Important Document Information

The Contents of This Document do not represent = any Existing Facility.

Please Note that none of the material may be us= ed without the written permission of the author

– Bob J. Kaplan

These pages have t= wo main purposes, first, to present an example that can be used as a template for u= p-and-coming Training Manual Writers and second, to give prospective clients of Bob Kapl= an an example of his work on a mid-range documentation project (see project sc= ale level notes).

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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.

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The process and in= strument diagrams included in the appendix are an advanced option and were created a= s a separate project.

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The backbone of a = complete “training intervention” is the training manual. A properly constructed training manual containing up-to-date material, quizzes, and a certification examination can greatly reduce the amount of time the learner takes to achieve competency in performing the portion of their job covered = by the manual. It also significantly reduces the amount of time needed for on-the-job training and, if applicable, classroom instruction. Another significant benefit is to ensure that each trainee receives a complete and thorough education, thus minimizing the possibility of some critical bit of information “falling through the cracks”. A well written manual= can be used to fulfill legal requirements imposed by such organizations as OSHA= (in the USA) or OHS, and business requirements like those imposed by ISO (ISO-9000+).=

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Much of the materi= al used in the creation of a comprehensive training manual can also be used to crea= te an “on-line” version with interactivity and automatic score keeping. Although a computer based training (CBT) course can be completed u= sing only the material contained in the training manual, the opportunity should = be taken to add animation and video clips, which can significantly improve the training outcome. Attaching the appropriate section review segment to the section quiz helps ensure that the trainee has absorbed the material covered before moving on. Adding sound, visual effects, “talking head” narration, and other sensory stimulating devices helps keep the trainee interested and thus further increases the training outcome.

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Making a proper determination of the scope of the training manual project is essential befo= re any work on the manual is started. The budget and the required timeline are= the two main factors that determine the training manual’s complexity and thoroughness.

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In some cases the = most important consideration is to produce the most thorough and effective train= ing intervention possible within a reasonable length of time. An example of this would be a training manual for certification of a employee performing criti= cal tasks that, if improperly performed, could cause significant loss of production, equipment, life and limb. Tasks that, if improperly performed, could result in significant damage to the environment are usually included = in this group.

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Some customers have requirements that range downwards in cost and time from the above. From a customer’s point of view, this usually means that they must compensate through an increased level of On-The-Job (OTJ) training and classroom instruction, or by accepting some level of additional risk that some tasks = may be performed improperly.

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I have created gui= delines for the rough classification of training manual scope on scale from 1 to 6 = and assigned the primary components to each level as follows.

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Level 1 – Pu= re text. Examples are Step by step Standard Operation Procedures (SOPs), Emergency Procedures, or Environmental Guidelines.

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Level 2 – Th= e above plus a simplified main process diagram and non step-by-step descriptive text (process overview, for example).

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Level 3 – The previous plus annotated photos, equipment descriptions, detailed process description, main and functional group process diagrams, imported ancilliary material (such as log-sheets), additional sections on safety, alarms and troubleshooting, process parameters, and emergency procedures. <= /span>

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Level 4 – Al= l of the previous plus section quizzes and final certification exam. Simplified main process isometric sketch. Detailed isometric sketches of key component syst= ems. One additional document review. Additional procedures and diagrams – = lock and tag sheets, for example.

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Level 5 – Al= l of the previous levels plus a training checklist for use in the field to track the training conducted – can include daily training “sign off”= ;. Additional annotated photos and diagrams. Computer Based Training Module (CBT) with vi= deo of critical procedures and automated score-keeping.

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Level 6 – Cu= stomer requirements can be unique. For example, most custom training manuals will = have a very restricted number of controlled copies that, once produced, are maintained by the customer| however, a training manual slated for mass production in bound form usually calls for an overall increase in quality of certain components such as photos. In these cases, additional levels of rev= iew are nessesary as it is no longer possible to deal with errors by reprinting= and replacing a few copies of a single page. Other additions “over and above” level five are Process and Instrument Diagrams (P&IDs), tr= aining aids, wall diagrams, posters, etc.

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As with most proje= cts, at a certain point the law of diminishing returns kicks in where escalating co= sts yield increasingly smaller boosts in quality and/or content.

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The above classifi= cation levels can not be used directly to determine the cost of producing a Traini= ng Manual. Other factors are||

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· location <= o:p>

· availabili= ty of employees for interviews

· availabili= ty of supervisors for discussions and to answer questions

· presence of equipment manuals, PIDs, and other blue prints.

· presence of existing training materials and Standard Operating Procedures

· accuracy o= f the existing materials

· access to equipment

· labelling = of equipment on “the floor”

· number of procedures

· complexity= of job/task

· availabili= ty of proper on-site office space and equipment

· efficiency= of remote communications (faxes, email, telephone)

· number of discrete components covered by the manual

· the base knowledge of employees using the manual

· time allot= ted for completion

· number of original drawings / sketches required

· complexity= of original drawings

In estimating the cost of the manual, first determine the scope of the project= (1 to 6), next, address the above points and find good answers to questions th= at arise by interviewing staff and other stakeholders. It may be easier to find out the maximum amount of money allotted towards the project and scale the project accordingly (be careful not to compromise on the quality or accurac= y of your work – drop job/tasks rather than produce shitty work).

Another option is to work at an hourly rate. Be sure that the client is knows this rate, realizes that it will be you who will be keeping track of time –= ; be sure to keep accurate records, and that most of your work will be conducted “off-site”. Working for an hourly rate (plus costs) works best = if the client is kept up-to-date on the progress of the project versus the time used – provide weekly updates but do not include all the details that= you use to track your time. The details are tracked in case of a dispute. Lastl= y, if you already have a working relationship with the customer, this billing approach may be more attractive to both parties.

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Stylized Process and Instrument Diagram

Creators Note - The above diagram is a synthe= sis of five separate Process and Instrument Diagrams (P&ID) created by Bob Kap= lan from “scratch”. This type of graphic, with the original file be= ing a vector rather than bitmapped graphic, can be enlarged to any size and printed. This makes it perfect for mounting on a control room wall for quick reference. The drawing can be used extensively in a computer based training application (CBT) as is or animated to better show process flows during different procedures. This drawing was created using Corel Draw. Which means that it can be saved in most other vector based graphics programs’ fi= le format (AutoCAD, for example).

These procedures are reviewed annually each Nov= ember.
SOP Chan= ge Submission Sheet=

Page #	Change Request
1
2
3
4
5
6
7
8
9

SOP Change Control Sheet

Date	Description	Page	Approval

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 Manager’s Office

Approval must be obt= ained before removing a copy from its assigned location. The document must be returned within seven days. The copy located in the Landfill Gas Plant Offi= ce & Control Room area must NEVER be removed.

Initial Sign off and Validations

Re= viewed By	Bob Kaplan	Da= te:	May 08, 2008<= /o:p>
Ap= proved By	Bo= b Kaplan	Da= te:	Ma= y 24, 2008
Op= erations Approval	No	Da= te:	N/= A
Ti= tle:	La= ndfill Gas Plant Standard Operating Procedures

Table of Conten= ts

1.0 Introduction. 2

1.1 = Process Overview. 3

1.1.0 Main Proces= s. 3

1.1.1 Diethylene = Glycol (DEG) System.. 14

1.1.2 Ethylene Gl= ycol (EG) Cooling System.. 19

1.1.3 Flare Efflu= ent System.. 20

2.0 Purpose. 22

3.0 Definitions. 23

4.0 Responsibilities. 24

5.0 Routine Checks and Activities= . 25

5.01 Daily= . 25

5.02 Weekl= y. 28

5.03 Other Routine Checks. 29

5.1 Routine Procedures. 31

5.1.1 Purging Liq= uid from Inlet Separator 31

5.1.2 Daily H2S Scavenger and H2O Addition to V-110. 32

5.1.3 Purging Liq= uid from V-200. 34

5.1.4 Changing Lean/Rich DEG Filters. 35

5.1.5 Purging liq= uid from V-330 K/O Pot and V-340 Coalescer Filter base. 36

5.1.6 Changing Coalescer Filter Material 37

5.1.7 Adding Fres= h DEG to System.. 38

5.1.8 Unloading F= lare Knockout Tank. 39

5.1.9 Preparing C= ooling Towers for Winter 40

5.1.10 Lighting Reboiler= 41

5.1.11 Plant GC Calibrat= ion. 42

5.1.12 Plant GC Bakeout Procedure. 43

5.2.0 Plant Start= up Procedure

6.1 Typical Bub= ble Cap. 49

6.2 Typical Chi= mney Tray. 49

6.3 Plant Air Compressor Photos. 49

6.4 West Landfi= ll Gas Compressor Photo. 50

6.5 V-100 Inlet Separator and Blowers Photo. 50

6.6 LFG Compres= sor Discharge and Purge Outlet Valves. 51

6.7 LFG Compres= sor Recycle Line Block and Check Valves. 51

7.0 Forms. 54

7.01 Daily Logsheet Example. 54

7.02 Spill Report Checklist 55

INDEX. 62

1.0= = Introduction

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The following procedures are a guide for startup, shutdown, and routine operati= on of the L7-i.com Landfill Gas Plant. They are intended to help insure the sa= fe and efficient execution of these activities. Changing conditions may dictate the alteration of certain steps; however, the procedures as described in th= is document have stood the test of time in that they maximize safety and minim= ize downtime.

1.1 Process Overview

1.1= .0 Main Process

Summary

Blowers, located in the Landfi= ll 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 press= ure to the main gas compressor(s). The compressor discharges into a 12-tray bub= ble 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 usa= ge at Norflux’s L7-i.com Generating Station.

Simplified Process Flow Diagram

Details o= f Main Process

The anaerobic decomposition of the organic waste component of the garbage burie= d in the landfill produces Landfill gas - abbreviated as LFG. The gas is primari= ly composed of methane and carbon dioxide; however, a small yet significant percentage of highly toxic compounds such as hydrogen sulphide a= nd BTEX a= re 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 signifi= cant 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 disp= osal 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 elimin= ate 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 1-2½ psig (7-18 kPag) is applied to the inlet line, which in turn creates a constant “suction” on the entire collection syst= em. Centrifugal blowers, located inside the plant, create the vacuum.<= span style=3D'mso-spacerun:yes'>

The LFG, saturated with water, discharges from the wells at temperatures typically around 60-90ºF (16-32ºC). As the water saturated gas flows towards the plant, it cools below its dew point, causing the water to condense througho= ut 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 f= ine 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, et= hyl 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 expos= ure 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. Re= fer to appropriate safety literature and always use safe trade practices.<= /o:p>

From the inlet line,= LFG flows into the vertical hydro cyclone recirculating Inlet Separator<= !--[if supportFields]>= XE "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

Gas leaving V-100 e= nters the main Blower Suction Header (= H-804), which is a cylindrical horizontal vessel equ= ipped 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 Suction hdr

Blower Suctions (3)

Plant Inlet Header

Inlet Block Valve

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 landfi= ll gas well network. Normally there are two blowers running, feeding one recip= rocating compressor, but the plant PLC h= as 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 capacit= y of 1280 CFM. Three suction line butterfly valves set the blower flow rates.

LFG discharges from the blowers at 1½-7 psig (10-50 kPa). The compressing effect of the blowers imparts substantial heat to the gas, with temperature= s of 160-175ºF (74-80ºC) being typical. The heated LFG is passed throu= gh 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.<= /o:p>

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

NOTE:

All plant effluent s= ources – liquids and gases – are connected to the main flare header. R= efer to the Flare E= ffluent heading in this section for more detailed information.
Cooled gas and condensed free liquids exit HE-100 a= nd enter the Pre-clean Contactor Tower (= V-110), 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 a= gent 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 concentra= tion 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 chemic= al 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 t= he flare header. In winter months, this may be necessary every two weeks.

V-110 Pre-clean Contactor / H2S Remover= <= /h2>

and= V-200 Pre-clean Knockout<= /span>

Gas Compressor

The sweet, dry, and cool gas l= eaving 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 90-9= 7 psi (620-670 kPa). The intercoolers tubes are composed of stainless steel. See attachment section and the following page for more images of LFG Compressor= s.

= The compressors are protected by the 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.

3D"Text A recycle line equipped with a pneumatic control v= alve (FCV-831) allows the gas to be recycle= d from the compressor discharge back to HE-100 inlet. FCV-831 allows the compresso= r(s) to run without surging when the total plant throughput is lower than the su= rge point. The controller takes its flow signal from the same differential pres= sure (DP) element that supplies the sales gas chart. The valve fails open. On ma= nual 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.

Inlet Header

Panel Gauges

South High Pressure Cylinder

HP Outlet (North End)

Gearbox / Drive

North High Pressure Cy= linder

Low Pressure Cylinders

East Side of <= st1:place w:st=3D"on">East LFG Compressor

Electric Motor Driver

Inlet Header

North Low Pres. Cyl

Intercooler

North High Pres. Cyl

Both LFG Compressors

Upon discharging from the compressors, the gas enters the Gas/DEG H= eat 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 exchanger’s 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= XE "HE-310" . This heat exchanger is a two-pass shell and t= ube 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=

V-300 Main Dehydration Contactor

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 thro= ugh 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 bo= ttom half trays. There is a stainless steel mist pad at the top of the tower. Diethylene glycol (DEG) is circulated through the to= wer 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 con= tinue its path to the DEG regeneration system. As the LFG travels up throug= h 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 c= arried 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 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 m= ust 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.

From V-340, the LFG is metered through an orifice plate differential flow meter w= here 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<= !--[if supportFields]>= XE "TR-01" ) are recorded on this chart. From this data, an accurate pressure and temperature compensated flow rate can be calculated u= sing a mathematical formula.

V-330 Overhead Knockout Pot, V-340 Coalescer Filter, and Pressure Controllers

Two Kimray backpressure controllers a= ct in complimentary fashion to maintain plant and sales gas line pressure. PCV-10= 0, which outlets to the sales gas line, is set a= t 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 attemp= t 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 pressu= re 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 wi= ll bleed off plant pressure to it until it reaches its setpoint of 75 psig = 211; 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 l= ine and flows into the L7-i.com Generating Station C= ustody 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 stati= on. Water and H2S concentration, as well as the heating value, are also continuously monitored. From here, t= he gas flows into one or both of two boilers where it is burnt to generate steam.<= o:p>

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 tower’s chimney tray through the Rich DEG f= ilter (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 Sti= ll (= V-312) and its direct-fired reboiler (= HE-311).

Diethylene Glycol (DEG) System

The DEG R= ecovery Still (V-312) or DEG Stripper i= s a relatively small distillation column with stainless steel pall packing ring= s. The packing functions as both separation medi= a 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 f= eed-tray at the base of the column. These lighter components flow overhead to the fl= are knockout tank; the heavier DEG component falls down to the reboiler.

Pilot and Burner Access Port

Reboiler Firebox / Firetube Area

DEG Recovery Still Main Section

Internal Reflux Condenser Section

Burner Exhaust Stack

DEG Recovery Still (V-312) and Gas Fired Reboiler

Lite-off Port

Burner Gas Piping

Exhaust Stack

Tower Packing: Pall Ring=

Gas Fired Reboiler – We= st Side

= The Reboiler section consists of two horizontal cylindrical vessels connected b= y a “downcommer” pipe. The lower vessel (V-311) contains dehydrated DEG (Lean DEG) and functions as an “Accumulator”, from which the DEG pu= mp(s) take suction. The upper vessel contains the gas fired reboiler firetube element that heats the incoming Ric= h DEG (saturated) for distillation. The l= iquid 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 g= as travels up through the Reboiler/Sti= ll and overhead to the flare K/O tank with the rest of the tower overheads.

Lean DEG Outlet

Accumulator V-311

“Downcommer”

Reboiler Sightglass

Reboiler HE-312

Gas Fired Reboiler (V-312) and Accumulator (V-311)

The reflux condenser, a double looped stainless steel tube, is loca= ted 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 i= s fed into the U-shaped condenser tube-side to provide the cooling. It has been s= hown that this system is of limited benefit and is therefore seldom put in servi= ce.

DEG Pumps

Pump Discharge Line(s)

DEG from Accumulator

To Reflux Condenser

To Cooling Tower

From Cooling Tower

Cooling Tower Bypass

Cooled DEG to V-300

Diethylene Glycol (DEG) P= umps and Piping

The lean DEG i= n the Accumulator f= lows to the suction of the Lean DEG pump(s) (P-100 &= amp; P-310) and is pumped through the DEG Cooling Tower (= HE-330). The primary element in the cooling 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 spr= ay water is collected at the base of the tower and recirculated back to the sp= ray 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 extern= al water storage tank. In the winter m= onths, 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 f= lows through a globe valve, which is used to manually set the flow to V-300. The flow-rate is indicated locally by a turbi= ne 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).

DEG Flow Meter

DEG Globe Valve

Hat Tray Level Control

Lean DEG Pumps

V-300 – Main Contactor

DEG Addition To V-300 Piping=

A small carbon filter (= V-350), used to remove liquid hydrocarbons, takes a slipstream flow o= f lean DEG f= rom 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 XE "DEG" Slipstream Carbon Filter

&nbs= p;

1.1= .2 Ethylene Glycol (EG) Cooling System

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

; = Compressor Intercoolers

; = Compressor Jacket Coolers

; = Compressor Oil Coolers

; = HE-100 P= re-clean Gas / Glycol Cooler

; = HE-310 C= ontactor Precooler / Compressor Aftercooler

Cooled EG is pumped = from the EG Receiver t= o 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 i= s almost identical to the DEG C= ooling Tower as described previously. After bei= ng cooled in the tower, the EG flows back to the EG Receiver where it starts i= ts cycle again.

During normal operat= ion, the EG Receiver l= evel is constant; any change in level indicates a problem. An atmospheric vent at t= he top of the EG Receiver has been fitted with extension piping that outlets n= ear 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 ei= ther an EG piping leak or a tube leak in HE-100, which operates at a process side pressure tha= t is less than the EG system.

East EG Circ Pump

West EG Circ Pump

H2S Scavenger

Storage

3D"Text

EG Inlet to HE-100 – throttle valve

HE-100 Pre-clean Gas Cooler

EG Circulation Pumps

1.1= .3 Flare Effluent System

Flare Knockout Tank and Stack

The majority of plant equipment capable of producing gas or liquid effluent has connections to the main fla= re 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.<= o:p>

= V-420 is a double walled fiber-glass vess= el with a retractable probe installed between the inner and outer walls. This probe is withdrawn regularly and checked to ensure that it is completely dr= y. The presence of liquid indicates that the inner hull is leaking, at which p= oint the vessel would have to be taken out of service for repair. In this case, = the vessel should be shutdown and emptied as soon as possible as a failure of t= he 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 Unloa= ding Pump (= P-120) that takes suction from the bottom of the tan= k and discharges to the unloading standpipe. The standpipe is located near the southwest gate of the plant site. The liquid effluent is transported by tan= ker truck to a hazardous waste disposal facility.

The flarestack is equipped with a flame arrestor t= hat 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 reestablis= hed quickly should it go out. A thermocouple installed near the windguard sense= s a flameout a= nd triggers an alarm in the control room.

Refer to PID LFGP-05 from more information.

Flare Stack Burning Full Flow of Plant Gas

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.

3.0 = ; Definitions XE "Definitions"

BTEX	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.
Bubble Cap Tray	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. <= /span>
Chimney Tray	Dehydration Contac= tor - 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. <= /span>
DEG	Diethylene Glycol= – Absorption Material
EG	Ethylene Glycol - = Coolant
HDPE	High Density Poly= ethylene – Plastic piping material
LFGP	Landfill Gas Plant=
LFG	Landfill Gas – in any stage from raw well gas to sales gas
SOP	Standard Operating Procedure = &nb= sp; = &nb= sp; = &nb= sp;

4.0 &= nbsp; 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; t= he designation of whom is at the discretion of the LFGP Superintendent.

These procedures, and any future ch= anges made to them, must be signed off by Landfill Gas Plant Superintendent to be considered “official”.

5.0= = Routine Checks and Activities

5.01 Daily

= Step	=	Key Points
<= /span>	<= /span>	<= /span>
1. &nbs= p; Complete daily checks and logsheet round.	<= /span>	; &nbs= p; Record readings on the daily run log when appropriate.
<= /span>	<= /span>	<= /span>
2. &nbs= p; Check for leaks throughout the plant.	<= /span>	; &nbs= p; A LFG leak into the plant will first show up = on the PLC panel hydrocarbon sensor. Care should be taken when first investigati= ng a high hydrocarbon in ambient air alarm.
<= /span>	<= /span>	<= /span>
3. &nbs= p; Check LFG analysis printout.	<= /span>	; &nbs= p; Ensure that oxygen is well below 4 %. ; &nbs= p; Look for signs of air leaks into system by observing ratio of oxygen and nitrogen.
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4. &nbs= p; Check blower suction header pressure and temperature	<= /span>	; &nbs= p; Pressure should be –8 to –20 kPa @ normal flow rate; pressure can fluctuate due to water movement in the sys= tem.
<= /span>