Energy for Agriculture (E4A)

 

Quality Management System (QMS)General Quality Manual

September 2015

ENERGY FOR AGRICULTURE

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TABLE OF CONTENTS

TABLE OF CONTENTS ................................................................................................. 2

PURPOSE OF THIS MANUAL ...................................................................................... 3

1. INTRODUCTION .................................................................................................... 4

1.1 Classification of Biodigesters ........................................................................... 4

1.2 Selection of Type of Biodigester ....................................................................... 8

1.3 Components of ZamDigester ........................................................................... 9

Organisation Structure of E4A .................................................................................. 9

2. CONCEPT OF QUALITY IN BIODIGESTER PROJECT ............................................. 11

2.1 Backgorund ................................................................................................. 11

2.2 General Approach and Strategy of Quality Management System (QMS) .............. 12

2.3 Quality Control Process ................................................................................. 21

3. ROLES AND RESPONSIBILITIES OF STAKEHOLDERS .......................................... 25

3.1 Role of Biodigester Owners............................................................................ 25

3.2 Role of RBSU Technicians .............................................................................. 26

3.3 Role of NBSU ............................................................................................... 27

3.4 Role of Biogas Construction Enterprise/Installer/Mason ..................................... 28

ANNEX-1: QUALITY STANDARDS FOR ZAMDIGESTER-2015 ..................................... 30

ANNEX-2: TOLERANCES .......................................................................................... 36

ANNEX-3: FORMS AND FORMATS FOR QC ................................................................ 37

ANNEX-4: QUALITY CONTROL TOOLS AND EQUIPMENT .......................................... 54

ANNEX-5: QUALITY CHECK OF BIODIGESTERS AND KNOWLEDGE OF USERS........... 57

ANNEX-6: MONITORING PARAMETERS FOR ZAMDIGESTER ..................................... 58

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PURPOSE OF THIS MANUAL

Non-functioning and poorly functioning biodigesters cause not only capital waste but also do a

lot of harms and damages to the reputation of biodigester technology and eventually to the

desired future expansion of biodigester project. The satisfied biodigester users usually

become the main and effective promotional tools and extension media for the dissemination

of the technology and vice-versa. And hence, to safeguard the interest of the users,

implementing agencies, and donors; it is important that the biodigesters function to the

desired level. This is only possible when the biodigesters are selected, constructed and

operated as per the set quality standards. To ensure the quality of biodigesters, it is

important that effective and stringent quality control mechanisms are formulated and

enforced efficiently. The quality on training and capacity building; promotion and extension

activities; construction, operation and maintenance of biodigesters have to be a major

concern. As the rate of installation of biodigester will be increasing in the country year by

year, more careful attention has to be paid to ensure the quality of the final product. This

increases calls for more effective quality management system in place. This quality manual is

a document containing the quality policy, quality objectives, quality control process and

description of the quality management system to be practiced under the framework of Energy

for Agriculture (E4A) project.

The notion of quality is of utmost important for E4A project as it aims at creating a solid

foundation in the country for the subsequent projects in the future. There is need to ensure

each and every biodigester installed functions as anticipated. Non-functioning biodigester will

pose negative effect at different levels as follows:

At Client’s level: Sub-standard quality of product leading to unsatisfied clients,

gossip/negative image, loss of investment, and waste of land and initiative.

At Mason’s/constructor’s level: Bad reputation, loosing of job, no growth and loss of

investment.

At Project’s level: Waste of resources, loss of momentum, slowdown of distribution, set

back of the project, drop out of donors, and ultimate failure of the project.

This Quality manual explains the requirements to ensure that the quality standard are

enforced and complied with. It specifies requirements for Quality Management Systems

(QMS) by which E4A;

a. Develops and implements a policy and corresponding objectives which take into account

statutory and regulatory/legal and other requirements to which E4A subscribes.

b. Demonstrates its ability to consistently provide product and services that satisfies

customers/stakeholders, and

c. Enhance customer/stakeholders satisfaction through the effective application of the

systems, including processes for continual improvement of the systems and the assurance

of conformity to customer requirements.

This manual will help biogas engineers, quality inspectors, monitoring and evaluation officers

and biogas technicians to carry out the task of quality control effectively and efficiently.

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1. INTRODUCTION

1.1 CLASSIFICATION OF BIODIGESTERS

There are different designs of household biodigesters being disseminated in different parts of

the globe today. Broadly, they can be classified based upon type of digester, type of feeding,

and methods of construction as described below:

a. Based upon type of gas holder

i. Floating Gas Holder

In 1956 the floating drum biodigester, popularly known as KVIC (Khadi and Village Industries

Commission) Gobar Gas plant, was introduced in India.

In this design, the digester chamber is made of

brick/stone masonry in cement mortar. A mild steel

drum is placed on top of the digester to store the biogas

produced in the digester. Thus, there are two separate

structures for gas production and collection.

The advantage of the floating drum design is the

constant gas pressure, which is equal to the gasholder’s

weight divided by its surface. This means that lamps,

stoves and other appliances don’t need any further

adjustments once they have been correctly set to a certain pressure rating. Another

advantage is that the risen level the gasholder indicates quantity of the available gas. With

the introduction of fixed dome Chinese model plant, the floating drum plants became obsolete

because of comparatively high investment and maintenance cost.

Advantages Disadvantages

• Constant gas pressure

• Suitable for larger plants

• Easy to understand

• Shallow digging work required and

therefore suitable for areas with high

water tables

• Can be transported to other areas,

suitable for roaming population

• Low initial investment cost

• Very vulnerable for damages by

playing children, stray cattle, etc.

• Frequent repairs and protection

measures are necessary;

• Low gas pressure, unsuitable for gas

lamps;

• Limited lifetime of the plastic,

especially when exposed to sunlight,

<2 years;

• Sensitive to ambient temperature

variations

• Requires a large surface area

• Expensive to build

• Cannot be built in remote areas,

nearby metal workshops are

necessary

• Regular (annual) maintenance

required

• Fairly sensitive to temperature

changes, less suitable in mountainous

regions

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ii. Fixed Gas holder

The fixed dome also known as Chinese model biodigester was

developed and built in China as early as 1936. It consists of an

underground brick/stone masonry compartment (fermentation

chamber) with a dome on the top for gas storage. In this design,

the fermentation chamber and gas holder are combined as one

unit. This design eliminates the use of costlier mild steel gas

holder which is susceptible to corrosion. The life of fixed dome

type plant is longer (over 20 years) compared to the floating drum

design. The original Chinese model is usually complete made out

of concrete and constructed with the help of moulds. Based on the

principles of fixed dome model from China many different designs

have been made in other countries.

Advantages Disadvantages

• Underground structure, stable

temperature, space saving

• On the spot construction with locally

available materials

• Durable, no moving parts, with little

maintenance.

• Fluctuating gas pressure

• Expensive construction cost in some

countries (cement)

• Artisan skill levels required

iii. Balloon Type

This type of biodigesters use plastic membrane of different types to store biogas produced in

digester. These types of digesters are low-cost, easy to install, and easy to transport into

remote areas, while yielding sufficient gas for both cooking and lighting needs. However, the

life-span of plastic bag digesters is relatively shorter depending upon the type of plastic

membrane used, provisions of covering/roofing, provision of fencing, and effectiveness of

operation and maintenance activities.

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b. Based upon type of Feeding

i. Continuous Feeding

The rural household digesters are fed once a day with the proper mix of dung and water/urine

and the fresh input displaces the same volume of digested bioslurry from the digester. Every

day a certain quantity of fresh input is fed into the digester which is expected to remain in the

digester for a prescribed retention time and produces gas over this length of time before being

discharged.

ii. Batch Feeding

In this process the whole digester is filled once with raw materials for gas production along with

some starting (seed) material. This is allowed to ferment and produce gas over a certain length

of time and when gas yields become very low the digester is emptied of all the sludge which can

be supplied as manure. In this system gas production begins at a low level and goes on

increasing only to drop down again after reaching the peak. Because of variable gas production

level, high cost and periodic emptying and filling of digesters, this process has not become

popular. Examples of these digesters are small size garbage plant and crop-residues plant.

iii. Semi-batch /continuous Feeding

A combination of batch-fed and continuous fed digestion is known semi-batch or semi-

continuous digestion. Such a digestion system is used where the waste like garbage etc., which

are available on daily or weekly basis but cannot be reduced to make slurry. In the semi-batch

system, the animal manure can be added on a daily basis after the initial loading is done with

garbage, agricultural waste, leaves, crop residence and water hyacinth etc.

c. Based upon methods of installation

Likewise, based upon the methods of installation biodigesters could be classified as (i) Pre-

fabricated model and (ii) constructed in site model.

d. Based upon ownership of Biodigesters

Based upon the ownership of biodigesters, they can be classified as (i) domestic biodigesters

and (ii) institutional biodigesters and (iii) community biodigesters.

The following are some of the models being used in different parts of the world.

Flooding drum models (India) Floating drum Model (Nepal) Janatha Fixed Dome (India)

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KT 1 Fixed Dome, Vietnam Chinese Fixed Dome Plastic Bag digester

GGC Model Deenbandhu Fixed Dome, India

CAMARTEC and Modified CAMARTEC Biodigesters – Tanzania and Uganda

Vacvina Digester, Vietnam Bangladesh IDCOL Model

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Steel Digester – Indonesia Prefab fiber reinforced – China

1.2 SELECTION OF TYPE OF BIODIGESTER

To successfully achieve anticipated objectives of biogas project, it is imperative that the best

suited model/design of biodigester is selected for the wide-scale dissemination. Varieties of

models/designs of biodigesters are being used in different countries in the world with successful

track records. Based upon the performance of the existing plants and experiences from other

biogas countries, attempts should be made to select the best model for the wide-scale

dissemination of the biogas technology in the country.

The following factors have been considered to evaluate the suitability of biodigesters in Zambia

assuming that the adaptability of any biodigesters in a given context depends mainly upon

these factors.

a. Climatic and geo-physical parameters: Ambient temperature, geo-physical conditions of the

soil and condition of ground water-table

b. Technological Parameters: Structural strength against different load conditions (structural

durability), methods of construction/supervision time and effort in quality control, methods

of operation and maintenance, applicability/adoptability of the design in different

geographical context for mass dissemination, prospects for sharing of technical information

and know-how.

c. Affordability of potential farmers to install biodigester: availability of construction materials;

availability of human resources (skilled and unskilled) at the local level, cost of installation,

operation and maintenance, transportation facilities.

d. Purpose of the use of the products from biodigester: use of gas for cooking, lighting and/or

operating a dual-fuel engine; use of slurry as organic fertilizer.

e. Performance of existing models, if any, in the local and/or regional conditions: existing

physical status and functioning, user's level of satisfaction.

f. Quality and quantity of available feeding materials: type of feeding materials (cattle dung,

human excreta etc.), availability of water for mixing, no. of cattle per household

Based upon above mentioned criteria, the fixed-dome double spherical model of biodigester

maned as ZamDigester has been developed for wide scale dissemination of the technology in

Zambia.

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1.3 COMPONENTS OF ZAMDIGESTER

The major components of ZamDigester are: inlet (mixing chamber and water/urine collection

chamber), digester (digestion chamber), gas holder (storage chamber), outlet (displacement

chamber), gas conveyance and application system (pipes and appliances) and slurry compost

pit(s). The mix of dung and water (mixed in inlet or mixing chamber) passes through the inlet

pipe to the digester. The mixer produces gas through digestion process in the digester and the

produced gas is stored in the gas holder (top of dome). The digested slurry passes out from

digester to outlet tank (displacement chamber) and flows out to the compost pits through

overflow opening in the outlet tank. The gas is then supplied to the kitchen through the pipe

line.

The ZamDigester generally consists in detail of:

1. Inlet (Mixing Tank)

2. Inlet Pipe(s) separate for cattle

dung/pig manure and latrine

3. Digester

4. Gas Holder (dome)

5. Manhole

6. Outlet (Displacement Chamber)

and overflow opening

7. Main Gas Pipe and Turret

8. Main Gas Valve

9. Pipeline

10. Water Outlet (Water Trap or Drain)

11. Gas Tap

12. Gas Stove with rubber hose pipe

13. Compost pit(s)

ORGANISATION STRUCTURE OF E4A

E4A project aims at installing 3,375 biodigesters in farming households in years’ time starting

from May 2015, providing them access to clean energy, increased employment and income, and

improved living condition through the productive use of products – biogas and bioslurry,

through:

• Development, strengthening and facilitating a commercially viable and market oriented

biogas sector in Zambia (Supply and Demand side management as well as facilitating

creation of enabling policy environment

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• Provision of Technical Assistance to transfer know-how, experience and technical

information available from successful implementation of other biogas programs

• Maximizing the benefits of the operated biodigester for productive uses, in particular the

optimum use of biogas and bio-slurry

The structure of E4A comprises of two major units, the implementation unit (National Biogas

Support Unit - NBSU and Regional Biogas Support Unit - RBSU) and Technical Support Team

(SNV Advisory team) as mentioned below:

Biogas Support Units (NBSU and RBSU)

• NBSU Coordinator

• Chief Biogas Engineer (CBO)

• Promotion and M&E Officer (PM&EO)

• Finance and Admin Officer (Part-time)

• Secretary/Admin Assistant

• Regional Biogas Technicians

SNV Advisory

• Country Director (Part-time)

• Project Manager

• Senior Project Officer

• Finance/Project Accounting

• Procurement and Contracting (Part-time)

The flowing diagram illustrates the project functions and respective actors:

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As shown in the diagramme, the major responsibility of quality assurance rests on the users

themselves, masons from construction companies, technical staff members of National and

Regional Biogas Support Units.

2. CONCEPT OF QUALITY IN BIODIGESTER PROJECT

2.1 BACKGORUND

‘Quality is not an act; it is a habit’ – Aristotle

In general, quality is the degree of compliance of a process or its outcome with a predetermined

set of criteria, which are presumed essential to the ultimate value it provides. Quality is doing

the right things in right way. A product or process that is reliable, and that performs its

intended function is said to be a quality product. Quality is the extent to which products,

services, and processes, are free from defects, constraints, and items which do not add value

for customers. The quality of a product or service refers to the perception of the degree to

which the product or service meets the customer's expectations. In technical usage, quality can

have two meanings:

a. The characteristics of a product or service that bear on its ability to satisfy stated or implied

needs.

b. The product or services should be free of deficiencies.

In the case of Energy for Agriculture (E4A) project, the quality is basically related to the

following aspects of project implementation:

a. Quality of the design of biodigester: The biodigester should be cost-effective; users’

friendly; easy to construct, operate and maintain.

b. Quality of training and capacity building activities: Correct training need assessment;

proper selection of training participants, proper selection of facilitators, suitable training

contents, session plans and scheduling; appropriate training methods; effective practical

sessions; effective evaluation of training; timely follow-up of the evaluation findings.

c. Quality of promotion and extension works: Potential customers are fully aware and

understand all the benefits and costs. They are provided with factual data and information

and are be aware of their roles and responsibilities for quality control.

d. Quality of the construction (including selection of construction materials and appliances):

Strict adherence of set quality standards on site selection, selection of construction materials

and appliances and construction.

e. Quality of the operation and maintenance by the users and technical backstopping from

the installer: Effective training to users’, provision of users’ manual, timely follow-up visits

by the installer.

f. Quality of after-sale-services on behalf of the installers: Strict adherence of terms and

condition of after-sale-service provisions including timely actions to the complaints from

users, routine visits and problem-solving.

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g. Quality of financial and administrative procedures and practices: Proper utilisation of

fund; timely disbursement of credit and/or subsidy amount, if any; proper book-keeping;

less-lengthy procedures; fast, friendly and useful customer services.

If the biodigester is able to do what is anticipated by the project personnel and what the user

wants it to do, then it is a quality plant. In other words, if the final product fulfils the anticipated

requirements, it can be referred as a quality plant. Hence, quality is the performance excellence

of biodigester as viewed by all stakeholders. Thus, if the installed biodigester:

has the right dimensions, configuration and features,

does what it's supposed to do,

is reliable and durable,

is delivered on-time, and

is well-supported;

then it is quality biodigester.

2.2 GENERAL APPROACH AND STRATEGY OF QUALITY MANAGEMENT

SYSTEM (QMS)

The general aim of the Quality Management System (QMS) is to ensure that the overarching

objectives of the E4A are met in the best possible way with the available resources. The basic

objective of QMS in E4A is to ensure that the installed biodigesters meet the set quality

standards and they function optimally without any major problems for the anticipated duration

of time. Effective QMS not only helps in ensuring the compliance of quality standards but also

provides learning opportunity for the project personnel.

While enforcing QMS, E4A will make sure that the following four basic principles are considered:

a. Reliability of the information collected

b. Uniformity (consistency) of the information collected and analyzed

c. Impartiality (neutrality) while collecting information

d. Transparency when dealing

Quality Control visits are integral part QMS. The objective of the quality control is to encourage

stakeholders to comply with the set quality standards. Quality Control is all the means by which

the frequency of defects in a biodigester is reduced. It includes quality planning, quality

measuring and quality analysis. While conducting QC visits, E4A will ensure that the concerned

project personnel are aware of:

a. Purpose of quality control visits

b. Frequency of visits

c. Reporting and documentation methods

d. Corrective actions

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Quality Management in Biodigester Projects refers to the systematic monitoring and evaluation

of the various aspects of the project, services, or product (biodigesters) to ensure that

standards of quality are being met. It attempts to avoid, or at least minimize, issues that led to

defects in the first place.

The quality management strategy rests on four widely accepted premises of biogas project

dissemination:

a. It is usually exponentially cheaper to deal with defects when they’re caught early than it is

to fix them later

b. The higher the level of quality assurance (coverage, frequency, effectiveness), the easier it

is to catch defects early

c. It is important to apply techniques to highlight defects in the requirements specification

(“building the wrong thing”) as well as in the implementation (“building it wrong”), and to

address not only functional requirements but also other areas of quality like maintainability,

scalability and performance, usability and accessibility, security and more.

d. Quality management task becomes more effective, if it is outsourced to a capable institution

in the long run.

The following table illustrates in brief the short and long-term strategy for quality assurance

under the framework of E4A.

Project

Functions

Short-term Strategy Long-term Strategy

Promotion

and

marketing

Develop Information, Education

and Communication (IEC)

materials, organize community

meetings and capacitate

masons/biogas companies to

promotion and marketing.

NBSU/RBSU takes the lead role in

doing so.

Strengthen the capacity of Biogas

Construction Companies/

enterprises to take overall

responsibility of the task of

promotion and marketing.

Training and

Capacity

Building

The NBSU through SNV TA,

conduct technical training to build

capacity of stakeholders including

local artisans and project staff-

members.

Capacitate local institutions/

vocational training centres, training

organizations to conduct training

and capacity building activities

Two key principles of Quality Management System

are:

The biodigesters should be suitable for the

intended purpose: fit for purpose

Mistakes/defects should be eliminated: right

first time

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Project

Functions

Short-tern Strategy Long-term Strategy

Construction

and after-

sale-services

NBSU/RBSU with TA from SNV

enhances skill of local artisans

and mobilise them to form

biodigester construction

companies.

Focus on private sector (biogas

construction enterprises)

development and

institutionalization of construction

and after-sale-services

Quality

Control

Technical staff from NBSU/RBSU

will take the lead role. SNV will

build their capacities to carry out

quality control activities.

NBSU/RBSU will be fully capacitated

to take the overall responsibility.

NBSU will build capacity of

government, semi government or

other suitable organizations and

out-source the task of quality

control to them.

The following sections describe the general strategy in detail.

Strategy-1: The task of Quality Control is associated with all project functions

Quality Control (QC) will refer to the operational techniques and the activities used to fulfil and

verify requirements of quality within the framework of E4A. QC is the planned process of

identifying established technical specifications for the project and exercising influence through

the collection of specific (usually highly technical and standardized) data. The basis for decision

on any necessary corrective action is provided by analyzing the data and comparing it to system

specifications/requirements. At E4A, it implies all those planned or systematic actions necessary

to provide adequate confidence that the biodigester is of the type and quality needed and

expected by the stakeholders.

In E4A, quality control is involved in developing systems to ensure biodigesters are designed

and constructed to meet or exceed users’ requirements. As with cost control, the most

important decisions regarding the quality of a biodigester are made during the design and

planning stages rather than during construction. It is during these preliminary stages that

component configurations, material specifications and functional performance are decided.

Quality control during construction consists largely of insuring conformance to this original

design and planning decisions.

The following figure illustrates the general functions required for any national project on

domestic biogas within the framework of E4A. The concept of quality is associated with each

and every function.

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Program Functions

Quality Concept

Promotion and Marketing

Training and Capacity Building

Construction and After-sale-services

Operation and Maintenance

Financing

Extension, Research and Development

Program Management and

Administration

Quality of promotional tools and techniques

Quality of information dissemination

Correct selection of unique selling point

Correct selection of audiences

Training need assessment Correct selection of participants Correct selection of facilitators/trainers Correct selection of training venue, training

methods and tools Certification, accreditation and registration Provisions of refresher training

Convenient, effective and efficient subsidy and credit

channelling mechanisms

Selection of correct design Selection of right client Selection of suitable site for construction Selection of quality construction materials and

appliances Provision of guarantee Provision of Users’ training and instruction manual Provision of compulsory routine monitoring visits Effective enforcement and compliance of quality

standards

Provision of pre and post construction training to users

Availability of spare parts Provision of compulsory visits of

installers on call Provision of warranty system System to collect complains from users

Provision of Users’ training on bio-slurry use Provision of Bioslurry use Manual Provision of routine Biogas Users’ Survey Identification of R&D needs based upon filed

findings Effective on-site use of research findings

Provision of Quality Control of the Quality Control Initiatives

Provisions of Technical Audits Selection of right partners Effective networking with local and external

stakeholders Effective service delivery mechanism Provisions of regular coordination, follow up and

sharing meetings Participatory program management system Effective documentation of lessons learnt and

timely sharing of information Effective advocacy, lobbying and networking for

policy formulations

Quality control is increasingly important concern during biogas project implementation. Defects

or failures in constructed biodigesters can result in costs. Even with minor defects, re-

construction may be required and facility operations impaired. Increased costs and delays are

the results. The structured QC system is therefore important for the following main reasons:

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a. To maximize performance, reliability and lifetime of every biodigester

b. To maximize the value for money for Biogas customers, E4A donors and Government of

Zambia

c. To maximize the potential livelihood benefits to customers and communities

d. To minimize the risk of accidents or damage to users or property

e. To maintain the reputation, credibility and value of the Biogas Project in Zambia

Strategy-2: Strong Focus on Capacity Building of Relevant Stakeholders

The overall aim of quality management in the long run will be to build the capacity of NBSU and

RBSU staff members to carry out the tasks of quality assurance. They will internalize the

process of quality control and feel ownership of the process. For this to happen, they will be

provided with appropriate capacity building initiatives related to quality assurance. Once they

are provided with such capacity building package, they will be given responsibilities to carry out

quality control activities.

Capacity building of constructors/masons, vocational training institutes, government line

agencies and other stakeholders involved in biodigester sector is crucial for effective quality

control. Knowledge and skills of biodigester technicians and masons are vital in ensuring the

quality of construction, operation and maintenance. QC activities therefore will begin from the

very onset of these training projects.

Quality control will be considered to be a ‘bottom-up’ activity. Rather than imposing it from the

top, the actors in the lower tire will realize the importance and provide effort to ensure the

quality. The constructors/mason and the biogas households will be encouraged and capacitated

to play a major role in ensuring the overall quality of biodigester and hence, they will be

provided with effective training packages on quality management.

To ensure effectiveness of the training programme, it is important that:

a. right persons are selected for the training

b. right trainers are selected to facilitate the training sessions

c. training contents, session plans and scheduling are suitable to meet the training objectives

d. the training methods are suitable for the particular audiences in particular learning

environment

e. the practical demonstration and on-the-job training sessions are effective

f. the evaluation of training is carried out effectively and the findings are used to improve

similar training in the future

g. timely follow-up is made to evaluate the application of learning from the training in the

workplace

The users in biogas households will be provided with at least the following two types of training:

a. Pre-construction training to familiarize them with benefits of biodigesters, installation

modality, incentives and support services being provided to them by the project, general

quality standards and their roles and responsibilities on quality control.

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b. Post-construction training to strengthen their knowledge and skills on effective operation,

routine repair and maintenance activities, provisions of after-sale-services and complaints

mechanisms.

Strategy-3: Formulation and Enforcement of Quality Standards

Quality standard is a framework for achieving a recognized level of excellence within the

project. These are stipulations of measurable physical properties or characteristics, which

materials, equipment or constructed items must have as a minimum. Achievement of a quality

standards demonstrates that the project activities have met the requirements laid out by a

quality control authority. In general, quality standards are the benchmarks of levels of service

or design specification.

Standards, as a rule or principle, are used as a basis for judgment or comparison – whether the

installed biodigester fulfills the basic requirements. These are statistics that measure changes or

deviations and provides impetus to analyze whether any deviation will have detrimental effects

on functioning. It helps in identifying the level of accuracy in complying the set criteria.

To facilitate effective monitoring for ensuring quality, standards have been developed under the

framework of E4A. The quality standards are basically related to the following aspects:

a. Quality standards related to location and size of biodigesters

b. Quality standards related to the design of biodigesters

c. Quality standards related to construction of structural parts and installation of pipes, fittings

are appliances.

d. Quality standards for the operation and maintenance of biodigesters (after-sale-services on

behalf of the installers and routine O&M on behalf of users)

The details on standards for ZamDigester have been given in Annex-1. These include, the

standards, their specifications including the tolerances (the ‘what’ part), and category as well as

potential consequences, if these standards are not met (the ‘why’ part).

These standards have been categorized under three different groups keeping in view their

importance. The critical standards are those which need to be followed strictly and no

compromise should be allowed. Failure to comply with these standards will have serious adverse

effect on the end product and on the project as a whole. The major standards are very

important for the smooth functioning of the biodigesters and failure to comply these standards

results in serious problems with the functioning. The minor standards are also important for

the successful operation of biodigester however, these can sometimes be manipulated based

upon the site conditions. Still care should be provided to adhere with these standards.

Various surveys on Quality of Biodigester Construction have confirmed that failure to achieve

appropriate Quality of Construction is a problem. The pressure to reduce the initial costs of

construction and supervision were found to have had an adverse effect on quality, as could be

predicted. Within the conventional processes for the construction contract, the installers, who

are keen to get the job of installation of biodigesters, can do so by offering low prices, but at

the risk of not being able to produce construction work which fulfills the specification or meets

sustainable standards. Likewise, technical supervisors are often under pressure to reduce the

cost of construction supervision. Inadequate supervision leads to sub-standard quality of

construction. Lack of quality in construction of biodigester is often manifested in poor or non-

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sustainable workmanship, and unsafe structures, and in delays, cost overruns and disputes in

construction contracts.

E4A believes that construction of biodigester should be sustainable, and to this end, it is the

policy of E4A that each actor in the construction process should be committed to satisfying its

obligations in respect to achieving Quality of Construction.

Construction is not value-free and hence the approach that organizations take in solving

problems is influenced strongly by the values and beliefs they hold. Values and beliefs drive

attitude and behavior, and thus outcomes. If improved quality management and quality of

construction is desired, then it will be necessary for quality management and quality of

construction to be embodied within the values and belief system of the client body. If this is not

the case, all the good intentions of the suppliers of services, goods and processes further down

the project cycle will have limited impact.

E4A will allow to have a certain tolerance limits for every quality standards based upon their

importance. Tolerance is the degree to which the set quality standard can vary or deviate

without jeopardizing the functioning of the biodigester. In E4A case, tolerance is the permissible

limit of variation in the physical dimensions of biodigester. Dimensions of biodigester may vary

within certain practical limits without significantly affecting functioning of the final product.

Tolerances are specified to allow reasonable leeway for imperfections and inherent variability

without compromising performance. Tolerances are fixed based upon the anticipated degree of

precisions to ensure effective operation of biodigesters. Most of the quality standards developed

for the construction of biodigester allow certain tolerances. The maximum tolerance limits are

given in Annex-2.

Strategy-4: Provision of Reward and Penalty Mechanisms

The disadvantage or painful consequences resulting from an action or condition that is against

the set quality standards are referred to as ‘penalty’ whereas something given or received in

Hence, both the supervisors as well as constructors (installers) should realize the

following facts to ensure good quality of biodigesters:

a. To recognize the importance of quality of construction.

b. To adopt quality management systems.

c. To provide procedures for corrective action when quality control and /or

acceptance criteria are not met.

d. To provide feedback to concerned persons/authorities for improvement of

quality of construction.

e. To recruit, train and assign a skilled work force.

f. To take measures to ensure that the persons involved in construction and

supervision are qualified, and/or accredited as required.

19

recompense for full compliance of the quality standards is a ‘reward’. Penalties are imposed

when the quality of works and the final products are of inferior quality than the anticipated

whilst rewards are awarded when the product fully meets or even exceeds the expected level of

quality.

The quality control system in E4A proposes reward provision to encourage those doing

exceptional works. The following reward mechanism will be practiced:

a. Installer(s) who construct biodigesters with minimum or no defects will be awarded as ‘best

installer(s) of the year’. The best installer will be provided with certain incentives and

rewards.

b. The best installer will be rewarded with technical, financial and institutional supports to

establish/strengthen a biodigester construction company.

c. The RBSU technicians who do outstanding job will be awarded as ‘best technician(s) of the

year’ and awarded with certain incentives. The best technician(s) will be given opportunity

for exposure visits or participation in any national/international training/workshop/seminar

on biodigester technology.

Likewise, the following ‘penalty mechanisms’ will be practiced to ensure the quality while

constructing and supervising the construction of biodigesters:

a. Poor quality work, the defaults, will surface in the database through the QC reports and

through QC on QC reports. The installer/mason(s) and technicians will be warned on such

defects based upon the severity of the defects. Repeated offenders against the quality

standards will be removed from the project and the defects will be corrected by utilizing the

functionality incentive not paid to the mason.

b. If certain mistakes are commonly made in a throughout all sites, this will be addressed at

the new technical training and at annual refresher trainings for masons and supervisors.

c. If RBSU technical persons fail in their role of quality inspectors, the technicians will be

provided with a warning. Technicians who, after a first warning, commit the same mistakes

again will be removed from the project;

d. On a monthly basis the RBSU have to report on the complaints they have received from the

users and the action they have taken. If a user claims that he/she has registered a

complaint and this is not responded by the local RBSU technicians, NBSU will investigate and

possible actions will be taken.

e. The installer(s)/companies will be categorized in three categories, such as (a) best

performing (b) satisfactorily performing and (c) poorly performing, based upon responses

from the users and operational conditions of biodigesters they install. The poorly performing

installers will be warned to improve their performance within a certain timeframe. If their

performance rating still falls under ‘poorly performing’ such installers will not be entertained

under the framework of the project for certain period of time.

Strategy-5: Operationalization of Database

E4A will install database-oriented software in order to keep track of the construction of

biodigesters both quantitatively and qualitatively. This software will be used to monitor the

biodigester dissemination progress, monitor the construction process, control the quality of the

construction, keep track of the trained professional involved in the construction and monitor

their after sale service and finally keep track of some financial data. E4A will ensure that: (a)

each biodigester has a unique serial number engraved in a permanent nameplate. The

identification numbers are listed in the database; and (b) the GPS coordinates of the location of

20

each biogas digester is recorded in the database. The software will be designed to be easy to

use even for non-experienced computer users by providing simple and intuitive data entry

forms.

Each completed biodigester will be given a unique code number after the completion of

construction works while filling the ‘Construction Completion Form’ besides other attributes such

as GPS location, address etc. All the information along with unique code number will be

managed in a computerized database. The following coding system will be practices:

Year of Construction – Province Code – Company/Mason Code - Plant Number

Provinces will be coded with suitable notions (usually three letters, such as LUS for Lusaka).

Likewise the name of company/mason is also coded accordingly with suitable coding (for

example LBC for Lusaka Biogas Construction Company). The coding for the first ZamDigester

constructed by Lusaka Biogas Construction Company in 2015 in Lusaka province will therefore

be:

13-LUS-LBC-0001.

The following roles in terms of database operation will be given care:

a. RBSU in the provinces (fields)

Follows the progress of the project in his/her province.

Enters data for his/her province.

Views the data from his/her province.

Provides feedback to biogas installer/masons.

Transmits the RBSU data to the NBSU.

b. NBSU Chief Biogas Engineer in Centre

Views and updates the data from all provinces.

Eventually gathers the provincial data.

Prints reports.

Provides feedbacks to RBSU.

c. E4A Financial Administrator

Checks the subsidy payments (for early 750 biodigesters)

Checks the payment of functionality incentives to masons

Provides feedbacks to NBSU.

d. E4A M&E Officer

Creates new accounts

21

Administers the Dbase.

Provides feedbacks to concerned personnel.

The following points will be taken care of while designing and operating central database:

a. The Software will be developed using MS Access 2003 – relational or extended relational

database system

b. The Software will be easy to use and will remind the user of the forms on which the data is

collected.

c. The Software will support several concurrent users accessing the same data.

Strategy-6: Outsourcing of Customer Support Service

E4A will carry out the required quality management tasks in the field through its trained

technical officers at NBSU and RBSU. The task of customer support service will be out-sourced

to capable private sector organization. The selection of such institutions will be done from open

bidding process guided by the Terms of Reference which is given in Annex-3.

The following flow-diagram illustrates the process of out-sourcing the task of Customer Support

Centre to local organization. E4A will make sure that the capacity of the local organization is

built to internalize the whole process of QM tasks.

2.3 QUALITY CONTROL PROCESS

As mentioned earlier ‘quality control’ will be the integral part of all the project functions. The

general rule will be (i) under-construction controls first by the technical persons of

company/installer (100% of the biodigester), then by the RBSU quality inspectors (sampling

according to skill and experience of mason and available resources – at least 50% in the initial

phase of the project); (ii) construction completion inspection by RBSU quality inspectors, on

100% of constructed plants (iii) monitoring of compliance of after-sale obligations (on at least

50% of the biodigester in the initial phase of the project) and (iv) quality control of quality

control activities by NBSU technical persons on randomly sampled biodigesters (10 to 20%

depending upon resources availability).

All the inspection findings are then entered into a Dbase; evaluated and monthly feedback

provided to respective stakeholders. Company grading, incentives and penalty, need of training,

revision of manuals etc. are done based upon database output.

The following diagram details the QC process:

22

Potential Farmer Approaches

Installer

Feasibility Study done (From 2a)

If feasible,

Drawing, cost and quantity estimation consulted with the farmer. Construction Contract

Signed (Form – 3)

If not feasible

Inform the farmer why not

feasible

Construction

Quality Control visit by Installer – 100% of the biogas plant (Form-4)

Quality Control visit by project quality

inspectors - 10-25% of the biogas plant

(Form-4)

Feebback provided

Construction Completed and Completion Report

Submitted (Form-5)

Form-5, acceptd

Guarantee Card Issued, Subsidy

payment recommended

Initial Feeding of plant

recomended

Acceptance Visit (Validation

of Form – 5)

Form-5, not accepted

Acceptance visit done by quality inspectors from project – 100% plants visited

Installer instructed to correct the

defaults

Operational Stage

Users receives operation and maintenance

training

Users receives instruction (O & M)

manual

Installer provides After-sale-service as per Guarantee terms

and conditions

QC Inspectors monitors the compliance of

guarantee provisions (Form – 7)

Performance monitoring including Do-No-Harm Assessment is done at least once in 6 months

(Form -6)

List of Potential Farmers is prepared (Form-1)

Baseline Information

collected (Form – 2b)

All data (Form-1 to Form-7) are

entered into a computer database

Reports prepared and acted upon

If found complied with,

guarantee terms and condition,

gurantee fee relaeased

23

Quality Control Visits are the main tools to monitor the quality of works being carried out at

the field level. The diagram below shows the scope of quality control visits:

The following diagram illustrates proposed timeline of such QC visits.

The diagram illustrates the visits generally necessary during the process of the installation of

biodigesters. Among these, RBSU technician should visit the site together with BCC technician

for the first and second visits. NBSU technical officers will visit some of the randomly sampled

sites for site verification. The fourth (general inspection) could be optional depending upon the

need. Besides these visits, at least two visits will be made or two telephone call will be made to

monitor the quality of after-sale-services within a year from the date of plant operation.

The 'Plant Completion Report', will also include proper measurement of different vital

components of biodigester such as diameter of digester, pressure height, diameter and height

of outlet tank etc (as given in Annex-4). This form should be filled before the initial feeding of

the plant. RBSU technicians will be trained to fill this form for all the new plants. NBSU

technicians will randomly sample some of the filled forms (at least 25%) at the site and validate

it instantly. Subsidy could be released immediately after the approval of 'Plant Completion

Report'.

The scope of work during the QC visit includes assisting and checking the construction and

providing feedback to mason. The purpose is also to make sure that the masons are qualified

enough to carry out their activities. General process for QC visits will be as follows:

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a. The mason/installer/BCC submits the details on under-construction as well as completed

biodigesters to the RBSU Technician.

b. The RBSU technician selects the biodigesters to be inspected from the list of under-

construction and completed plants on the basis of random sampling

c. Field visit schedule is prepared

d. Site verifications are carried out using the standard formats

e. The filled forms are signed by three parties (concerned mason, owner and the RBSU

technician)

f. The data and information are entered into computer database

g. Necessary feedback and suggestions is given to the installer/mason through the field

technician based upon the analysis of the data and information

h. The installer/mason follows/acts upon the feedback and suggestions immediately

i. NBSU Technical Officers select some plants on random sampling basis (under-construction,

construction-competed and operational) and carries out validation of data and information

collected by field technicians.

Sampling of Biodigesters for QC is done carefully to represent the number of biodigester

installed. Quality control in biodigester construction typically involves insuring compliance with

minimum standards of material and workmanship in order to insure the performance of the

facility according to the design. For the purpose of insuring compliance, random samples and

statistical methods are commonly used as the basis for accepting or rejecting work completed.

Rejection is based on non-conformance or violation of the relevant design specifications.

Quality control visits by RBSU and NBSU to under-construction and completed biodigesters are

very important to check the compliance of the quality standards by the masons. Visits to all the

biodigester will not be possible because of the resource constraints. Therefore, random

sampling or stratified random sampling methods (stratifications made based upon responsible

supervisors or masons, provinces, districts, types and/or sizes of biodigesters etc.) will be used

to select the biodigesters for quality control visits. The sampling will be done by district

technicians.

The following general formula could be used for deciding the sample size

n = sample size

N = Population (number of plants constructed)

e = level of desired precision or margin of error, expressed as a fraction of 1 (usually

5% to 10%)

For example, if 300 plants are being constructed in a province in a particular year, the district

technician will visit at least 171 plants not to exceed margin of error by 5%, 75 plants not to

2)(1 eN

Nn

25

exceed the error by 10% and 23 plants not to exceed the error by 20%. The greater the

precision anticipated, the larger will be the sample size.

Though the frequency of visit and sample size depends on the skills of masons, internal quality

management mechanism of the installer/company and available resources to carry out the

quality control visits, the following picture shows the minimum requirement to ensure quality of

biodigesters.

3. ROLES AND RESPONSIBILITIES OF STAKEHOLDERS

3.1 ROLE OF BIODIGESTER OWNERS

The biodigester owners are the most important stakeholders in quality control of biodigester

during construction as well as operation and maintenance phases. They are responsible to:

a. Participate in pre and post construction training sessions.

b. Prepare construction sites and collect materials according to the instruction of the

installer/mason and/or RBSU technician.

c. Set the construction schedule and deadlines in consultation with the RBSU and the

installer/mason.

d. Provide required unskilled labor for the digging work and to assist the masons during

construction as per the contract provision.

e. Constantly monitor the work of installer/mason.

f. Operate the plant as stipulated in the operation manual.

g. Carry out routine repair and maintenance works as per maintenance manual.

h. Report problems to the installer/mason and/or NBSU.

i. Respond to calls from Customer Service Centre and call them in case of any problem related

to operation of biodigester.

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j. Lodge complaints in RBSU/NBSU if the installer/mason does not respond to the call for

problem solving.

3.2 ROLE OF RBSU TECHNICIANS

RBSU technicians will be responsible for the protection of farmers against incompetent and/or

careless installer/BCC/masons. It is done through quality control during the construction on

randomly sampled plants and completion control of all plants. During these visits the

technicians will methodically inspect biodigesters using appropriate inspection forms. The

technician will ensure that no plant is handed over to the user if he/she is not completely

satisfied that the completed plant, including pipeline and appliances, will function as it is

supposed to. The above described control mechanism is also laid-down in the construction

contract signed by mason, RBSU technician and user.

The detail tasks of NBSU Technician are:

a. Select suitable households to register with the Project for technical and financial assistances

with the help of local masons/BCCs.

b. Help users select suitable designs, sizes, locations for biodigesters and required

construction materials as per the quality standards.

c. If required, assist users in obtaining a biodigester construction loan with a recognized

financial institution.

d. Help users purchase/prepare accessories and tools as per required technical standards for

the biodigesters.

e. Introduce trained and certified mason’s team/mason to the users for their selections and

construction agreements.

f. Help and provide document to users instructing construction supervising procedure,

including their roles during and after the construction works, in order to assure construction

and installation quality.

g. Supervise the work of local masons during construction and installation of biodigesters in

order to control construction quality. The biodigesters to be visited are selected randomly

from the list of under-construction biodigesters informed by the installer/masons. Data and

information are recorded in the standard Construction Monitoring Form (given in Annex).

Masons are instructed to correct any deviations from the standards. Any mason who

violates seriously the construction requirements are reported to NBSU for final actions such

as stopping mason’s jobs, revoking certificates, cancellation of construction contracts etc.

h. Fill database or submit the filled Construction Monitoring Form to NBSU for entering the

data and information into the database.

i. Instruct biodigester users to prepare feedstock as per quality requirements before operating

plants.

j. Visit all the completed plants for filling Construction Completion Report (also known as

Acceptance Report) (given in Annex). This visit is made after the completion of construction

works but before the initial feeding of the biodigester. Measurements of various key

components are taken and crossed checked with the standard. Test and Acceptance jobs

are carried out in cooperation with users and mason. The data and information is filled and

27

Construction Completion Report and is signed by the three parties (RBSU technician, mason

and the user). The biodigester code is mentioned in the Construction Completion Report for

project management. Biodigester owners are instructed to feed the biodigesters only if the

quality standards are met. Any rectification needed is carried out by the mason in an

agreed timeframe.

k. Submit the Construction Completion Reports from fields to RBSU for data entry or if access

is given enter the data and information into the database and register the biodigester into

project management file.

l. Instruct biodigester users on methods to apply feedstock and start up the biodigesters

according to technical requirements.

m. Supervise, follow up, support masons’ team, and solve complains from biodigester users if

required.

n. Carry out checking of existing physical status and functioning of biodigesters and the

warranty responsibilities at least once in six months during the warranty period of 2 years

in randomly sampled biogas households. Biodigester Performance Monitoring Form (given in

Annex) will be used during this visit. The information could also be collected through phone

calls if the users do not have any specific complain.

o. Report NBSU if the mason/masons’ team violates the term and conditions set out in

warranty provision.

3.3 ROLE OF NBSU

Given the limited resources (human and financial) and time, NBSU may not be in a position to

visit all under-construction or completed biodigesters to ensure the compliance of quality

standards by the installer/masons. The role of NBSU should be to build the capacity of RBSU

biogas technicians to internalize the quality control process. To ensure this to happen, NBSU

should:

a. Train RBSU technicians

b. Accompany RBSU technicians to the field to monitor their works at the field level and

provide necessary back-stopping services at site

c. Ensure that RBSU technicians are building capacity of masons and BCCs to effectively carry

out the quality control activities through transferring of their skills and knowledge

d. Carry out QC control visits to randomly sampled biodigesters to validate the data and

information collected and submitted by RBSU technician.

NBSU should realise that capacity building of local masons, BCC supervisor, RBSU technicians

and other stakeholders involved in biogas sector is crucial for the sustainability of the project.

Knowledge and skills of RBSU technicians and masons are vital in ensuring the quality of

construction, operation and maintenance. QC activities should commence from the very

beginning of these training projects. To ensure effective learning from training the following

issues should be considered:

a. Proper selection of training participants

28

b. Proper selection of facilitators

c. Suitable training contents, session plans and scheduling

d. Appropriate training methods

e. Effective practical sessions

f. Effective evaluation of training

g. Timely follow-up of the evaluation findings

The NBSU should facilitate the RBSUs to formulate selection criteria for the participants and

ensure that these criteria are adhered to. For example the selection criteria for masons could

be:

a. Formal education of at least up to 5th standard. Should be able to read technical drawings

and other instructions provided to them from time to time

b. At least 2 years of experience in construction works as a mason or plumber. Previous

experience in biodigester construction would be an added advantage.

c. Be a permanent resident of the province

d. Have good reputation in community – should be a trusted person

e. Good interpersonal and communication skill

f. Receptive to community’s need and willingness to support them

g. Age between 20 to 60 years

h. Good health

Likewise, NBSU should monitor the training project to evaluate the overall effectiveness of such

project.

3.4 ROLE OF BIOGAS CONSTRUCTION ENTERPRISE/INSTALLER/MASON

Biogas Construction Companies (BCCs)/installer and/or mason, who wish to corporate with the

E4A and benefit from the incentive scheme, will be required to seek recognition from the NBSU.

Such recognition is subject to a series of strict conditions such as:

a. Approval of standard design and sizes of biodigesters;

b. Trained, certified and registered masons for the construction of biodigesters;

c. Construction of biodigesters on the basis of detailed quality standards;

d. Provision of E4A approved quality biodigester appliances (pipes, valve, stove, water trap,

lamp);

e. Provision of proper user training and provision of a user instruction manual;

29

f. Provision of one year guarantee on appliances and two years guarantee on the civil structure

of the biodigester, including an annual maintenance visit during the guarantee period;

g. Timely visit of a technician to the biodigester in case of a complaint from the user;

h. Proper administrative system in place.

The activities of the Installer/Mason depends to a large extent on his/her interest and

initiatives. The masons/ masons’ team assigned for the construction of biodigester will have the

following responsibilities:

a. Construct the biodigesters according to the E4A quality standards and details as stipulated

in construction manual.

b. Complete the construction works including fitting of pipes and appliances within a stipulated

timeframe.

c. Instruct the biodigester users on the proper feeding procedures of biodigesters and on the

proper use of biogas and bioslurry.

d. Provide warranty on the construction within 24 months period with effect from the data of

completion as mentioned in the completion report.

e. Repair and maintain biodigesters and solve any technical and operational problems in

accordance with the conditions described in the warranty certificate.

f. Visit the functional biodigesters at least twice a year during the warranty period to check the

plant and appliances even if no complaints are lodged by the users.

g. Involve in marketing, participate in pre-construction and post construction training to users

and initial feasibility visits to potential and interested farmers.

30

Annex-1: Quality Standards for ZamDigester-2015

Standards Specifications Why?

A. Biodigester Location and Size

1. Site Selection The site should allow easy construction

The site should allow easy operation, eg:

feeding with manure and water, opening

and closing main gas valve, and draining

water drain.

The site should ensure that the

biodigester is safe from damage by

vehicles or equipment

The site should not cause nuisance or

danger for people using the area

The site must have enough space to

construct the digester as shown in the

technical drawings

Major

A suitable site avoids accidents/

difficulties during construction. It also

facilitates easy operation and

maintenance of biodigester. The

benefits of biogas could be optimized if

it is constructed in proper sites.

2. Number of

biodigesters per

household

Only one plant per household unless

approved by E4A

Critical

To benefit as many households as

possible from the incentives and

supports from the government no

house should be provided with two

plants.

3. Proximity to

Kitchen

The biodigester must not be more than 50

meters from the kitchen (where gas will be

used).

Minor

Longer distance means more

investment in pipes. Long distance

increases the risk of gas leakage and

damaging of pipes. It also results in

the decrease of gas pressure which

could only be compensated with costly

larger pipes.

4. Proximity to

structures, trees

or equipment that

caused vibration

on earth

All parts of the digester should at a

reasonable distance from structures, trees or

any machines that creates vibrations on

ground.

Major

There will be risk of structure collapse

or damage during construction due to

excavation for digester. Heavy

vibrations increase the risk of cracks in

walls and dome of biodigester

endangering its functioning to a

greater extent.

5. Sizing of the

Digester

The size of biodigester should be determined

according to quantity of dung available (kg

per day). If the household has more dung

available than is needed, then the

biodigester size can be chosen by estimating

the average gas consumption: 0.33-0.4 m3

per person per day. If animals are not

always kept in a stable close to the

biodigester then the whole quantity of

produced dung may not be available for

feeding – must be estimated what

proportion can be collected.

Critical

Under-feeding or over-feeding of

biodigesters alters the hydraulic

retention time. If fed less, slurry

remains in the digester even after

releasing all the gas inherited by it

creating a dead volume in the plant. If

fed more, slurry comes out of the plant

before releasing all the biogas

inherited by it, causing deficiency of

gas; foul odour in the surrounding and

escape of pathogens without being

killed.

31

Standards Specifications Why?

6. Initial Feeding of

the Digester:

The plant should be fed with required quality

of initial feeding with proper water-dung

ratio as described in O&M manual.

Critical

Users tend to feed the plant with more

water than recommended as a large

quantity of dung is needed for initial

feeding. More water will result in

settling of solid particles in the floor

creating dead volume. Users should be

instructed to collect dung for some

days or borrow from neighboring

households if possible.

B. Standards of Materials and appliances

7. Good quality

bricks/Districts

Best quality locally available

Properly Burnt (for bricks), straight,

regular size+shape

No cracks or broken parts

Able to bear pressure up to 120kg

Test 1: Hit 2 bricks together lightly to test

quality - they should make a clear metallic

sound

Test 2: Hold 2 bricks/Districts in a “T” shape

and drop them from waist height onto

ground. They should not break.

Before use, bricks must be soaked for a few

minutes in clean water (to ensure the mortar

sets properly)

Major

Bricks/Districts are the main structural

component of the biodigester design,

so poor quality could cause failure of

the walls or dome resulting in gas

leakage.

8. Good quality sand a) For concreting works coarse and granular

sand is needed while for plastering, fine

sand is needed.

b) The sand should be clean and contain less

than 3% impurities (do bottle test – see

below)

.

Bottle Test

Put about 10cm of sand into a clear

bottle and fill it with clean water

Shake the bottle well then leave standing

for 15-30 minutes so a layer of sand and a

layer of mud forms

if the layer of mud is more than 3mm

thick above the layer of sand (or 3% of sand

layer thickness), then the sand must be

washed before use (too much mud/silt)

Major

Sand is mixed with cement to use in

construction. The presence of silt and

clay in sand reduced the bonding

capacity of cement. The structure

becomes vulnerable to cracks, bulging

and wear &t tear.

9. Good quality

cement

Portland Cement of High Quality Brand

Fresh and free of lumps

Cement should always be stored off the

floor (raised on planks) and at least 20cm

away from walls

Major

Poor quality will make the construction

more difficult (poor consistency) and

reduce strength of the biodigester.

10. Good quality

aggregate

Clean (free of dust+ impurities)

Hard (not breakable between fingers)

Maximum 2cm (which is less than 25%

of the thickness of the structure being made,

eg: pit covers)

Major

These are used in casting the slab for

compensating tank. Soft, dirty and

too-large gravel will weaken the

concrete. As the thickness of slab will

be less than 7 cm, the size of

aggregate should not be more than ¼

of the thickness.

11. Good quality main

dome gas pipe

Galvanized, light quality iron

At least 60cm long

Diameter bigger than 15 mm

Joints properly sealed

Major

Strength of pipe and quality of

connections is very important to avoid

leaks.

32

Standards Specifications Why?

12. Good quality main

gas valve

High quality (easy to operate, durable

and resistant to rusting)

Major

It should be opened and closed every

time the gas is used, so high quality

and durability is needed to reduce risk

of gas leakage.

13. Good quality pipes

and fittings

(socket, elbow,

tee and nipples.)

Galvanized Iron Pipe or PVC

Minimum 0.5 inch diameter or 0.75” if

over 60m length (or 30m if 2 burners used

at same time)

The fittings used in the pipeline of a

biodigesters are socket, elbow, tee and

nipples. These fitting should meet the

required quality standards.

Major

Pipes convey biogas from the plant to

kitchen. It is not always possible to

bury the pipes underground hence

they are prone to damage where

exposed. Minor damage could result in

heavy leakage of biogas.

14. Good quality

water drain

Approved by quality control authority.

Must be able to drain the accumulated

water inside the pipeline.

Major

Low quality water drains increases the

risk of gas leakage.

15. Good quality gas

tap

Easy to operate- not too tight or loose

Nylon washer should be greased properly

Major

Gas taps are used quite often and

hence are prone to wear and tear.

Minor defect may lead to gas leakage.

16. Good quality gas

stove

Approved by E4A

Single or double burner

Adjustable primary air intake

Evenly spread burner holes

Easy to use and repair

Major

High quality stove will ensure users’

satisfaction as such stoves are burn

with higher efficiency. Low quality

stoves will not only make the users

unsatisfied but also is prone to gas

leakage and accidents.

17. Good quality gas

Lamp

Approved by E4A Major

High quality lamps will ensure users’

satisfaction as such lamps will burn

with higher efficiency. Low quality

lamps will not only make the users

unsatisfied but also is prone to gas

leakage and accidents.

C. Construction Standards

18. Approved model

of biodigesters

ZamDigester model of plants as per the

design and drawing

Critical

ZamDigester models are approved

designs. Various capacity building

projects as well as cost and estimation

of biodigesters are carried out for

these models.

19. Only trained

masons carry out

the construction

work

The mason registered in E4A office after

successfully completing the required training

courses on biodigester construction

Critical

An untrained person does not know the

details of quality standards and

methods of construction. Relative

positioning of different components is

very important for the effective

functioning of any biodigester. Only

the trained persons know the

consequences of not following the

standard dimensions and quality

standards.

20. Biodigester

appropriately

placed under the

ground

The depth of digging as per drawing, ±10

cm.

In case of high water table or rocky

strata the depth can be changed with proper

justification AND proper stabilisation

measures are provided around the structure.

Major

If placed properly, the plant will not be

affected adversely by the external and

internal forces acting upon it. The

plant will be safe from external socks,

erosions and vandalisms. Moreover, if

plant are constructed at proper depth,

temperature inside the digester will be

maintained even during winter season.

33

Standards Specifications Why?

21. Proper Diameter

and height of

digester and gas

holder

The radius of the tank should not differ by

±3% of the standard dimension

The overall height should not differ by ±5

cm

Major

Correct diameter/depth ratio is very

important for the stability as well as

effective functioning of a biodigester. If

the diameter is more or less, the plant

will be bigger or smaller and the

relative volume of digester, dome and

compensating tank will be disturbed

adding risk to smooth operation.

22. Proper back-filling

in the outside of

the wall of

digester

The space between natural soil and the

digester wall is filled with soils and

compacted well.

Major

If the space is not filled, the force

excreted by the slurry inside the

digester will not be counterbalanced

which will cause cracks in the walls.

23. Proper plastering

inside the gas-

holder

Gas holder is treated with 5 layers of

plastering as indicated in the construction

manual. The finished surface is smooth and

free from cracks.

Critical

The gas holder is very sensitive part of

the biodigester. If it is not gas tight,

the produced gas will escape resulting

in shortage of biogas for use. Leaky

gas holder results in a total failure of

the biodigester.

24. Proper top-filling

over gas holder

The height of top-filling is at least equal to

40 cm from the top of the dome.

Major

The top-filling over gas holder acts as

counter-weight to balance the pressure

of biogas accumulated in the gas

holder. It avoids the risk of cracks in

gas holder. It also helps in stabilising

the temperature inside the digester.

25. Proper placing

and construction

of manhole

The manhole should be constructed exactly

opposite to the inlet pipe.

The height of the manhole should not differ

from ±5 cm from the standard.

The diameter of manhole should differ by ±5

cm from the standard

Major

Wrong placing of manhole will affect

the hydraulic retention time. If the

vertical level difference between the

top of round wall of the digester and

floor of compensating tank differs, the

volume of effective gas storage is

affected.

26. Proper Diameter

and height of

compensating

tank

The radius of the tank should not differ by

±3% of the standard dimension

Major

The size of compensating tank is

determined by the storage volume of

the gas holder. If the volume of

compensating tank is less than the

designed, the pressure required to

push the biogas from gas holder to the

point of application will be less.

27. Proper backfilling

against the walls

of compensating

tank

The outside of the outlet walls is properly

compacted with rammed soil to prevent soil

erosion.

Major

If the outer space is not filled, the

force excreted by the slurry inside the

compensating tank will not be

counterbalanced which will cause

cracks in the walls.

28. Proper cover of

compensating

tank

The compensating tank should be covered

with proper concrete slab. The thickness of

slab should not differ by ±1 cm from

standard.

A small opening should be placed in one of

the cover slabs for inspecting inside of the

compensating chamber.

Major

The RCC cover is important to avoid

people and animal falling inside the

compensating tank by accident. It also

avoids excessive evaporation of slurry

accumulated in the tank.

The opening in one of cover slabs

facilitates the inspection of inside of

compensating tank without removing

the heavy concrete slabs.

34

Standards Specifications Why?

29. Correct

positioning of the

inlet pipe(s)

The inlet pipe is placed to discharge exactly

at the hart line (imaginary line that joins

centre of digester, manhole and outlet tank).

The bottom edge of the inlet pipe should be

as per the drawing. If because of space

limitation, the inlet pipe could not be fit as

per standard, a small baffle wall has to be

constructed in the digester to avoid short-

circuiting of slurry.

Major

If the inlet pipe is not placed exactly

opposite to the outlet pipe, hydraulic

retention time will be shortened

meaning that the slurry will flow out to

the compensating tank quicker than

anticipated. As the slurry will flow to

outlet pipe from the nearest short

route, there will be risk of creation of a

dead volume in the digester. The baffle

wall will prevent the slurry to follow

the shortest route. Short circuiting of

slurry in a latrine attached plant will

invite health risks as the pathogens

could not be destroyed during the

digestion process.

30. Correct

positioning of

inlet tank or toilet

pan level

The bottom of inlet tank should be at least

15 cm higher level than that of overflow

opening in the compensating tank.

Major

If the bottom of the inlet tank or toilet

pan level is at lower level than

overflow opening in the compensating

tank, the digested slurry will flow

towards the inlet tank rather than

coming out from overflow opening.

31. Correct fitting of

main gas valve

No fittings in between elbow in the dome

gas pipe and the main valve. The joint is

properly sealed with Teflon tape and good

quality adhesive.

Critical

Any defects in fitting the main gas

valve will result in gas leakage.

32. No unnecessary

fittings in the

pipeline

Pipeline contains minimum joints as

required.

Major

The more the fittings in the pipeline,

the more the joints and the more the

chances of gas leakage.

33. Proper burial of

pipeline

The pipeline is buried to at least 30 cm

where possible. It is protected well with

clamps and covers where burial is not

possible.

Major

Exposed pipe is vulnerable to damage.

Exposure of PVC pipe to sunlight

makes it brittle and prone to breakage.

34. Water drain able

to drain the whole

quantity of

condensed water

and protected in

a well maintained

chamber

The profile of pipeline should be maintained

properly so that the whole quantity of

accumulated water is easily drained.

Water drain should be protected in a

chamber. The size of the chamber should be

such that it is easy to operate water drain

and rain water does not enter into it. The pit

should be provided with a good cover.

Major

If the condensed water that

accumulated in the lowest profile in the

pipeline is not drained periodically, it

Districts the flow of gas and disturbs

the functioning of appliances.

If not protected in small chamber, the

water drain is prone to clogging and

damages.

35. Correct fitting of

gas tap

The gas tap is placed in convenient place

and the joint is sealed with Teflon tape and

good adhesive.

Major

Improper fitting of gas taps will result

in gas leakages and difficulty in

operation.

36. Correct fitting of

gas stove

The connecting pipe from gas tap to the

stove is correctly fitted to avoid the gas

leakage and with enough length so the stove

can rest easily on a table or the ground.

Major

Improper fitting of gas taps will result

in gas leakages, difficulty in operation

and increased risk of accidents.

37. Correct fitting of

gas lamp

The gas lamp is located in safe and

convenient place. The lamp must be

installed at least 60cm below the ceiling to

avoid risk of fire. The joint must be sealed

with Teflon tape and good adhesive.

Major

Improper fitting of gas taps will result

in gas leakages, difficulty in operation

and increased risk of accidents.

35

Standards Specifications Why?

38. Correct fitting of

Gas Pressure

meter

U-shaped pressure gauge (manometer)

made up-of a transparent plastic or glass

tube and filled with coloured water or a

clock-type digital or analogue pressure

meter has to be installed in the conveyance

system, near the point of application of the

gas, to monitor the pressure of gas.

Whatever may be the type this device

should be the best among those available in

the local market and should meet set quality

standards, if any.

Major

The pressure gauge is fitted to monitor

the pressure of gas that flows to the

appliances. When the needle of the

pressure gauge indicates higher

pressure, then the gas tap should be

adjusted to allow less gas to flow to

the stove or lamp and vice versa.

Importantly, when the indicator shows

full pressure, gas has to be used;

otherwise there is chance of gas

leakage to the atmosphere, which

should not happen from the

environmental point of view. Likewise,

when the gas pressure is very low, one

has to stop using the gas to avoid

slurry in the pipeline. If the pressure is

less than 15 cm water column, it is not

preferable to use gas anymore.

39. Proper

construction of

slurry composting

pit

2 compost pits with the total volume of at

least equal to volume of the plant should be

constructed. The depth of the compost pits

must not exceed 1 metre and the distance

between the two compost pits must not be

more than 50 cm. The length and width at

the top must be more than of the bottom

and 10 cm mud has to be added on all sides

to raise the height from the ground level to

avoid rain water enter the compost pits.

Major

In addition to the major plant

nutrients, bioslurry also provides

micro-nutrients. It is beneficial for

improvement of the physical structure

of the soil, increased soil fertility,

increased water-holding capacity of the

soil and enhanced activity of the

micro-organisms in the soil.

D. Standards on O & M and After-sales-services

40. User’s instructed

on operation and

minor repair

works

At least one member from the user’s

household is provided with proper

orientation on operation and minor

maintenance of biodigester. User must be

able to satisfactorily answer at least 20 of

the 28 questions in the User Training

Knowledge Test (see below).

Major

Proper operation and maintenance

(O&M) of different components of a

biodigester is very important for its

efficient and long-term functioning.

The users have the major

responsibility of carrying out

operational and minor maintenance

activities as anticipated. It is therefore,

necessary to orient users on these

activities upon the completion of the

construction works.

41. User Manual Biogas User Manual is provided to the users Critical

It is not uncommon that users may

face some problems to operate

biodigesters. It may not be possible to

receive the help of technicians at all

times. This manual provides

information to the users on effective

operation and maintenance of

biodigesters. The manual will help the

users to identify problems and provide

solutions accordingly.

42. Warranty and

After-sale-service

provisions

Warranty Certificate for at least 2 year is

provided to the user with clear explanation

of conditions in presence of the

Installer/Mason, and user pays Warranty Fee

that is held in trust by E4A

Critical

The after-sale-services ensure having

well-functioning biodigesters with

satisfied and positive users, leading to

farmer-to-farmer motivation.

36

Standards Specifications Why?

43. Performance

monitoring of

Biodigester

The biodigester should be visited at least

once in six months by the project technical

persons to monitor overall performance

Major

It is compulsory that all the install

biodigesters function to the anticipated

level. Non-functional plant will have

negative effect on carbon trading and

overall future of the project.

Annex-2: Tolerances

SN Description Tolerances

1. Inner Diameter of digester ± 3%

2. Total inner height of digester ± 10 cm

3. Height from floor to bottom of inlet pipe ± 5cm

4. Height from floor to top of manhole (floor of outlet) ± 5cm

5. Height between top of round wall and floor of outlet tank ± 3cm

6. Diameter of outlet tank ± 3%

7. Height of outlet tank up to the bottom of over flow

opening ± 5cm

9. Thickness of slab ± 1cm

10. Height of inlet floor from the ground level ± 5 cm

12. Height of inspection chamber ± 5cm

13. Height of top filling over dome ± 5cm

37

Annex-3: Forms and Formats for QC

Energy for Agriculture (E4A): QUALITY CONTROL LOG BOOK

1. Biodigester

Code No.

Serial Number:………………………………. GPS Easting:………………. GPS Northing…………….…….

2. Householder Name:……………………………………. Telephone Number:…………………………….ID Card No. …………..

3. Address Village:…………………..…………….… District:……………………..…… Province:…………………..……….

4. Mason Name:………………………………………………. E4A Registration Number:……………………………..

5. Biodigester Size …........................m3

6. Construction Period Started: ..………………..………. Completed: …..…………………….…….

Quality Control Status

Form Title Completed By Checked

(name,date)

Data

Entered

(name,date)

2a Site Survey for Potential

Households

Signed:……………. Name:………………..…………..

Position:……………………Date:……………

2 b Baseline Survey Form Signed:……………. Name:…………………..………..

Position:……………………Date:……………

3 Construction Contract Signed:……………. Name:…………………..………..

Position:……………………Date:……………

4 Quality Inspection Form -

During Construction

Signed:……………. Name:……………..……………..

Position:……………………Date:……………

5 Quality Inspection Form -

Final Acceptance (Before

Filling)

Signed:……………. Name:……………………..……..

Position:……………………Date:……………

6 General Monitoring

Inspection Form

Signed:……………. Name:……………………………..

Position:……………………Date:……………

7 Warranty Certificate Signed:……………. Name:…………………..………..

Position:……………………Date:……………

8 Warranty Audit (Monitoring

before the maturation of

warranty period)

Signed:……………. Name:……………………………..

Position:……………………Date:……………

Timeline for Inspections:

38

Form - 01

Energy For Agriculture (E4A): LIST OF POTENTIAL CUSTOMERS

No. Full Name of

household head

Address Number of domestic animals

Province District Village Buffalo Cow Pig Poultry Other

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

21

22

23

24

25

26

39

Form-02(a)

Energy for Agriculture (E4A): Field Survey form for Potential

households

1. General Information Date of survey ....................................

Name of household head: ........................................................... Telephone No: ........................

Province:………………………….………. District:………………………………………. Village:………………………………………

Number of people in family: Adult: Children (age <10): Total:

2. Land information

Enough land area available for construction: Yes No

Flooding/Water inundation problems in wet season: Yes No

3. Water and Sanitation Information Sanitary Infrastructure (tick) Water source on use (tick) General sanitary Condition of (tick)

Simple Pit latrine River water Good Fair Bad

Improved latrine Lake/Pond Kitchen

No latrine Deep Tube well Latrine

Drainage system Shallow Tube well Water Source

Dug-wells Drainage System

Piped Water Tap Household

wastes disposal

Canal

4. Animal husbandry development activities Livestock Numbers

Adult Calf If open-grazed, for how many

hours/day?

Stall-fed Open-grazed Stall-fed Open-grazed

Cow/Oxen

Buffalo

Pigs

Poultry

Total quantity of dung/poultry litter production ………………………..kg/day

Distance between Cattle-shed/Kraal and kitchen: ……………………… m

5. Credit demand

Do you need loan to install biodigester: Yes No

If yes, what amount?..................................

Remarks: HH suitable for Construction Not-suitable for Construction

Recommended size of Biodigester: 4/ 6/ 9/ 14/ 21 cum

Survey officer

(Full name and signature)

Biogas Household head

(signature)

40

FORM-02(B

ENERGY FOR AGRICULTURE (E4A)

BASELINE SURVEY FORM

Instruction: Conduct this survey with each new customer, during construction-phase.

A. General Household Information

1a) Name of household Head:……………………….

b) Male Female

c) Main occupation:…………………………………

2. Address:

a) Village:…………… b) District: ………………

c) Province: ……………………………………

3a) Name of interviewer:

……………………………

b) Date: ……………………..

4. Condition of the house:

a) Building material: Stone Brick Wood Thatched Others..................................

b) Roofing material: Tile CGI Sheet Thatched Others.............................................

5.a) Total Number of people in household: 5.b) Number of people between 10 and 60 years old:

5.c) Number of children below 10 years old: 5.d) Number of people above 60 years old:

B. Income and Expenditure

6. Main source(s) of income (Rank from the most to the least important in numerical order, start from 1 which is the most important):

Farming/cultivation Livestock Business, specify:………………………… Government Service

Other service, specify………. Small trade Others, specify:............................................................

7. Household Income (estimate average): a. …………………………………….. per month

8. Total Household Expenditure (estimate average): a. …………………………………….. per month

9. Household Assets How many in the Household? Estimated Value?

Television a)…………………………….. b)………………..ZMW

Motorbike a)…………………………….. b)………………..ZMW

Car/jeep/bus a)…………………………….. b) ………………..ZMW

Stereo g)…………………………….. h)………………..ZMW

Tractor i)…………………………….. j) ………………..ZMW

Diesel Generator k)…………………………….. l) ………………..ZMW

Other: …………………………………………….. m)………………………….. n) ………………..ZMW

10. a) Do you have any agricultural land: Yes, Owning Yes, Renting No

b) If ‘Yes’, how many ha: Cultivated:………………..(ha) Other:………………..(ha)

B. Energy Use and Expenditure

Energy Type Main Use

(Cooking, Lighting)

Where from?

(Market, Forest)

Cost? ZMW per unit

(hours/day if free)

Quantity Used

in Dry

Season?

Quantity

Used in Wet

Season?

11. Firewood* (kg) a) b) c) d) e)

12. Charcoal* (kg) a) b) c) d) e)

13. LPG (kg) a) b) c) d) e)

14. Kerosene (litre) a) b) c) d) e)

15. Electricity (unit) a) b) c) d) e)

16. Diesel (litre) a) b) c) d) e)

17. Petrol (litre) a) b) c) d) e)

18. Other: …………… a) b) c) d) e)

19. Other……………… a) b) c) d) e)

* If collected from forest, mention whether twigs/branches are collected or a whole tree is fell down to prepare firewood/charcoal

41

C. Fertilizer Use and Expenditure

Fertilizer Type Main Use

Rice, Vegetables

etc

Where

from?

Market, etc

Cost?

ZMW per

Unit

(or hours/

day if free)

Quantity

Used in Dry

Season? (per year)

Quantity

Used in Wet

Season? (per year)

Distance

of use

from

Biodiges

ter (m)

20. Farm Yard Manure

(Animal Dung)

a) b) c) d) e) f)

21. Chemical Fertilizer

Type-1 (name &

composition)…………….

Type-2………………

Type-3…………….

a) b) c) d) e) f)

22. …………… a) b) c) d) e) f)

D. Health, Sanitation and Environmental Conditions

23) Has anyone in this household had a serious respiratory problem in the last 6 months? Yes No

24) Has anyone in this household had a serious eye infection or problem in the last 6 month? Yes No

25) How often the children in the households get diarrheal diseases?

Quite Often Some times in 3-4 months Very rare

26) How often does someone in the household get sick? ………………..times per month

27) How often is there a problem with bad smell from animal or household wastes? …………………….. times per month

28) Where is the cattle dung and household wastes dumped?

In wet pit or lagoon In semi wet areas In dry areas (this info is needed for Carbon Finance)

29) Where do you defecate?

In private latrine In open spaces surrounding the house In open spaces far from house

D. Household Tasks

Minutes per Day

(estimate average)

Who usually does this?

(eg: Husband, Mother,

Daughter, Son etc)

30. Collecting Firewood a) b)

31. Cooking Breakfast a) b)

32. Cooking Lunch a) b)

33. Cooking Dinner a) b)

34. Cooking Animal Feed a) b)

35. Cleaning cooking vessels a) b)

36. Collecting water a) b)

37. Collecting the feed/fodder and feeding

cattle

a) b)

38. Other Cooking: ………………………. a) b)

39. Do all the children above 6 in the

household go to school?

Yes all Only the boys Only the girls None

Thank you very much!

42

Form-03

ENERGY FOR AGRUCULTURE (E4A)

BIODIGESTER CONSTRUCTION CONTRACT Province:……………………. Plant serial no.:…………………….

1. Party A: E4A Supported Household.

Name of Household Head:………………………………………………………….;

Address:……………………………………………………………….……… Tel: .......................................

ID document type and number:…………………………………………………….

2. Party B: Regional Biogas Support Unit (RBSU)

Name of Officer:………………………………………………………………

Address:……………………………………………………..……………………………. Tel:……………………………………………………………………

3. Party C: Biodigester Construction Company or Enterprise (BCE)

Biodigester Mason Name:…………………………………………………………...

Address:……………………………………………………………………… Tel:......................................................

ID document type and number:…………………………………………………….

All parties agree to participate in the construction of a biodigester at the premises of Party A, upon the

following conditions:

Article 1. Scope of work

To construct a biodigester, according the quality standards set by the E4A, sized … m3 at the premises of Party A.

Article 2. Obligations

Party A: The Biogas Household

a. In consultation with Parties B and C, set a deadline for the start and completion of the work.

b. Select/Prepare the construction site and collect materials according the instructions of Party C.

c. Decide and agree the mode of labour or material contributions and pay the BCE/mason accordingly. If all the

construction materials and labours (skilled and non-skilled) is to be arranged by the BCE/mason arrange

payment accordingly. Provide adequate labour for the digging work and to assist the Mason during the

construction if it is to be managed by biogas household.

d. Pay for the construction work as agreed in Article 3.

e. Transfer all rights, credits, entitlements, benefits or allowances arising from or in connection with

any greenhouse gas emissions reductions arising from the operation of the biodigester (Emission

Reductions), and agree to take all necessary action required to ensure the transfer of those Emission

Reductions to the E4A.

Party B: The E4A RBSU

Conducts a survey at the premises of Party A with Party C to determine the conditions for biodigester construction

and advise Party A accordingly.

a. Provides Party A with an information sheet containing the required quantities as well as cost estimation of

construction materials, appliances, skilled and unskilled labour, and cost of warrantee and other fees.

b. Assures that the BCE/Mason recruited by Party C, is trained, experienced and certified in his/her profession.

c. Gives full essential technical support to Parties A and C whenever needed.

d. Monitors the quality of the construction works through sample construction inspections and provides on-the-spot

instructions to mason, if modifications/rectification needed.

e. Conducts a Plant Completion Inspection in all completed plants. If the plant is considered by the Supervisor to be

complete and fit to function without problems, it will be handed over to Party A. Party A will receive a signed and

stamped Completion report from Party B.

f. Guarantees the provision of functionality incentive to Party C as per set mode of payment.

g. Ensures that the users are trained on operation and maintenance of biodigester as well as on bioslurry

application.

h. Ensures that two-year warrantee certificate is issued by Party C to party A.

Party C: The BCE/Biogas Mason

a. Constructs the biodigester according to the E4A quality standards.

b. Completes the construction works, including pipefitting and appliances connection, within 20 calendar days. If

there is a delay due to reasons beyond the influence of the BCE/mason such as high ground water or rocky soil,

a new completion date will be determined in consultation with Party A and B.

c. If, due to illness or other personal reasons, unable to complete the work in time, contact Party B for consultation

on how to complete the assignment within the agreed period.

d. Instructs the biodigester user (Party A) on the proper feeding procedure of the biodigester and on the proper use

of the biodigester appliances.

e. Will work in a responsible manner and therewith minimize the risks of accidents.

43

f. No claims can be made by Party C to Parties A or B in relation to injuries sustained during the construction

process.

g. After completion, leaves the construction site in a fit to be seen state.

h. Provides warranty on the construction within a 24 months (two years) period since the completion date

mentioned on the completion report.

i. Repairs the biodigester if any technical problem occurs, in accordance with the warrantee conditions described in

the warrantee certificate.

j. Visits the biodigester at least once in six months during the 2 year warrantee period to check the plant and

appliances, even if no complaints are lodged by Party A.

Article 3. Cost of installation and Payment

The cost of installation of biodigester will be based upon the cost and quantity estimation supplied to Party A by Party

B. Party A can decide whether he/she will handover overall responsibility of collection/supply of construction

materials and un-skilled labors to the BCE/mason OR supply all or part of these.

The cost of construction materials such as, sand, gravel, cement, reinforcement rods, GI pipe, can be paid by Party A

directly to the supplier with whom he/she purchases them. Party A will also make sure these materials will be at the

construction site in time. Party C will advise Party A on the required quality and quantity of these materials. The cost

of the skilled labor, amounting to ZMW….........., will be paid directly by Party A to Party C upon completion of the

construction.

However the following items could be supplied by Party C to Party A. Party A will pay Party C the cost as follows:

Item: Number Cost per Item Total Cost

Pressure Gauge

Dome gas pipe

Biogas Stove

Biogas Lamp

Biogas Rice-cooker

Biogas Water-heater

……………………………

……………………………

Party A has to fulfill all financial obligations to Parties C upon completion of the construction including the pipefitting

and the installation of the appliances.

Article 4. Construction Starting and Completion Date

The construction will start on ………..(day)/……..…(month)/…………....(year) at the latest.

The construction will finish on ………..(day)/…………(month)/……….…..(year) at the latest.

Article 5. Unilateral Termination of construction contract and compensation:

Each party has rights to terminate the construction contract unilaterally and can request for compensation when the

other party offend contract provisions. However, there should valid reasons for such termination.

The offending party has to compensate all expenses which the other party had paid for the lost, unless otherwise

stated.

Article 6. Complain and dispute settlement:

All complains and disputes will be considered and settled by the three parties base on mutual interest. If the

concerned parties cannot reach final agreement then the matter will be brought before Civil Court for final decision.

This contract is made in 3 copies of the same value and become effective since the signing date.

Date:………….(day)/………….(month)/………………..(year)

Party A: Head of Household; Full name + signature --------------------------------------------------------------------

Party B: E4A/RBSU Representative Full name + signature --------------------------------------------------------------

Party C: BCE Representative Full name + signature ---------------------------------------------------------------------

44

Form-04

ENERGY FOR AGRICULTURE (E4A)

QUALITY INSPECTION FORM – UNDER CONSTRUCTION PLANT Date of Inspection:………… Plant Code No: ……….

1. General Details Auditing (QC on QC)

1. a) Name of Owner :…………………….………..…(b) Tel No:……………….(c) ID Card No……..

b) Address: Village.:……….….......… District:…………………….….…… Province:………………..…….

2. Date of Commencement of the Construction ………………………………(dd/mm/yy) Pass □ Fail □

3. Name of Mason………………………………………….. 4. Regd. Number of Mason:……………… Pass □ Fail □

5 No. of families using the biodigester? a)1 □ b) 2 □ b) 3 □ Pass □ Fail □

B. Biodigester Feeding

1. Biodigester Size ............................................m3 Pass □ Fail □

2. No. of Cattle/Buffalo

Adult……. Calf………. Total……….

3. No. of Pig

Adult…….Calf………. Total……

4. Poultry:

Total No.……….

Pass □ Fail □

5 Total dung production …………kg Pass □ Fail □

6 Is dung being collected for the initial feeding? a) Yes □ No □ Pass □ Fail □

7 Provision of toilet attachment a) Yes □ No □ Pass □ Fail □

C. Location of Biodigester Site Pass □ Fail □

1. Is Biodigester location suitable? a) Yes □ No □ b) Comment:…………………… Pass □ Fail □

2. Distance from: a) Kitchen: ..…m b) Animal Shed: ..…m c)Structure: ….……m

d)Tree: ……m e) Drinking Well:…..m f) Main road ....m

Pass □ Fail □

3. Flood/stagnant water problem a)Yes □ No □ Pass □ Fail □

D. Bricks / Blocks Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Shape Good □ Fair □ Bad □ Pass □ Fail □

2. Sound Good □ Fair □ Bad □ Pass □ Fail □

3. Drop test Good □ Fair □ Bad □ Pass □ Fail □

4. Are they the best locally available? Yes □ No □ Pass □ Fail □

E. Sand Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Bottle test ………..….% impurity Pass □ Fail □

F. Gravel Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Cleanliness Good □ Fair □ Bad □ Pass □ Fail □

2. Maximum size …….……. mm Pass □ Fail □

3. Shape Good □ Fair □ Bad □ Pass □ Fail □

G. Cement Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Quality of Cement Good □ Fair □ Bad □ Pass □ Fail □

2. Brand name …………………….. Pass □ Fail □

3. Lumps Yes □ No □ Pass □ Fail □

H. Emulsion Paint Pass □ Fail □ Action:………………………………….. Pass □ Fail □

4. Quality of Paint Good □ Fair □ Bad □ Pass □ Fail □

5. Brand name ……………………. □ Pass □ Fail □

H. MS Reinforcement rod Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Diameter ………. mm Pass □ Fail □

2. Condition of Rods (not too rusted

etc)

Good □ Fair □ Bad □ Pass □ Fail □

I. Construction Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Layout of plant made correctly? Yes □ No □ Pass □ Fail □

2. Diameter of digester a)………cm (Standard = ………cm) Pass □ Fail □

3. Depth of excavation a)………cm (Standard = ………cm) Pass □ Fail □

J. Overall Quality Pass □ Fail □ Pass □ Fail □

1. Quality of construction of digester and dome Good □ Bad □ Not Complete □ Pass □ Fail □

2. Quality of construction of outlet tank Good □ Bad □ Not Complete □ Pass □ Fail □

3. Quality of construction of inlet tank Pass □ Fail □

4. Overall Quality of Workmanship Good □ Fair □ Bad □ Pass □ Fail □

K. Financing (ask users) Pass □ Fail □ Pass □ Fail □

1 Do the users know the cost of biodigester and their contribution? Yes □ No □ Pass □ Fail □

2 Do the users know about the credit and subsidy mechanisms? Yes □ No □ Pass □ Fail □

L Items to be Fixed by Mason/Overall Comments

Signature of Inspector: Signature of QC

Inspector:

Signature of Mason: Comment:

Signature of the user:

45

Form-05

ENERGY FOR AGRICULTURE (E4A)

QUALITY INSPECTION FORM – FINAL ACCEPTANCE (BEFORE FILLING) Date of Inspection:……………..……… Plant Code No:……………………………………

A. Biodigester Details

1. Name and Address of Owner Name…………………………………ID Card No:……….

Village:…………………..……..District………………………………. Province………………………….

2. Name of Mason Name………………………………………………………..……………… Regd. No. …………………….

3. Biodigester Size .................................................m3

4. Construction Period a)Started: ..…………. b)Completed: .....………. c)Total Days: ………..

5. Reason if longer than 30 days …………………………………………………………………………………………………

6. Is there a toilet at the customer’s house? Yes □ No □

7. Is the toilet connected to the biodigester? a)Yes □ No □ b) Will connect later

8. Total quantity of Dung available for Feeding per day ………………… kg

To be filled by RBSU Supervisors Auditing(QC on QC)

B. General Construction Quality Pass □ Fail □ Action:…………………………………..

1. Site suitable for Biodigester Yes □ No □ Pass □ Fail □

2. Top filling over dome Good □ Fair □ Bad □ Pass □ Fail □

3. General quality of workmanship Good □ Fair □ Bad □ Pass □ Fail □

4. Total quantity of cement used …….. bags Pass □ Fail □

D. Inlet Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Type of inlet Mixing chamber □ Channel for flushing □ Pass □ Fail □

2. Finishing Good □ Fair □ Bad □ Pass □ Fail □

3. Inlet floor vs. bottom of overflow opening well above □ just above □ below □ Pass □ Fail □

E. Digester and gas holder Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Finishing of floor and walls Good □ Fair □ Bad □ Pass □ Fail □

2. Plastering inside the digester and gas holder Good □ Fair □ Bad □ Pass □ Fail □

Inlet pipe position in the digester Good □ Fair □ Bad □ Pass □ Fail □

F. Outlet Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Floor and wall finishing Good □ Fair □ Bad □ Pass □ Fail □

2. Backfilling against the wall Good □ Fair □ Bad □ Pass □ Fail □

G. Toilet (if connected) Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Position of Pan level vs. bottom of overflow opening well above □ just above □ below □ Pass □ Fail □

2. Pipe Provisions for future attachment Yes □ No □ Pass □ Fail □

3. Positioning of inlet pipe in the digester Good □ Fair □ Bad □ Pass □ Fail □

H. Pipes and Accessories Pass □ Fail □ Action:………………………………….. Pass □ Fail □

1. Quality of dome gas pipe Good □ Fair □ Bad □ Pass □ Fail □

2. Quality of main gas valve Good □ Fair □ Bad □ Pass □ Fail □

3. Type of gas pipe PVC □ Flexible plastic □ GI □ (dia Φ: …) Pass □ Fail □

4. Total length of gas pipe …..m

5. Quality of gas pipe Good □ Fair □ Bad □ Pass □ Fail □

6. Unnecessary fittings Yes □ No □ Pass □ Fail □

7. Depth of pipe trench ……… cm Not buried □ Pass □ Fail □

8. Sealing agent Good □ Fair □ Bad □ Pass □ Fail □

9. Quality of stove Good □ Fair □ Bad □ Pass □ Fail □

10. Number of burners 1 □ 2 □ 3 □ Pass □ Fail □

11. Location of stove Appropriate □ Not Appropriate □ Pass □ Fail □

12. Quality of connecting pipe Good □ Fair □ Bad □ Pass □ Fail □

13. Quality of gas tap Good □ Fair □ Bad □ Pass □ Fail □

14. No. of lamps 0 □ 1 □ 2 □ Pass □ Fail □

15. Quality of lamp Good □ Fair □ Bad □ Pass □ Fail □

16. Location of lamp Appropriate □ Not Appropriate □ Pass □ Fail □

17. Quality of gas pressure gauge Good □ Fair □ Bad □ Pass □ Fail □

18. Water drain at lowest point in pipeline? Yes □ No □ Pass □ Fail □

19. Water drain pit constructed correctly? Yes □ No □ Pass □ Fail □

20. Water drain pit cover ok, and in place? Yes □ No □ Pass □ Fail □

I. Gas Tightness and Water Tightness (if used) Pass □ Fail □ Action:………………………….

1. Gas Tightness (if done) Pass □ Fail □ Pass □ Fail □

2. Water Tightness (if done) Pass □ Fail □ Pass □ Fail □

J. Compost Pit

1 Compost pits constructed? None □ One □ Two □ Pass □ Fail □

46

2 Total volume of pits (approximate) ………………. Cum m

K. Financing

1. What was the actual total cost of your plant including your contributions? ZMW……….………………. Pass □ Fail □

2. Credit taken from Not taken □ Bank □ MFI □ Other:……… Pass □ Fail □

3. How long did it take to arrange the loan? a)……… days b) Not Applicable □ Pass □ Fail □

4. What is interest rate and repayment period of loan? a)…..…% per month b) Period………....months Pass □ Fail □

5. How much subsidy did you receive? No subsidy □ ZMW. …………

6. Did anyone get any training on how to use the biodigester? Yes □ No □ Pass □ Fail □

7. Have you received Biodigester O& M Manual? Yes □ No □ Pass □ Fail □

8. Have you received guarantee certificate? Yes □ No □ Pass □ Fail □

Final Measurement of Various Components (inspection to be made before filling the plant)

Passed Inspection – □ Approved for Dung Feeding □ Not Approved for Dung Feeding

Comments ................................................................................................................................................................................

....................................................................................................................................................................................................

Inspected by RBSU Officer Name:……………………………....……….Signature:….………………………. Date:……………..

Witnessed by the Mason Name:…………………………....………….Signature:….………………………. Date:……………..

Witnessed by the User Name:………………………....…………….Signature:….………………………. Date:……………..

SN Component Dimension QC on QC

Actual Standard Deviation Tolerances

1. Inner Diameter of digester: ± 3% Pass/fail

2. Total inner height of digester: ± 5cm Pass/fail

3. Height from floor of the digester to bottom of inlet

pipe ± 5cm

Pass/fail

4. Length and breadth of manhole floor: ± 2cm Pass/fail

5. Height of manhole (height of round wall): ±5cm Pass/fail

6. Height of manhole up to the floor of outlet: ± 5cm Pass/fail

7. Height of outlet up to the bottom of over flow opening ± 5cm Pass/fail

8. Height of overflow opening: ± 2cm Pass/fail

9. Thickness of slab: ± 1cm Pass/fail

10. Diameter of outlet tank: ± 3% Pass/fail

11. Height of outlet tank: ± 5cm Pass/fail

12. Height of inlet tank/chamber from the ground level: ± 5cm Pass/fail

13. Inner height of the inlet chamber: ± 5cm Pass/fail

14. Size of turret: ± 5cm Pass/fail

15. Height of turret: ± 5cm Pass/fail

16. Height of top filling over dome: ± 5 cm Pass/fail

17. Inner diameter of inlet ± 2cm Pass/fail

47

Form-06

Energy for Agriculture (E4A)

BIODIGESTER PERFORMANCE MONITORING FORM Inspection date:……………………

Household Details

1. 1 Biodigester Code ……………………..

2. 2 Name if User (a)Name:………………………………………..……… (b)Telephone Number:………………………

3. 3 Address (a)Village:……………………….. (b)District…………:…………… (c) Province:…………………

4. 4 Biodigester Size ............................m3

5. 5 Date of Visit .......................................................................

6. 6 User Visited ………………………………………………………………. (Name and position in house)

7. 7 Purpose of Visit (a)Regular QC Check □ (b)Problem Reported □

8. 8 User’s General Satisfaction (a)Very Happy □ (b) Quite happy but some problems □ (c)Disappointed □

9. 9 User’s view on current

performance? (a)No problems□ (b) Ok but some problems□ (c) Plant not functioning □

Problems Reported:…………………………………………………………………………………………

10

Information on Gas-use

(a) Use of Gas Stove

(b) Use of Gas Lamp

(c) Sufficiency of gas

………………… hours per day total

…………………. hours per day total

(a)More than Enough □ (b) Enough □ (c) Not Enough □

(i) If not enough, - how often do you not have enough gas?

(a) Daily □ (b) Sometimes in a week □ (c) sometimes in a month □

(ii) What you think is the reason for insufficient gas?

(a) Less feeding□ (b) Problem with plant□ (c) Longer hours of gas use □

(d)others .............. □

(iii) If more than enough, - How often do you have too much gas?

………………times/mth

- What do you do if there is too much gas?

Flare it □ Use it for something □ Let it escape □

11

Do you use the Bioslurry? a) Yes □ No □

b) If Yes, how is it?: (a) Better than FYM □ (b) Same as FYM □ (c) Inferior

than FYM □

b) If No, why not?:

………………………………………..………………………………………………………..

12 General Condition of Plant (a) Good Condition □ (b) Satisfactory Condition □ (c) Poor Condition □

Comments: …………………………………………………………………………………………………………

13

Any problems found by

inspector?

No, working fine □ Some small problems □ Major problems □

Problems Found:

……………………………………………………………………………………………………….

14 Repair Actions during Visit,

if any:

a………………………………………… b…………………………………………………..

c………………………………….

15 Condition of Plant after

Actions: (a)No problems□ (b)Ok but some problems □ (c)Problems remained same □ Problems Remaining:……………………………………………………………………………………………

16 Instructions given to the

User:

a………………………………………………………………………………….

b……………………………………………………………………….…………

17 Follow-up Actions Needed

(+ dates):

a………………………………………………………………………………….

b………………………………….…………………………………………………

Inspector User

…………………………………………

Name:…………………………… Date:……………

Position:…………………..

………………………………………….

Name:………………………………….. Date:……………

48

Form-07

ENERGY FOR AGRICULTURE (E4A)

BIODIGESTER MONITORING BEFORE THE MATURATION OF WARRANTY PERIOD

(This evaluation shall be filled about one week before the end of warranty period and should be done

on-site accurately and with high responsibility. Any points that do not comply with the real figure or

condition lead to cause penalty and compensate on own expenses.)

General Information: To be filled by the RBSU Supervisor

Date of Visit …….…/…………….…/…………………….

Name of Plant Owner .……………..……….

Biodigester Code ………………………….

Address Village……………………….. District………..………..….... Province………..……………

Name of Mason …………………………….

Biodigester Size: 4/ 6/ 9/ 14/ 21 cum

Plant Completed Date

End of warranty Period Date

…..…/………../………….

….…./…….../……….….

Visited by (Mason) ……………….……

Name of user(s) consulted 1.……………..….…………………………… 2. ……………….…………….…………..……

Number Animal

Feeding per day

Cow.......….…Buffalo........... Other…………………….

...............Kg

Plant Structure

Condition of Inlet/mixing tank

Condition of turret (inspection)

Condition of main gas valve

Condition of outlet tank

Condition of Water drain Chamber

Condition of Top filling

Good Fair Damaged

Good Fair Damaged

Good Fair Damaged

Good Fair Damaged

Good Fair Damaged

Enough Not enough No filling

Pipe System and Appliances

Leakage in pipe line

Condition of Pressure gauge

Usual pressure in:

- early morning

- Noon

- late evening

Yes No

Proper Not Proper

Close main valve for10-20 min. and check – ask the users

…………..…

………..……

……………..

No. of Gas Stoves

Functioning of Gas Stove(s)

No. of Lamps

Functioning of gas lamps

Functioning of water trap

Functioning of gas taps

1 / 2 /3

Fine□ Minor problems□ Major problems□

1 / 2 / 3 / 4 / 5

Fine□ Minor problems□ Major problems□

Fine□ Minor problems□ Major problems□

Fine□ Minor problems□ Major problems□

Use of Gas Stove

Use of Gas Lamp

Enough gas to cook/light

How often not enough gas

Reason for insufficient gas

How often too much gas

What the users do if too much gas

………………… hours per day total

…………………. hours per day total

Yes □ No □

Daily □ Sometimes in a week □ sometimes in a month □

Less feeding □ Problem with plant □ Longer hours of gas use □ others …… □

Very Often □ Sometimes □ Never □

Flare it □ Use it for something else □ Let it escape □

Slurry Management

No. of Slurry pit

Size of slurry pit

Compost hut

Condition of compost hut

Use of liquid slurry

Use of semi-liquid slurry

Use of compost

Overall Situation of slurry use

0/ 1/ 2/ 3

Enough Small Very Small

Constructed Not constructed

Good Fair Poor

Yes No

Yes No

Yes No

Properly Managed Fairly managed Poorly managed

Documentation present:

- User manual

- Slurry booklet

- Guarantee Card

- Other document………………

Yes No

Yes No

Yes No

Yes No

49

A-S-S and Repairing record:

1st visit: - Date

- Works done

- Cost of Repair works

2nd visit: - Date

- Works done

- Cost of Repair works

3rd visit : -Date

- Works done

- Cost of Repair works

description: (copy from the guarantee certificate backside)

…….../……./…………………………

1.……………………………………………2.…………………………………………3……………………...……………

Nu………………………………………....

…….../……./…………………………

1.……………………………………………2.…………………………………………3……………………...……………

Nu………………………………………....

…….../……./…………………………

1.……………………………………………2.…………………………………………3……………………...……………

Nu………………………………………....

Users Trained Yes No

User’s level of satisfaction Fully satisfied □ Partly satisfied □ Not-satisfied □

Reason for not satisfying

o ……………………………………

o ……………………………………

o ……………………………………

User’s view on current performance No problems □ Ok but some problems □ Plant not functioning □

Existing problems reported by the

user(s), if any

1. …………………………….……

2. …………………………………

3. …………………………………

Overall condition of plant

Good Fair Poor

Comments on Overall Condition

and functioning of the plant

…………………………………………

…………………………………………

…………………………………………

Recommendation for follow-up

action including the deadline

…………………………………………

…………………………………………

Recommendation for Release of Guarantee amount Yes No

Signature of RBSU Supervisor: …………………………………… Signature/Finger Print of Plant Owner: ……………………..….

Date: ……/……../20………………… Date: ……/……../20……………

50

Form - 08

ENERGY FOR AGRICULTURE (E4A)

ACTIVITY REPORTING FROM FIELD

Date: Month……/Quarter..........., 200.....

Items Activities Planned Activity Actual Progress Remarks

A Promotion and Marketing

A.1 Promotion activities

a Public Media

b Deliver brochures, leaflets, posts

A.2 Investigate potential customers

A.3 Promotion activities to customers

A.4 Registration for Biodigesters

B Construction and Maintenance

B.1 Construction of biodigester

B.2 Maintenance

C Training

C.1 Biogas technician

C.2 Biogas mason

a Biogas experienced mason

b Biogas fresh mason

C.3 Biogas user

C.4 Related officers

D Comprehensive application

extension

D.1 Model design

D.2 Biogas newsletter

Petition:

...................................................................................................................................................................

...................................................................................................................................................................

...................................................................................................................................................................

...........................................................................................................................................................

Date: …… month……20……

Prepared by…………………… Reviewed by:………………..

(Full name + signature) (Signature + stamp)

51

Form - 09

ENERGY FOR AGRICULTURE (E4A)

LIST OF BIODIGESTER USERS FOR SUBSIDY PAYMENT

Period: From …..…/…..…/20…………… to ……/……/20…………

SN Name Address ID No. Plant

code

Date of

acceptance Village District Province

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

Date: ………. month……………20……….…

Prepared by…………………… Reviewed by:………………..

(Full name + signature) (Signature + stamp)

52

Form - 10

ENERGY FOR AGRICULTURE (E4A)

BIODIGESTER WARRANTY CERTIFICATE

Biodigester Size: .......... m3 Plant Code: .... – .... – .... / ......

Name of User: ........................................... Tel No.: ……………..……………………

Address: Village..................... District..................... Province…………….…………….

Date of Plant Acceptance: ........./ ......../20……. Warranty Expiry Date:……/…../20……

Warranty Performing BCE:………………………………………….… BCE Code: .... – .... – ....

Address: ............................................................... Telephone: ...............................

Name of BCE Representative: .................................. Position:................…………………....

Terms and Conditions:

1) Warranty period will be 24 months for structural components, such as inlet, digester, gas-holder, outlet, water-

drain pit; and 12 months for pipe-fittings and appliances such as biogas stove, lamp, water-drain, mixing device,

main valve and gas taps, effective from the date of acceptance.

2) BCE will visit the biodigester within three days after receiving complain from the user and carry out the needed

repair works to solve the existing problem(s).

3) BCE will visit the plant at least once in a year during the warranty period to monitor the condition of biodigester

even if there are no complaints lodged from the user.

4) BCE is responsible to bear the costs of repair and maintenance within the warranty period. However, if the

problem is caused because of negligence/mishandling from the users the cost of construction materials and/or

appliances as well as unskilled labors has to be paid by the users. BCE will only bear the cost of skilled labors to

carry out the repair works in this case.

5) BCE will not be responsible for any problem encountered because of the use of sub-standard quality of

construction materials and appliances on behalf of the users while carrying out repair works.

6) This warranty is not valid for any defects or damages as a result of natural disasters such as landslides, floods,

earthquake etc.

7) BCE will not be responsible for any defects or damages caused because of improper operation and maintenance

activities on behalf of the users which are not as per the instructions from BCE or User’s Manual.

8) Warranty will be null and void for any defects/problems caused by any sorts of repair activities carried out by the

users without informing BCE.

9) The representative of BCE visiting the plant under the framework of this warranty provision will fill the

information as anticipated in the table given in the backside of this warranty card.

10) The user has rights to contact Energy for Agriculture (E4A) to lodge complain if BCE does not fulfill the

commitment. E4A will take necessary action against the BCE, including non-payment of warranty amount.

Name of BCE Representative…………………………..

Signature:……………………………………………………….

Position:…………………………………………………………

Date: ……………………………………………………………

Name of Plant Owner:………………………………..

Signature:……………………………………………………

Date:……………………………….…………………………..

53

Details of works carried out

Date of visit Purpose of visit

(routine/called by user)

Repair activities carried out during

the visit

Name of technician

(Full name + signature)

54

Annex-4: Quality Control Tools and Equipment

Routine Monitoring Tools

(a) Measuring Tape – 5m long

(b) Pressure Meter (Digital or analogue)

(c) pH Meter

(d) Digital Thermometer

Used for measuring

different components

of biodigester.

To measure the pH

(acidity and

alkalinity) level of

the influent and

effluent.

To measure/monitor

temperature

(ambient and various

locations inside the

biodigester).

Used to measure gas

pressure and detect

leakages in the

biodigester and pipe

systems.

55

To locate the exact

locations of

biodigesters.

To assess the

performance of

filtration

system by

measuring the

percentage of

methane and

CO2 in biogas.

(e) GPS Receivers

(f) Plier

(g) Screw Driver

(h) Pipe Wrench

Specialised Monitoring Tools

(a) Biogas Analyser

56

To measure the

quantity of biogas

consumed by a

specific end use

applications such as

generators.

To facilitate

measurement of

different

components of

filled

biodigesters

To check leakages through

gas holders, pipelines and

appliances.

To collect

sample of

bioslurry

from

biodigesters

(b) Bioslurry Sampler

(c) Folding Pipe

(d) Foot Pump or Bicycle Pump

(e) Biogas Flow Meter

57

Annex-5: Quality Check of Biodigesters and knowledge of Users

Parameters Size of Biodigester

4 6 9 14 21

Dung Feeding in Kg 20-40 40-60 60-90 100-140 150-210

Gas production in litre

(35-40 litres of biogas per kg of

cattle dung)

700-1400 1400-2100 2100-3200 3500-4900 5300-7400

Single Burner Stove Burning time in

hours

3 to 4 5 to 6 8 to 9 12 to 15 18 to 20

Methane content > 50% > 50% > 50% > 50% > 50%

Maximum pressure at NTP in kPa 7 8 9 10 12

pH 6.5 – 7.5 6.5 – 7.5 6.5 – 7.5 6.5 – 7.5 6.5 – 7.5

Total Solid in influent 6-10% 6-10% 6-10% 6-10% 6-10%

User Training and knowledge Pass (min 20/28 correct) □ Fail □

Action:……………………….

1. How much dung must you feed into the plant each day? a)…………… b) Pass □ Fail □ Pass □ Fail □

2. How much water must you feed into the plant each

day?

a)…………… b) Pass □ Fail □ Pass □ Fail □

3. What determines the quantity of gas production? a)…………… b) Pass □ Fail □ Pass □ Fail □

4. When should you close the main gas valve? a)…………… b) Pass □ Fail □ Pass □ Fail □

5. How do you check for gas leaks? a)…………… b) Pass □ Fail □ Pass □ Fail □

6. What should you do if there is a problem with your

plant?

a)…………… b) Pass □ Fail □ Pass □ Fail □

7. How do you drain water from the gas pipes? a)…………… b) Pass □ Fail □ Pass □ Fail □

8. How often should you drain water from the gas pipes? a)…………… b) Pass □ Fail □ Pass □ Fail □

9. What must you always check and do at the outlet tank? a)…………… b) Pass □ Fail □ Pass □ Fail □

10. How do you light the stove? (ask user to do for you) a)…………… b) Pass □ Fail □ Pass □ Fail □

11. With the gas tap, how should you make the flame look

and sound?

a)…………… b) Pass □ Fail □ Pass □ Fail □

12. How can you ensure the efficient burning of the stove? a)…………… b) Pass □ Fail □ Pass □ Fail □

13. How do you light the lamp? (ask user to do for you) a)…………… b) Pass □ Fail □ Pass □ Fail □

14. How can you save gas so that you have longer time for

use?

a)…………… b) Pass □ Fail □ Pass □ Fail □

15. How do you use bioslurry? a)…………… b) Pass □ Fail □ Pass □ Fail □

16. How do you make good compost fertilizer using

bioslurry?

a)…………… b) Pass □ Fail □ Pass □ Fail □

17. What are some of the advantages of bioslurry over

conventional farm-yard manure?

a)…………… b) Pass □ Fail □ Pass □ Fail □

18. What are some of the safety precautions while using

biogas?

a)…………… b) Pass □ Fail □ Pass □ Fail □

19. How can you estimate the quantity of gas inside the gas

holder?

a)…………… b) Pass □ Fail □ Pass □ Fail □

20. What should you do if the digester is always full (more

gas than you need)?

a)…………… b) Pass □ Fail □ Pass □ Fail □

21. What is the use of the gas pressure meter? a)…………… b) Pass □ Fail □ Pass □ Fail □

22. How do you avoid the scum formation in the biogas

plant?

a)…………… b) Pass □ Fail □ Pass □ Fail □

23. If the gas stops because of a scum layer forming inside

the digester, how would you fix it?

a)…………… b) Pass □ Fail □ Pass □ Fail □

24. What should be taken care while emptying the biogas

plant?

a)…………… b) Pass □ Fail □ Pass □ Fail □

58

Annex-6: Monitoring Parameters for ZamDigester

SN Parameter Frequency Equipment Monitoring

1 Feeding of cattle-dung Daily at set times (end of

afternoon?)

Bucket, weighing scale Initially daily by local

technician, later perhaps

by hh

2 Feeding of water Daily at set times (end of

afternoon?)

Bucket Initially daily by local

technician, later perhaps

by hh

3 Mixing of dung and

water

Daily at set times (end of

afternoon?)

Visual Initially daily by local

technician

4 Biogas consumption Continuous Gas flow meter, Sulphur

filter

Initially daily by local

technician, later less

5 Digester temperature Daily at set times, fixed

position

Min-max thermometer

(or more advanced?)

Daily by local technician /

continuous

6 Ambient temperature Daily at set times, fixed

position

Min-max thermometer

(or more advanced?)

Daily by local technician /

continuous

7 pH Weekly at set point; before

feeding, in the digester, in

the outlet discharge point

pH meter, litmus paper Weekly by local technician

8a Max gas pressure Daily in the morning, before

first gas consumption

Pressure meter Daily by local technician,

later perhaps by hh

8b Max outlet slurry level Daily in the morning, before

first gas consumption

Measurement stick,

measuring tape

Daily by local technician,

together with pressure.

Later perhaps by hh

9a Min gas pressure Daily in the evening, after

last gas consumption

Pressure meter Daily by local technician,

together with pressure.

Later perhaps by hh

9b Min outlet slurry level Daily in the evening, after

last gas consumption

Measurement stick,

measuring tape

Daily by local technician,

together with pressure.

Later perhaps by hh

10 Biogas stove-use

hours

Daily Clock Initially daily by local

technician, later by hh.

11 Biogas lamp-use hours Daily Clock Initially daily by local

technician, later by hh.

12a Closing of main valve Daily in the evening, after

last gas consumption

Clock Initially daily by local

technician, later by hh.

12b Opening of main valve Daily in the morning, before

first gas consumption

Clock Initially daily by local

technician, later by hh.

13a TS and VS fresh dung Twice for each plant, after

process is stabilized (three

months operation)

Containers, oven,

weighing scale, simple

lab equipment

By research institute,

laboratory

13b TS and VS slurry in

outlet

Twice for each plant, after

process is stabilized (three

months operation)

Containers, oven,

weighing scale, simple

lab equipment

By research institute,

laboratory

14 Water tightness In sampled plant. Once

upon commissioning and

once at the end of the

testing period

Lots of water, measuring

tape. Details on Biogas

Technology Manual

By Project Technical

Officers

15 Gas tightness For each plant. Once upon

commissioning and once at

the end of the testing

period

Lots of water, measuring

tape, pressure gauge.

Details on Biogas

Technology Manual

By Project Technical

Officers

16 Sediment and scum

content

Each plant to be checked,

at the end of the testing

period

Buckets, visual, weighing

scale, camera, folding

rod

By Project Technical

Officers

17 Daily Biogas

Production

At least once in a month for

12 months

Measuring tape, visual By Project Technical

Officers in the beginning

and later by local

technicians

59

Lusaka Office:

SNV Netherlands Development Organisation7 Nkanchibaya Road, Rhodes Park

P. O. Box 31771, Lusaka, ZambiaT: +260 1 255174/175

F: +260 1 255176

Kasama Office:

SNV Netherlands Development OrganisationPlot 2623 Lunzuwa Road, Central TownP. O. Box 410576, Kasama, ZambiaT: +260 04 222988F: +260 21 222986

www.snvworld.org/zambia

This Quality Management Manual for fixed dome biodigester aimed at Quality Inspectors, Biodigester Technicians and M&E Officers is prepared by Prakash C. Ghimire for Energy for

Agriculture (E4A) project. Any query related to this manual could be addressed to pghimire@snvworld.org.

This manual is solely for the internal use of Energy for Agriculture (E4A) project to facilitate quality management process and ensure the compliance of quality standards. Any information from this

document may be copied or reprinted, subject to the condition that it is properly credited and cited.