HomeMy WebLinkAboutGLSD - Organics to Energy Project - Miscellaneous - 240 CHARLES STREET 8/1/2018 (3) GREATER LARENCE SANITARY DISTRICT
ORGANICS TO ENERGY, PHASE II
Packaged Biogas Treatment System
OPERATION AND MAINTENANCE INSTRUCTIONS
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Unison Solutions, Inc.
5451 Chavenelle Rd
Dubuque IA 52002
(563) 585-0967
www.unisonsolutions.com
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75 State Street,Suite 701
Boston,Massachusetts 02109 \
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Unison O&M Manual (wfapplicable drawings)
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Title Sheet
Title: Packaged Biogas Treatment System Submittal
Project Title: Greater Lawrence Sanitary District Organics to Energy Project
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Equipment: Packaged Biogas Treatment System
Specifications: Section 13240
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General Contractor: Methuen Construction Company, Inc.
Contact:Jay Spooner
40 Lowell Rd.
Salem, NH 03079
Telephone: (603) 328-2234
E-mail: ist)ooner@methuenconstruction.com
Engineer: CDM Smith
Contact: Benjamin Mosher
670 N. Commercial St., Suite 201
Manchester, NH 03101
Telephone: (603) 222-8381
E-mail: mosherbr@cdmsmith.com
Manufacturer: Unison Solutions, Inc.
Project No.: 243
Contact: Nathan Huebner a
5451 Chavenelle Rd.
Dubuque, Iowa 52002
Telephone: (563) 585-0967
E-mail: Nathan.Huebner@unisonsolutions.com
Fax: (563) 585-0970
Parts &Service: Unison Solutions, Inc.
Telephone: (563) 585-0967
Local Area Sales Representative:
Open
Contact: Nathan Huebner
Unison Solutions, Inc.
5451 Chavenelle Rd.
Dubuque, Iowa 52002
Telephone: (563) 585-0967
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TABLE OF CONTENTS
Warranty Statement
System Safety
Section 1—System Overview
— System Overview
— System Manual Valve Listing
— Understanding the System
— System Summary
Section 2—Operator Interface '
Section 3—Start-up/Shutdown Procedures
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Section 5—Alarm Procedures
— Alarm Procedures
— Troubleshooting Guide
— Alarm List
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Section 8— Electrical
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Table of Contents Page 1
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Page 2
Table of Contents
UNISON
SOLUTIONS
WARRANTY STATEMENT
Unison Solutions,Inc.(Unison)is committed to providing quality products and services to its customers.As a
demonstration of this commitment,Unison offers the following warranty on its products. )
Grant of Warranty:Unison provides this warranty for its equipment under the terms and conditions which are detailed
herein.This warranty is granted to the person,corporation,organization,or legal entity(Owner),which owns the
equipment on date of start-up,This warranty applies to the owner during the warranty period,and is not transferable.
21,
Warranty Coverage:Equipment that is determined by Unison to have malfunctioned during the warranty period under
normal use solely as a result of defects in manufacturing workmanship or materials shall be repaired or replaced at
Unison's option.Unison's liability under this warranty to the Owner shall be limited to Unison's decision to repair or
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replace,at its factory or in the field,items deemed defective after inspection at the factory or in the field.
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Warranty Exclusions:All equipment,parts and work not manufactured or performed by Unison carry their own
manufacturer's warranty and are not covered by this warranty.Unison's warranty does not override,extend,displace or
limit those warranties.Unison's only obligation regarding equipment,parts and work manufactured or performed by \
others shall be to assign to the Owner whatever warranty Unison receives from the original manufacturer.Unison does
] not warrant its products from malfunction or failure due to shipping or storage damage,deterioration due to exposure to e
the elements,vandalism,accidents,power disturbances,or acts of nature or God.This warranty does not cover damage
due to misapplication,abuse,neglect,misuse,improper installation,or lack of proper service and/or maintenance,nor
does it cover normal wear and tear.This warranty does not apply to modifications not specifically authorized in writing by
Unison or to parts and labor for repairs not made by Unison or an authorized warranty service provider.This warranty
does not cover incidental or consequential damages or expenses incurred by the Owner or any other party resulting from
the order,and/or use of its equipment,whether arising from breach of warranty,non-conformity to order specifications,
F delay in delivery,or any loss sustained by the Owner.No agent or employee of Unison has any authority to make verbal
j representations or warranties of any goods manufactured and sold by Unison without the written authorization signed by
an authorized officer of Unison.Unison warrants the equipment designed and fabricated to perform in accordance with
_ f the specifications as stated in the proposal for the equipment and while the equipment is properly operated within the
site specific design limits for that equipment.Any alterations or repair of Unison's equipment by personnel other than
those directly employed by,or authorized by Unison shall void the warranty unless otherwise stated under specific written
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guidelines issued by Unison to the Owner.This warranty does not cover corrosion or premature wear or failure of
I components resulting from the effects caused by siloxanes,hydrogen sulfide or volatile organic compounds in excess of
the design limits. All media must be purchased through Unison Solutions or approved in writing by Unison Solutions dur
ing warranty period.Media purchased though alternate sources and not approved in writing by Unison shall void the war-
ranty.The design limit is based on site specific gas data provided by the Owner prior to the proposal for the
equipment.Owner shall be responsible for all maintenance service,including,but not limited to,lubricating and cleaning
the equipment,replacing expendable parts,media,making minor adjustments and performing operating checks,all in
I accordance with the procedures outlined in Unison's maintenance literature.Unison does not warrant the future availabil-
ity of expendable maintenance items.
Warranty Period:This Unison warranty is valid for 18 months from the time the equipment is shipped from Unison's
j factory or 12 months from the date of startup,whichever occurs first.
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i Repairs During Warranty Period:All warranty claim requests must be initiated with a Return Material Authorization(RMA)
number for processing and tracking purposes.The RMA number shall be issued to the Owner upon claim approval and/or
field inspection.When field service is deemed necessary in order to determine a warranty claim,the costs associated with ]
s travel,lodging,etc.shall be the responsibility of the Owner except under prior agreement for a field inspection.This
warranty does not include reimbursement of any costs for shipping the equipment or parts to Unison or an authorized
a service establishment,or for labor and/or materials required for removal or reinstallation of equipment or parts in
connection with a warranty repair.This warranty covers only those repairs that have been conducted by Unison or by a
Unison authorized warranty service provider,or by someone specifically authorized by Unison to perform a particular
repair or service activity.All component parts replaced under the terms of this warranty shall become the property of
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Unison. I
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UNISON ASSUMES NO OTHER WARRANTY FOR ITS EQUIPMENT,EITHER EXPRESS OR IMPLIED,INCLUDING ANY IMPLIED
WARRANTY OF MERCHANTABILITY,FITNESS FOR ANY PARTICULAR PURPOSE,OR NON INFRINGEMENT,OR LIABILITY
FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE.
5451 Chavenelle Road,Dubuque,Iowa 52002 [01563.585.0967 [F]563.585.0970 a www.unisonsolutions.com
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2013 Unison Solutions,Inc. WARRANTY STATEMENT
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SYSTEM SAFETY
This guideline is intended to be an aid for owners and operators of biogas conditioning
systems in developing safety programs. A facility owner, manager, or supervisor with
appropriate training and applicable knowledge in biogas conditioning systems should develop a �
safety program adhering to the applicable federal, state, and local codes and agencies.
It is recommended that all personnel that may be exposed to the hazards associated �
with biogas conditioning systems be properly trained. Only trained, authorized personnel
should perform maintenance or operate the system. Training should be documented and kept
on file for future reference. The training material should be reviewed whenever a site
condition changes or as often as the facility owner, manager or supervisor deems appropriate.
It is the sole responsibility of the system owner to comply with all applicable codes and
agencies. Unison Solutions, Inc. assumes no responsibility for the unsafe operation and service
of the system. The information provided herein may help identify hazards and develop safe
work procedures when operating and servicing the gas conditioning system. Refer to the
system O&M Manual provided for specific manufacturer recommendations. Safety labels may
also be applied throughout the system to warn of potential hazards.
Possible Hazards:
A. High Voltage
G. Combustible solids
B. Hot Surfaces H. Rotating parts
C. Pressurized gases and liquids I. Confined spaces
D. Poisonous gases J. Falling objects
E. Explosive gases K. Asphyxiating gases
F. Harmful chemicals
General Safety Guidelines:
� A. Do NOT operate system without guards, doors, and covers in place.
B. Do NOT remove, bypass, or modify safety devices.
Page 1
System Safety
C. Do NOT operate system if it is not in proper working condition.
D. Do NOT allow open flames in the vicinity of the system.
E. Do NOT allow unauthorized personnel to operate or service the system.
F. Do NOT climb in or on the system during operation.
System Maintenance:
Only trained, authorized personnel should perform maintenance on the gas conditioning
system. Always follow an approved Lockout/Tagout program to ensure safety. Components
within the system can energize and move at anytime, so all sources of energy need to be
identified and have the ability to be isolated for maintenance. Also, please note that
components utilizing a yellow wire within the gas conditioning system control panel are
energized from a source other than the panel disconnect.
Pressurized Vessels/Piping:
Vessels and piping will remain pressurized even after the system is shutdown and power
is removed from the panel and peripheral components. Observe multiple pressure instruments
before attempting to service the equipment. When opening a valve or removing a pipe
component, do not stand directly in line with the component or valve. Open the valve or
remove the pipe component slowly. Never modify vessels or piping without authorization from
the manufacturer as doing so will void the system warranty. NEVER make modifications to or
weld onto a pressure vessel. A pressure vessel is defined as a closed container designed to hold
gases or liquids at a pressure substantially different from the ambient pressure.
Hydrogen Sulfide:
Hydrogen Sulfide, commonly referred to as HzS, is an extremely hazardous and toxic
compound found in biogas. It is a colorless, flammable gas that can be identified in relatively
low concentrations by its characteristic rotten egg odor. HzS has a very low odor threshold,
with its smell being easily perceptible at concentrations well below 1ppm in air. The odor
increases as the gas becomes more concentrated, with the strong rotten egg smell recognizable
System Safety Page 2
up to 30ppm. Above this level, the gas is reported to have a sickeningly sweet odor up to
around 100ppm. However, at concentrations above 100ppm, a person's ability to detect the ;
gas is affected by rapid temporary paralysis of the olfactory nerves in the nose, leading to a loss
of the sense of smell. This means that the gas can be present at dangerously high
concentrations with no perceivable odor. Prolonged exposure to lower concentrations can also ,
result in similar effects of olfactory fatigue. This unusual property of HzS makes it extremely
dangerous to rely totally on the sense of smell to warn of the presence of the gas.
Volatile Organic Compounds:
Volatile Organic Compounds, commonly referred to as VOCs, are present in biogas in
varying concentrations. Exposure to VOCs can cause acute and chronic health disorders.
Filtering biogas captures and concentrates VOCs. Proper PPE should be used when removing
and replacing biogas filter media. Personnel trained to remove and replace the filter media
should also be properly trained on the required PPE.
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System Safety
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System Safety
Page 4
SYSTEM OVERVIEW
The Unison Solutions, model BGS-1300-243-HS, gas conditioning system is designed to
supply up to 1300 scfm of clean, dry, digester gas, compressed to 5.0 psig. The system is
comprised of several parts including:
• Inlet heat exchanger (shipped loose) — HX-940 [Unison HX 301]
• Iron Sponge HzS removal system with spray wash system—HSR-941 thru 944
[Unison FLT 301 thru 3041
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• Two fully redundant gas blower skid(s) which pressurizes the gas.
• Moisture removal skid which cools, removes moisture and regulates discharge
temperature
• Glycol chiller(s) which supply cold glycol for use by the gas conditioning system —
COMP-972-1 and -2 [Unison CHL 141 and 142]
• Activated carbon siloxane removal system SSR-961 thru 963 [Unison FLT 361
thru 3631 and particulate filter—PF 964 [Unison FLT 351]
• System control panel which monitors and controls all the parameters in the gas
conditioning system
The remote mounted heat exchanger and gas blower and moisture removal skids are
designed for indoor operation in a Class I, Division 1 area. The control panel (indoor) and glycol
chiller (outdoor) are designed for operation in an unclassified area.
The control panel is equipped with a Programmable Logic Controller (PLC) that receives
data from transmitters and digital inputs. The PLC also protects the equipment during process
interruptions. The control panel includes auxiliary terminals for a remote run command input,
a customer fault input, and a customer end use device run feedback input. Dry contact outputs
are included for skid run status, skid warning status, skid fault status, and end use device run
permissive. An Ethernet connection is also available for connection to the GLSD facility SCADA
system.
Section 1 System Overview Page 1
Process gas first enters the inlet tube and shell heat exchanger HX-940 [Unison HX-301]
which is used to ensure the inlet gas temperature to the HzS removal system is at least 80°F.
Unison will monitor the gas temperature between TIT/TE-940-A and B [Unison TIT-301 and
302]. If the gas temperature differential increases more than 10'F, then we will signal SV-940
[Unison VS-8001 to open therefore re-saturating the gas prior to the HzS vessels. Removal of
excess moisture not absorbed by the gas will be the responsibility of others. The gas then
travels through three HzS removal vessels HSR-941 through 943 [Unison FLT-301 through 303] �
(41" additional vessel HSR-944 [Unison FLT-3041 is in standby) piped in parallel configuration
(interconnect piping by others). Each vessel is equipped with a spray wash system (solenoid
valve SV-941 through SV-944 [Unison VS-801 through 804] and nozzles mounted in the lid)
which will be activated if the gas temperature coming into the vessel exceeds 120°F. After
exiting the HzS vessels, the gas travels through one of two fully redundant gas blower skids
(Duty and standby). The gas enters a blower inlet moisture/particulate filter BBF-951 or 952
[Unison FLT-321 or 322] which removes any carryover Iron Sponge media or dust. Next, the gas
stream will travel through a positive displacement blower BLR-951 or BLR-952 [Unison BLR-331
or 332], where it is compressed to approximately 6.8 psig. The compressed gas, which is now at
a temperature of approximately 168-180'F, flows through an effluent water after-cooler heat
exchanger HX-954 [Unison HX-340] which will reduce the gas temperature to approximately
90°F. The gas then flows through a dual core heat exchanger HX-955 [Unison HX-341]. The
liquid side of the heat exchanger is fed by a glycol chiller COMP-972-1 or 2 [Unison CHL-141 or
1421 located remotely from the gas conditioning skid. Inside the heat exchanger, hot incoming
gas is first pre-cooled by cold outgoing gas. The gas is then chilled to approximately 40'F by the
glycol from the chiller. Moisture is separated from the gas stream and condensate is collected
in a no-gas loss tank [Unison TK-742] and removed. After the moisture is removed from the gas
stream, the gas goes back through the first core of the heat exchanger and it is reheated by the
hot gas entering the heat exchanger.
External to the heat exchanger, a cold gas bypass is fitted with a butterfly valve before
joining back together with the main gas discharge pipe. The butterfly valve [Unison Vy-342] can
be adjusted to achieve the desired reheat temperature (temperature of cold and hot gas mixed
Page 2
Section 1 System Overview
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together] before entering the Siloxane removal vessels. The design reheat temperature of 80°F
will provide a final relative humidity of approximately 24% and a final dew point of 40°F.
After the gas discharges from the skid, it flows through three Siloxane removal vessels
SSR 961 through SSR 963 [Unison FLT-361 through 363]. The vessels will be configured in a
lead/la /la piping configuration interconnect piping b others). After exiting the Siloxane o
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removal vessels, the gas flows through a final discharge filter PF-964 [Unison FLT-351] to ensure
that any carryover Siloxane media/dust is removed. The filter is designed to remove 99.5% of
particles greater than 3µ. The gas is then ready for delivery to the end use devices at a pressure
of 5 psig and temperature of 80°F with a relative humidity of approximately 24%.
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Section 1 System Overview Page 3
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Section 1 System Overview Page 4
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SYSTEM MANUAL VALVE LISTING
Normal
operating '
Valve# position Function
Effluent Water Lines
VB 141 Open Close to isolate HX-954[Unison. HX 3240]
VB 142 Open Iclose to isolate HX-954 [Unison HX 340]
Glycol Coolant Lines
Open Close to isolate system Glycol piping �
VB 144 Closed Open to drain S3 R 1 1
°°B 145 Closed Open to drain system Glycol piping
VB 145 Closed Open to vent system Glycol piping
VB 147 Closed Open to drain system Glycol piping '
VB 148 Open Close to isolate system Glycol piping
VG 141 Variable Adjust to dial in Glycol flow(typ.not adjusted after start-up)
.` 142 Variable Adjust to dial in Glycol flow(typ. not adjusted after start-up)
Biogas Lines
VY 30i I Open Close to isolate system upstream of HX-940[Unison HX 30€]
VY 302 1 Open Close to isolate system downstream of HX-940 [Un,iso- HX 3011
VB-3001 I Closed Open to purge HRS-941[Unison FL` 30']
VB-3002 I Closed Open to purge HRS-941 [Unison FLU 301]
VB-3003 Closed Open to vent HRS-941 [Unison FLT 3011
,V B 301 4 Closed Open to purge HRS-942 [Unison FL m 30=]
VB-33005 Closed Open to purge HRS-942 [Un iso n FLT 302]
VB-30063 Closed Open to vent HRS-942 [Unison FL=302]
VB-3007 1 Closed Open to purge HRS-943 [Unison FL;333]
p
VB-3003 Closed Open to purge HRS-943 [Unisons FLT 30 ]
VB-3009 Closed Open to vent HRS-943 [Unison FL;303]
VB-3010 Closed Open to purge HRS-944 [Unison FLU 304] `g
VB-3011 Closed Open to purge HRS-944[Unison FLi 304] 110
VB-3012 Closed Open to vent HRS-944[Unison FLT 304]
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V -321 Open Closed to isolate blower skid 1(BLR-951 [Unison BLR 331])
VY-322 Open Closed to isolate blower skid 1(BLR-952 [Unison BLR 332])
VY-331 Open Closed to isolate blower skid 1(BLR-951 [Unison BLR 331])
VY-332 Open Closed to isolate blower skid 1(BLR-952 [Unis-on 6LR 332])
VY-3 40 Open Closed to isolate heat exchanger skid
VY-341 Open Closed to isolate HX-954 [Unison HX 340] �;
=VB-342 Closed Open to vent Drying Skid
VY-342 Variable Adjust to modify cold gas bypass(typ. not adjusted after start-up0
VY-343 Open Closed to isolate heat exchanger skid
Condensate Lines ,
VB-721 Closed Open to manual drain BBF-9S1 [Unison F Li 321]
=B-722 Open Close to isolate auto drain/S R 72
VB-7-lq Closed Open to manual drain BBF-952 [Unison FLU 322]
VB-724 Open Close to isolate auto drain J ST R 722
VB 1-131- Closed Open to drain SHL 331 I
Pa e 5
Section 1 System Overview g
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SYSTEM MANUAL VALVE LISTING cont'd
VR-732 Closed Open to drain SII.332
Vv B-7 Closed Open to manual drain HX-945 [Unison HX 340]
VR 742 Open Closed to isolate auto drain/STP 741
VB 743 Closed Open to manual drain TK 741
VP 744 Open Closed to isolate auto drain J STP 742
VR 745 Closed Open to manual drain HX-955 [Unison HX 341]
`tR 746 Closed Open to manual drain T 742 B.,
VR-761 Closed Open to drain SSR-961 [Unison FAT 3611 OR
B 7 62 Closed Open to drain SSR-962 [Unison FILT 362]
VB-763 Closed Open to drain SSR-963 [Unison FIT 3631
R,
VR-751 Closed Open to drain PF-964[Unison F i-T 351]
Instrument Valves
Vi 321 Open Close to isolate PDIT 951 [UniSon PD3 i 321]
1" 322 Closed Open to calibrate PDIT 951 [Unison PDiT 321] �
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V!323 Open Close to isolate PDIT 951 [Unison PDIT 21]
V_324 Closed Open to calibrate PDIT 951[Unison PDIT 3211
V1 325 Open Close to isolate PDIT 952 [Unison PDIT 322]
V1 326 Closed Open to calibrate PDIT 952 [Unison PDIT 3221
V= 327 Open Close to isolate PDIT 952 [unison PDIT 322]
V1 328 Closed Open to calibrate PDIT 952 [Unison PDAT 322]
l?351 i PD1 e OR
Open Close to isolate PDIT 964 [Un'Son . 1-1]
V; 352 Closed Open to calibrate PDIT 964[Unison PDIT 351]
Vi 353 Open Close to isolate PDIT 964 [Un;Son PD=T 351]
15 V!
�, �— Closed Open to calibrate PDIT 964[Unison P;,T 351]
V 761 Closed SSR-961 [unison FAT 361] Nitrogen Fill Port
Vi 762 Closed SSR-961 [Unison FI_T 3611 Nitrogen Vent Port
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V1 763 Closed SSR-962 [Unison FFT 362] Nitrogen Fill Port
V! 764 Closed SSR-962 [Unison F-L T 362] Nitrogen Vent Port
V!765 Closed SSR-963 [Unison FI_T363] Nitrogen Fill Port
=1 71616 Closed SSR-963 [Unison FL-1 363] Nitrogen Vent Port:
Section 1 System Overview Page 6
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UNDERSTANDING THE SYSTEM
H2S REMOVAL VESSELS
Flame Arrestors
TSE 301-304
SIRDZ
B
Water
Connections
TP 801-804
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Pressure Safety ValvesIn
PSV 301-304
Biogas Inlet Connections
TP 302,4, 6, 8
Biogas Outlet Connections \
TP 303, 5, 7, 9
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(INLET BIOGAS HEAT EXCHANGER NOT SHOWN)
Section 1 System Overview Page 7
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UNDERSTANDING THE SYSTEM "K,
,
BLOWER SKIDS (QUANTITY 2)
Blower Enclosure
BLR 331 & 332
M 331 & 332
J-Box
Pressure Safety halves
PSV 331 & 332
Biogas Outlets
TP 331 & 332
,
Condensate Pump
PMP 721 & 722
Biogas Condensate Connection
TP 321 & 322 TP 721 & 722
�.
HEAT EXCHANGER SKID (QUANTITY 1)
Biogas Outlet
TP 342 Biogas Inlet
TP 341
Heat
Exchanger
HX 340 H :
t
J Boxes
Condensate
Connection
(CONTROL PANEL AND GLYCOL CHILLER NOT SHOWN) TP 741 &742
Section 1 System Overview Page 8 �,
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UNDERSTANDING THE SYSTEM
SILOXANE REMOVAL VESSELS .
Access Ladder
& Platform Access Pressure Safety Valves
Manways PSV 362,364,&'366
Pressure Safety Valves
PSV 361, 363, & 365
Flame Arrestors
�� w TSE 361, 363, & 365
Biogas Outlet Flanges
TP 364, 365, & 366
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` Biogas Inlet Flanges
TP 361, 362, & 363
Nlanw�y
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Section 1 System Overview Page 9
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Section 1 System Overview Rage 10
SYSTEM SUMMARY
Inlet Conditions Discharge Conditions
Design Flow 1300 scfm Design Flow 1300 scfm
Design Pressure 11" W.C. Design Pressure 5 psig
Design Temperature 40°F Design Temperature 80°F
Design R.H. 100% Design R.H. 24% ;
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Inlet Process Connection 12" Class 150 pattern Wafer Valve
Discharge Process Connection 10" Class 150 RF Flange
Condensate Connections Heat Exchanger Skid 1" Class 150 RF Flange
Condensate Connection Blower Skids 1/2" Class 150 RF Flange
Condensate Process Connection H2S Rmv) 3" Class 150 RF Flange
Water Injection H2S Removal 1" FNPT
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Heated Water Supply/Return H2S Inlet Heater 2" Class 150 RF Flange
Effluent Water Supply/Return Exchanger Skid 4" Class 150 RF Flange
Glycol Chiller Process Connections 2" FNPT
Glycol Process Connections Biogas Skids 3" Class 150 RF Flange
Section 1 System Overview Page 11 '�
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