Gas Plant Land Fill

All content, including technical writing, SOPs, graphic design, photography, layout, and Process and Instrument Diagrams
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
Norflux Note Norflux is a fictitious company created only for use in this document. L7-i.com Landfill Gas Plant
Standard Operating Procedures
SOP-LFGP-01
Norflux
Power Generation
NORFLUX LANDFILL GAS PLANT
NUMBER: BJK-Trial3.2
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 be used as a template for up-and-coming Training Manual Writers and second, to give prospective clients of Bob Kaplan an example of his work on a mid-range documentation project (see project scale level notes on web page). This manual is an example of a mid-complexity project that stopped short of including section quizzes and a certification exam. For that reason it might more properly be considered as an advanced SOP manual rather than a full-blown training manual. The process and instrument diagrams included in the appendix are an advanced option and were created as a separate project.
REV: May 21, 2003
PREAMBLE
Page i
Norflux
Power Generation
These procedures are reviewed annually each November.
REV: May 21, 2003
PREAMBLE
Page ii
Norflux
Power Generation
Page # 1 2 3 4 5 6 7 8 9
SOP Change Submission Sheet

Change Request
SOP Change Control Sheet

Date Description Page Approval
REV: May 21, 2003
PREAMBLE
Page iii
Norflux
Power Generation
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 document must be returned within seven days. The copy located in the Landfill Gas Plant Office & Control Room area must NEVER be removed.
REV: May 21, 2003
PREAMBLE
Page iv
Norflux
Power Generation
Initial Sign off and Validations

Reviewed By Approved By Operations Approval Title: Bob Kaplan Bob Kaplan No Date: Date: Date: May 08, 2008 May 24, 2008 N/A
Landfill Gas Plant Standard Operating Procedures
REV: May 21, 2003
PREAMBLE
Page v
Norflux
Power Generation
L7-i LANDFILL GAS PLANT
NUMBER: RJK-025
1.0 Introduction
The following procedures are a guide for startup, shutdown, and routine operation of the L7-i.com Landfill Gas Plant. They are intended to help insure the safe and efficient execution of these activities. Changing conditions may dictate the alteration of certain steps; however, the procedures as described in this document have stood the test of time in that they maximize safety and minimize downtime.
Stylized Process and Instrument Diagram
REV: May 21, 2003
LFGP SOP
Page 1
Norflux
Power Generation
NUMBER: RJK-025
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 five separate Process and Instrument Diagrams (P&ID). This note has been included here to bring up important points regarding the utility of such a sketch 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 and identifying lines and equipment out in the field. The original image file is a vector graphic rather than a bitmapped graphic, which means that it can be enlarged to any size and printed without pixilation or any other loss of clarity. Such a sketch is perfect for mounting on a control room wall for quick reference. The drawing is the perfect backbone for use in a computer based training application. It can be animated to show key process flows during different procedures. It was created using Corel Draw and can be saved in most other vector based graphics programs file format (AutoCAD, for example). This diagram has been singled out as it demonstrates the advantage of having someone like Bob Kaplan producing your training material. Bob is a Power Engineer with varied experience as a Process Operator, Graphics Artist, Technical Writer, Internet Technician, and more. Skills from each of these fields were necessary to produce the desired outcome a functional and easy to follow graphical summary of the entire process. The following is a rough breakdown of the skill sets. 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. This makes the sketch not only an excellent training aid, but also an invaluable reference tool for use during process upsets and emergencies. Technical Writer experience determined that the value of the sketch in helping to explain the 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 and placement of components in the sketch - it also made sure that the proper drawing program was selected and that it was used in a quick and efficient manner. Internet Technician experience was needed to determine the most effective way to deploy 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 other Manufacturing sectors. It is rarer yet to find someone who also has significant experience in creating software help files; user manuals; emergency procedures; computer based training modules; business process analysis and documentation; QC manuals; FAQs; plant-site energy distribution analysis and documentation; web pages; and web applications. It is rare, but not impossible; Bob Kaplan has all of this experience and more. Having all of these skills applied to your 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 as both team leader and as a valuable participant. Contact Bob at rjkaplan@l7-i.com REV: May 21, 2003 LFGP SOP Page 2
Norflux
Power Generation
1.1.0 Main Process
NUMBER: RJK-025
1.1 Process Overview
Summary
Blowers, located in the Landfill Gas Plant (LFGP), apply suction to a network of methane rich wells located throughout the L7-i.com Landfill. The blowers discharge into the initial gas purification section that provides cool, dry and H2S free feed at low pressure to the main gas compressor(s). The compressor discharges into a 12-tray bubble cap contactor tower that produces high pressure dehydrated gas into the main sales line. The current end-use of the gas is to supplement natural gas usage at Norfluxs L7-i.com Generating Station.
Simplified Process Flow Diagram
REV: May 21, 2003
LFGP SOP
Page 3
Norflux
Power Generation
NUMBER: RJK-025
Details of Main Process

The anaerobic decomposition of the organic waste component of the garbage buried in the landfill produces Landfill gas - abbreviated as LFG. The gas is primarily composed of methane and carbon dioxide; however, a small yet significant percentage of highly toxic compounds such as hydrogen sulphide and BTEX are also present. In the absence of a collection system, LFG can have a significant negative impact on the environment by creating toxic conditions, offensive odors, 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 also becomes a significant asset when its disposal generates electricity. It should be noted that Methane gas is 21 times more potent than Carbon Dioxide as a greenhouse gas so it is important to 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 to a 14 main plant inlet line. A vacuum pressure of negative 1-2 psig (7-18 kPag) is applied to the inlet line, which in turn creates a constant suction on the entire collection system. Centrifugal blowers, located inside the plant, create the vacuum. The LFG, saturated with water, discharges from the wells at temperatures typically around 6090F (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 placed condensate 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, are entrained with the LFG as it flows into the main plant inlet. In addition, other chemicals, in both liquid and gaseous form enter the plant with the LFG. Portions of these additional chemicals are potentially toxic, including hydrogen sulfide (H2S), and a combination of benzene, toluene, ethyl benzene, and xylene (BTEX). CAUTION: Every effort should be made to ensure that personnel do not come into direct contact with these chemicals without adequate personal protective equipment. Potential pathways of exposure include inhalation, ingestion, and skin contact. Take appropriate safety precautions when the possibility of contact exists. Various plant safety related issues, practices, and procedures are beyond the scope of this document. Refer to appropriate safety literature and always use safe trade practices.
REV: May 21, 2003
LFGP SOP
Page 4
Norflux
Power Generation
NUMBER: RJK-025
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 particulates greater 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 operated centrifugal base pump (P-877).
Inlet Separator Piping Sketch
REV: May 21, 2003
LFGP SOP
Page 5
Norflux
Power Generation
NUMBER: RJK-025
Gas leaving V-100 enters the main Blower Suction Header (H-804), which is a cylindrical horizontal 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 a degree of protection for the blowers.
Blower Suctions (3)
Plant Inlet Header
Inlet Block Valve
Blower Suction hdr
V-100 Outlet
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 PLC has flexibility to run one, two, or three blowers and one or two compressors depending on gas flow-rates into the plant. Each blower has a rated capacity of 1280 CFM. Three suction line butterfly valves set the blower flow rates. LFG discharges from the blowers at 1-7 psig (10-50 kPa). The compressing effect of the blowers imparts substantial heat to the gas, with temperatures of 160-175F (74-80C) being typical. 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 two pass shell and tube heat exchanger equipped with stainless steel tubes. Gas flows through the tubes and cooled ethylene glycol circulates through the shell. HE-100's gas inlet PSV protects both it and other associated equipment from excess pressure.
REV: May 21, 2003
LFGP SOP
Page 6
Norflux
Power Generation
NUMBER: RJK-025
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 to the Flare Effluent heading in this section for more detailed information.
REV: May 21, 2003
LFGP SOP
Page 7
Norflux
Power Generation
NUMBER: RJK-025
Cooled gas and condensed free liquids exit HE-100 and enter the Pre-clean Contactor Tower (V110), the primary function of which is to remove hydrogen sulfide (H2S). It also functions as water wash 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 gas stream, absorbing H2S along the way. The scavenger is spent over time and must be replenished on a daily basis. Enough fresh chemical is added to keep the sales gas concentration of H2S below 15 ppm. Fresh water is also added daily. The water captures particulates from the gas stream and helps to keep the H2S scavenger chemical from forming hard deposits in the tower packing. To prevent high viscosity liquids and particulates from building up in the base, the tower bottoms 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), a large knockout vessel that removes liquid mist particles from the gas stream before it enters the compressors. The liquids that collect in the bottom of this vessel are also periodically pumped to the flare header. In winter months, this may be necessary every two weeks.
V-110 Pre-clean Contactor / H2S Remover and V-200 Pre-clean Knockout
REV: May 21, 2003
LFGP SOP
Page 8
Norflux
Power Generation
NUMBER: RJK-025
The sweet, dry, and cool gas leaving V-200 enters the inlet lines of the Joy Reciprocating Compressors (K-200 & K-210). The two compressors are identical. Each is a two-stage design with intercoolers between stages. They are driven by 300 HP electric motors rotating at 585 RPM. Maximum discharge operating pressure is 125 psig (862 kPag); however, the plant pressure controllers PCV-100 and PCV-101 keep the discharge pressure at 90-97 psi (620-670 kPa). The intercoolers tubes are composed of stainless steel. See attachment section and the following page for more images of LFG Compressors. The compressors are protected by the following shutdown initiators:
Gas Compressor
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 the gas to be recycled from the compressor discharge back to HE-100 inlet. FCV831 allows the compressor(s) to run without surging when the total plant throughput is lower than the surge point. The controller takes its flow signal from the same differential pressure (DP) element that supplies the sales gas chart. The valve fails open. On manual control, 15 psi is closed, zero psi is wide open, with 10 psi being the most common operational setting. When on automatic, the controller is set to a desired DP; the valve opens when the DP drops below the setpoint, increasing the flow through the compressor. See attachment section for more images of this system.
FC-831
REV: May 21, 2003
LFGP SOP
Page 9
Norflux
Power Generation
NUMBER: RJK-025
Inlet Header
Panel Gauges
Low Pressure Cylinders
North High Pressure Cylinder
Gearbox / Drive
HP Outlet (North End)
South High Pressure Cylinder
East Side of East LFG Compressor
Inlet Header
North Low Pres. Cyl
Intercooler
North High Pres. Cyl
Electric Motor Driver
Both LFG Compressors
REV: May 21, 2003
LFGP SOP
Page 10
Norflux
Power Generation
NUMBER: RJK-025
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 from LFG 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. This exchangers 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
REV: May 21, 2003
LFGP SOP
Page 11
Norflux
Power Generation
NUMBER: RJK-025
From HE-310, the gas enters the base of the main contactor tower (V-300). This tower has a bottom free water knockout section that collects water that has condensed out of the gas stream due to the upstream cooling by the two heat exchangers. The water is dumped daily through a manual one-inch ball valve to the flare header. The main section of the tower is equipped with 12 bubble cap trays with stainless steel caps on the bottom half trays. There is a stainless steel mist pad at the top of the tower. Diethylene glycol (DEG) is circulated through the tower starting at the top tray. The DEG absorbs water as it cascades down through each tray until it reaches the bottom chimney tray, at which point it is saturated with water. This Rich DEG is discharged from the tower to continue its path to the DEG regeneration system. As the LFG travels up through the tower it becomes increasingly dry until it is almost completely dehydrated as it discharges off the top. The dry gas stream next enters a liquid knockout drum (V-330) that helps remove droplets of DEG carried overhead with the LFG. It also serves to catch liquid slugs during system upsets. V-330 is also equipped with a demister, sight glass, and
V-300 Main Dehydration Contactor drain.
To further remove fine liquid mist out of the gas, a coalescer filter pot (V-340) is installed downstream of V-330. It holds six coalescer filter elements that must be changed periodically. It is also equipped with two liquid drain off points - an upper and lower - that must be operated periodically. At a differential of 12 psi (84 kPa), the filter elements must be changed out or liquids will re-entrain into the gas stream.
REV: May 21, 2003
LFGP SOP
Page 12
Norflux
Power Generation
NUMBER: RJK-025
From V-340, the LFG is metered through an orifice plate differential flow meter where it is continuously 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, an accurate pressure and temperature compensated flow rate can be calculated using a mathematical 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 sales gas 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 the sales gas line is blocked in, the plant pressure will rise and PCV-100 will open in an attempt to lower it by sending the gas to the sales gas line. Since it is blocked in, this will have no effect and the 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, while controlling the plant pressure at 90 psig. When the sales gas line is unblocked, PCV-100 will bleed off plant pressure to it until it reaches its setpoint of 75 psig at which point it will begin to control the pressure at the lower setpoint. Meanwhile, PCV-101 will close completely as the plant pressure 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 L7i.com Generating Station Custody Transfer Station. A liquid knockout vessel that requires occasional 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 H2S concentration, as well as the heating value, are also continuously monitored. From here, the gas flows into one or both of two boilers where it is burnt to generate steam.
REV: May 21, 2003
LFGP SOP
Page 13
Norflux
Power Generation
NUMBER: RJK-025
1.1.1 Diethylene Glycol (DEG) System

After absorbing water in Main Contactor Tower (V-300), the rich DEG, i.e. DEG saturated with water, flows from the towers chimney tray through the Rich DEG filter (V-120) and the chimney tray level control valve (LCV-1) to the LFG/DEG heat exchanger (HE-300). In HE-300, the DEG absorbs heat from the hot gas leaving the compressors. From HE-300, the DEG flows to the DEG Recovery 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 with stainless steel pall packing rings. The packing functions as both separation media and a mechanical defoamer. The upper portion of the column contains an integral reflux condenser section. 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 component falls down to the reboiler.
REV: May 21, 2003
LFGP SOP
Page 14
Norflux
Power Generation
NUMBER: RJK-025
Burner Exhaust Stack
Internal Reflux Condenser Section
DEG Recovery Still Main Section
Reboiler Firebox / Firetube Area
Pilot and Burner Access Port
DEG Recovery Still (V-312) and Gas Fired Reboiler
Exhaust Stack
Burner Gas Piping
Lite-off Port
Tower Packing: Pall Ring
Gas Fired Reboiler West Side
The Reboiler section consists of two horizontal cylindrical vessels connected by a downcommer pipe. The lower vessel (V-311) contains dehydrated DEG (Lean DEG) and functions as an Accumulator, from which the DEG pump(s) take suction. The upper vessel contains the gas fired reboiler firetube element that heats the incoming Rich DEG (saturated) for distillation. The liquid outlet side of the upper vessel is equipped with a weir that maintains the optimum level required to ensure that the reboiler firetubes are always submerged - thus preventing overheating of the firetubes. The mostly dry DEG in the top reboiler vessel overflows the weir and falls through the downcommer to the lower vessel (accumulator). A small amount of dry LFG is sparged into the accumulator to absorb any remaining moisture. The sparge gas travels up through the Reboiler/Still and overhead to the flare K/O tank with the rest of the tower overheads.
REV: May 21, 2003
LFGP SOP
Page 15
Norflux
Power Generation
NUMBER: RJK-025
Reboiler HE-312
Reboiler Sightglass
Downcommer
Accumulator V-311
Lean DEG Outlet
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 the tower. 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 of cooled lean DEG is fed into the U-shaped condenser tube-side to provide the cooling. It has been shown that this system is of limited benefit and is therefore seldom put in service.
To Reflux Condenser To Cooling Tower From Cooling Tower DEG Pumps Cooling Tower Bypass Cooled DEG to V-300 DEG from Accumulator Pump Discharge Line(s)
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
REV: May 21, 2003
LFGP SOP
Page 16
Norflux
Power Generation
NUMBER: RJK-025
tower is a closed loop heat exchanger section, where the DEG passes through a bank of tubes that transfer heat to the evaporating spray water falling counter to the air flow from the forced draft 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 are made up for by a flow of fresh water, controlled by an internal level float, from the external water storage tank. In the winter months, the cooling tower is operated dry with the spray water system deactivated and drained.
Level Float Access
Spray Water Pump
DEG Cooling Tower Spray Pump
DEG Cooling Tower Forced Draft Fan

EG CT DEG CT
External Water Storage Tank
EG & DEG Cooling Towers
From the cooling tower the cooled lean DEG flows through a globe valve, which is used to manually 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 (V300), particulate matter is removed in the Lean DEG Filter (V-121).
REV: May 21, 2003
LFGP SOP
Page 17
Norflux
Power Generation
NUMBER: RJK-025
V-300 Main Contactor
DEG Flow Meter
DEG Globe Valve Hat Tray Level Control
Lean DEG Pumps
DEG Addition To V-300 Piping

A small carbon filter (V-350), used to remove liquid hydrocarbons, takes a slipstream flow of lean DEG from the filtered DEG entering the contactor tower. After passing through the filter, this slipstream joins with the rich DEG as it enters the heat recovery exchanger (HE-300).
V-350 DEG Slipstream Carbon Filter
REV: May 21, 2003
LFGP SOP
Page 18
Norflux
Power Generation
NUMBER: RJK-025
1.1.2 Ethylene Glycol (EG) Cooling System

Plant cooling is supplied by a closed Ethylene Glycol (EG) circulation system, which cools the following:

Compressor Intercoolers Compressor Jacket 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 heat exchangers to provide cooling, the heated EG outlet from these exchangers joins in a common header 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 the EG Receiver where it starts its cycle again. During normal operation, the EG Receiver level is constant; any change in level indicates a problem. An atmospheric vent at the top of the EG Receiver has been fitted with extension piping that outlets near the east side of HE-100. Any flow from this outlet indicates a cooler is leaking into the EG system. A loss of level in the EG Receiver indicates either an EG piping leak or a tube leak in HE-100, which operates at a process side pressure that is less than the EG system.
H2S Scavenger Storage
HE-100 Preclean Gas Cooler
West EG Circ Pump
EG Inlet to HE100 throttle valve
East EG Circ Pump
EG Circulation Pumps
REV: May 21, 2003
LFGP SOP
Page 19
Norflux
Power Generation
NUMBER: RJK-025
1.1.3 Flare Effluent System

The majority of plant equipment capable of producing gas or liquid effluent has connections to the main flare header. This header discharges into the under-ground Flare Knockout Tank (V-420), located a few feet upstream of the flare-stack inlet. Liquids accumulate in V-420 while gases pass through to the 38 ft (12 meter) flare stack (S-400) where they are incinerated. V-420 is a double walled fiberglass vessel with a retractable probe installed between the inner and outer walls. This probe is withdrawn regularly and checked to ensure that it is completely dry. The presence of liquid indicates that the inner hull is leaking, at which point the vessel would have to be taken out of service for repair. In this case, the vessel Flare Knockout Tank and Stack should 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 (15,750 liters). A liquid waste disposal company is called in to unload the tank when its level approaches capacity. The vessel is equipped with a 160 l/min Effluent Unloading Pump (P-120) that takes suction from the bottom of the tank and discharges to the unloading standpipe. The standpipe is located near the southwest gate of the plant site. The liquid effluent is transported by tanker truck to a hazardous waste disposal facility. The flarestack is equipped with a flame arrestor that prevents a backflash ignition in an area other than the top of the stack. An electric igniter on a one-minute timer ensures that the flame is reestablished quickly should it go out. A thermocouple installed near the windguard senses a flameout and triggers an alarm in the control room. Refer to PID LFGP-05 from more information.
REV: May 21, 2003
LFGP SOP
Page 20
Norflux
Power Generation
NUMBER: RJK-025
Flare Stack Burning Full Flow of Plant Gas
REV: May 21, 2003
LFGP SOP
Page 21
Norflux
Power Generation
NUMBER: RJK-025
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.
REV: May 21, 2003
LFGP SOP
Page 22
Norflux
Power Generation
NUMBER: RJK-025
3.0
BTEX
Definitions
Benzene, Toluene, Ethyl benzene, and Xylene volatile monoaromatic hydrocarbons which are commonly found together in crude petroleum; they are also a component of crude landfill gas. Generally considered harmful to health. A bubble cap tray has riser or chimney fitted over each hole, and a cap that covers the riser. The cap is mounted so that there is a space between riser and cap to allow the passage of vapor. Vapor rising through the chimney is directed downward by the cap, through slots on its side, and bubbles through the liquid on the tray.
Bubble Cap Tray
Chimney Tray
Dehydration Contactor - A circular metal plate, with a large chimney in the center used to collect liquid (rich DEG), without preventing upward flow of vapor (wet LFG) from the feed zone below. Diethylene Glycol Absorption Material Ethylene Glycol - Coolant High Density Polyethylene Plastic piping material Landfill Gas Plant Landfill Gas in any stage from raw well gas to sales gas Standard Operating Procedure
DEG EG HDPE LFGP LFG SOP
REV: May 21, 2003
LFGP SOP
Page 23
Norflux
Power Generation
NUMBER: RJK-025
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.
REV: May 21, 2003
LFGP SOP
Page 24
Norflux
Power Generation
NUMBER: RJK-025
5.0 Routine Checks and Activities

5.01 Daily
Step 1. Complete daily checks and logsheet round.

Key Points Record readings on the daily run log when appropriate. A LFG leak into the plant will first show up on the PLC panel hydrocarbon sensor. Care should be taken when first investigating a high hydrocarbon in ambient air alarm. Ensure that oxygen is well below 4 %. Look for signs of air leaks into system by observing ratio of oxygen and nitrogen. Pressure should be 8 to 20 kPa @ normal flow rate; pressure can fluctuate due to water movement in the system. Pump out if level at half glass. See Routine procedures. It should be warm, not hot, to the touch.
2. Check for leaks throughout the plant.
3. Check LFG analysis printout.

4. Check blower suction header pressure and temperature
5. Check Inlet Separator V-100 gage-glass level.
6. Check blower motor temperatures by briefly placing hand on housing. 7. Check blower discharge temperature 8. Blowers: Listen for abnormal sounds and check for excessive vibration. 9. Check inboard blower bearing temperature by hand or use gun thermometer.
~ 75C
Temperature should be ~150F (66C). Temperature greater than 175F (79C) is excessive. Water must be added immediately if no level is shown on sight glass. In the winter, fill to top of sight glass. In summer, add scavenger chemical and water to top of gauge glass plus 100 usg by meter. See SOP. When V-110 inlet temperature drops below 18C an undesirably large amount of water will condense in tower. EG valve is sensitive, start by moving it about one cm than make moves of 1/10 cm at a time. Page 25
10. Add water and H2S scavenger chemical to V-110, pump level to flare header if required (every 3 weeks).
11. Check V-110 Inlet temperature and adjust HE-100 EG inlet valve as required to maintain 18-22 C
REV: May 21, 2003
LFGP SOP
Norflux
Power Generation
Step
NUMBER: RJK-025
Key Points

12. Check blower discharge pressure and temperature gages located near V-110. 13. Check V-200 level and pump to flare when greater than glass. 14. Check glycol pump discharge temperature. 15. Check inside water tank level.
Normal Temp: 65 - 85 C Normal Pressure: 10 40 kPa See routine procedures.

Note on logsheet, investigate if high. When external water tank is out of service for winter, the internal tank must be filled by calling a water truck in. Truck should be called in for next day when level is <100 imp gals or for Monday when <200 imp gals on Friday. This is normally required about once every eight days. When external water tank is in service, fill the internal tank by gravitating water through hose from external tank Internal tank can only be filled to 600-imp gallon level by this method. Normally EG addition should never be required. Level should NOT fluctuate. Motor should be cool to the touch. Normally, the west pump is operated with the east being kept as a spare. Normal: 220-240 kPa. To protect shell from excess pressure.
16. Check that EG Receiver level is at six inch marker on sight glass. 17. Check EG pumps for vibration and temperature.
18. Check EG pump discharge pressure. 19. Check that EG outlet line from Pre-clean HE is sealed open. Also ensure that all other EG outlet lines from heat exchangers are sealed open. 20. Check H2S Scavenger storage tank level.

The supplier should be called when level is below 50 gals. Order 450 gals. Leave room for expansion.
21. Check LFG compressor(s) oil level. 22. Ensure that LFG compressor interstage pressures are equal. 23. Check plant air compressor oil level. 24. Drain bottoms from V-300 by opening one inch ball valve on base for three minutes.

Unequal pressure indicates valve failure.
Outlets to flare header
REV: May 21, 2003
LFGP SOP
Page 26
Norflux
Power Generation
26. Check reboiler is full.
NUMBER: RJK-025
Step 25. Check that lean DEG flow is set at 510 litters/minute. Adjust globe valve as required.

Key Points
Due to outlet weir, this level will be constant. Should show at bottom of sight glass.
27. Check accumulator level, add DEG as required. 28. Check Reboiler temperature 29. Check Stripping tower overhead temperature. 30. Check DEG filter differential pressure and change filters as required (see routine procedure). 31. Check V-330 Contactor K/O pot level.

Normal: 70 100 deg C DP of 15 psi indicates time to change filters.
Dump to pail as required, see routine procedure. DP: 10-12 psi - time to change, see SOP. Dump liquid as required. See SOP. Open hydrant valve slowly. Normally required daily. Daily usage: ~1/2 tank
32. Check Coalescer differential pressure and sight glasses. 33. Check level in External Water Tank, fill from hydrant if approaching tank (summer only). 34. Ensure that cooling tower belts are in good shape, and at proper tension and not squealing. 35. Check level in cooling tower basins. 36. Ensure that flare ignitor is operating ~once per minute. 37. Dip Flare Tank level and arrange for unloading if required.

Ensure that floats are operating properly.
Unload at 180 cm.
REV: May 21, 2003
LFGP SOP
Page 27
Norflux
Power Generation
Step
NUMBER: RJK-025
5.02 Weekly
Key Points
1. Clean up piping with pressure washer (summer months only) 2. Dump water from plant air compressor receiver tank every two weeks. 3. Change sales gas circular chart. 4. Pump V-110 level to flare using bottom suction valve every 3 weeks. See SOP.
Blowdown Valve
Sales Gas Seven Day Circular Chart
Plant Air Compressor Receiver Tank
REV: May 21, 2003
LFGP SOP
Page 28
Norflux
Power Generation
Step
NUMBER: RJK-025
5.03 Other Routine Checks

Key Points

1. Drain Reboiler secondary containment vessel as required 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 2000 operating hours as follows:

The following can be greased while running:

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
Blower motor bearings Blower inboard bearing
The following bearings require that the unit be shutdown 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 clean out sludge by hand.
5. Stroke both cooling tower louvers when preparing for winter. 6. Check Flare Knockout Tank for leaks once / month. Use standby man.

Carefully remove leak detection dip stick and check for liquid. Use extreme caution and follow safe practices when entering flare pit.
7. Clean reboiler burner annually and adjust air ratio control disk / regulator. 8. Check reboiler cycling time on a regular basis. The preferred cycle is 15 minutes off and 45 minutes on.

If the reboiler is cycling more frequently, the burner flame can be adjusted down by lowering the burner pressure. Burner pressure is governed by a regulator and should be kept between 8 and 15 PSI. 1/3 of a barrel every one or two weeks or when Accumulator sight glass shows less than inch.
9. Add DEG to system when required.
10. Add a litre of antifoam to system every three to four weeks or as required.
REV: May 21, 2003
LFGP SOP
Page 29
Norflux
Power Generation
Step 11. Calibrate GC when required
NUMBER: RJK-025
Key Points

See SOP Caution, incorrect Bake Out can permanently damage GC. See SOP.
12. Bake out GC when there is not longer space between curve bottoms.
REV: May 21, 2003
LFGP SOP
Page 30
Norflux
Power Generation
NUMBER: RJK-025
5.1 Routine Procedures

5.1.1 Purging Liquid from Inlet Separator
Step 1. Open pump suction valve to Separator Base. 2. Open pump discharge to flare header 3. Start pump.

Key Points
Pump should gain suction within minute. System under vacuum If pump has difficulty gaining suction, clean Y strainer on suction line. Due to system being under vacuum, the strainer will have to be isolated, disassembled, and cleaned by hand.
4. Run pump for hour or until separator is empty of liquid
Note: Vessel should be pumped out when level reaches glass on sight glass
V-100 Discharge Piping to Flare
V-100 Base Pump
Recirculation Valve
V-100 Base Suction Valve
Suction Line Strainer
V-100 Inlet Separator Base Pump and Piping
REV: May 21, 2003
LFGP SOP
Page 31
Norflux
Power Generation
Step 1. Stop circulating pump.
NUMBER: RJK-025
5.1.2 Daily H2S Scavenger and H2O Addition to V-110

Key Points
2. Line up pump suction valves to draw from H2S Scavenger chemical tank. 3. Line up pump discharge valves to allow flow through meter to V-110. 4. Start Pump and add H2S scavenger.
Switch from normal V-110 circulating suction line 2nd from bottom.
Run pump until 4 gallons scavenger chemical has been added according to meter.
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 as determined by V-110 level sight glass and ambient temperature. Max amount is based on ambient temperature of approx. 30 deg C; during extremely cold periods, no water addition 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 Discharge pressure should increase.
10. Start pump.
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.
REV: May 21, 2003
LFGP SOP
Page 32
Norflux
Power Generation
NUMBER: RJK-025
V-110
Flow Meter
Discharge Pressure
Normal Suction
Pump-out Suction
Base/Circulation Pump
Backup Pump
V-110 Base Piping
V-110 Sight Glass / H2S Scavenger Tank
H2S Scav. Tank / V-110 Suction Lines
REV: May 21, 2003
LFGP SOP
Page 33
Norflux
Power Generation
Step
NUMBER: RJK-025
5.1.3 Purging Liquid from V-200

Key Points
1. Shutdown H2S scavenger circulation pump and close V-110 suction and discharge valves. 2. Line up the pump suction to draw from V-200 and the pump 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-110 circulation pump.

Entire procedure should take less than 1 hour to prevent H2S levels in sales gas becoming excessive.
NOTE: Vessel should be pumped out when sight glass indicates glass. On average, this will take about one month to build up; however, liquid accumulation rate is inversely related to ambient temperature i.e. Liquid will accumulate faster during cold weather.
REV: May 21, 2003
LFGP SOP
Page 34
Norflux
Power Generation
Step 1. Open filter bypass valve.
NUMBER: RJK-025
5.1.4 Changing Lean/Rich DEG Filters

Key Points
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 drain over barrel.

6. Exercise internal bypass mechanism to ensure proper functionality. 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.
Used filters should be allowed to drain into barrel for two weeks. They should then be disposed of in a Hazardous Material bin (45 gallon drum with overpack). Liquid in barrel should be disposed of by adding back to DEG.
NOTES:

Filters should be changed when differential pressure reaches 15 psi. Filters contain an internal spring loaded disk that automatically bypasses the filter material when a high differential pressure develops. Used drained filters must be disposed of in accordance with the LFGP Hazardous Waste Disposal Document.
REV: May 21, 2003
LFGP SOP
Page 35
Norflux
Power Generation
Step
NUMBER: RJK-025
5.1.5 Purging liquid from V-330 K/O Pot and V-340 Coalescer Filter base.
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 like foam, this can extend the time taken to execute procedure 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-330 and monthly for V-340.
REV: May 21, 2003
LFGP SOP
Page 36
Norflux
Power Generation
Step
NUMBER: RJK-025
Changing Coalescer Filter Material

Key Points
1. Prepare vessel for filter change as follows: a. Block in inlet valve b. Block in outlet valve c. 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 differential pressure gage reads 10 12 PSI (8 to 12 months.)
REV: May 21, 2003
LFGP SOP
Page 37
Norflux
Power Generation
Step
NUMBER: RJK-025
Adding Fresh DEG to System

Key Points
1. Place unloading hose in DEG barrel. 2. Connect free end of hose to DEG pump suction strainer blowdown coupling. 3. Open strainer blowdown valve. 4. Slowly close suction valve from Accumulator (V-311). 5. When required amount of fresh DEG has been added, open suction valve from Accumulator (V-311) and close strainer blowdown valve.

Strainer blowdown valve: V958. Accumulator suction valve: V948. Observe liquid level in barrel to determine when enough DEG has been added. Strainer blowdown valve: V958. Accumulator suction valve: V948. Drain DEG in hose back to barrel.
6. Disconnect hose from strainer hose coupling.
NOTE: Fresh DEG is added when Reboiler Accumulator level shows inch on bottom sight glass; 2-3 times per month depending on operating conditions.
V-311 DEG Accumulator Reboiler Burner Main Gas Reboiler Burner Pilot Gas DEG Pump(s) Suction Line Accumulator Suction Valve V948 Suction Valve to DEG Drums V958
Reboiler Accumulator Outlet to DEG Pumps
REV: May 21, 2003
LFGP SOP
Page 38
Norflux
Power Generation
NUMBER: RJK-025
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 of flare stack spreading burning liquid around base of flare stack. Step 1. Call liquid waste disposal company, currently Sellers

Key Points Normally they are called the day before they are required; however, they can arrive in approximately one hour if required immediately. The truck will unload K/O tank while parked at the side of the road.
2. When truck arrives, open southwest gate and unlock camlock plug on flare K/O tank unloading point (located immediately south of SW gate). 3. Connect truck unloading line to K/O tank unloading point and connect grounding cable. 4. Start unloading pump.
Responsibility: Truck Driver
The pump switch is located on light standard post near flare stack. The truck driver will monitor the unloading process and inform LFGP operator to stop pump when truck tank volume stops increasing or when truck tank is full. Unloading normally takes an hour and 15 minutes +/- 5 minutes. Responsibility: Truck Driver.
5. Stop unloading pump when informed by truck driver that unloading is complete.
6. Disconnect truck unloading line from K/O tank unloading point. 7. Replace and lock Camlock plug / close gate. 8. Ensure that waste shipping manifest is properly completed.
Refer to previously completed manifests as an example.
REV: May 21, 2003
LFGP SOP
Page 39
Norflux
Power Generation
Step 1. Shutdown spray water pumps.
NUMBER: RJK-025
Preparing Cooling Towers for Winter

Key Points
2. Drain tower sumps and piping by breaking unions as required. 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 be destroyed if allowed to freeze.
NOTE: During colder months, the Cooling Tower is run dry with the fans running but no spray water. The towers must be prepared for winter operation as soon freezing temperatures are forecast usually mid October.
REV: May 21, 2003
LFGP SOP
Page 40
Norflux
Power Generation
Step
NUMBER: RJK-025
Lighting Reboiler
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 into burner port. 4. Open pilot valve and slowly open main burner gas valve (15 seconds from closed to open).

Listen for flame ignition Check flame after removing igniter
REV: May 21, 2003
LFGP SOP
Page 41
Norflux
Power Generation
Step
NUMBER: RJK-025
Plant GC Calibration
Key Points
1. Measure peaks for O2, N2, and methane using mouse cursor and record values. 2. From the menu, choose Method Peak table. 3. Enter channel A RT values in the appropriate fields for O2, N2, and methane. 4. Choose Save from the menu.

Run Calibration gas through GC to verify accuracy.
Note: After a power failure the remote button must be pressed on the GC prior to restarting EZChrom. Printer power must also be cycled.
REV: May 21, 2003
LFGP SOP
Page 42
Norflux
Power Generation
Step 1. Stop run
NUMBER: RJK-025
Plant GC Bakeout Procedure

Key Points

Press Esc Loads the column bakeout parameters
2. Choose Method Open from menu. Select bakeman from list and click okay. 3. Choose Instrument, Send current method from the menu. 4. Choose Instrument, Receive current method from the menu. 5. Choose Instrument, Status from the menu and ensure that the following maximum temperatures are not exceeded: A - 180 deg C B - 160 deg C 6. Allow columns to bake out for 1 hours minimum. 7. Stop run by pressing Esc 8. Choose Method Open from menu. Select cblfg1z from list and click okay. 9. Choose Instrument, Send current method from the menu. 10. Choose Instrument, Receive current method from the menu. 11. Choose Instrument, Status from the menu and observe as temperatures cool to normal values: A - 65 deg C B - 50 deg C
Sends the method to the GC.
Sends the method back from the GC.
Exceeding these temperatures will destroy the respective column. Once temperatures have peaked safely, they no longer need to be monitored continuously.
Loads normal GC parameters.
Sends the method to the GC.
Sends the method back from the GC.
The columns must be at normal temperatures before an accurate GC run can take place.
12. Select start to begin normal operation.
GC should start a run immediately.
REV: May 21, 2003
LFGP SOP
Page 43
Norflux
Power Generation
NUMBER: RJK-025
5.2.0 Plant Startup Procedure

NOTE: The following procedure assumes that no piping or vessels have been taken apart and that the plant has been left in standby mode. Step 1. Manually shut off various electrical switches located out in the plant as follows:

Key Points Switches only work in manual mode not in auto mode. It is important to position the switches to off on the blowers, compressors, and DEG circulating pumps before pushing the plant reset button or the plant will start up in an uncontrolled manner. V800 and V802
All three blowers Both compressors Both DEG circ pumps
2. Ensure the main gas suction valves to the plant are wide open. 3. Ensure all blower suction valves are open. 4. Push plant reset button and place compressor run selection switch in appropriate position.

V806, V807, & V808 Compressor Run selector switch settings: 1 West compressor 2 East compressor 1&2 Both compressors
5. Place the attended/unattended selector switch in the attended mode. 6. Start the main ethylene glycol circulating pump 7. Manually prelube the compressor(s).

West pump Rotate hand crank the required number of times. This ensures that the second prelubing is quick after the blowers are started. Normally two are run, the other left as a spare.
8. Start the blowers.
9. Manually prelube the compressor(s) a second time.
REV: May 21, 2003
LFGP SOP
Page 44
Norflux
Power Generation
Step 10. Start the compressor(s)
NUMBER: RJK-025
Key Points This must be done within 45 seconds of turning on the blowers or a timer on the PLC will shut down the blowers-This shutdown feature is in the program logic because the blowers will sustain internal damage if they are dead headed for any length of time. If you exceed the above-mentioned 45 seconds, you will have to start over again (manual switches turned off of blowers and compressors and plant reset button pushed inside plant office). A closed downstream valve may cause excess pressure on either gage. Normal oil pressure for cold unit is up to 80 psig. Once unit has come up to operating temperature, normal oil pressure is from 35 to 50 psig. P-100 or P-310 V933 - located next to Halliburton liquid flow meter (FQ-5). With the sales gas line blocked in at power station, the gas should be at ~90 psig and flaring. Ensure that Kimray controller keeps gas pressure well below 100 psig. Excess pressure (over 100 psig) will pop the sales gas line PSV - an undesirable situation because this PSV does not always reseat and therefore must be sent out for recertification. This would cause substantial plant downtime.
11. Check the panel-mounted gauges for normal pressure buildup on both left and right cylinders. 12. Check the oil pressure gauge to ensure normal function of lubrication system.

13. Line up and start the DEG circulating pump. 14. Set the DEG flow rate using the manual globe valve to 5 10 liters/minute as indicated by FQ-5. 15. Check the gas flow chart to ensure that gas pressure is building up normally.

16. Ensure that Kimray backpressure control valve is operating correctly controlling pressure by diverting sales gas to flare.
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 full flow of gas-It is normal for them take five or ten minutes to accept full volumes of gas. Summertime only.
18. Start the cooling tower air fans and spray water pumps.
REV: May 21, 2003
LFGP SOP
Page 45
Norflux
Power Generation
NUMBER: RJK-025
Step 19. Walk through the plant again to ensure all equipment is heating up normally and that there are no problems (normal gauge pressures and no abnormal vibrations or noises).
Key Points
20. Check chromatograph readings to ensure that oxygen concentration is below 1.5 %.
Oxygen readings in excess of 1.5% are abnormal and should be corrected immediately.
DANGER
If oxygen exceeds 4%, the plant must be shut down immediately. In this case, press the manual ESD button on PLC panel. The source of air ingression must be identified and corrected before attempting to bring the plant online. Failure to adhere to this procedure could result in a plant explosion.
REV: May 21, 2003
LFGP SOP
Page 46
Norflux
Power Generation
NOTE:
NUMBER: RJK-025
Plant Startup With Purging - If any vessels or piping are taken apart when the plant is down then the 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 the manual flare valves on the compressors before starting them. Also, open the manual contactor drain valve; which is also tied in to the flare system. To ensure good displacement of the foreign air these valves should be open to flare for at least five minutes before they can be closed. See attachment section 6.6 for photo of east compressor purge outlet piping.
REV: May 21, 2003
LFGP SOP
Page 47
Norflux
Power Generation
NUMBER: RJK-025
5.3.0
Plant Shutdown Procedure
Note: In case of an emergency, the plant can quickly be shutdown by pressing the ESD button on the PLC panel.
Step 1. Contact Generating Station and inform them of impending shutdown. 2. Shutdown blowers by moving local switches to the off position. 3. Shutdown DEG pump. 4. Shutdown spray water pumps and fans on both Cooling Towers. 5. During warm weather, shutdown EG circulation pump after a minimum of hour. During cold weather, leave EG circulating for duration of shutdown.

Key Points 412-3281 or 412-3360
The compressor will automatically shutdown.
It is important to leave EG circulating for a period after plant shutdown to prevent thermal shock to the compressor(s). EG is left circulating in winter to help prevent freeze-ups. V-100, V-110, V200, & V-300`
6. In winter, drain liquids from all major vessels. 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 to changes in barometric pressure.
REV: May 21, 2003
LFGP SOP
Page 48
Norflux
Power Generation
6.1
NUMBER: RJK-025
6.0 Attachments
Typical Bubble Cap
6.2
Typical Chimney Tray
6.3
Plant Air Compressor Photos
Cylinders Motor
Filter
Receiver
Oil Level Sight Glass
Pressure Gage
Blowdown
Air Compressor & Receiver
Air Compressor Close-up
REV: May 21, 2003
LFGP SOP
Page 49
Norflux
Power Generation
6.4
NUMBER: RJK-025
West Landfill Gas Compressor Photo

LP Cyl Inlets
Murphy Vib Switch LP Cyl LP Cyl Oil Hand Crank
Oil Cooler HP Cyl HP Cyl Crankcase Oil Level
West LFG Compressor
6.5
V-100 Inlet Separator and Blowers Photo

Blower Outlet Header
LFG Blowers (3)
V-100 Inlet Separator
V-100 Base Pump
V-100 and Blowers
REV: May 21, 2003
LFGP SOP
Page 50
Norflux
Power Generation
6.6
NUMBER: RJK-025
LFG Compressor Discharge and Purge Outlet Valves

Compressor Disch Valve
High Disch Pressure Trip
Purge Outlet Valve
High Disch. Temp Trip
East LFG Compressor Discharge Piping
6.7
LFG Compressor Recycle Line Block and Check Valves

Compressor Disch Line
Recycle Line
Recycle Check Valve
Recycle Block Valve
Main LFG Outlet Line from Compressors
REV: May 21, 2003
LFGP SOP
Page 51
Norflux
Power Generation
6.8
NUMBER: RJK-025
Supplemental Images
V-300 Main Contactor Hat Tray Draw-off
V-330 OH K/O Pot & V-340 Coalescer
REV: May 21, 2003
LFGP SOP
Page 52
Norflux
Power Generation
NUMBER: RJK-025
Addition Line Pump Inside Water Tank
Dip Check Unloading Line
Flare Stack KO Tank Pump Pit
REV: May 21, 2003
LFGP SOP
Page 53
Norflux
Power Generation
NUMBER: RJK-025
7.0 Forms
7.01 Daily Logsheet Example
REV: May 21, 2003
LFGP SOP
Page 54
Norflux
Power Generation
NUMBER: RJK-025
7.02 Spill Report Checklist
Chemical & Oil Spill Report Checklist

Date: Alberta Environmental Protection File # Operating Supervisor NORFLUX Report #
Initial Information Part A

Name Phone #
Reported by
Location of spill area: Address Cause of Spill Time of report Amount of Chemical or Oil Spilled (liters)
Additional Information Part B

Alberta Environment Informed? Time Alberta Environments Comments Yes No Inspectors Name
How was cleanup done?
Soil analysis required? Results Site clean up date Faxed NORFLUX Environmental Affairs Date Report compiled by File Closed? Fax # ppm
Yes Time Time Phone # Approved by
No
Senior Sustainable Development Engineer notified
REV: May 21, 2003
LFGP SOP
Page 55
L7-i Landfill Gas Plant SOP PIDs
Rev. May 25, 2007
56
Rev. May 25, 2007
57
Rev. May 25, 2007
58
Rev. May 25, 2007
59
Rev. May 25, 2007
60
L7-i Landfill Gas Plant SOP PIDs Norflux Environmental Practices Example of Environmental Checklist The following environmental related checks must be performed at the assigned frequency: Inspected Item Plantsite Purpose of Check Prevention of gas or liquid releases to air/ground Flarestack Ignition Manual Switch-Audible & Prevention of unburnt System Visual gases to atmosphere Flarestack Ignition Professional Electrical Prevention of unburnt System Inspection gases to atmosphere Flare Knockout Tank Visual Inspection of Prevention of liquids Interwall Dipstick release to soil Flare Knockout Tank 24 Hour Visual Leak Test Prevention of liquids release to soil Flare line 8" 900 Visual Inspection of Prevention of gas or Disch. Elbow interior pipe wall liquid releases to air/ground Condensate Independent Laboratory Proper Handling, Storage Wastewater Analysis and Shipping Flarestack Influent Independent Laboratory Prevention of excessive Analysis emissions to air Solid Hazardous Independent Laboratory Proper Handling, Storage Waste Analysis and Shipping Type of Inspection Walk around-Visual & Audible Frequency Daily Inspection Results Leaks- Yes/No
Weekly Yearly Weekly Yearly Yearly
Working-Yes/No Defects Requiring Fixup Y/N Dipstick Dry & Clean Y/N Gauge Stick Reading Change Y/N Excessive corrosion Y/N Report Submitted to Alberta Environ. Report Submitted to Alberta Environ. Proper Characterization Y/N
Yearly Yearly Yearly
Proposed Future Checks Inspected Item Type of Inspection Flare line Monitoring Visual Well Flare line Cathodic Electrical Tester Protection
Purpose of Check Prevention of liquids release to soil Prevention of liquids release to soil
Frequency Monthly? Monthly?
Inspection Results Well Dry Y/N Functioning Y/N
Rev. May 25, 2007
61

Gas Plant Land Fill

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Gas Plant Land Fill

Uploaded by

Copyright:

Available Formats

All content, including technical writing, SOPs, graphic design, photography, layout, and Process and Instrument Diagrams

created by Bob J. Kaplan Norflux

Landfill Gas Plant

Practices and Procedures Manual

Standard Operating Procedures

NORFLUX LANDFILL GAS PLANT

Standard Operating Procedures

REV: May 21, 2003

NORFLUX LANDFILL GAS PLANT

Standard Operating Procedures

These procedures are reviewed annually each November.

REV: May 21, 2003

NORFLUX LANDFILL GAS PLANT

Standard Operating Procedures

SOP Change Submission Sheet

SOP Change Control Sheet

REV: May 21, 2003

NORFLUX LANDFILL GAS PLANT

Standard Operating Procedures

REV: May 21, 2003

NORFLUX LANDFILL GAS PLANT

Standard Operating Procedures

Initial Sign off and Validations

Landfill Gas Plant Standard Operating Procedures

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

Stylized Process and Instrument Diagram

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

Creators Note to Potential Customers and/or Employers

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

1.1 Process Overview

Simplified Process Flow Diagram

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

Details of Main Process

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

Inlet Separator Piping Sketch

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

Blower Suctions (3)

Plant Inlet Header

Inlet Block Valve

Blower Suction hdr

Plant Inlet Piping

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

Process Flow from Blower Suction Header to HE-100 - Sketch

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

V-110 Pre-clean Contactor / H2S Remover and V-200 Pre-clean Knockout

REV: May 21, 2003

L7-i LANDFILL GAS PLANT

Standard Operating Procedures

REV: May 21, 2003