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Training of Trainers (TOT) on Constructionand Supervision ofSINIDU Model Biogas Plant for EthiopiaTrainee’s ManualPrepared forNational Biogas Programme (NBP)EREDPC/SNV EthiopiaByPrakash C. GhimireAsia Biogas Programme, SNVMay 20081
Table of ContentPURPOSE OF THIS MANUAL .31. INTRODUCTION OF TRAINING PROGRAMME.ERROR! BOOKMARK NOT DEFINED.42. INTRODUCTION TO THE NATIONAL BIOGAS PROGRAMME (NBP).113. OVERVIEW OF BIOGAS TECHNOLOGY .154. OVERVIEW ON DESIGN AND CONSTRUCTION.315. BIODIGESTER SIZE, CONSTRUCTION SITE AND CONSTRUCTION MATERIALS .376. PROPER BIODIGESTER CONSTRUCTION .417. USE OF BIOSLURRY AND COMPOSTING .498. TECHNOLOGY PROMOTION AND QUALITY CONTROL .519. OVERVIEW ON OPERATION AND MAINTENANCE.6510. ROLES OF STAKEHOLDERS, SUPERVISORS AND MASONS .77ANNEXES .82Annex-1: Training SchedulesAnnex-2: Quality StandardsAnnex-3: Forms and FormatsAnnex-4: Drawing of a Biodigester2
Purpose of this ManualBuilding of a quality biodigester requires good knowledge and skills on the part of the constructor, themason. Good functioning or performance of a biodigester is associated with the selection of the right size,choosing the right site for construction, selecting the construction materials and appliances to complywith the quality standards, constructing the components with strict adherence to the norms and ensuringeffective operation and maintenance activities – all of which are the responsibilities of the mason. In otherwords, the mason has a very important role to play in the effective functioning of a biodigester. It istherefore important that the mason responsible for all the works as mentioned above is provided with awell-designed training and orientation programme.Building of a quality biodigester not only requires good knowledge and skills on the part of theconstructor, the mason, but also effective supervision of installation and post-installation activities onbehalf of a supervisor. Non-functioning and poorly functioning biodigesters do not only cause capitalwaste but also do a lot of harm and damage to the reputation of biodigester technology and eventually tothe desired future expansion of the biogas program. In other words, the satisfied users are the mostimportant and effective extension media for the promotion of the technology and vice-versa. To safeguardthe quality of biodigesters, it is important that effective quality control mechanisms be formulated and getenforced properly. The quality of construction, operation and maintenance of biodigesters is a majorconcern and supervisors have a vital role to play in this regard. This manual envisages helping theparticipants in imparting effective technical training programmes and preparing the participants as multiskilled persons to construct/supervise the construction of biodigester as well as to promote the technologyat the grass-roots level.3
1.INTRODUCTION1.1BackgroundAccess to modern energy is a key element in rural development. However, despite all attention given toenergy issues in Ethiopia in the past, rural communities continue to be deprived of basic energy services.Modern forms of energy are simply not available in rural areas while traditional sources are rapidly beingdepleted, thereby deepening the rural energy crisis.Woody biomass represents the principal form of cooking and lighting fuel in Ethiopia’s rural areas. Anincreasing fraction of the population is being confronted with the difficult choice between eating its foodpoorly cooked and travelling long distances to collect fuel for cooking. The scarcity of fuel wood has ledto an increased utilization of dung and agri-residues for cooking, which could otherwise have been usedto enhance the nutrient status and texture of the soil and contribute positively to agricultural production.Biogas offers an attractive option to replace unsustainable utilization of wood and charcoal. It complieswith the principles put forward in the country’s Energy Policy and Environmental Protection Strategy,and closely meets the terms of the Plan for Accelerated and Sustained Development to End Poverty(PASDEP) as well: it is a local, renewable resource that addresses the basic needs of rural householdsamongst which energy; it supports decentralised access to household energy; its by-product – bio-slurry –enhances agricultural productivity and promotes organic farming, thus offering opportunities for nichemarkets and export. On the whole, it ensures environmental sustainability and its use as domestic fuelimproves development conditions and opportunities for women and girls. Last but not least, it lends itselfto commercial development, hence contributing to the development of the private sector and the technicaland human capacity of the Technical Vocational Education and Training Centres (TVETs).Biogas technology was introduced in Ethiopia as early as 1979. In the last two and a half decades, around1000 biogas plants were constructed in various parts of the country. Presently, approximately 40 % ofthese plants are not operational due to a lack of effective management and follow-up, technical problems,loss of interest, reduced animal holdings, evacuation of ownership and water problems. Other reasons forthe limited success of the technology in Ethiopia include the adoption of a project-based stand-aloneapproach without follow-up structure in place, variations in design, and the absence of a standardizedbiogas technology.Due to the renewed interest in biogas, and in order to unleash the potential for this bio-fuel in Ethiopia, afeasibility study was commissioned to assess the prospects for domestic biogas in the country. This studyled to a formal partnership between the Ethiopian Rural Energy Promotion and Development Centre(EREDPC) and SNV/Ethiopia, and in 2007 a joint EREDPC/SNV team was established to develop aprogramme implementation document. An extensive stakeholders’ consultation process at both regionaland national level resulted in more than 120 representatives of the government, non-governmentalorganisations, and the private and financial sectors gaining awareness about the features and functionsrequired for a national biogas programme (NBP), and providing ample inputs for the development of theprogramme.In the process to build the capacity of local artisans especially the masons and supervisors, by impartingthem detail technical knowledge and skills on methods of construction and supervisions of the householdBiogas Plant, a Training of Trainers (TOT) has been felt needed. The participants of this TOT areexpected to organise and conduct technical training programs to masons and supervisors in the future.1.2Training ObjectivesThe overall objective of the Demonstration phase is to introduce biogas technology in general andSINDHU biogas plants in particular and to build capacity of stakeholders, especially that of EREDPC andMEA to disseminate the technology including conducting quality training courses on Construction andSupervision of SINIDU (SINIDU) Biogas Plants and within selected private construction cooperatives to4
construct and supervise SINIDU biogas plants in Ethiopia, according to the quality standards formulatedby NDBP.The following are the specific objectives: To familiarize the concerned persons on Biogas Technology, the National Biogas ProgrammeEthiopia (NBPE) and related issues.To acquaint the participants on technological aspects of SINIDU Biogas Plant being introduced inEthiopia.To build skills and enhance knowledge of participants on Biogas Plant construction through on-thejob training.To build capacity of participants on imparting training on construction, monitoring, supervision andO&M of Biogas Plants by enhancing training and facilitation skills.To enhance knowledge of the participants on promotion of biogas technology and quality control ofplant construction as well as operation and maintenance.To construct 100 demonstration biogas plants in 4 selected regions.1.3Expected OutputThe overall output expected from the TOT is the enhanced knowledge and improved skills of theconcerned individuals related to dissemination of biogas technology including the internalization of thetraining process by the individuals as well as by EREDPC and MEA to be able to impart training tomasons and supervisors to construct, monitor, supervise, operate and maintain Biogas Plants in Ethiopia.After the training they will be able to conduct further training and engage and train nationally recognizedtraining institutes for biogas plant related technical training courses in Ethiopia.The following are the specific outputs expected from the TOT:ooooo1.4The participants will be familiar about the National Biogas Programme Ethiopia.The participants will acquire detailed knowledge on biogas technology, its importance and use ofBiogas Plant-products (biogas and bio-slurry)The participants will have hands-on knowledge and skills on:o Reading plant drawingso Selection of plant-size, construction sites and construction materialso Plant lay-out, digging of pits and construction of foundationo Construction of digester and gas storage tanko Construction of Inlet and Outlet chamberso Laying of pipelines and installation of applianceso Construction of slurry pits and importance of compostingo Routine operation and maintenance activitieso Monitoring and supervision of construction of bio-digesterso Quality standards on Biogas Plant construction, operation and maintenanceThe participants will know and realize the roles and responsibilities of Masons and Supervisorson promotion and extension of Biogas Plant technology.The participants will demonstrate ability to transfer skills and knowledge on above mentionedissues to the larger audiences (masons and supervisors) in the future (Hands on skill to conducttechnical training programme to masons and supervisors).ParticipantsParticipants in TOT will include:ooBiogas Experts from the Ethiopian Rural Energy Demonstration and Promotion Centre(EREDPC) (3 persons).Biogas experts from Regional Mines and Energy Agencies (MEAs) (8 persons)5
ooo1.5Energy Experts form Woredas ( 4 persons)Representative Dairy Cooperative Debra Zeit (1 person)Representatives from 8 Woreda base construction cooperative or enterprises. 1 Supervisor and 1mason (8 persons)Training Venue and DurationThe overall training programme will be conducted in two different phases: Theoretical deliberation with practical demonstration; andOn-the-job practical exercises.The theoretical part of the training will be conducted in a established training centre. The participants willbe provided with theoretical and practical knowledge through classroom sessions and construction of ademonstration Biogas Plant in a household premise near the training centre. The theoretical training andinstallation of demonstration Biogas Plant will be conducted for 7-8 days.The on-the-job practical exercises on Biogas Plant construction will be carried out in different locations inthe four regional states at the farmers’ household premises for 15 days.6.Training ContentsThe contents of training programme has been finalised keeping in view the objectives and expectedoutcomes. The following table briefly describes the contents of the training programme.Table-1: Training Topics, Contents and Methods of DeliberationMain TopicContentsTrainingobjectivesexpected eed for the trainingObjectives of the trainingExpected OutputsIntroduction of Pilot Programon Biogasa.b.c.Evolution of Biogas Pilot Program in EthiopiaProgram objectives and targetsProgress/activities undertaken till yBiogasa.b.c.d.Biogas in generalIdeal Conditions for gas productionBenefits of BiogasUse of BiogasPresentationDiscussionandOverview on Biogas PlantConstruction and Design/Drawingsa.b.c.d.e.Types of biogas plantDifferent Components of a biogas PlantFunctioning of a biogas PlantPlant being introduced in Ethiopia (GGC Model)Familiarization on design and drawing of GGCModel of Biogas PlantPresentation,DiscussionandVideo show(?)Selection of Biogas Plant Size,ConstructionSiteandConstruction Materialsa.Points to be considered while selecting the size ofBiogas Plant (feeding availability vs. family size)Quantification of dung based upon cattle numbersHydraulic retention timeSelection of appropriate size of Biogas Plant basedupon dung availabilityPoints to be considered while selecting site forBiogas Plant construction (location of plant vs. cattleshed, kitchen, water fetching points etc.)Types and quality standards of construction trationtob.c.d.e.f.6
Laying out and Digging of PitConstruction of baseConstruction of Digesterg.Quantity requirements of construction materialsa.Methods of laying out of Biogas Plant (fixing therelative positions of inlet, digester, manhole andslurry pits)Methods of digging the pitFixation of the centre pointPreparation of the baseFirming-up of foundation baseMethods of preparing mortarMethods of fixing the base for round wallLaying of bricks and mortar to construct wallChecking of central pillar for its verticalityFixation of chord/string to facilitate the constructionof round-wallsMethods of preparing mortar and bricks forconstruction of wallConstruction of round wallFixing of inlet pipeConstruction of manholeConstruction of floor (brick soling and plastering)Plastering of wallsBackfilling in cavity outside the wallCuring of wallFilling of earth in digesterShaping of the dome with the use of templatePreparation of surface for concreting (watering andsprinkling of sand)Fixing of the position of main gas pipeConcreting of dome and maintaining the thickness ofdomeFixation of main gas pipeCuring of concreteTaking out of soil-mouldPreparation works (scrubbing and washing)Application of plastering layersApplication of acrylic emulsion paintImportance of dome plasteringPreparation for the baseBrick soling and plastering of the baseConstruction of wallsPlastering of wallsCasting and fixing of RCC cover slabSoil stabilization to safeguard walls against slurrypressureCuring of plastered surfacePreparation for the baseConstruction of baseConstruction of round wallFixation of mixing devicePlastering and finishing woksCuring of plastered surfaceConstruction of TurretFixation of pipeline alignment and digging of trenchInstallation of main gas valvePipe-laying worksInstallation of water-trap and chamberFixation of gas taps, rubber hose pipe, stove andlampsChecking for leakagesSite preparation and laying outb.c.d.a.b.c.d.a.b.c.Construction of Dome (gasholder)d.e.f.g.h.i.j.a.b.c.d.e.Plastering of DomeConstruction of OutletConstruction of InletInstallation of Pipeline andAppliancesConstruction of Slurry ntation,
Overview on Operation andMaintenanceb.c.d.a.b.c.d.Quality Management (Qualitystandards, Supervision andMonitoring)a.b.c.d.e.f.Role of Mason and c.d.e.Digging of pitsStabilizing of the slopesImportance of composting and shading of pitsFilling up of the digester with feedstockImportance of routine operation activities (plantfeeding, use of gas valves, draining condensed waterfrom pipeline etc.)Minor maintenance activitiesPotential problems and likely solutions (ex. Slurry inthe pipeline)Importance of Quality ManagementQuality Standards and Quality Management SystemsSupervision and monitoring visits and feedback toMasons/UsersFamiliarisation with forms and formats and practiceto fill these formsFilling of Quality Control Form for Underconstruction Biogas Plant (Visit to underconstruction plant)Filling of Quality Control Form after the Completionof Construction (Visit to Completed plant to fillConstruction Completing tion,DiscussionandpracticaldemonstrationRoles of mason and supervisor for quality plantconstructionRole of mason and supervisor for promotion andextension of the technologyDifferent tools and techniques of trainingCommunication skillFacilitation skillAdult learning principlesPlanning and organising training ssionandPresentation,Discussionandpractical exercisesTraining Events and ProcessTraining management activities to be carried out during the process of the TOT can broadly be classifiedinto three phases as described below:1.7.1 Pre-training Preparatory PhasePre-training activities mainly include finalisation of design and drawing of SINIDU model of BiogasPlant, selection of participants, formulation of aim, objectives and expected results, planning of sessionsand events, preparation of hand-outs, arrangement of training aids and other logistic arrangements.1.7.2 In-training Operational PhaseThe in-training operational phase will be divided into two main sub-phases: theoretical classes withpractical demonstration, and on-the-job training. The schedules of each of the sub-phase have been givenin Annex-1. Operational activities included all the events that will take place during the conduction oftraining sessions. In general training sessions will consist of the following: Opening (formal/informal)Class room deliberations and discussionField demonstration and construction of one demonstration Biogas PlantInstallation of pilot Biogas Plants by the trainee in the process of on-the-job trainingSharing of lessons learnt and collection of comments and suggestionsClosing (formal/informal)8
The in-training program, especially the on-the-job training will be instrumental in internalising the stepsof installation. It is expected that the participants, after the training, will realise that the constructiontechnique is not as difficult as anticipated, if the steps and norms of construction are followed strictly.1.7.3 Post-training Concluding PhasePost training activities will include documentation of events, process and, review of learning andquestions that may emerge. Preparation of concise training report consisting of participants, session plans,schedules and evaluation by the participants on the training program will be a major part of the posttraining activities. The main outcome of the post-training phase will be the finalisation of the Curriculafor New Mason’s Training and Curricula for New Supervisor’s Training. Other main achievement duringthis phase will be the finalisation of cost and quality estimates based upon the field experience.1.8Programme Overview1.8.1 Inaugural (Opening) SessionThe formal inauguration program will be organised and conducted with active participat
Biogas Plant (feeding availability vs. family size) b. Quantification of dung based upon cattle numbers c. Hydraulic retention time d. Selection of appropriate size of Biogas Plant based upon dung availability e. Points to be considered while selecting site for Biogas Plant construction (location of plant vs. cattle shed, kitchen, water .
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Biogas originates from bacteria in the process of bio-degradation of organic material under anaerobic (without air) conditions. What is a biodigester? A biodigester is a tank that processes the organic material that produces biogas. A biodigester can come in different shapes and sizes, depending on the needs of the people using it and the local
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a. Types of biogas plant b. Different Components of a biogas Plant c. Functioning of a biogas Plant d. Plant being introduced in Laos (GGC Model) e. Familiarization on design and drawing of GGC Model of Biodigester Theoretical and Group exercise Selection of Biodigester Size, Construction Site and Construction Materials a.
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