Installation Manual - Sistema.Biosistema.bio/wp-content/uploads/2017/04/FdC-Installation-Manual.pdfSistema.bio® Installation Manual Introduction to TaroWorks TaroWorks is an Android

Installation Manualwww.sistema.bio

Technician tools 1Site characteristics 1Index of processes and forms 2Introduction to TaroWorks 3Farm evaluation 4Reactor size selection 4Trench dimensioning 6Biobolsa installation methods 8Biobolsa feeding methods 8Biobolsa installation 9Simple trench 12Double trench 13How to do hose leveling 16Installation with retaining wall 17Reactor installation 20Sistema Biobolsa® components 21Biogas line installation 26Biogas line 27Water traps 29Biogas filter 30Perimeter fence 31Biogas use 32Biol management system 33Handling and transportion 34Installation follow-up 35

Humidity tramp 25Filter to reduce hydrogen sulfide (H2S) 26Protecting the system 27Formulaire de suivi d’installation fiabilisée 28Notes 29

Contents

1Sistema.bio®/ Installation Manual

Technician tools

Site Characteristics

The site should count with: • Sufficient water and its availability during most of the year. • Availability of animals (bovine, porcine, caprine, fowl and/or rabbits) for the daily production of the required manure (or its equivalent every 2-3 days) for feeding the Sistema Biobolsa.

It’s necessary that the user has: • Received enough information related to the system in order to make an informed decision. • Agreed to purchase and use the Sistema Biobolsa through self-will. • Manifested understanding about the time and/or resources required to operate the system; due to the fact that the Sistema Biobolsa does not function without adequate operation practices by the user. • Manifested understanding about the fact that the Sistema Biobolsa® is not an isolated technology, but it is a piece of an integral production system that includes waste treatment, energy generation and fertilizer production, which implies an integral management of resources. • Manifested understanding and acceptance of the risks associated with handling biogas and biol.

ToolboxHexagonal wrench for clampsCrescent wrench (>1.5”)Electrician tweezersHose cutter (1”)Multipurpose cutterFlexometer (8 m)Measuring tape (20 m)ChiselHammerMalletArch with fretsawButane nozzleButane canGlue for PVCScissorsLeveling hoseShovel / peak / digging toolsCloth Teflon tape (1”)6 stakes (50 cm)

Omega clamps (1”)NailsPVC spiked fittings (1”)PVC teePVC 90-degree elbow (1”)Campanas de 1” a 1/2” Half-turn capsCutterStillson wrench

Security equipmentWaterSafety glassesGlovesPlastic bootsAntibacterial gel

Electronic equipmentpH meterMobile Phone with TaroWorks appRecommended: Bring hard copies field formats.

Servicing equipmentGasoline pump (2”)Corrugated suction pipe (3 m)Canvas hose (20 m)

Maintenance equipmentMud pump (3”)


Index of processes and forms

The sale-installation process of each Sistema Biobolsa is documented in a digital database. For this reason, it is important that the certified technician is knowledgeable about the importance of data collection on each farm (livestock unit) through either the mobile app TaroWorks or printed forms.

The following table shows the stages of the sale-installation process in which the technician is involved, as well as the forms that should be filled on each stage, and the mandatory documents that the user must sign.

Field formats

# Name of the stage Activities in TaroWorks Printed Formats Required documents

Long Diagnostic

2. New contact and long

diagnostic.

FdC - Long Diagnostic.pdf N/A3. Diagnóstico contacto existentes

Purchase order

Site

preparation1. Site validation format.

FdC - Site Validation

Format

TRENCH DESIGN DOUBLE

MODEL.pdf

TRENCH DESIGN SIMPLE

MODEL.pdfProduction order

Instalation 4. Secure installation format.FdC - Secure installation

format.pdfFdC – User Contract.pdf

Follow up

1. Follow up 1FdC – Followup 1- 30

days.pdf

N/A

2. Follow up 2FdC - Followup 2- 90

days.pdf

3. Follow up 3FdC - Followup 3- 180

days.pdf

5. Extraordinary follow upFdC - Extraordinary

Monitoring.pdf

6. Service visit. FdC – Service Format.pdf

All of the mandatory forms and documents are available in the Promoter Package in the following link:PAQUETE PROMOTOR SB-2016\PAQUETE PROMOTOR 2016- EQUIPO SB (I)\TECNICO_FORMATOS DE CAMPOPAQUETE PROMOTOR SB-2016\PAQUETE PROMOTOR 2016- EQUIPO SB (I)\TECNICO_ZANJAS


Introduction to TaroWorks

TaroWorks is an Android app that has the purpose of: • Transferring data from a mobile phone to the data base • Allowing to do data collection outside of the network coverage areas • Improving the quality of data • Help fieldwork personnel to monitor their performance • Only technicians authorized by Sistema Biobolsa have access to TaroWorks.

ConsiderationsSync: It is the data exchange between TaroWorks on the mobile phone and the system in the officeAll completed works come out of TaroWorks and get into Salesforce (digital database), and then they get eliminated from the mobile phoneThe mobile phone does get updatesIn order to sync, it is ideal to do so under a wifi connection, or under a strong data network signalTo use the GPS:Activate GPS on the cell phone settingsUse satellites to determine locationWorks better without obstructions between the cell phone and the skyIt has high battery demand (turn off while not in use)


Content

It is important that the technician in charge of the installation performs an exhaustive visual inspection, in addition to a comprehensive interview with the future user. This will ensure that the Sistema Biobolsa is operated in accordance with the family needs.

Evaluation goals:1. Understand the current management practices of the farm including:

1.1 Availability of fresh Manure (type and quantity) based on the number of animals in the farm. 1.2 Availability of Water. The system can’t be installed if there’s no water availability throughout the entire year. 1.3 Energy demand by the family or farm. (Making an estimate based on consumption data of LPG and firewood). 1.4 Fertilizer demand. It is important to make an estimate of the quantity of fertilizer that the family currently uses. 1.5 Adequate space for the installation of the Sistema Biobolsa. 1.6 Available space to move the manure mix, biol and biogas.

2. Identify the main needs of the farm: waste treatment, energy savings, fertilizer savings or sanitation.3. Identify the potential benefits of the Sistema Biobolsa® in the lives of the family or users.4. Clearly explain to the family that the installation site location of the Sistema Biobolsa should consider the long term planning of the farm.5. Visualize with the family the installation of the biodigester and clearly answer any questions they may have.6. Make it clear that the success of the project depends on them, and that they will be responsible to take the actions required to achieve project success.7. Perform visual documentation through site pictures.8. Obtain the contact information needed to follow-up in the future.

NOTE: Taking into account these considerations, fill out the evaluation form in the Appendix.

Reactor size selection

Factors to be considered for determining the appropriate size of the Sistema Biobolsa:1. Availability of water.2. Availability of manure.3. Energy demand.4. Fertilizer demand: Ensure that the selected system produces a quantity of biol that the user can handle.

The sizing table (see following page) shows the size of the Sistema Biobolsa according to the factors mentioned above.

¿How to calculate the quantity of manure?

To find out the quantity of daily manure available, we suggest the following procedure:a) Completely clean out the animal pens.b) Wait for an entire day (24 hours).c) Measure in 19 liter buckets the accumulated manure. How many buckets were filled? d) Repeat for 3 or 4 days. e) Add up all the buckets filled during the 3-4 day period and divide by the number of days. This will be the average daily manure production.

Farm evaluation

?


Reactor size selection

Biobolsa Model

Solids treated per day

(L)

Semi-confined (heads)

Daily biogas

production (m3/day

Daily biogas

production

(hours/day)*

Biogas production

(kg propane/m

onth) **

Electricity generation (kWh/day)

Biol production (ha/year)

Daily biol

production

(L/day)

Biobolsa Model


(L)

Hogs ( 50 kg)

Daily biogas

production (m3/day

Daily biogas

production

(hours/day)*

Biogas production

(kg propane/m

onth) **


Biol productio

n (ha/year)

Daily biol

production

(L/day)

BB4-t 30 12 1.2 2.4 14.4 2.4 4 120 BB4-trop 20 12 1.2 1.6 14.4 2.4 4 120

BB4 36 14 1.4 2.9 17.3 2.9 5 144 BB4 24 15 1.4 1.9 17.3 2.9 5 144

BB6 52 20 2.1 4.2 25.0 4.2 7 208 BB6 34 21 2.0 2.7 24.3 4.1 7 203BB8 85 34 3.4 6.8 40.8 6.8 12 340 BB8 57 35 3.4 4.6 41.0 6.8 12 342BB10 97 39 3.9 7.8 46.6 7.8 14 388 BB10 65 40 3.9 5.2 46.8 7.8 14 390BB12 109 44 4.4 8.7 52.3 8.7 15 436 BB12 73 45 4.4 5.8 52.6 8.8 15 438BB14 125 50 5.0 10.0 59.8 10.0 17 499 BB14 83 52 5.0 6.6 59.8 10.0 17 499BB16 170 68 6.8 13.6 81.6 13.6 24 680 BB16 113 70 6.8 9.0 81.4 13.6 24 678BB20 194 78 7.8 15.5 93.1 15.5 27 776 BB20 130 81 7.8 10.4 93.6 15.6 27 780BB25 219 88 8.8 17.5 105.1 17.5 31 876 BB25 146 91 8.8 11.7 105.1 17.5 31 876BB30 267 107 10.7 21.4 128.2 21.4 37 1068 BB30 178 110 10.7 14.2 128.2 21.4 37 1068BB40 364 146 14.6 29.1 174.7 29.1 51 1456 BB40 243 151 14.6 19.4 175.0 29.2 51 1458BB50 437 175 17.5 35.0 209.8 35.0 61 1748 BB50 291 181 17.5 23.3 209.5 34.9 61 1746BB60 534 214 21.4 42.7 256.3 42.7 75 2136 BB60 356 221 21.4 28.5 256.3 42.7 75 2136BB80 729 292 29.2 58.3 349.9 58.3 102 2916 BB80 486 302 29.2 38.9 349.9 58.3 102 2916BB120 1093 437 43.7 87.4 524.6 87.4 153 4372 BB120 729 452 43.7 58.3 524.9 87.5 153 4374BB160 1457 583 58.3 116.6 699.4 116.6 204 5828 BB160 971 602 58.3 77.7 699.1 116.5 204 5826BB200 1821 728 72.8 145.7 874.1 145.7 255 7284 BB200 1214 753 72.8 97.1 874.1 145.7 255 7284

Biobolsa Model


(L)


Daily biogas

production (m3/day

Daily biogas

production

(hours/day)*

Biogas production

(kg propane/m

onth) **



Daily biol

production

(L/day)

Biobolsa Model


(L)

Hogs ( 50 kg)

Daily biogas

production (m3/day

Daily biogas

production

(hours/day)*

Biogas production

(kg propane/m

onth) **


Biol productio

n (ha/year)

Daily biol

production

(L/day)

BB4 24 2 0.9 1.9 11.4 1.9 3 95 BB4 16 10 0.9 1.3 11.4 1.9 3 95BB6 34 3 1.4 2.7 16.2 2.7 5 135 BB6 23 14 1.4 1.8 16.2 2.7 5 135BB8 56 6 2.2 4.4 26.7 4.4 8 222 BB8 37 23 2.2 3.0 26.7 4.4 8 222BB10 64 6 2.5 5.1 30.6 5.1 9 255 BB10 42 26 2.5 3.4 30.6 5.1 9 255BB12 72 7 2.9 5.7 34.5 5.7 10 287 BB12 48 30 2.9 3.8 34.5 5.7 10 287BB14 83 8 3.3 6.6 39.9 6.6 12 332 BB14 55 34 3.3 4.4 39.9 6.6 12 332BB16 111 11 4.4 8.9 53.4 8.9 16 445 BB16 74 46 4.4 5.9 53.4 8.9 16 445BB20 127 13 5.1 10.2 61.1 10.2 18 510 BB20 85 53 5.1 6.8 61.1 10.2 18 510BB25 145 14 5.8 11.6 69.4 11.6 20 579 BB25 96 60 5.8 7.7 69.4 11.6 20 579BB30 177 18 7.1 14.2 85.0 14.2 25 708 BB30 118 73 7.1 9.4 85.0 14.2 25 708BB40 242 24 9.7 19.3 116.1 19.3 34 967 BB40 161 100 9.7 12.9 116.1 19.3 34 967BB50 289 29 11.6 23.1 138.9 23.1 41 1157 BB50 193 120 11.6 15.4 138.9 23.1 41 1157BB60 354 35 14.2 28.3 169.9 28.3 50 1416 BB60 236 146 14.2 18.9 169.9 28.3 50 1416BB80 484 48 19.3 38.7 232.1 38.7 68 1934 BB80 322 200 19.3 25.8 232.1 38.7 68 1934BB120 725 73 29.0 58.0 348.2 58.0 102 2901 BB120 484 300 29.0 38.7 348.2 58.0 102 2901BB160 967 97 38.7 77.4 464.2 77.4 135 3869 BB160 645 400 38.7 51.6 464.2 77.4 135 3869BB200 1209 121 48.4 96.7 580.3 96.7 169 4836 BB200 806 500 48.4 64.5 580.3 96.7 169 4836

Biobolsa Model


(L)


Daily biogas

production (m3/day

Daily biogas

production

(hours/day)*

Biogas production

(kg propane/m

onth) **



Daily biol

production

(L/day)

Biobolsa Model


(L)

Hogs ( 50 kg)

Daily biogas

production (m3/day

Daily biogas

production

(hours/day)*

Biogas production

(kg propane/m

onth) **


Biol productio

n (ha/year)

Daily biol

production

(L/day)

BB4 14 1 0.6 1.1 6.8 1.1 2 57 BB4 9 6 0.6 0.8 6.8 1.1 2 57BB6 20 2 0.8 1.6 9.7 1.6 3 81 BB6 14 8 0.8 1.1 9.7 1.6 3 81BB8 33 3 1.3 2.7 16.0 2.7 5 133 BB8 22 14 1.3 1.8 16.0 2.7 5 133BB10 38 4 1.5 3.1 18.3 3.1 5 153 BB10 25 16 1.5 2.0 18.3 3.1 5 153BB12 43 4 1.7 3.4 20.7 3.4 6 172 BB12 29 18 1.7 2.3 20.7 3.4 6 172BB14 50 5 2.0 4.0 23.9 4.0 7 199 BB14 33 21 2.0 2.7 23.9 4.0 7 199BB16 67 7 2.7 5.3 32.0 5.3 9 267 BB16 44 28 2.7 3.6 32.0 5.3 9 267BB20 76 8 3.1 6.1 36.7 6.1 11 306 BB20 51 32 3.1 4.1 36.7 6.1 11 306BB25 87 9 3.5 6.9 41.7 6.9 12 347 BB25 58 36 3.5 4.6 41.7 6.9 12 347BB30 106 11 4.2 8.5 51.0 8.5 15 425 BB30 71 44 4.2 5.7 51.0 8.5 15 425BB40 145 15 5.8 11.6 69.6 11.6 20 580 BB40 97 60 5.8 7.7 69.6 11.6 20 580BB50 174 17 6.9 13.9 83.3 13.9 24 694 BB50 116 72 6.9 9.3 83.3 13.9 24 694BB60 212 21 8.5 17.0 102.0 17.0 30 850 BB60 142 88 8.5 11.3 102.0 17.0 30 850BB80 290 29 11.6 23.2 139.3 23.2 41 1161 BB80 193 120 11.6 15.5 139.3 23.2 41 1161BB120 435 44 17.4 34.8 208.9 34.8 61 1741 BB120 290 180 17.4 23.2 208.9 34.8 61 1741BB160 580 58 23.2 46.4 278.5 46.4 81 2321 BB160 387 240 23.2 30.9 278.5 46.4 81 2321BB200 725 73 29.0 58.0 348.2 58.0 102 2901 BB200 484 300 29.0 38.7 348.2 58.0 102 2901

* La producción de biogás es un estimado promedio basado en un uso de biodigestor estándar** La producción de biogás es variable dependiendo dependiendo de condiciones a las que el sistema opere.

Warm weather dairies >23˚C Other warm weather sites >23˚C

Temperate dairies 15˚C to 22˚C | other temperate sites 15˚C to 22˚C Other temperate sites 15˚C to 22˚C

Cold weather dairies <15˚C Other cold weather sites <15˚C


Trench dimensioning

Trench CHANFER

Biobolsa Model Width (m) Lenght (m) Depth (m) Height (m) Depth (m)

BB4-T 5.0 1.10 0.70 0.3 0.3

BB4 6.0 1.10 0.70 0.3 0.3

BB6-S 8.5 1.10 0.70 0.3 0.3

BB6-D 3.0 2.20 1.20 0.6 0.6

BB8-D 3.5 2.20 1.20 0.6 0.6

BB10-D 4.0 2.20 1.20 0.6 0.6

BB12 4.5 2.20 1.20 0.6 0.6

BB14 5.2 2.20 1.20 0.6 0.6

BB16 6.0 2.20 1.20 0.6 0.6

BB20 7.5 2.20 1.20 0.6 0.6

BB25 9.0 2.20 1.20 0.6 0.6

BB30 11.0 2.20 1.20 0.6 0.6

BB40 15.0 2.20 1.20 0.6 0.6

110 cm

20cm

40 cm70 cm

50 cm(level)

40 cm

30 cm

30 cm30 cm

70 cm

www.sistemabiobolsa.com

70 cm35 cm

50cm

35 cm

50cm

100 cm

90

cm

100

150cm

cm

Contact :

Name: Date :

Model: Length : Depth : Width:

TRENCH FOR BIOBOLSA: SIMPLE

Water : Manure :

Trench Length:

Gap for 4” PVC entrances and exits

Chanfer

4" PVC tube

Interior length according to Bibolsa Model

TRENCH

Effluent capture and

storage


storageTRENCH

REACTOR TRENCH EFFLUENT CAPTURE AND STORAGE TRENCHREACTOR TRENCH

Trench Length:

220 cm

20cm

90 cm120 cm

1.0 m(Level)

60 cm

60 cm

Gap for 4” PVC entrances and exits

Chanfer

60 cm60 cm

4" PVC tube

120 cm

120 cm90 cm

50cm

Interior length according to Bibolsa Model

90 cm

50cm

100 cm

90

300cm

TRENCH

100

150

300 cm

Contact :


REACTOR TRENCH EFFLUENT CAPTURE AND STORAGE TRENCH


storage


storageTRENCH

REACTOR TRENCH

Name: Date :

Model: Length : Depth : Width:

TRENCH FOR BIOBOLSA: DOUBLE

Water : Manure :

Stage: Site preparation

Figure A: Simple System Figure B: Double System


The considerations for the installation site location of the Sistema Biobolsa are as follows:

• Using the dimensions of the selected system, confirm that the site has sufficient space, considering the mixing chamber and biol storage pit.

• It is recommended that the installation site is no further than 50 m from the location where biogas will be used. In case of requiring a longer biogas line, contact Sistema Biobolsa® for assistance.

• Evaluate the current site for manure disposal. This could be a good site to install the system given the current user practices.

• Leave sufficient space to feed the Biobolsa with a wheel-barrow or bucket (it is recommended to use automated feeding methods, for example, gravity or pipes).

• Leave at least 1.50 m of space for the mixing chamber that feeds the biodigester, plus a ramp if necessary. On the side of the system’s effluent, leave enough space for the biol pit.

• In order to increase the temperature inside the Biobol-sa, select a site that’s exposed to sunlight, especially on temperate and cold regions. The selected site must not interfere with the daily activities of the farm. For instance, avoid locations destined to the passage of vehicles, peo-ple or animals.

• The Biobolsa should count with sufficient space around the perimeter in order to ease the access for operation and maintenance.

• Take advantage of existing structures to help reduce the cost of fencing and roofing. For example, a good site op-tion will be next to an existing wall (it’s important to ensure the load bearing capacity of the wall).

• For the biol storage pit consider enough space to store 10 to 20 days of biol production.

• Consider space to build a perimeter fence or wall, and a roof to protect the system.


There are two ways in which the Biobolsa can be installed (a) TRENCH: The system can be installed inside a trench, meaning that it will be partially covered by the ground as shown on figure 1 (b) RETAINING WALL: The Biobolsa is laid out at ground level and lateral-ly contained by a block structure as shown in figure 2.

NOTE: The first installation method is recommended, unless the terrain will not allow for an excavation due to a rocky surface or high phreatic level.

1. Manual Feeding: If it is desired to allow manure to enter the Biobolsa by gravity, the site should be below the manure production location.2. Gravity: If the manure is conducted directly by small channels from the pens, the system should be located in the lowest possible point in order to allow the manure mix to flow by gravity.3. Pumping: If the manure is disposed by gravity to a pit, and then pumped to the biodigester; it’s of vital importance to consider the distance from the pit to the Biobolsa.

Avoid locations that are prone to flooding during the rainy season or that are exposed to high winds.

Biobolsa feeding methods

Biobolsa installation methods

Fig.2Fig.1


Biobolsa Installation

Prior to site preparation, confirm that the user has agreed to the installation site location and to the size of the Sistema Biobolsa that is going to be installed.

Trench Excavation

For areas that are not rocky or prone to flooding, the excavation represents a low investment and soil works well to contain the liquid capacity of the biodigester.

Step1:

Utilize Table 2 for confirming the trench dimensions corre-sponding to the selected Sistema Biobolsa model. For mark-ing the trench see Diagrams for simple and double trench types (page 12 y 13 of this manual).

*NOTE: Verify that it exists sufficient space for the feeding area and effluent storage of the biodigester.

1 1


Step 2:

The depth of the trench can be increased but never reduced. The depth indicated in Table 2 is the minimum required to retain and give shape to the biodigester.

The trench can go deeper if this helps in allowing the ma-nure mix to flow by gravity, in such case keep in mind that the effluent pipe for the release of biol will end up below ground level.

1 0Sistema.bio®/ Installation Manual

Step 3: Start by excavating in a straight manner, 40 cm in depth for sausage models and 60 cm for double models. See diagrams for the sausage and double trench types (p. 10 y 11 of this manual).At this point it is important to check for the correct flat excavation level. (See section: How to do hose leveling)

Step 4:

Within the mark of the chamfer, excavate an additional 30 cm for sausage models and 60 cm double models. Once done, perform an excavation level check.

Step 5:

Cut the chamfer in a diagonal between the two levels (on the four sides of the excavation). The chamfers need to end up as shown on diagram 5. There should not be any steps, and all transitions must be straight.

Step 6:

Once the trench is finalized according to the specified dimensions, place a string in the middle of the trench so the level of the flat part of the excavation can be checked. This is a fundamental aspect that guarantees the correct functioning of the system.

Corte

43


x

4 5

CHANFER


x-60

DIS

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O D

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AN

JA: T

ipo

Sal

chic

ha

x

Tam

año

o M

od

elo

de

Bio

sist

ema:

Vue

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auch

e

Vue

de fa

ce

Vue

de d

esso

us

Vue

de g

auch

e

Cou

pe C

C

C

30

30 50 30

30

Vue

de d

esso

us

Vue

de F

aceDét

ail 1

Dét

ail 1

30

40 30

Det

ail Y

30

DIS

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AN

JA:

Tip

o S

alc

hic

ha 40

30

40

Hig

hest

poi

nt b

efor

e th

e slo

pe o

f the

cha

mfe

r

Simple trench Stage: Site preparation


AA

Cou

pe B

B

DIS

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AN

JA: T

ipo

Cu

adra

do

Tam

año

o M

od

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Bio

sist

ema:

Vue

de d

esso

us

Vue

de fa

ce

Vue

de g

auch

e

Vue

de d

esso

us

xX-

100

Cou

pe A

A

Vue

de fa

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gau

che

5050

80

20100

DIS

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AN

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Tip

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do

60

60

60

50

40

80

20

100

60

20100

Dét

ail Z

80

Poin

t le

plus

hau

t av

ant d

esce

nte

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Double Trench Stage: Site preparation


Step 7: Make sure that the excavation edges are completely free of soil in a way that the biodigester is allowed to expand without obstructions.

Detail Y

30

DISEÑO DE ZANJA: Tipo Salchicha

40

30

40

Highest point before the slope of the chamfer


Step 8:

Once the trench is ready, additional cuts need to be made for the 4” PVC inflow/outflow pipes at the two excavation ends, following the dimensions corresponding to the model under installation.

Step 9:

Trace a perimeter around the trench with a shovel or lime powder.

Step 10:

Make a small trench around the perimeter of the digester trench that will serve as an anchor point for the geotextile once placed inside the digester trench. Ideally, this support trench will be located 40 cm around the perimeter of the digester trench, and it will be 30 cm wide and 20 cm deep.

Step A: Extend the leveling hose to verify that it is flexible and does not have any folds.

Step B: Fill the hose with water, making sure that air bubbles don’t get trapped inside.

20cm50cm

30cm

40cm

20cm50cm

30cm

90cm

8

Double model

Simple model

9


H

J

Step C: Place two stakes on the ground away from the exca-vation but centered at both ends of the trench.

Step D: Attach a string to one of the stakes.

Step E: Extend the string to the other stake and temporarily attach it. Step F: Grab the hose between two people (avoiding any water spills), and place the hose ends towards the stakes

Step G: The water level in the hose needs to reach the string height at point A.

Step H: The person at point B will adjust the height of the string on the stake until it reaches the water level in the hose.

Step I: Fix this end of the string and confirm that the two extremes of the string correspond to the water level in the hose.

Step J: Using a measuring tape, make sure that a constant elevation is measured along the length of the trench. The measured height will depend on the size of the stakes and the point at which the string was attached to them.

How to get level with hose

A



In the case that is not possible to excavate the trench depth indicated on Table 2, the trench depth can be achieved by combining excavation with the construction of a wall made out of earth, blocks or cement. The objective is to give the trench the minimum dimensions that will allow the Biobolsa to take the required shape.

Implications: 1. The construction costs associated with a retaining structure that is strong enough to hold the contents of the Biobolsa.2. The mixing chamber required to feed the biodigester will be located above ground level, thus requiring a higher effort to feed the biodigester.3. In the case of walls made out of bricks, blocks or cement, reinforced concrete will be required for structural sup port (see Figure 3), and earth chamfers will need to be made. 4. It is possible to build the walls with gravel, sand or compacted soil, and still guarantee the shape and dimensions indicated on Table 1, and have enough strength to support the fluid pressure inside the Biobolsa.

Installation with rataining wall Stage: Site preparation

5.0 m1.1 m

0.8 m

concrete block wall with internalsteelreinforcement 15-15*4

Stone masonry base with leveling of stone and debris brick wall 15*20*40 cm

Concrete inner floor,5 cm thick


Fig

. 3


Step 1:

According to Table 2, confirm that the inner dimensions of the retaining wall correspond to the Biobolsa model to be installed.

Step 2:

Level the ground inside the Biobolsa retaining structure according to the instructions shown on “How to do hose level-ing.” Confirm inner dimensions of the retaining wall, with chamfers of 30 cm by 30 cm for sausage models, and 60 cm by 60 cm for double models, in accordance with trench design drawings.

Step 3:

Confirm that the holes for the 4” pipes are made on the walls with the dimensions specified on the corresponding dia-grams.

Soil

Brick 1 2

3


Reactor installation

The following steps are applicable to all sizes of reactors. The system must be installed only after completing full site preparation according to the previous section.

Step 1:

Carefully inspect the prepared site, and remove any rocks and hard/sharp objects that can potentially damage the Biobolsa.

Confirm dimensions three times, by measuring excavation edges and corners. ¡Take all necessary time for this inspection in order to avoid problems in the future; the site must be in ideal conditions!

Stage: Installation


Step 2:

On a clean place free of sharp and obstructing objects, open the Sistema Biobolsa Package and identify the following parts:

1. Geotextile- protective ground cover2. Biobolsa (reactor)3. Two PVC exits with 4” ends4. Initial gas duct (2” PVC pipe)5. Biogas line connectors 6. Pressure release valve. 7. Mixing chamber with 4” outlet

8. Burner and grill with two burners9. Two 4” PVC wye fittings10. PVC entrances and exits”45°11. H2S reduction filters 12. Biogas humidity trap 13. Efluent tank

Take all pieces away from the geotextile (the large black cloth) and move them to a secure and protected location.

Sistema Biobolsa Components

129 10

711

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Step 3:

Place the geotextile cloth over the trench to cover it entirely. It must cover the bottom (A) and the walls (B), leaving the excess equally distributed outside the trench (C). Stretch it gently and uniformly, keeping in mind that adjustments won’t be possible once the bio-digester is installed.

(D) The four sides of the geotextile will be placed over the anchorage trench and will be fixed in placed by filling with soil, making sure that there’s enough inside the trench to be in touch with all of the trench surface.

The systems with the double design type come with two pieces of geotextile cloth. These cloths can properly reach the anchor-age trench on one direction, but only cover the side of the walls in the other direction. The two pieces must be placed on top of each other, but in opposite directions in a way that the trench perimeter is fully covered.

Step 4:

Be especially careful in this step Keeping the Biobolsa reactor folded, carry it (between 2, 3 or 4 people depending on the size/weight) to the inside of the trench.Place the folded Biobolsa reactor inside the trench or retaining walls, with the 2” biogas opening facing upward and precisely in the middle of the trench.

D

D


Carefully unfold the long sides of the Biobolsa (keeping the lateral folds), by taking the 4” inflow and outflow points to the ends of the trench, and leave them facing upward.

Be cautious in not damaging the biodigester while moving and opening it. Adjust the Biobolsa so the inflow and outflow points end up at the same level. The four corners should be in contact with the ground, without any folds. To adjust the position of the Biobolsa, pull on the edges of the reactor, avoiding to touch the PVC tubbin

• The Biobolsa should be correctly in place before it’s filled with

water. The Biobolsa won’t be able to be adjusted once filled with

water. It is recommended to verify levels with the hose once

the biodigester is in place in order to ensure the quality of the

installation.

• Open the lateral folds, and leave the Biobolsa completely open

prior to start the water filling process. While the Biobolsa is

opened, care must be taken to not alter its alignment. Afterwards,

confirm that the biogas outflow is perfectly aligned in the center of

the trench, facing upward.

• Once in place, the reactor is left entirely open covering the

ground.

Step 5:

Confirm that the Biobolsa is left centered in the trench and the two ends are leveled, taking a level measurement at both ends in addition to 2-3 strategic points along the system. Once the correct level of the Biobolsa has been confirmed, the water filling process can begin.

The water used for filling the Biobolsa does not have to be potable, but it must be free of chlorine, soap and chemicals. Ensure that the water entering the biodigester is free of dirt or sand, and that it is more or less clear. Slowly fill up the Biobolsa making sure that its alignment is not altered and no wrinkles form on its surface. This will allow for the water to be uniformly distributed. Keep filling up with water until the level of the 4” inflow and outflow points is reached.

Step 6: Connect the biogas outflow to the reactor, and then connect the transparent hose to the biogas outflow and the pres-sure release valve with the clamps included in the package (Fig.7).

Identify the direction in which biogas will be sent for its use. Using PVC glue, connect the initial biogas outflow the biogas outflow of the reactor, with the biogas connector for hose pointing in the direction of biogas travel. The control valve (blue) should remain closed at this point and it could be hanged or simply left sitting on the ground next to the trench.


Step 7:

Connect the inflow and outflow tubes with the 45° connectors; the straight tube and wye as shown on figure 5. When water is visible through the tube openings (inflow and outflow) and it is noticed that they’re completely filled with water, a hydraulic seal has been formed (Figure 6). The hydraulic seal will allow for organic waste to enter the biodigester but it won’t allow gases to scape, creating the necessary conditions for anaerobic digestion.

Note: On sites that do not count with a water pump or deep wells, it is recommended to hire a water truck to achieve the filling of 70% of the Biobolsa.

Fig. 7

Fig. 8


Step 8:

Connect the mixing chamber (made of geomembrane) to the inflow of the biodigester using the 4” PVC wye connector. The “solitary” end of the wye connector is plugged to the Biobolsa, and the 45 degree end is plugged to the mixing chamber, leaving opened the opposite end at which the Biobolsa was connected. The opened end will allow for visual inspection inside the Biobolsa and give access for mainte-nance when needed. It is not recommended to glue these connections at this point, only confirm that a hydraulic seal has been formed.

Step 9:

Fill the Sistema Biobolsa with the equivalent of 10 days of regular feeding that corresponds to the size of the installed Biobolsa, with fresh manure free of grass, sand, stones, trash, or any other unapt materials. Only use the minimum amount of water needed to allow the mixture to easily flow into the biodigester.

This will be the seed of the biodigester. If biol is available at a nearby location, it could be included in the initial filling process (5 to 10 buckets), thus improving the quality of the seed. The seed will be most effective if bovine manure is used, and if not available at the farm, it’s recommended to obtain it from an outside source.

Note: 1) In colder regions the activation time of the Biobolsa system is longer. The initial load will correspond to the daily load in order to prevent a system overload. 2) If swine manure is used in temperate regions, only use the equivalent load of 5 days.

1

Fig. 5

Fig. 6


The biogas system includes:

1. Pressure release valve2. Biogas filter3. Biogas line4. Two water traps (a piece of hose with a closed end and the other end connected to a tee connector)5. Bruner(s)

All of these components come in modular manner and can be installed according to the site specific needs.

Pressure release valveThe pressure release valve is designed to let biogas scape whenever the biogas pressure reaches 30 cm of water head. When the biogas reaches this pressure, it will be able to escape through the hose inside the water container. For it to work properly, THE VALVE MUST ALWAYS BE COMPLETELY FILLED WITH WATER.

Considerations:

• This valve could be installed either in the ground next to the reactor, or attached to a wall near the reactor. The valve performance will not be

affected by the chosen method.

• t is recommended to install the valve on a visible location, in a way that the water level of the valve can be checked and replaced as needed.

• The control valve will always be installed after the pressure release valve. This will allow the pressure release valve to keep working in case

that the control valve is closed.

• The pressure release valve must be installed in a ventilated or open space, allowing biogas to easily dissipate into the atmosphere. Although

biogas release must be avoided and excess biogas should all be burned.

• Fill up the water container to its maximum capacity. The small tube inside water container should always be filled with water; the less water

in the container, the lower the biogas pressure in the system.

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Biogas line installation Stage: Installation


Considerations:

• The biogas line is the flexible hose or PVC tube that conducts biogas from the reactor to the point(s) of biogas burning, like the stove, water

heater or engine.

• This line is NOT the same as the lines used for LPG, natural gas or butane, which are pressurized gases (under high pressure). Biogas is under

atmospheric pressure, meaning that is not compressed, and as a result water hoses, like polyduct or PVC, work well.

• Biogas contains a fraction of water that is evaporated and then condensed along the length of the biogas line. The biogas line should be visible

at all points, and it should not be buried under any circumstances.

• Biogas line sagging must be avoided in order to prevent water to accumulate.

• The biogas line should not get in the way of people, animals or machinery in the farm.

• The biogas line should not pass through locations where it can get damaged.

• If sagging of the biogas line can’t be avoided, a water trap that comes in the Sistema Biobolsa package must be installed in the low points.

Biogas line Stage: Installation

Upwards

Avoid low points


Step 1:

Make a work plan that includes a map with the biogas line drawn on it, and takes into account the aforementioned consid-erations. It is common to use poles, trees, roofs, walls and other existing structures to support the biogas line. If existing structures are not available, poles can be installed.

Step 2:

Install the biogas line by fixating it in a safe manner and guaranteeing its slope and protection. It is common to attach the biogas line using omega clamps or metallic wire. If a hose segment is not sufficient to finish the biogas line route, then additional segments can be added by using connectors and clamps, and ensuring proper impermeability.

Step 3:

Connect the biogas line from the reactor biogas release using a clamp.

Step 4:

Inspect the entire line after installation, confirming that all connections are well secured, and that the Biobolsa control valve is closed.

Farm

Post

Biobolsa

Biogashumidity trap

Biogashumidity trap

Hose

Metal hose clamps


The water trap is designed to easily remove any accumulated water along the biogas line. They’re not always necessary because in some farms the installa-tion of the biogas line will not sag.

Considerations :

• The places where it will be common for water to accumulate are near the point of biogas use, where the line is lowered before entering a building or where it turns to be connected to the point of biogas use.

• On very long biogas lines it’s not necessary to install water traps. Water accumulation can be identified with time

• The water traps need to be easy to reach in order to remove the cap and allow water to flow out of the system.

Step 1: Identify the location where a water trap will be installed.Step 2: Cut the biogas line. Step 3: Insert a clamp on each of the ends created by the cut. Then insert the water trap connector inside both ends, and finally secure both clamps at the connector locations.Step 4: Confirm that the cap at the end of the water trap is well closed.

For more information on system maintenance consult the Usuer’s Manual available at: www.sistemabiobolsa.com

Water traps Étape: Installation

Farm / Domestic instalation biodigester


The biogas filter is designed to remove excessive amounts of hydrogen sulfide (H2S) in biogas, which could damage and corrode equipment, in addition to causing bad odors.

The filter consists of a screw cap that allows access to the filtration me-dia inside, and it has biogas line connectors at both ends which facilitate installation. For more information on system maintenance consult the Usuer’s Manual available at:


Considerations :

• The average time for filtration media replacement is one month, it is then important to place the biogas filter in an ac-cessible location.

• It is convenient to install all of the biogas system components in the same location (pressure release valve and biogas filter). The filter must be installed at an angle from the horizontal in order to avoid water accumulation.

Step 1: Identify the location where the biogas filter will be installed.Step 2: Cut the biogas line. Step 3: Insert a clamp on each of the ends created by the cut. Then insert the biogas filter connectors inside both ends, and finally secure both clamps at the connector locations.Step 4: Confirm that the cap of the biogas filter is well closed.

Biogas filter


The Sistema Biobolsa must be protected by a perimeter fence and preferably with a roof. This will extend the life of the reactor and access will be restricted to unauthorized personnel that does not know how to operate the system. Moreover, the Biobolsa will be protected against objects that may fall over it like bushes or stones, and animals won’t be able to damage the system.

Perimeter fence

Examples:

Stage: Installation


The possible uses of biogas are as follows: kitchen burners, water or space heating, engines for electricity generation, or productive uses (lighting, water pumping, suction pumps, etc). Biogas can also be used in cooling systems.

Cosiderations:

• Biogas is highly versatile and it can feed different processes, however; each use must have its separate control biogas valve. • Not any equipment made for LPG, natural gas or butane will work with biogas without adjustments. The installations must be verified by a Sistema Biobolsa® technician.• The biogas line can have tee connections for sending biogas to a variety of locations for its use, but it must be considered that the biogas line has a limited total capacity. Moreover, the pressure of the system is limited, if biogas is used in different locations simultaneously, this will reduce the availability of biogas.

Step 1: Identify the location where the biogas use will be installed.Step 2: Cut the biogas line. Step 3: Insert a clamp on each of the ends created by the cut. Then insert the biogas use connector inside both ends, and finally secure both clamps at the connector locations.Step 4: Confirm that the control gas for the biogas use is well closed.

Biogas use Etapa: Instalación


The Sistema Biobolsa constantly produces biol in direct proportion to the quantity of waste that it receives. This needsto be considered in the biol management process, which includes storage, transportation to the point of use and cropland application. Biol should not spill and create ponds in the farm, and this should be avoided by implementing a drainage system that may include pipes or open channels.

For more information see the User’s Manuald and Biol Manual available at: www.sistemabiobolsa.com

Sistema Biobolsa biol pits are made of the same material as the reactors, which makes them easy and quick to assemble. It re-quires an excavation the size of the pit itself, and it can be fixed to the ground by burring the strips along its edges on the ground. Ensure that pit level allows for biol to flow into it by gravity from the Biobolsa. The storage pit can be built with cement or prefabricated plastic tanks. The pond should not have more than one meter in depth in order to prevent anaerobic processes to occur.

¬Biol management system Etapa: Instalación


Handling of biol and effluents

If either biol storage is not available or there’s excess produc-tion, a disposal strategy must be implemented that drains biol into a compost zone or nearby sewer line. Ideally, biol should drain to cropland, pasture or trees so the nutrients it contains are not wasted.

A compost bin can simply be a pit filled with dry organic waste that doesn’t allow for the accumulation of biol at a depth greater than one meter. Ideally this material is aeriated and regularly mixed.

Another option for the disposal of biol is through infiltration pits filled with rocks or gravel that allows biol infiltration into the ground on a large surface area, which could be covered with vegetation for nutrient absorption. It is important to ensure that biol is kept under aerobic conditions to prevent methane release into the atmosphere.

Biol is in liquid state and it can be extracted by mud pumps or even water pumps. If a water pump is used, it is recommended to filter biol using a sieve at the Biobolsa effluent, and an addi-tional sieve at the pump intake point.

Sieve filtration is recommended when applying biol with sprayer pumps, hoses or fertilizer appliers.

Biol transportation can be made in buckets or other larger containers that allows biol to be moved in a liquid form inside a vehicle, trailer or manually.

Handling and transportation


Installation follow-up

Monitoring and follow-up of each system is fundamental and it’s the main way Sistema Biobolsa has to guarantee the correct use and benefit maximization of this technology. For this reason, we have a complete follow-up plan that guarantees adoption and use of the technology in all project implementation steps. To see the corresponding forms go to the Processes and Forms index at the beginning of this manual. Follow-up 1: post-installationIt is made within 30 days after the installation. It is important to physically inspect the system and verify that the hydraulic seals remain in place. In addition, inspect that the first load was correctly fed into the system and that the user understood the biodigester feeding process. Even when it was all clearly explained during the installation, additional questions may arise. The post-installation visit will be made with Follow-up Form 1 (see Appendix).

Follow-up 2: Adoption visitsAfter 90 days of installation, a phone call or visit must be made in order to confirm the adequate use of the system and answer any questions the user may have. The adoption visit is made with the Follow-up Form 2 of the Promoter Package or with the TaroWorks survey.

Follow-up 3: Long term visitsThe monitoring and long term visits allow to follow-up after 180 days of installation. This monitoring MUST be made by a site visit, and it can’t be made over the phone. The goal is to capture all information pertaining to the farm in order to see the changes and impacts achieved since installation.

Customer service visitsThe customer must have contact information of the local technician, regional and central offices to be able to contact Sistema Biobol-sa in case of any doubt or service report. Any visit of service phone call must use the form Customer Service Form in the Appendix.

Extraordinary visitsThese are visits that fall outside of the 3 mandatory visit structure which may be due to a reported issue.

Etapa: Seguimiento


Installation tracking form

www.sistemabiobolsa.com.mx 1 de 1

OFICINA CENTRAL SISTEMA BIOBOLSA Amatlan 37, Piso 4 Col. Condesa, México DF, CP 06140 Tel. +52 (55) 52 11 8617

Installation Check List ______________________________________________________________________________________________ Technician: System ID: Installation Date (dd/mm/yyyy): User name: ______________________________________________________________________________________________

Pre-installation 1 Confirm that the Full Diagnostic is completed. 2 Confirm that you have all the tools and parts needed for the installation. 3 Confirm the location, level, and dimensions of the trench or retention walls. 4 Confirm that there is water and manure ready for the initial feeding 5 Clean in and around the trench.

Installation 1 Lay the geotextile centered in the trench, leaving sufficient material on all sides to fix the material. 2 Stretch the geotextile so that it is centered and neat, leaving a clean site for the installation. 3 Fix the geotextile with stone or a small anchor trench so all the material is secured.

4 Place the reactor in the center and unroll the system, confiring the correct location of the gas exit and the entrance and exit tubes.

5 Pull the reactor tight and confirm the two exit tubes are completely level. (of 4 inches.)

6 Install, fill and connect the pressure relief valve and connect it to the gas exit of the digester with the flexible clear piping.

7 Fill the digester with water until there is water in the entrance and exit tubes. 8 Confirm the installation of the biol receptor. 9 Confirm the gas line route to the biogas end uses. 10 Confirm there is suffucuent gas line, unions and hose clamps to complete the line. 11 Install water traps at low points in the gas line. 12 Connect the gas lines to the biogas appliances. 13 Confirm all valves are closed. Post-Installation 1 Fill the complete system information in the user manual. 2 Conduct a full step by step training of the daily use and the maintenance. 3 Fill out and get signatures for all contracts. Make sure to leave copies with client and take copies for the office. 4 Confirm the date of the next visit or contact ______/________/_________

Data to collect

What is the planned use of gas? What is the planned use of the biol? How long was the gas line? Observations and Pending Work


Notes


Notes


Contact:

Mexico City: +52 (55) 52 11- 8617Mobile Kenya: +254 727 369 018

[email protected]

www.sistema.bio

We specialize in development projects focused on communities, micro-regions, states, and countries with afocus on education, local capacity-building, and impact-monitoring.

Documents

Installation Manual - Sistema.Biosistema.bio/wp-content/uploads/2017/04/FdC-Installation-Manual.pdfSistema.bio® Installation Manual Introduction to TaroWorks TaroWorks is an Android