped with a sight glass that indicates the liquid
level. When a level is detected, it is pumped out to the flare header by the manually operatedcentrifugal base pump (P-877).
Inlet Separator Piping Sketch
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 6
Gas leaving V-100 enters the main Blower Suction Header (H-804), which is a cylindricalhorizontal vessel equipped with a sight-glass and tie-in to the inlet separator pump. In the unlikely
event that a liquid slug passes overhead from V-100, it will collect in H-804; thus offering adegree of protection for the blowers.
Plant Inlet Piping
Three 75 hp Blowers (K-100, K-101, & K-102) draw a vacuum directly on the suction header, and
thus indirectly on the inlet separator, inlet header, and the entire landfill gas well network.Normally there are two blowers running, feeding one reciprocating compressor, but the plant PLChas flexibility to run one, two, or three blowers and one or two compressors depending on gasflow-rates into the plant. Each blower has a rated capacity of 1280 CFM. Three suction linebutterfly valves set the blower flow rates.
LFG discharges from the blowers at 1-7 psig (10-50 kPa). The compressing effect of theblowers imparts substantial heat to the gas, with temperatures of 160-175F (74-80C) beingtypical. The heated LFG is passed through the Pre-clean Gas / Glycol Heat Exchanger (HE-100)to increase efficiency through the compressor(s) and to aid in removing water. HE-100 is a twopass shell and tube heat exchanger equipped with stainless steel tubes. Gas flows through thetubes and cooled ethylene glycol circulates through the shell. HE-100's gas inlet PSV protectsboth it and other associated equipment from excess pressure.
Plant Inlet Header
Inlet Block Valve
Blower Suction hdr
Blower Suctions (3)
V-100 Outlet
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 7
Process Flow from Blower Suction Header to HE-100 - Sketch
NOTE:
All plant effluent sources liquids and gases are connected to the main flare header. Refer tothe Flare Effluent heading in this section for more detailed information.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 8
Cooled gas and condensed free liquids exit HE-100 and enter the Pre-clean Contactor Tower (V-110), the primary function of which is to remove hydrogen sulfide (H2S). It also functions as waterwash tower. V-110 is a packed vertical tower with H2S scavenger chemical injected into its upper
section. The H2S scavenging agent flows down the tower counter current to the uprising gasstream, absorbing H2S along the way. The scavenger is spent over time and must be replenishedon a daily basis. Enough fresh chemical is added to keep the sales gas concentration of H2Sbelow 15 ppm. Fresh water is also added daily. The water captures particulates from the gasstream and helps to keep the H2S scavenger chemical from forming hard deposits in the towerpacking. To prevent high viscosity liquids and particulates from building up in the base, the towerbottoms are periodically pumped off to the flare line.
After exiting the top of V-110, the gas stream enters the Pre-clean Knockout Separator (V-200), alarge knockout vessel that removes liquid mist particles from the gas stream before it enters thecompressors. The liquids that collect in the bottom of this vessel are also periodically pumped tothe flare header. In winter months, this may be necessary every two weeks.
V-110 Pre-clean Contactor / H2S Removerand V-200 Pre-clean Knockout
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 9
The sweet, dry, and cool gasleaving V-200 enters the inlet lines
of the J oy ReciprocatingCompressors (K-200 & K-210). Thetwo compressors are identical. Eachis a two-stage design withintercoolers between stages. Theyare driven by 300 HP electric motorsrotating at 585 RPM. Maximumdischarge operating pressure is 125psig (862 kPag); however, the plantpressure controllers PCV-100 andPCV-101 keep the dischargepressure at 90-97 psi (620-670kPa). The intercoolers tubes are
composed of stainless steel. Seeattachment section and the followingpage for more images of LFGCompressors.
The compressors are protected bythe following shutdown initiators:
High gas pressure High gas temperature Murphy high vibration High lube oil temperature Low lube oil level Low lube oil pressure
In addition, each compressor is equipped with a pressure relief valve on its discharge.
A recycle line equipped with a pneumatic control valve (FCV-831) allows thegas to be recycled from the compressor discharge back to HE-100 inlet. FCV-831 allows the compressor(s) to run without surging when the total plantthroughput is lower than the surge point. The controller takes its flow signalfrom the same differential pressure (DP) element that supplies the sales gaschart. The valve fails open. On manual control, 15 psi is closed, zero psi is wideopen, with 10 psi being the most common operational setting. When onautomatic, the controller is set to a desired DP; the valve opens when the DPdrops below the setpoint, increasing the flow through the compressor. Seeattachment section for more images of this system.
Gas Compressor
FC-831
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 10
Both LFG Compressors
East Side of East LFG Compressor
Panel Gauges
North High Pressure Cylinder
Low Pressure Cylinders
Gearbox / Drive
HP Outlet (North End)
South High Pressure Cylinder
Inlet Header
Inlet Header
Intercooler
Electric Motor Driver
North High Pres. Cyl
North Low Pres. Cyl
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 11
Upon discharging from the compressors, the gas enters the Gas/DEG Heat Exchanger (HE-300);a single pass shell and tube exchanger which acts to recover waste heat. Heat generated fromLFG compression passes from the shell side to the tube side where it is used to preheat the main
gas-dehydrating chemical, Diethylene Glycol (DEG), as part of the DEG regeneration cycle. Thisexchangers tubes have also been upgraded from carbon steel to stainless steel.
After giving off some of the heat of compression in HE-300, the gas is further cooled in HE-310.This heat exchanger is a two-pass shell and tube design with upgraded stainless steel tubes.Cooled ethylene glycol is circulated shell side and the LFG flow is tube side.
High Pressure Landfill Gas Coolers
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 12
From HE-310, the gas enters the base ofthe main contactor tower (V-300). This
tower has a bottom free water knockoutsection that collects water that hascondensed out of the gas stream due to theupstream cooling by the two heatexchangers. The water is dumped dailythrough a manual one-inch ball valve to theflare header.
The main section of the tower is equippedwith 12 bubble cap trays with stainless steelcaps on the bottom half trays. There is astainless steel mist pad at the top of thetower. Diethylene glycol (DEG) is circulated
through the tower starting at the top tray.The DEG absorbs water as it cascadesdown through each tray until it reaches thebottom chimney tray, at which point it issaturated with water. This Rich DEG isdischarged from the tower to continue itspath to the DEG regeneration system. Asthe LFG travels up through the tower itbecomes increasingly dry until it is almostcompletely dehydrated as it discharges offthe top.
The dry gas stream next enters a liquidknockout drum (V-330) that helps removedroplets of DEG carried overhead with theLFG. It also serves to catch liquid slugsduring system upsets. V-330 is alsoequipped with a demister, sight glass, and
drain.
To further remove fine liquid mist out of the gas, a coalescer filter pot (V-340) is installeddownstream of V-330. It holds six coalescer filter elements that must be changed periodically. It isalso equipped with two liquid drain off points - an upper and lower - that must be operatedperiodically. At a differential of 12 psi (84 kPa), the filter elements must be changed out or liquidswill re-entrain into the gas stream.
V-300 Main Dehydration Contactor
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 13
From V-340, the LFG is metered through an orifice plate differential flow meter where it iscontinuously charted on 7-day circular paper chart (FR-01). The static and differential pressures
(PR-01) as well as the gas temperature (TR-01) are recorded on this chart. From this data, anaccurate pressure and temperature compensated flow rate can be calculated using amathematical formula.
V-330 Overhead Knockout Pot, V-340 Coalescer Filter, and Pressure Controllers
Two Kimray backpressure controllers act in complimentary fashion to maintain plant and salesgas line pressure. PCV-100, which outlets to the sales gas line, is set at 75 psig. PCV-101, which
outlets to the flare line, is set at 90 psig. An example of how these PCVs work is as follows. If thesales gas line is blocked in, the plant pressure will rise and PCV-100 will open in an attempt tolower it by sending the gas to the sales gas line. Since it is blocked in, this will have no effect andthe pressure will continue to rise. When the pressure reaches 90 psig, the setpoint of PCV-101,PCV-101 will open up to the flare line; thus putting all of the plant gas flow to flare, whilecontrolling the plant pressure at 90 psig. When the sales gas line is unblocked, PCV-100 willbleed off plant pressure to it until it reaches its setpoint of 75 psig at which point it will begin tocontrol the pressure at the lower setpoint. Meanwhile, PCV-101 will close completely as the plantpressure will be well below its setpoint of 90 psig. Flaring will cease.
After metering the LFG, it exits the plant into an underground HDPE line and flows into the L7-i.com Generating Station Custody Transfer Station. A liquid knockout vessel that requiresoccasional emptying into a plastic storage tank is situated immediately inside the generating
station. The gas is metered through a turbine meter at the generating station. Water and H2Sconcentration, as well as the heating value, are also continuously monitored. From here, the gasflows into one or both of two boilers where it is burnt to generate steam.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 14
1.1.1 Diethylene Glycol (DEG) System
After absorbing water in Main Contactor Tower (V-300), the rich DEG, i.e. DEG saturated withwater, flows from the towers chimney tray through the Rich DEG filter (V-120) and the chimneytray level control valve (LCV-1) to the LFG/DEG heat exchanger (HE-300). In HE-300, the DEGabsorbs heat from the hot gas leaving the compressors. From HE-300, the DEG flows to the DEGRecovery Still (V-312) and its direct-fired reboiler (HE-311).
Diethylene Glycol (DEG) System
The DEG Recovery Still (V-312) or DEG Stripper is a relatively small distillation column withstainless steel pall packing rings. The packing functions as both separation media and amechanical defoamer. The upper portion of the column contains an integral reflux condensersection. A direct-fired reboiler (HE-311) provides the tower base-heat that drives the water, gas,
and light ends components up the column from the Rich DEG feed-tray at the base of the column.These lighter components flow overhead to the flare knockout tank; the heavier DEG componentfalls down to the reboiler.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 15
DEG Recovery Still (V-312) and Gas Fired Reboiler
Tower Packing: Pall Ring Gas Fired Reboiler West Side
The Reboiler section consists of two horizontal cylindrical vessels connected by a downcommerpipe. The lower vessel (V-311) contains dehydrated DEG (Lean DEG) and functions as anAccumulator, from which the DEG pump(s) take suction. The upper vessel contains the gasfired reboiler firetube element that heats the incoming Rich DEG (saturated) for distillation. Theliquid outlet side of the upper vessel is equipped with a weir that maintains the optimum levelrequired to ensure that the reboiler firetubes are always submerged - thus preventing overheatingof the firetubes. The mostly dry DEG in the top reboiler vessel overflows the weir and fallsthrough the downcommer to the lower vessel (accumulator). A small amount of dry LFG issparged into the accumulator to absorb any remaining moisture. The sparge gas travels upthrough the Reboiler/Still and overhead to the flare K/O tank with the rest of the tower overheads.
Burner Exhaust Stack
Internal Reflux Condenser Section
DEG Recover Still Main Section
Reboiler Firebox / Firetube Area
Pilot and Burner Access Port
Exhaust Stack
Lite-off Port
Burner Gas Piping
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 16
Gas Fired Reboiler (V-312) and Accumulator (V-311)
The reflux condenser, a double looped stainless steel tube, is located in the top section of thetower. It can be activated to condense a portion of the vapor so that it refluxes down the column;ultimately helping to purify the rising vapor before it exits the top of the tower. A sidestream ofcooled lean DEG is fed into the U-shaped condenser tube-side to provide the cooling. It has beenshown that this system is of limited benefit and is therefore seldom put in service.
Diethylene Glycol (DEG) Pumps and Piping
The lean DEG in the Accumulator flows to the suction of the Lean DEG pump(s) (P-100 & P-310)and is pumped through the DEG Cooling Tower (HE-330). The primary element in the cooling
Reboiler HE-312
Reboiler Si ht lass
Downcommer
Accumulator V-311
Lean DEG Outlet
To Cooling Tower
Coolin Tower B ass
From Cooling Tower
DEG Pumps
Cooled DEG to V-300
DEG from Accumulator
Pum Dischar e Line(s)
To Reflux Condenser
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 17
tower is a closed loop heat exchanger section, where the DEG passes through a bank of tubesthat transfer heat to the evaporating spray water falling counter to the air flow from the forceddraft fan at the tower base. The unevapourated spray water is collected at the base of the tower
and recirculated back to the spray nozzle headers by the spray water pump. Any water losses aremade up for by a flow of fresh water, controlled by an internal level float, from the external waterstorage tank. In the winter months, the cooling tower is operated dry with the spray watersystem deactivated and drained.
DEG Cooling Tower Spray Pump DEG Cooling Tower Forced DraftFan
External Water Storage Tank EG & DEG Cooling Towers
From the cooling tower the cooled lean DEG flows through a globe valve, which is used tomanually set the flow to V-300. The flow-rate is indicated locally by a turbine flow meter (FQ-05).Prior to starting the cycle again by flowing into the upper portion of the Main Contactor Tower (V-300), particulate matter is removed in the Lean DEG Filter (V-121).
LevelFloat
Access
SprayWaterPump
EG CT DEG CT
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 18
DEG Addition To V-300 Piping
A small carbon filter (V-350), used to remove liquid hydrocarbons, takes a slipstream flow of leanDEG from the filtered DEG entering the contactor tower. After passing through the filter, thisslipstream joins with the rich DEG as it enters the heat recovery exchanger (HE-300).
V-350 DEG Slipstream Carbon Filter
V-300 Main Contactor
DEG Globe Valve
DEG Flow Meter
Hat Tray Level Control
Lean DEG Pum s
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 19
1.1.2 Ethylene Glycol (EG) Cooling System
Plant cooling is supplied by a closed Ethylene Glycol (EG) circulation system, which cools thefollowing:
Compressor Intercoolers Compressor J acket Coolers Compressor Oil Coolers HE-100 Pre-clean Gas / Glycol Cooler HE-310 Contactor Precooler / Compressor Aftercooler
Cooled EG is pumped from the EG Receiver to a main header where it flows to the various heatexchangers to provide cooling, the heated EG outlet from these exchangers joins in a commonheader that flows to the EG Cooling Tower. The EG Cooling Tower is almost identical to the DEG
Cooling Tower as described previously. After being cooled in the tower, the EG flows back to theEG Receiver where it starts its cycle again.
During normal operation, the EG Receiver level is constant; any change in level indicates aproblem. An atmospheric vent at the top of the EG Receiver has been fitted with extension pipingthat outlets near the east side of HE-100. Any flow from this outlet indicates a cooler is leakinginto the EG system. A loss of level in the EG Receiver indicates either an EG piping leak or atube leak in HE-100, which operates at a process side pressure that is less than the EG system.
EG Circulation Pumps
H2S ScavengerStorage
West EG CircPump
East EG CircPump
HE-100 Pre-clean GasCooler
EG Inlet to HE-100 throttlevalve
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 20
1.1.3 Flare Effluent System
The majority of plant equipmentcapable of producing gas or liquideffluent has connections to themain flare header. This headerdischarges into the under-groundFlare Knockout Tank (V-420),located a few feet upstream of theflare-stack inlet. Liquidsaccumulate in V-420 while gasespass through to the 38 ft (12meter) flare stack (S-400) wherethey are incinerated.
V-420 is a double walled fiber-glass vessel with a retractableprobe installed between the innerand outer walls. This probe iswithdrawn regularly and checkedto ensure that it is completely dry.
The presence of liquid indicatesthat the inner hull is leaking, atwhich point the vessel would haveto be taken out of service forrepair. In this case, the vesselshould be shutdown and emptied
as soon as possible as a failure of the outer wall would release effluent to the environment.
The liquid level in V-420 is monitored daily. Its maximum capacity is 3,500 imp gallons (15,750liters). A liquid waste disposal company is called in to unload the tank when its level approachescapacity. The vessel is equipped with a 160 l/min Effluent Unloading Pump (P-120) that takessuction from the bottom of the tank and discharges to the unloading standpipe. The standpipe islocated near the southwest gate of the plant site. The liquid effluent is transported by tanker truckto a hazardous waste disposal facility.
The flarestack is equipped with a flame arrestor that prevents a backflash ignition in an area otherthan the top of the stack. An electric igniter on a one-minute timer ensures that the flame isreestablished quickly should it go out. A thermocouple installed near the windguard senses aflameout and triggers an alarm in the control room.
Refer to PID LFGP-05 from more information.
Flare Knockout Tank and Stack
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 21
Flare Stack Burning Full Flow of Plant Gas
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 22
2.0 Purpose
The primary purpose of this Standard Operating Procedure (SOP), and it component procedures,
is to assist plant personnel by providing systematic process operating instructions. It functions as
a reference for experienced personal and as a training aid for new operations staff.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 23
3.0 Definitions
BTEX Benzene, Toluene, Ethyl benzene, and Xylene volatile monoaromatichydrocarbons which are commonly found together in crude petroleum;they are also a component of crude landfill gas. Generally consideredharmful to health.
Bubble Cap Tray A bubble cap tray has riser or chimney fitted over each hole, and a capthat covers the riser. The cap is mounted so that there is a spacebetween riser and cap to allow the passage of vapor. Vapor rising throughthe chimney is directed downward by the cap, through slots on its side,and bubbles through the liquid on the tray.
Chimney Tray Dehydration Contactor - A circular metal plate, with a large chimney in thecenter used to collect liquid (rich DEG), without preventing upward flow ofvapor (wet LFG) from the feed zone below.
DEG Diethylene Glycol Absorption MaterialEG Ethylene Glycol - CoolantHDPE High Density Polyethylene Plastic piping materialLFGP Landfill Gas PlantLFG Landfill Gas in any stage from raw well gas to sales gasSOP Standard Operating Procedure
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 24
4.0 Responsibilities
Unless otherwise stated in a procedure step, the execution of all tasks described in this document
are the responsibility of the attending Gas Plant Operator; the designation of whom is at the
discretion of the LFGP Superintendent.
These procedures, and any future changes made to them, must be signed off by Landfill Gas
Plant Superintendent to be considered official.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 25
5.0 Routine Checks and Act ivi ties5.01 Daily
Step Key Points
1. Complete daily checks and logsheet round. Record readings on the daily run log whenappropriate.
2. Check for leaks throughout the plant. A LFG leak into the plant will first show up onthe PLC panel hydrocarbon sensor. Careshould be taken when first investigating ahigh hydrocarbon in ambient air alarm.
3. Check LFG analysis printout. Ensure that oxygen is well below 4 %. Look for signs of air leaks into system by
observing ratio of oxygen and nitrogen.
4. Check blower suction header pressure andtemperature
Pressure should be 8 to 20 kPa @ normalflow rate; pressure can fluctuate due to watermovement in the system.
5. Check Inlet Separator V-100 gage-glass level. Pump out if level at half glass. See Routineprocedures.
6. Check blower motor temperatures by briefly placinghand on housing.
It should be warm, not hot, to the touch.
7. Check blower discharge temperature ~75C
8. Blowers: Listen for abnormal sounds and check forexcessive vibration.
9. Check inboard blower bearing temperature by hand oruse gun thermometer.
Temperature should be ~150F (66C).Temperature greater than 175F (79C) isexcessive.
10. Add water and H2S scavenger chemical to V-110,pump level to flare header if required (every 3 weeks).
Water must be added immediately if no levelis shown on sight glass. In the winter, fill totop of sight glass. In summer, add scavenger
chemical and water to top of gauge glassplus 100 usg by meter. See SOP.
11. Check V-110 Inlet temperature and adjust HE-100 EGinlet valve as required to maintain 18-22 C
When V-110 inlet temperature drops below18C an undesirably large amount of waterwill condense in tower.
EG valve is sensitive, start by moving itabout one cm than make moves of 1/10 cmat a time.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 26
Step Key Points
12. Check blower discharge pressure and temperature
gages located near V-110.
Normal Temp: 65 - 85 C
Normal Pressure: 10 40 kPa
13. Check V-200 level and pump to flare when greater than glass.
See routine procedures.
14. Check glycol pump discharge temperature. Note on logsheet, investigate if high.
15. Check inside water tank level. When external water tank is out of service forwinter, the internal tank must be filled bycalling a water truck in. Truck should becalled in for next day when level is
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 27
Step Key Points
25. Check that lean DEG flow is set at 510 litters/minute.Adjust globe valve as required.
26. Check reboiler is full. Due to outlet weir, this level will be constant.
27. Check accumulator level, add DEG as required. Should show at bottom of sight glass.
28. Check Reboiler temperature
29. Check Stripping tower overhead temperature. Normal: 70 100 deg C
30. Check DEG filter differential pressure and changefilters as required (see routine procedure).
DP of 15 psi indicates time to change filters.
31. Check V-330 Contactor K/O pot level. Dump to pail as required, see routine
procedure.
32. Check Coalescer differential pressure and sightglasses.
DP: 10-12 psi - time to change, see SOP. Dump liquid as required. See SOP.
33. Check level in External Water Tank, fill from hydrant ifapproaching tank (summer only).
Open hydrant valve slowly. Normallyrequired daily. Daily usage: ~1/2 tank
34. Ensure that cooling tower belts are in good shape, andat proper tension and not squealing.
35. Check level in cooling tower basins. Ensure that floats are operating properly.
36. Ensure that flare ignitor is operating ~once per minute.
37. Dip Flare Tank level and arrange for unloading ifrequired.
Unload at 180 cm.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 28
5.02 Weekly
Step Key Points
1. Clean up piping with pressure washer (summer monthsonly)
2. Dump water from plant air compressor receiver tankevery two weeks.
3. Change sales gas circular chart.
4. Pump V-110 level to flare using bottom suction valveevery 3 weeks.
See SOP.
Sales Gas Seven Day Circular Chart Plant Air Compressor Receiver Tank
BlowdownValve
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 29
5.03 Other Routine Checks
Step Key Points
1. Drain Reboiler secondary containment vessel asrequired especially after heavy rain.
Shovel out snow if excessive. Use tiger torch to thaw water ice in winter if
required.
2. Grease various equipment bearings every 2000operating hours as follows:
Blower motor bearing - 30 shots Inboard blower bearing 30 shots Non- rubber blower couplings located under shroud
- 15 shots
Blower outboard bearing 15 shots Glycol pumps 15 shots Cooling Tower 15 shots DEG pumps 15 shots
The following can be greased while running:
Blower motor bearings Blower inboard bearing
The following bearings require that the unit beshutdown prior to being greased:
Blower outboard Blower coupling
Use Chevron SRI-2 grease Mark hour meters with next service due
number.
3. Wash floor as required or at least once per month(except in winter).
4. Inspect V-100 Inlet Separator on a yearly basis. Remove six inch access hand hole and cleanout sludge by hand.
5. Stroke both cooling tower louvers when preparing forwinter.
6. Check Flare Knockout Tank for leaks once / month.Use standby man.
Carefully remove leak detection dip stick andcheck for liquid. Use extreme caution andfollow safe practices when entering flare pit.
7. Clean reboiler burner annually and adjust air ratiocontrol disk / regulator.
8. Check reboiler cycling time on a regular basis. Thepreferred cycle is 15 minutes off and 45 minutes on.
If the reboiler is cycling more frequently, theburner flame can be adjusted down bylowering the burner pressure. Burner
pressure is governed by a regulator andshould be kept between 8 and 15 PSI.
9. Add DEG to system when required. 1/3 of a barrel every one or two weeks orwhen Accumulator sight glass shows lessthan inch.
10. Add a litre of antifoam to system every three to fourweeks or as required.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 30
Step Key Points
11. Calibrate GC when required See SOP
12. Bake out GC when there is not longer space betweencurve bottoms.
Caution, incorrect Bake Out canpermanently damage GC. See SOP.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 31
5.1 Routine Procedures5.1.1 Purging Liquid from Inlet Separator
Step Key Points
1. Open pump suction valve to Separator Base.
2. Open pump discharge to flare header
3. Start pump. Pump should gain suction within minute. System under vacuum
4. Run pump for hour or until separator is empty ofliquid
If pump has difficulty gaining suction, cleanY strainer on suction line. Due to systembeing under vacuum, the strainer will haveto be isolated, disassembled, and cleanedby hand.
Note: Vessel should be pumped out when level reaches glass on sight glass
V-100 Inlet Separator Base Pump and Piping
V-100 Base Suction Valve
Recirculation Valve
V-100 Base Pump
V-100 Discharge Piping to Flare
Suction Line Strainer
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 32
5.1.2 Daily H2S Scavenger and H2O Addition to V-110
Step Key Points
1. Stop circulating pump.
2. Line up pump suction valves to draw from H2SScavenger chemical tank.
Switch from normal V-110 circulating suctionline 2nd from bottom.
3. Line up pump discharge valves to allow flow throughmeter to V-110.
4. Start Pump and add H2S scavenger. Run pump until 4 gallons scavengerchemical has been added according tometer.
5. Stop pump.
6. Line up pump suction to draw from indoor water tank.
7. Start pump and add H2O. Add water to a maximum of 150 USG asdetermined by V-110 level sight glass andambient temperature. Max amount is basedon ambient temperature of approx. 30 deg C;during extremely cold periods, no wateraddition is required.
8. Stop pump.
9. Line up pump for normal circulation. Suction from second level outlet on V-110,discharge unchanged.
Meter not required. Pressure gage in service
10. Start pump. Discharge pressure should increase.
NOTE: Loss of circulation on V-110 for greater than 1 hour will result in high H2S in sales gas.High H2S levels could force generating station to stop LFG gas usage.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 33
V-110 Base Piping
V-110 Sight Glass / H2S Scavenger Tank H2S Scav. Tank / V-110 Suction Lines
Normal Suction
Pump-out Suction
Flow Meter
Discharge Pressure
Base/Circulation Pump
Backup Pump
V-110
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 34
5.1.3 Purging Liquid from V-200
Step Key Points
1. Shutdown H2S scavenger circulation pump and closeV-110 suction and discharge valves.
2. Line up the pump suction to draw from V-200 and thepump discharge to flow to flare header
3. Start pump and run pump for 20 minutes
4. Stop pump and put system back into service as V-110circulation pump.
Entire procedure should take less than 1hour to prevent H2S levels in sales gasbecoming excessive.
NOTE: Vessel should be pumped out when sight glass indicates glass. On average, this willtake about one month to build up; however, liquid accumulation rate is inversely related toambient temperature i.e. Liquid will accumulate faster during cold weather.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 35
5.1.4 Changing Lean/Rich DEG Filters
Step Key Points
1. Open filter bypass valve.
2. Close filter inlet and outlet valves.
3. Open bleed valve and depressurise filter.
4. Remove filter top.
5. Remove dirty filter elements to rack and allow to drainover barrel.
Used filters should be allowed to drain intobarrel for two weeks.
They should then be disposed of in a
Hazardous Material bin (45 gallon drum withoverpack).6. Exercise internal bypass mechanism to ensure proper
functionality. Liquid in barrel should be disposed of by
adding back to DEG.
7. Insert new filter elements.
8. Install filter cover.
9. Slowly open filter inlet valve and fill vessel with DEG.
10. When filter is full, close bleed valve.
11. Open filter outlet valve.
12. Close filter bypass valve.
NOTES: Filters should be changed when differential pressure reaches 15 psi.
Filters contain an internal spring loaded disk that automatically bypasses the filtermaterial when a high differential pressure develops.
Used drained filters must be disposed of in accordance with the LFGP HazardousWaste Disposal Document.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 36
5.1.5 Purging liquid from V-330 K/O Pot and V-340 Coalescer Filter base.
Step Key Points
1. Put bucket at K/O pot blowdown line outlet.
2. Slowly open blowdown valve.
3. Bleed liquid into bucket. Be aware that gas in solution breaks out likefoam, this can extend the time taken to executeprocedure by up to hour.
4. Close blowdown valve when liquid stops flowing.
5. Empty bucket using DEG addition system.
NOTE: Liquid should be drained from vessels as required, usually every three months for V-330and monthly for V-340.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 37
Changing Coalescer Filter Material
Step Key Points
1. Prepare vessel for filter change as follows:a. Block in inlet valveb. Block in outlet valvec. Open bleed valve
2. Loosen cover bolts slowly and remove cover.
3. Remove coalescer filter agent media.
4. Replace with fresh media.
5. Reassemble filter.
NOTE: The plant must be shutdown to replace filter material. This is required when differentialpressure gage reads 10 12 PSI (8 to 12 months.)
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 38
Adding Fresh DEG to System
Step Key Points
1. Place unloading hose in DEG barrel.
2. Connect free end of hose to DEG pump suctionstrainer blowdown coupling.
3. Open strainer blowdown valve. Strainer blowdown valve: V958.
4. Slowly close suction valve from Accumulator (V-311). Accumulator suction valve: V948.
5. When required amount of fresh DEG has been added,
open suction valve from Accumulator (V-311) and closestrainer blowdown valve.
Observe liquid level in barrel to determine
when enough DEG has been added. Strainer blowdown valve: V958. Accumulator suction valve: V948.
6. Disconnect hose from strainer hose coupling. Drain DEG in hose back to barrel.
NOTE: Fresh DEG is added when Reboiler Accumulator level shows inch on bottom sightglass; 2-3 times per month depending on operating conditions.
Reboiler Accumulator Outlet to DEG Pumps
V-311 DEG Accumulator
Reboiler Burner Main Gas
Reboiler Burner Pilot Gas
Suction Valve to DEG Drums V958
Accumulator Suction Valve V948
DEG Pum (s) Suction Line
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 39
Unloading Flare Knockout Tank
NOTE: The flare knockout tank is emptied when the dip gauge reads 180 cm or greater.
CAUTION: A high level in the flare K/O tank can result in liquid carryover and ignition at the top offlare stack spreading burning liquid around base of flare stack.
Step Key Points
1. Call liquid waste disposal company, currently Sellers Normally they are called the day before theyare required; however, they can arrive inapproximately one hour if requiredimmediately.
2. When truck arrives, open southwest gate and unlockcamlock plug on flare K/O tank unloading point (locatedimmediately south of SW gate).
The truck will unload K/O tank while parkedat the side of the road.
3. Connect truck unloading line to K/O tank unloadingpoint and connect grounding cable.
Responsibility: Truck Driver
4. Start unloading pump. The pump switch is located on light standardpost near flare stack.
5. Stop unloading pump when informed by truck driverthat unloading is complete.
The truck driver will monitor the unloadingprocess and inform LFGP operator to stoppump when truck tank volume stops
increasing or when truck tank is full. Unloading normally takes an hour and 15minutes +/- 5 minutes.
6. Disconnect truck unloading line from K/O tankunloading point.
Responsibility: Truck Driver.
7. Replace and lock Camlock plug / close gate.
8. Ensure that waste shipping manifest is properlycompleted.
Refer to previously completed manifests asan example.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 40
Preparing Cooling Towers for Winter
Step Key Points
1. Shutdown spray water pumps.
2. Drain tower sumps and piping by breaking unions asrequired.
3. Drain external water tank.
4. Disconnect and drain water addition line at hydrant.
5. Remove, drain, and store hydrant flow meter. The flow meter costs $3000 and will bedestroyed if allowed to freeze.
NOTE: During colder months, the Cooling Tower is run dry with the fans running but no spraywater. The towers must be prepared for winter operation as soon freezing temperatures areforecast usually mid October.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 41
Lighting Reboiler
Step Key Points
1. Shut gas to pilot and main burner.
2. Allow firebox to purge via natural draft for 3 minutes.
3. Light diesel soaked ignitor and insert it three feet intoburner port.
4. Open pilot valve and slowly open main burner gasvalve (15 seconds from closed to open).
Listen for flame ignition Check flame after removing igniter
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 42
Plant GC Calibration
Step Key Points
1. Measure peaks for O2, N2, and methane using mousecursor and record values.
2. From the menu, choose Method Peak table.
3. Enter channel A RT values in the appropriate fieldsfor O2, N2, and methane.
4. Choose Save from the menu. Run Calibration gas through GC to verifyaccuracy.
Note:
After a power failure the remote button must be pressed on the GC prior to restarting EZChrom.Printer power must also be cycled.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 43
Plant GC Bakeout Procedure
Step Key Points1. Stop run Press Esc
2. Choose Method Open from menu. Selectbakeman from list and click okay.
Loads the column bakeout parameters
3. Choose Instrument, Send current method from themenu.
Sends the method to the GC.
4. Choose Instrument, Receive current method fromthe menu.
Sends the method back from the GC.
5. Choose Instrument, Status from the menu and
ensure that the following maximum temperatures arenot exceeded: A - 180 deg C B - 160 deg C
Exceeding these temperatures will destroy
the respective column.
Once temperatures have peaked safely, theyno longer need to be monitored continuously.
6. Allow columns to bake out for 1 hours minimum.
7. Stop run by pressing Esc
8. Choose Method Open from menu. Select cblfg1zfrom list and click okay.
Loads normal GC parameters.
9. Choose Instrument, Send current method from the
menu.
Sends the method to the GC.
10. Choose Instrument, Receive current method fromthe menu.
Sends the method back from the GC.
11. Choose Instrument, Status from the menu andobserve as temperatures cool to normal values:
A - 65 deg C B - 50 deg C
The columns must be at normaltemperatures before an accurate GC runcan take place.
12. Select start to begin normal operation. GC should start a run immediately.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 44
5.2.0 Plant Startup ProcedureNOTE: The following procedure assumes that no piping or vessels have been taken apart andthat the plant has been left in standby mode.
Step Key Points
1. Manually shut off various electrical switches located outin the plant as follows:
All three blowers Both compressors Both DEG circ pumps
Switches only work in manual mode not inauto mode.
It is important to position the switches to offon the blowers, compressors, and DEGcirculating pumps before pushing the plant
reset button or the plant will start up in anuncontrolled manner.
2. Ensure the main gas suction valves to the plant arewide open.
V800 and V802
3. Ensure all blower suction valves are open. V806, V807, & V808
4. Push plant reset button and place compressor runselection switch in appropriate position.
Compressor Run selector switch settings:
1 West compressor2 East compressor1&2 Both compressors
5. Place the attended/unattended selector switch in theattended mode.
6. Start the main ethylene glycol circulating pump West pump
7. Manually prelube the compressor(s). Rotate hand crank the required number oftimes. This ensures that the secondprelubing is quick after the blowers arestarted.
8. Start the blowers. Normally two are run, the other left as aspare.
9. Manually prelube the compressor(s)a second time.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 45
Step Key Points
10. Start the compressor(s) This must be done within 45 seconds ofturning on the blowers or a timer on the PLC
will shut down the blowers-This shutdownfeature is in the program logic because theblowers will sustain internal damage if theyare dead headed for any length of time.
If you exceed the above-mentioned 45seconds, you will have to start over again(manual switches turned off of blowers andcompressors and plant reset button pushedinside plant office).
11. Check the panel-mounted gauges for normal pressurebuildup on both left and right cylinders.
A closed downstream valve may causeexcess pressure on either gage.
12. Check the oil pressure gauge to ensure normal functionof lubrication system.
Normal oil pressure for cold unit is up to 80psig. Once unit has come up to operating
temperature, normal oil pressure is from 35to 50 psig.
13. Line up and start the DEG circulating pump. P-100 or P-310
14. Set the DEG flow rate using the manual globe valve to5 10 liters/minute as indicated by FQ-5.
V933 - located next to Halliburton liquid flowmeter (FQ-5).
15. Check the gas flow chart to ensure that gas pressure isbuilding up normally.
With the sales gas line blocked in at powerstation, the gas should be at ~90 psig andflaring.
16. Ensure that Kimray backpressure control valve isoperating correctly controlling pressure by divertingsales gas to flare.
Ensure that Kimray controller keeps gaspressure well below 100 psig.
Excess pressure (over 100 psig) will pop thesales gas line PSV - an undesirable situationbecause this PSV does not always reseatand therefore must be sent out forrecertification. This would cause substantialplant downtime.
17. After five minutes, call generating station and instruct
them to start taking gas.
Monitor the gas sales chart to ensure that the
generating station is in fact taking the fullflow of gas-It is normal for them take five orten minutes to accept full volumes of gas.
18. Start the cooling tower air fans and spray water pumps. Summertime only.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 46
Step Key Points
19. Walk through the plant again to ensure all equipment isheating up normally and that there are no problems
(normal gauge pressures and no abnormal vibrationsor noises).
20. Check chromatograph readings to ensure that oxygenconcentration is below 1.5 %.
Oxygen readings in excess of 1.5% are abnormaland should be corrected immediately.
DANGERIf oxygen exceeds 4%, the plant must be shut down immediately. In this case, press the manualESD button on PLC panel. The source of air ingression must be identified and corrected beforeattempting to bring the plant online. Failure to adhere to this procedure could result in a plant
explosion.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 47
NOTE:
Plant Startup With Purging - If any vessels or piping are taken apart when the plant is down thenthe plant must be properly purged of any oxygen that may have found its way into the gas stream.
This also includes valve changes on the compressors. To purge air out the plant piping open themanual flare valves on the compressors before starting them. Also, open the manual contactordrain valve; which is also tied in to the flare system. To ensure good displacement of the foreignair these valves should be open to flare for at least five minutes before they can be closed. Seeattachment section 6.6 for photo of east compressor purge outlet piping.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 48
5.3.0 Plant Shutdown Procedure
Note: In case of an emergency, the plant can quickly be shutdown by pressing the ESD buttonon the PLC panel.
Step Key Points
1. Contact Generating Station and inform them ofimpending shutdown.
412-3281 or 412-3360
2. Shutdown blowers by moving local switches to the offposition.
The compressor will automatically shutdown.
3. Shutdown DEG pump.
4. Shutdown spray water pumps and fans on bothCooling Towers.
5. During warm weather, shutdown EG circulation pumpafter a minimum of hour. During cold weather, leaveEG circulating for duration of shutdown.
It is important to leave EG circulating for aperiod after plant shutdown to preventthermal shock to the compressor(s).
EG is left circulating in winter to help preventfreeze-ups.
6. In winter, drain liquids from all major vessels. V-100, V-110, V200, & V-300`
7. Reset PLC and press acknowledge button.
Note: The main LFG inlet valve is left open to help prevent air ingress to process over time due tochanges in barometric pressure.
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 49
6.0 Attachments6.1 Typical Bubble Cap
6.2 Typical Chimney Tray
6.3 Plant Air Compressor Photos
Air Compressor & Receiver Air Compressor Close-up
Oil LevelSight
Glass
PressureGageReceiver
Motor
Filter
Blowdown
Cylinders
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 50
6.4 West Landfill Gas Compressor Photo
West LFG Compressor
6.5 V-100 Inlet Separator and Blowers Photo
V-100 and Blowers
LP Cyl Inlets
Mur h Vib Switch
Crankcase Oil Level
HP Cyl
HP Cyl
LP Cyl LP Cyl
Oil Hand Crank
Oil Cooler
Blower Outlet Header
LFG Blowers (3)
V-100 Inlet Separator
V-100 Base Pum
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 51
6.6 LFG Compressor Discharge and Purge Outlet Valves
East LFG Compressor Discharge Piping
6.7 LFG Compressor Recycle Line Block and Check Valves
Main LFG Outlet Line from Compressors
Compressor Disch Valve
Hi h Disch Pressure Tri
Pur e Outlet Valve
High Disch. Temp Trip
Com ressor Disch Line
Recycle Line
Rec cle Check Valve
Rec cle Block Valve
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 52
6.8 Supplemental Images
V-300 Main Contactor Hat Tray Draw-off V-330 OH K/O Pot & V-340 Coalescer
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 53
Inside Water Tank Flare Stack KO Tank Pump Pit
Addition Line
Pum Unloadin Line
Di Check
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 54
7.0 Forms7.01 Daily Logsheet Example
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NorfluxPower Generation
L7-i LANDFILL GAS PLANT
Standard Operating Procedures
NUMBER: RJ K-025
REV: May 21, 2003 LFGP SOP Page 55
7.02 Spill Report Checkl ist
Chemical & Oil Spill Report Checklist
Date: NORFLUX Report#
Alberta Environmental Protection File #
Operating Supervisor
Initial Information Part A
Reported by
Name Phone #
Location of spill area:Address
Cause of Spill
Time of report
Amount of Chemical or Oil Spilled (liters)
Additional Information Par t B
Alberta Environment Informed? Yes No
Time Inspectors Name
Alberta Environments Comments
How was cleanup done?
Soil analysis required? Yes No
Results ppm Senior Sustainable Development Engineer notified
Site clean up date Time
Faxed NORFLUX Environmental Affairs Time
Date Fax # Phone #
Report compiled by
File Closed? Approved by
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L7-i Landfill Gas Plant SOP PIDs
Rev. May 25, 2007 56
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Rev. May 25, 2007 57
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Rev. May 25, 2007 58
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Rev. May 25, 2007 59
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Rev. May 25, 2007 60
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L7-i Landfill Gas Plant SOP PIDsNorflux
Environmental PracticesExample of Environmental Checklist
The following environmental related checks must be performed at the assigned frequency:
Inspected Item Type of Inspection Purpose of Check Frequency Inspection Results
Plantsite Walk around-Visual &
Audible
Prevention of gas or
liquid releases toair/ground
Daily Leaks- Yes/No
Flarestack IgnitionSystem
Manual Switch-Audible &Visual
Prevention of unburntgases to atmosphere
Weekly Working-Yes/No
Flarestack IgnitionSystem
Professional ElectricalInspection
Prevention of unburntgases to atmosphere
Yearly Defects Requiring Fiup Y/N
Flare Knockout TankInterwall
Visual Inspection ofDipstick
Prevention of liquidsrelease to soil
Weekly Dipstick Dry & CleanY/N
Flare Knockout Tank 24 Hour Visual Leak Test Prevention of liquidsrelease to soil
Yearly Gauge Stick ReadingChange Y/N
Flare line 8" 900Disch. Elbow
Visual Inspection ofinterior pipe wall
Prevention of gas orliquid releases toair/ground
Yearly Excessive corrosionY/N
CondensateWastewater
Independent LaboratoryAnalysis
Proper Handling, Storageand Shipping
Yearly Report Submitted toAlberta Environ.
Flarestack Influent Independent LaboratoryAnalysis
Prevention of excessiveemissions to air
Yearly Report Submitted toAlberta Environ.
Solid HazardousWaste
Independent LaboratoryAnalysis
Proper Handling, Storageand Shipping
Yearly Proper CharacterizatY/N
Proposed Future Checks
Inspected Item Type of Inspection Purpose of Check Frequency Inspection Results
Flare line MonitoringWell
Visual Prevention of liquidsrelease to soil
Monthly? Well Dry Y/N
Flare line CathodicProtection Electrical Tester Prevention of liquidsrelease to soil Monthly? Functioning Y/N