Biogas Safety first!

Inspections and tests
In order to make plant operation lastingly safe,
both initial and various periodically recurring inspections
and tests must be carried out for the
entire plant, parts of the plant and the documentation.
The inspections and tests can be divided into the
following separate segments:
structural safety
explosion protection
pressurised systems
electrical installations
water resources protection
pollution control
functional safety
fire protection
business organisation
The inspections and tests must be performed by
specially trained experts or by persons qualified to
conduct inspections and tests. In addition to the
necessary training and specific knowledge (including
professional experience in the field of biogas), the
inspectors must have at their disposal the requisite
test and inspection equipment. Proof of compliance
with these requirements should be provided.
With due regard for the respective national requirements,
the following types of inspection and testing
are recommended for biogas plants:
1. Document inspection: checks to ensure that the
documentation is complete, correct and up-todate.
2. Visual inspection and functional test: checks
to ensure that the technical and organisational
safety precautions are complete, correct and in
proper working order.
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TIP
Given the large number of different
periodically recurring inspections and tests
it makes sense to draw up an inspection and
test plan showing all the necessary inspections
and tests and the contact details of the inspector
/ test engineer required in each case.
The German Biogas Association considers the following
on-site inspections and tests on biogas plants to
be the minimum required (see Table 7).
Table 7: Minimum inspections and tests
recommended by the German Biogas Association
Test object
Fire extinguishers
Safety equipment
(e.g. gas warning
equipment, ventilation
systems and
inerting equipment)
Apparatus,
protection systems
and safety systems
Explosion protection
testing (general)
Inspection for
compliance with
water legislation
Safety-related
testing
Electrical testing
of switchgear /
‘E-Check’ inspection
Pressure vessels
Test frequency
Every 2 years
At least once a year
Every 3 years
Prior to commissioning
and periodically at least
every 6 years
Prior to commissioning,
then every 5 years, in
water protection areas
every 2.5 years
Prior to commissioning,
then every 3 or every
5 years (depending on
approval)
Every 4 years
External inspection every
2 years, internal inspection
every 5 years and strength
test every 10 years
The results of the inspections and tests are to be
documented in a test report, which must include at
least the following information:
1. Identification of the plant
2. Date of inspection or test
3. Type of inspection or test
4. Basis for the inspection or test
5. Scope of the inspection or test
6. Effectiveness and function of the
protective measures taken
7. Result of the test and date of the next
periodically recurring test
8. Records and test certificates must be kept at the
site of the plant being monitored for the entire
duration of use of the plant. In addition, it is
advisable to keep a copy at a different location.
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