Waste Spectrum Incinerators

Transcription

1 Volkan 75 Incinerator Manual Page 1 of 20 Introduction This Manual includes full descriptive literature, specifications and Data Sheets covering the Incinerators supplied by Waste Spectrum Environmental Limited. Before the incinerator is used, these instructions must be read and fully understood by the Operators who will carry out the work, and those who will run the equipment once it is commissioned and handed over. Model Covered This manual covers the following Waste Spectrum Incinerator that has been supplied in accordance to the ABPR legislation Low Capacity Incinerators please ensure that your reading information relevant to your model: VOLKAN 75 INCINERATOR ABPR Standard Operating Plan, Manual Temperature Recording, Declaration of Type Approval and CE certification information is given at the end of this manual. This document covers Gas burner types. United Kingdom Health & Safety at Work Act 1974 Section 6 (a) of this Act requires manufacturers to advise their customers on the safety and handling precautions to be observed when installing, operating, maintaining and servicing their products. The user s attention is therefore drawn to the following: The appropriate sections of this manual must be read carefully before installation Suitably trained personnel only, must carry out installation, operation and maintenance Normal safety precautions must be taken and appropriate procedures observed to avoid accidents Refer to the equipment suppliers, name and address below, for any technical advice or Waste Spectrum Environmental Limited Spectrum House Checketts Lane Industrial Estate Worcester WR3 7JW England Tel Fax sales@wastespectrum.com Website And Version Date 04 March 2011 Version

2 Volkan 75 Incinerator Manual Page 2 of 20 GENERAL CONTENTS 0.0 General safety warnings 1.0 GENERAL DESCRIPTION 1.1 PRINCIPLE OF OPERATION 1.2 CASING 1.3 DOORS 1.4 REFRACTORY LINING 1.5 MAIN AND AFTERBURNER CHAMBERS 1.6 BURNERS 1.7 TEMPERATURE MEASUREMENT ON INCINERATORS 1.8 DIMENSIONS AND WEIGHT 2.0 DELIVERY AND INSTALLATION 2.1 ITEMS SUPPLIED 2.2 UNLOADING 2.3 PLACEMENT OF THE MACHINE 2.4 CHIMNEY STACK 2.5 FUEL SUPPLY 3.0 OPERATION 3.1 STANDARD OPERATION 3.2 HOT LOADING 3.3 BURNER IGNITION 3.4 EMERGENCY STOP 4.0 FAULT CONDITIONS 4.1 FAULT FINDING 5.0 ROUTINE MAINTENANCE 5.1 DE-ASHING 5.2 CLEANING 5.3 SERVICING 5.4 ADJUSTING THE PILOT FLAME 5.5 REPLACEMENT PARTS 6.0 (no data in this section) 7.0 (no data in this section) 8.0 (no data in this section) 9.0 STANDARD OPERATING PLAN 10.0 DECLARATION OF TYPE APPROVAL 11.0 CONFORMITY CERTIFICATES AND TEST CERTIFICATES NOTE Throughout this manual the information refers to the Volkan 75 incinerator unless otherwise stated. Where applicable, this will be stated either by first giving the model name and then detail specific to that model, or in tabular form listing all models and their specific details.

3 Volkan 75 Incinerator Manual Page 3 of GENERAL SAFETY WARNINGS WARNING To reduce the risk of injury, all users of the incinerator much read and understand the Incinerator manual before use. WARNING Failure to follow all safety instructions may result in serious personal injury. WARNING Wear only suitable clothing for high temperature usage. IMPORTANT Servicing of incinerators requires care and knowledge of incinerators and burners. Servicing should only be performed by qualified personnel. Use only approved spares. These are available from Waste Spectrum Environmental Limited. IMPORTANT Use your incinerator only for the purpose for which it is designed and authorised. This is animal carcass incineration. Incineration of other items is outside the Animal By-Products Regulations (ABPR) and as such your incinerator and site is not licensed. It will also invalidate your warranty. Incineration of items such as plastics and acid containing items will cause severe and very obvious damage to the incinerator. WARNING This incinerator is VERY HOT when operating and afterwards when cooling down. WARNING The secondary (afterburner) chamber is designed to heat all gases up to a minimum of 850 o C. The exhaust from the top of the stack will be VERY HOT. It is possible that the exhaust gas temperature could be well in excess of 1000 o C.

4 Volkan 75 Incinerator Manual Page 4 of 20 WARNING The main (primary) chamber where the waste is loaded is designed to operate at a temperature that incinerates waste. It is possible that the inside contact surfaces could be well in excess of 500 o C. When the door is open, it is possible that the air exhausting from the chamber could be well in excess of 500 o C. WARNING The outside body of the incinerator will be VERY HOT. It is possible that the outside body surface temperature could be well in excess of 100 o C. WARNING When operating and when cooling down, it is possible that the stack outside surface temperature could be well in excess of 1000 o C. IMPORTANT The incinerator and the ash will take time to cool down. Ensure that both are cool before de-ashing the incinerator. WARNING De-ashing hot ash could result in the ash igniting and causing a fire.

5 Volkan 75 Incinerator Manual Page 5 of GENERAL DESCRIPTION 1.1 PRINCIPLE OF OPERATION The Volkan 75 incinerator is designed to operate without the use of any mains electrical input. The only requirement for fuel to the incinerator is the fuel gas supply (LPG) at the required pressure. Two burners are used to perform the incineration: The Main Burner operates in the primary chamber to heat and ignite the waste materials. It is positioned in the ash box of the assembly, firing up through refractory firebars into the holding space where the waste is loaded. The After Burner operates in the secondary chamber. Gases leaving the primary chamber are guided into the secondary chamber where they mix rapidly with the After Burner flame. The burner has tangential entry into the secondary chamber, which imparts a swirling action to the mixture of gases thus providing the most efficient smoke burn out. The primary chamber and secondary chamber are arranged as a shaft furnace with gases passing up from the primary chamber to the secondary chamber on top. Solid waste is contacted and burnt by rising gases from the ash box, while liquid waste falling into the ash box is consumed by the close proximity of the primary burner. The incinerator design ensures that the afterburner gas temperature reaches 850 o C with the secondary burner only ignited. At all times the 850 o C for 2 seconds ABPR requirement is met for the exhaust gases.

6 Volkan 75 Incinerator Manual Page 6 of CASING The casing of the Incinerator is a fully welded fabrication made from 3 mm steel. The secondary chamber is fixed in place on top of the main chamber and each burner is mounted through the casing. 1.3 DOORS There are two doors, the bottom door is for de-ashing and cleaning, the top door accesses the main chamber for waste loading and cleaning. The waste loading door door operates on a sliding rail mechanism. The ash door is a swing door. To open each door, using the handle pull the door slightly towards you and then slide to the left. Closing is the reverse of the opening procedure. It is important that both doors are fully closed during a burn. See fig 1 FIG REFRACTORY LINING The refractory lining of the incinerator is made up of a high performance monolithic dense refractory concrete hot face. Note: Cracking or crazing is normal in refractory concrete, due to the thermal cycling that concrete experiences in its normal operation. This is not a fault. 1.5 MAIN AND AFTERBURNER CHAMBERS The lower chamber is the Main chamber where an internal hearth block is inserted for the waste to burn. Above it, (inside the top fabrication) is the afterburner chamber.

7 Volkan 75 Incinerator Manual Page 7 of BURNERS The VOLKAN 75 is a 2-burner incinerator requiring a suitable and stable supply of LPG for efficient operation. See section 2.5 for LPG supply requirements. The incinerator uses the standard Segas flare burner in both the Main burner (lower) and After burner (upper) positions. Each burner comprises a burner head and nozzle connected to a thermo electric safety valve with a 4 position adjusting cock, one main and pilot outlet with Max-Min adjustable gas rate. See Fig 2 & 3 Refer to the Fault section and Component sections for further details or fault diagnostics. FIG 2 FIG TEMPERATURE MEASUREMENT ON INCINERATORS The temperature measurement equipment supplied as standard on WSE incinerators is a K type ceramic sheath thermocouple with compensating cable and readout instrument. The stated accuracy of measurement of these components is that given by the manufacturers. Manufacturer s certificates of conformity state that the methods used to produce the components are to strict quality standards, thus the accuracy of the instruments is supported by the certificates. The combined error of the components is within +/- 12 degrees Centigrade at 1000 degrees. 1.8 VOLKAN 75 INCINERATOR DIMENSIONS AND WEIGHT Height Width Weight 3500mm 800mm 700kg

8 Volkan 75 Incinerator Manual Page 8 of DELIVERY AND INSTALLATION 2.1 RECEIVED ITEMS Upon receipt of your incinerator, you will find the following additional items on top or inside the machine. 1 off Stainless steel flue extension 1 off 25ml can of High temperature touch up paint 1 off Operating manual including Declaration of Type Approval and Standard Operating Plan 1 off Hand held temperature readout 2.2 UNLOADING NOTE HEAVY EQUIPMENT Refer to Dimensions and Weights section for details. Crane or hoist using the 2 lifting points provided and using appropriate lifting shackles and straps. 2.3 PLACEMENT OF THE MACHINE The machine should be mounted on a level concrete raft of sufficient strength and size.. It is suggested that a minimum of clearance of 3m be kept to surrounding buildings. 2.4 CHIMNEY STACK When the chimney is assembled, the height of the chimney is 1m from the top of the incinerator. Planning may be required, depending on the point of use, i.e. Farm or Industrial. The best way to assemble the chimney is as follows: Place the smaller diameter end of the double skinned chimney section directly over the spigot on top of the after chamber.

9 Volkan 75 Incinerator Manual Page 9 of FUEL SUPPLY The VOLKAN 75 is a 2-burner incinerator requiring a suitable and stable supply of LPG for efficient operation. Selecting and locating the most suitable LPG supply on your site is important - you should consult an approved LPG supplier to determine the best method of supply for your particular application. Give your LPG supplier the following information to help them make the right decisions for you: LPG requirements for the Volkan 75 Incinerator can be expressed in the following terms: LPG Consumption: Heat input requirement: Up to 3.0 kgs per hour with both burners running at the correct pressure up to 42kw As a general rule, please consider the following: Bulk Supply Tanks We would suggest a minimum size of 1200 litres. Bottled LPG Supply The Volkan 75 will require a minimum of 4 x 47kg bottles (or equivalent), inter-connected using a suitable High Outlet Pressure Automatic Changeover Kit. Although single 47kg bottles may provide the necessary pressure readings, they will not supply sufficient heat value to correctly operate both burners. Connection to single 47kg bottles will result in one or other of the burners failing to operate correctly. Remember that the heat value of available LPG will vary, depending on the level of liquid fuel in each bottle, and the ambient temperature during each operation. See section 2.6 for details of a suggested supplier who will supply by mail order. The incinerator is fitted with a gas regulator (see Fig4 opposite) having a pressure range of 50 to 150mb. FIG 4 This should initially be set at 150mb (Setting 10 on the regulator) and then adjusted to suit the installation. See also section 3.1 of this manual for operating information.

10 Volkan 75 Incinerator Manual Page 10 of BOTTLE SUPPLY 4 WAY CHANGEOVER VALVE High Outlet Pressure Automatic Changeover Kits, For Propane 1 Bar Outlet Pressure If you plan to use 47 kg or smaller cylinders it is suggested you use a four cylinder Changeover kit. You must use a high pressure (1 bar) unit and not the 37 mbar domestic version. The four cylinder kit comprises one automatic changeover regulator, two 20" and two 33" pigtails with high pressure black hose to BS 3212 : Type 2, POL connectors incorporating excess flow and non-return valves, and a 1/2 " F x F shut-off valve. A suitable unit and the supplier are shown below. Four Cylinder Kit - available from supplier detailed below: Part No. Description Unit Price High pressure four cylinder kit This equipment is available from: B.E.S. Ltd Unit 3, Junction 6 Industrial Park Electric Avenue, Birmingham B6 7JA Tel: Fax: sales@bes.ltd.uk Technical Note: Assuming your application is agricultural, you do not need to be CORGI registered to fit this appliance. If your supplier or gas installer has any doubts on this please refer them to Statutory Instruments 1998 No The Gas Safety (Installation and Use) regulations For the same reason you do not need an OPSO valve either.[the incinerator mounted regulator is rated at 7.5 Bar inlet pressure.}

11 Volkan 75 Incinerator Manual Page 11 of OPERATION CAUTION: THE INCINERATOR WILL BECOME VERY HOT DURING OPERATION. TAKE APPROPRATE CARE AND WEAR APPROPRIATE PROTECTIVE EQUIPMENT. 3.1 OPERATION SETTING THE GAS PRESSURE LIGHTING THE PILOT TURNING ON BURNERS ADDING TO THE LOAD during a burn cycle The incinerator is fitted with a gas regulator. The range of the regulator is mb pressure. We suggest that the regulator is set to Maximum (150mb, setting 10 on the regulator) and adjusted downwards so that the burner flame size can be controlled with it s lever-operated valve. To adjust the pressure using the regulator, simply rotate the valve fitted on top in the required direction. See FIG 4 above Ensure that the pilot light is correctly adjusted (see section 5.3 Servicing). Turn on the gas supply at the cylinder. Remove the weather guard. Beginning with the afterburner, depress the lever-operated valve and light the pilot valve with a suitable ignition source. Once the pilot is lit the valve handle may be allowed to return for spring pressure the pilot should remain lit Both burners may only be lit after the pilot has been lit. To light the burners, rotate the lever operated valve until the pilot flame ignites the gas, then select a suitable intensity by adjusting this valve to MIN and MAX Once lit, replace the weather guard. To add more waste at appropriate times during the burn cycle, turn the main burner valve back to the pilot position to extinguish the main flame, leave the afterburner turned on. Open the loading door and add the waste. Now turn the main burner valve back to its original position so the main burner lights and continue the burn.

12 Volkan 75 Incinerator Manual Page 12 of HOT LOADING Loading the incinerator Wear appropriate personal protective equipment, paying particular attention to hand and eye protection. Have a quantity of waste in mind that is in your experience reasonable to load quickly without causing a potential blockage. Prepare the load into a packaged form that is easily handled by one man. For example, when handling small individual carcases, using plastic bags. Place the bags close to the front of the incinerator. Extinguish the main flame as above in section 3.1. Open the loading door carefully - stand back, as the door opens there may well be an immediate heat release initially. Load the waste in a controlled fashion, taking care that the waste does not interfere with either the main burner s flame patch, or the exit flue for the waste gasses. Close the incinerator door. Restart the main burner. Repeat this process to reload at any time during a main burn cycle. 3.3 EMERGENCY STOP Turn the gas supply off at cylinder isolator.

13 Volkan 75 Incinerator Manual Page 13 of FAULT CONDITIONS 4.1 FAULT FINDING Condition Cause Remedy Burners will not ignite Gas turned off at supply Turn on gas supply Burners keep going out Windy conditions extinguishing flames Burner flames unstable Segas burners are dirty or have blocked air intakes Ensure weather guards are always replaced once the burners are lit. Clean burners thoroughly Main gas will not ignite even when pilot is lit Pilot will not stay lit Un-burnt material at end of cycle Liquid leakage onto floor Excessive smoking during burn cycle Cracking of Refractory concrete Not turning the gas cock in the correct direction, or far enough. 1. Pilot needs adjustment 2. Not holding in the gas valve for long enough period once pilot flame is ignited Cycle selected is too short. Too much material loaded. Over filling of main chamber, or excessively wet material Various reasons: 1.Overfilling main chamber 2. Excessive ash build-up 3. Main burner flame too high 4. After burner flame too low Due to the thermal cycling that the concrete experiences in its normal operation. Rotate the gas cock until you reach the end stop, this is the maximum setting, the gas will then ignite 1. Adjust pilots see section 5.3 Servicing 2. When the pilot is ignited hold the valve in for at least 20 seconds. Select longer time. Keep to load limits. In accordance to Standard Operating Plan, do not remove ash. Re-incinerate waste. Ensure that you do not overfill the main chamber. Ensure that waste material is not excessively wet. Leave a small amount of ash in main chamber to soak up liquids See sections relevant to operation. This is not a fault.

14 Volkan 75 Incinerator Manual Page 14 of ROUTINE MAINTENANCE NOTE SWITCH OFF MACHINE and ISOLATE GAS SUPPLY WEAR APPROPRIATE EYE PROTECTION WEAR APPROPRIATE HAND PROTECTION WEAR APPROPRIATE DUST PROTECTION 5.1 DE-ASHING This incinerator is designed to run with a certain amount of ash always present inside, to an appropriate depth of one inch. This helps retain rendered liquids and limits fat absorption into the refractory. Eventually de-ashing will be necessary. Use light strokes with a shovel or extended rod with raking plate attached. Take care to wear gloves when de-ashing, as the ash is usually hot for some time after burning has stopped. Remove all light ash, but leave anything that appears to be in any composed form. The ash produced is light and easily blown by the wind, so eye and dust protection is recommended. 5.2 CLEANING Refer also to the standard Operating Plan for cleaning information. Apart from the de-ashing noted above, regular cleaning is required to ensure that a hygienic workplace is maintained. Do this only when cold. To allow the incinerator to operate within it s normal parameters we recommend that the burner heads are cleaned every 3 to 4 burns. NOTE: If engineers are called to site to investigate potential faults and the faults are found to be due to dirty burners, you may be subject to charges. Recommended cleaning procedures for Segas burners 1. Isolate the gas supply. 2. Remove burner weather shield. 3. Unscrew the Segas head from the port located in the holding bracket. 4. Clean off deposits attached to the burner tube and the diffuser holes surrounding the nozzle with the soft wire brush, avoid contact with the nozzle face. Use a screwdriver blade to remove stubborn deposits. 5. Wipe of any remaining material with rag. 6. If there is a suspected combustion problem, then remove the nozzle with the socket spanner, and fit a new nozzle of the exact same type flow rate and angle. 7. Reassemble burner in reverse order of above. Ensure that a suitable thread seal tape is used when the burner is re-fitted into the port.

15 Volkan 75 Incinerator Manual Page 15 of SERVICING It is recommended that the incinerator is serviced annually by Waste Spectrum Incinerator service engineers or other competent service engineers knowledgeable on incinerators. 5.4 Adjusting the Pilot Flame Fig 5 Ensure that the pilot light is positioned as shown above Fig 6 Working through the aperture in the support plate: A) Unscrew and remove the cover plate to reveal the pilot adjustment. B) Screw the pilot adjustment right back without removing it. C) Screw the cover back on 5.5 REPLACEMENT PARTS Parts that are in direct contact with flames and heated gas do not carry a manufacturer s warranty, but are available to purchase as spare parts. Please contact us to discuss your requirements and for current prices. Sections 6, 7 and 8 of this manual are intentionally blank. The following pages are: 9.0 Standard Operating Procedures 10.0 Declaration of Type Approval 11.0 Conformity and Test Certification Further printed copies or electronic copies of these can be provided please contact the Sales Office.

16 Otter Incinerator Manual Page 16 of 20 Standard Operating Plan Low Capacity On-farm incinerator This document relates ONLY to Waste Spectrum Environmental incinerators. For specific details of operation please refer to the operating manual. General incinerator considerations Ensure that the physical separation of livestock is maintained at all times. Ensure that the pest control program that includes the incinerator and hard standing is maintained and recorded at all times. Ensure that the annual incinerator service is scheduled. Fallen Stock Handling Ensure fallen stock is from own farm only. Transport fallen stock in a safe and hygienic manner using manual lifting, bucket scoop, plastic bag or reusable container. Plastic bags used to store by-products may be incinerated. Store fallen stock in a designated area. Ideally incinerate within 24 hours. Do not cut up animals. (Large animals must be passed on a to a High Capacity plant) Try not to mix SRM and non-srm animals. If mixed, all ash is considered SRM. Before incineration Ensure that the incinerator Type Approval burner settings are met or bettered. Ensure that the drainage is operational. Start incinerator and wait until observed temperature is 850 o C. Load incinerator. It is a DEFRA requirement that this is done hot. Take extreme care. During incineration Use only equipment dedicated to the incinerator. This includes clothing and tools. Operate the incinerator in accordance to the Operating Manual. Temperature Records For 10% (1 in 10) burns, record the temperature reading every 2 hours. After incineration Clean the hard standing and any vehicles, containers or equipment used. When the incinerator requires de-ashing, remove ash into a sealed container marked appropriately and dispose of as required: o Non-SRM spread to either own land or landfill o SRM to landfill If absorption material is used for drainage, load used material into the incinerator before cleaning the area. Abnormal operation, Faults and Servicing Should there be a Fault, refer to the Operating Manual. Where the Fault is failure to reach 850 o C, the waste must be left inside the incinerator and reincinerated. If the ash produced is not complete ash, the waste must be left inside the incinerator and reincinerated.

17 Otter Incinerator Manual Page 17 of 20 Manual Temperature Recording This is not required if the automatic temperature recording option has been installed. For manual recording it is a requirement that 10% (1 in 10) incinerator burns are recorded for temperature. The temperature needs to be recorded every 2 hours. The following table is a suggested format which can be photocopied for your use. Electronic copies can be ed on request please contact sales@wastespectrum.com Date Date Date Start Time Start Time Start Time Time Temp. Time Temp. Time Temp. 0 Hr 0 Hr 0 Hr +2 Hr +2 Hr +2 Hr +4 Hr +4 Hr +4 Hr +6 Hr +6 Hr +6 Hr +8 Hr +8 Hr +8 Hr +10 Hr +10 Hr +10 Hr Date Date Date Start Time Start Time Start Time Time Temp. Time Temp. Time Temp. 0 Hr 0 Hr 0 Hr +2 Hr +2 Hr +2 Hr +4 Hr +4 Hr +4 Hr +6 Hr +6 Hr +6 Hr +8 Hr +8 Hr +8 Hr +10 Hr +10 Hr +10 Hr Date Date Date Start Time Start Time Start Time Time Temp. Time Temp. Time Temp. 0 Hr 0 Hr 0 Hr +2 Hr +2 Hr +2 Hr +4 Hr +4 Hr +4 Hr +6 Hr +6 Hr +6 Hr +8 Hr +8 Hr +8 Hr +10 Hr +10 Hr +10 Hr Date Date Date Start Time Start Time Start Time Time Temp. Time Temp. Time Temp. 0 Hr 0 Hr 0 Hr +2 Hr +2 Hr +2 Hr +4 Hr +4 Hr +4 Hr +6 Hr +6 Hr +6 Hr +8 Hr +8 Hr +8 Hr +10 Hr +10 Hr +10 Hr

18 Otter Incinerator Manual Page 18 of 20

19 Otter Incinerator Manual Page 19 of 20 NOTE The Volkan 75 is a re-branding of the Otter Incinerator.

20 Otter Incinerator Manual Page 20 of CONFORMITY CERTIFICATES AND TEST CERTIFICATES CERTIFICATE OF CONFORMITY EC Declaration of Conformity Type of Equipment Animal Waste Incinerator Models Volkan 75 Manufacturer Waste Spectrum Environmental Limited Spectrum House, Checketts Lane Industrial Estate Worcester WR3 7JW, England Standards Animal By-Products Regulation (EC) 1069/2009 UK Department of Environment Procedural Guidance Document PG 5/3 (04) Low Voltage Directive 93/68/EEC EMC Directive 89/336/EEC Waste Spectrum Environmental Limited Steven Hunt 4 th March 2011