TESTING AND COMISSIONING PLAN

Odor control system

ISSUED FOR JUNEBERT JAYAVARMAN BRANKO COKO

0 11.10.2020
APPROVAL
Revision Date Purpose Prepared By Checked By Approved By
 LIMITS OF USE
THIS MANUAL REMAINS THE SOLE AND EXCLUSIVE PROPERTY OF BIOAIR
SOLUTIONS, L.L.C., ITS SUBSIDIARIES, AFFILIATES AND/OR ASSIGNS ("BIOAIR").
BIOAIR MAKES THIS MANUAL AVAILABLE TO OWNERS AND OPERATORS
("OPERATOR(S)") OF EQUIPMENT SUPPLIED BY BIOAIR ("BIOAIR EQUIPMENT") TO
ASSIST THEM WITH THE INSTALLATION, OPERATION AND MAINTENANCE OF THE
BIOAIR EQUIPMENT ("USE OF BIOAIR EQUIPMENT").

ALL PERSONS INVOLVED WITH THE USE OF BIOAIR EQUIPMENT MUST BE

PROPERLY TRAINED AND KNOWLEDGEABLE ON THE USE OF BIOAIR EQUIPMENT
AND AWARE OF ALL HAZARDS BEFORE ENGAGING IN SUCH ACTIVITIES. THIS
MANUAL AND ALL OTHER WARNINGS AND WRITTEN MATERIALS SUPPLIED BY
BIOAIR, AS WELL AS ALL OTHER APPLICABLE SAFETY MANUALS, STANDARDS AND
REGULATIONS, ("MATERIALS") SHOULD BE REVIEWED BY ALL PERSONS BEFORE
PARTICIPATING IN THE USE OF BIOAIR EQUIPMENT. IT IS THE SOLE
RESPONSIBILITY OF THE OPERATOR TO ASSURE THAT ALL PERSONS INVOLVED
WITH THE USE OF BIOAIR EQUIPMENT, OR WORKING ON OR NEAR THE BIOAIR
EQUIPMENT, HAVE PROPER SAFETY TRAINING, ARE ADVISED OF THE PROPER
MEANS AND METHODS OF PERFORMING THEIR WORK, HAVE BEEN PROVIDED
WITH THE MATERIALS AND ARE AWARE OF ALL THE HAZARDS AND RISKS THAT
MUST BE ELIMINATED OR AVOIDED.

THIS MANUAL DOES NOT AND SHOULD NOT BE CONSTRUED TO MODIFY THE
CONTRACT OF SALE FOR THE BIOAIR EQUIPMENT ("CONTRACT"). WITHOUT
LIMITING THE GENERALITY OF THE FOREGOING, THIS MANUAL DOES NOT
CREATE ANY NEW AND/OR MODIFY ANY WARRANTY, LIMITATION OF REMEDY OR
LIMITATION OF LIABILITY PROVISION CONTAINED IN THE CONTRACT.

EXCEPT AS SPECIFICALLY SET FORTH IN THE CONTRACT, BIOAIR MAKES NO

WARRANTIES, EXPRESS OR IMPLIED, OF ANY KIND OR NATURE WHATSOEVER
INCLUDING, BUT NOT LIMITED TO, WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR ANY PARTICULAR USE.
Table of Contents:

1. Introduction 4

2. Reference Documents 4

3. Manufacture Certification of Installation Compliance 4

4. Commissioning Team 4

5. Commissioning Overview 4

5.1 Commissioning Process Description 4

5.2 Commissioning Goals and Objectives 5

5.3 Pre-Commissioning 5

5.4 Commissioning 5

6. Tools and Equipments 6

7. Scope of Commissioning Activities 6

7.1 Dry Commissioning Installation Inspection & Verification Checklists 6

7.2 Wet Commissioning Installation Inspection & Verification Checklists 7

7.3 Commissioning Equipment Scope 7

7.4 Odour Control Unit Start-Up 8

7.5 System Conversation to Final Operation 8

8. Certificate of Proper Installation 9

9. Appendix - Installation, Verification, & Commissioning Checklists 10

1. INTRODUCTION

The purpose of this commissioning plan is to provide instructions on the steps to follow the
successful installation of the odour control system. Below are the details, reference documents for
the proper procedures, tools necessary, personnel, and deliverables relevant to startup of the odour
control system. All commissioning = will be outlined in this document & its attachment.

BioAir without question will make sure all commissioning and testing follows the site’s and BioAir’s
health and safety requirements.

BioAir welcomes the customer/client to perform their own audit of the commissioning and submit
feedback or concerns to BioAir for review and execution.

2. REFERENCE DOCUMENTS

Drawing No. Description:

EF63+EB7S_P20202 GENERAL ARRANGEMENT ECOFILTER EF63 + ECOCARB EB7S
PIPING AND INSTRUMENTATION DIAGRAM ECOFILTER EF63 +
EF63+1xEB7S-PID_P20202
ECOCARB EB7S
CD20202-GA-R2 GA & WIRING DIAGRAM FOR ELECTRICAL ICA PANELS
Various OEM Equipment Manufacturer’s literature

3. MANUFACTURE CERTIFICATION OF INSTALLATION COMPLIANCE

Once system has been inspected and deemed properly installed, BioAir will issue a certificate
stating that the system has been installed per the instructions and guidelines and is ready for full
startup and operations.

4. COMMISSIONING TEAM
BioAir’s commissioning team will consist of the following roles:

• Project Manager
• Commissioning Engineer
• Startup Supervisor

5. COMMISSIONING OVERVIEW

5.1 Commissioning Process Description

BioAir will deliver all required equipment to the job site for the mechanical and electrical
installation. Following the installation BioAir will be able to properly startup, performance
test, and turnover the new biological odour control equipment to the end customer to
successfully operate.
5.2 Commissioning Goals and Objectives

The goal of the commissioning process is to ensure the system as a whole has been
installed correctly and that it is ready to be put into full service. The main objectives are as
follows:

• Ensure system has been installed per manufacturer’s instructions and all features are
defect-free and ready for use.
• Ensure system operates properly after startup with no errors or issues
• Ensure system meets project requirements and specifications

Commissioning also ensures the following:

• System inspection is documented for reference

• Completeness of Operation and Maintenance Manual is verified
• Training of operators is completed, to service equipment and ensure proper system
operation
• System is handed over to owner/operator on permanent basis

5.3 Pre-Commissioning

This step verifies all equipment has been installed per design documentation, is free from
all marks or damage, and is ready to be put into operation.

During Pre-Commissioning the installing contractor, automation equipment supplier and

BioAir will verify the equipment is ready for commissioning. All check worksheets will be
listed in the Appendix below.
• Test of electrical equipment for functionality
o Testing of the control logic, sensors, and programming.
o Testing of fail-safes and interlocks
• Test of all the equipment
o Running of all electrical equipment for functionality.
o Mechanical checks of installed mechanical equipment to assure proper
installation.
o Air balancing of system airflow by BioAir.

5.4 Commissioning

Once the Pre-Commissioning has been completed, and the equipment has been inspected
and deemed properly installed by BioAir, the Commissioning will follow BioAir’s startup
operation process.

Commissioning will be completed when BioAir has deemed the system’s biological process
is fully acclimated and the system is ready to begin the performance proving period.
6. TOOLS AND EQUIPMENTS

• Electrical Nose Plier & Vise Grip

• Personal protective equipment
• H2S Personal Safety Monitor
• Multimeter
• Analog Simulators
• Screw drivers Set
• Ratchet Set
• Adjustable Wrench
• Hammer
• Toolbox with Padlock/Key.
• Calibrated Instrumentation Set
a. Hot Tip Anemometer
b. 4-20mA Loop Simulator
c. Pressure Gauge (Pa)
d. Pressure Gauge (kPa)
e. Portable pH meter
• pH paper
• Tape Rule

7. SCOPE OF COMMISSIONING ACTIVITIES

During the Pre-Commissioning, each check list below (issued by the installation contractor) needs
to be reviewed by BioAir’s commissioning engineer and should cover all the bullets listed.

7.1 Dry Commissioning Installation Inspection & Verification Checklists

• Electrical Installation Check:

a. Point to Point Check
b. Motor Megger and Rotation Check
c. Testing all electrical equipment for functionality
d. Testing of fail-safes and interlocks
• Odor Control Fans:
a. Visual Inspection of all parts including bearings, shafts, frame, wheel, etc.
b. Verify Fan rotation direction and orientation
c. Verify Fan speed on VFD at the design airflow
d. Note Airflow balancing is not in BioAir scope of work
• EcoFilter System Startup Inspection Checklist:
a. Visual Inspection of all parts
• Startup System Inspection Checklist:
a. Visual Inspection of all parts
 • Instruments:
a. Visual Inspection of all parts
• Additional Process Instrumentation Inspection Checklist

7.2 Wet Commissioning Installation Inspection & Verification Checklists

Wet commissioning should be after the above prerequisites are approved.

• EcoFilter System Startup Inspection Checklist

• Startup System Inspection Checklist
• Additional Process Instrumentation Inspection Checklist
• Pressure Testing of Piping – Visual Inspections of all joints
a. Water Pressure testing of all PVC piping
i. Piping from Recirculation Tank to Water Panel to be pressure tested at
full pump dead head pressure.
ii. Piping from Water Panel outlet to Nozzle Assembly to be pressure
tested at in-process design conditions.
b. Air Pressure Testing of all GRP Ductwork

7.3 Commissioning Equipment Scope

The commissioning process covers the following process associated with the Odor Control system.

OP.
ITEM PART NO. QTY. DESCRIPTION WT.
(KG)
1 RA063100_P20202 1 ECOFILTER EF63 REACTOR ASSEMBLY, FRP 4500
2 EB071000_P20202 1 ECOCARB EB07S, REACTOR ASSEMBLY, FRP 3750
3 NA121500_P20202 1 DN600, PS15-69, NOZZLE ASSEMBLY, FRP 45
4 ST124800_P20202 1 DN300 x 1219H, PS15-69, OUTLET STACK, FRP 25
5 DV122000 2 DN300, PS15-69, BACKDRAFT DAMPER VALVE, FRP 13
6 DV122100 9 DN300, PS15-69, ISOLATION-LEVER DAMPER VALVE, FRP 13
7 FC120000 8 DN300, PS15-69, FLEX CONNECTOR, EPDM 15
8 BT121600_P20202 4 DN300, PS15-69, BLOWER INLET TRANSITION PIECE, FRP 10
9 CHP-10 2 VERANTIS CHP-10, CW, UB, ARRG. 4, FRP 150
10 DW120000_P20202 1 DN300, PS15-69, INTERCONNECTING DUCTWORK, FRP 100
11 DW120001_P20202 1 DN300, PS15-69, INTERCONNECTING DUCTWORK, FRP 100
12 DW120002_P20202 1 DN300, PS15-69, INTERCONNECTING DUCTWORK, FRP 50
13 DW120003_P20202 1 DN300, PS15-69, INTERCONNECTING DUCTWORK, FRP 150
14 DW120004_P20202 1 DN300, PS15-69, INTERCONNECTING DUCTWORK, FRP 20
15 DW120005_P20202 1 DN300, PS15-69, INTERCONNECTING DUCTWORK, FRP 150
16 DW120006_P20202 1 DN300, PS15-69, INTERCONNECTING DUCTWORK, FRP 100
17 RS000750_P20202 1 DN40, ANSI 150, STARTUP SYSTEM, PVC-U 55
18 MW075150 1 DN20, SCH80, MAKE-UP WATER ASSEMBLY, PVC-U 4
19 WP151010_P20202 1 DN40, ANSI 150, WATER PANEL, FRP 60
20 NB100000_P20202 1 378 LITER (100 GAL), NUTRIENT TANK, POLYEHTYLENE 200
21 PS343300_P20202 1 WATER PANEL STAND, 316SS 60
22 PS100000_P20202 1 ELECTRICAL PANEL STAND, 316SS 60
23 SS000100_P20202 1 WATER PANEL STAND SUNSHIELD, 316SS 15
24 SW000100_P19203 2 DIFFERENTIAL PRESSURE GAUGE MOUNTING BRACKET, 316SS 1
 25 SW000101_P20202 3 INSTRUMENT MOUNTING BRACKET, 316SS 3
26 732.15.160 2 WIKA DIFFERENTIAL PRESSURE GAUGE 1
27 8344123 / 6809710 2 DRAGER POLYTRON 5100, INLET H2S TRANSMITTER / SENSOR, 0-1000PPM 2
28 8344123 / 6810435 1 DRAGER POLYTRON 5100, OUTLET H2S TRANSMITTER / SENSOR, 0-5PPM 2
29 6810536 3 CALIBRATION ADAPTER, VITON 1
30 58P 3 ؼ", FNPT, 58P SAMPLE FILTER, PC 1
31 FR2A12SVVT 3 0.04 - 0.5 LPM ROTAMETER 1
32 AF1-S-123000 1 MCDONNELL & MILLER AIR FLOW SWITCH 1
33 CD20202 1 ELECTRICAL CONTROL PANEL, FRP 75

7.4 Odour Control Unit Start-Up

When EcoFilter system (OCU) is initially started up, it operates in startup operating mode for the
first 4 weeks. This involves the recirculation of drain water through the EcoFilter system in order to
aid in growth of the biology and its adherence to the EcoBase media.

In startup mode, the irrigation settings will be set to standard times by the BioAir’s commissioning
team in order to control the moisture and pH levels in the media of the BioFilter.

After 1-4 weeks, the biology is well established in the media and the system can be converted to
normal operation, then allowed to acclimate to normal operating conditions.

During this period, system H2S removal performance should be monitored as advised by BioAir
personnel. Inlet and Outlet H2S levels can be monitored via HMI. Readings can be logged along
with other system data on BioAir’s Process Data Recording Sheet.

After startup, the system should be operated, monitored and maintained in accordance with BioAir’s
Operator Handbook on Section 2.5 of the O&M Manual.

7.5 System Conversion to Final Operation

Once the pH of the process drain water reaches ≈ 2.0, the system can be converted from startup
mode to normal operation. Please follow these steps to complete conversion for EcoFilter.

• At the electric control panel (ECP), turn Irrigation Switch (SW5) to CLOSED and the
Startup Pump Switch (SW3) to OFF. Turn nutrient pump switch (SW4) to OFF as well.
• Open the water retention valve on the startup piping assembly and allow all water to
drain out of each vessel system. This will take some time (likely 1+ hour)
• Close the ball valves in the Ø2” pipe that connects the startup piping assembly from the
recirculation tank and the leading to the water panels. Open the ball valves that will
redirect the drains to the common site drain.

Once system is mechanically converted, change to the approximate following settings:

• Cycle Time: 10 minutes
• Irrigation Time: 300 seconds
• Nutrient Dosing: OFF (controlled by switches)
8. Certificate of Proper Installation

After the following items have been achieved, BioAir will issue a Certificate of Proper Installation:
• Installed in accordance with BioAir Solutions project documents
• Inspected, checked and adjusted (if required)
• Serviced with proper initial lubricants
• Electrical and Mechanical connections meet quality and safety standards
• All applicable safety equipment has been properly installed
• Functional Tests performed
• Mechanically & Electrically Started Up
• Biologically Started Up

Training

Operator training will be conducted to monitor and service equipment when needed, as well as
adjust parameters to keep system removal at optimal levels.

This includes both site training with the equipment and classroom training for in-depth transfer
of knowledge on system functions and operation. Training will be coordinated with SBG to
accommodate shift schedules of operations staff.

Parameter check sheet (Startup)

Project Name/No.: _______________________ Date: _______

On site:

Cycle = _____
Irrigation time = _________
Nutrient time = _________
Water flow rate ( lpm) = ___________
Pressure gauge above WP (PSI/bar) = ____
DP gauge of Blower (mbar) = _____
DP gauge of Reactor (mbar) = _____
Verify valves open/close correctly
Verify nutrient dosing OK, keeps prime, fittings tightened
Nutrients remaining in barrel = _____ gal / nutrient level = _____ cm
Record active alarms & alarm history including dates/times
Total Airflow = _____ (record measurement details in notebook)
pH @ time: ____ @ ____ : ___@ ___ : :____ @ ___
H2S (Inlet) @ time: ___@____ : : ___@___ : : ___ @___
H2S (Outlet) @ time: ___ @___ : : ___ @___ : : ___ @ ___
9. Appendix - Installation, Verification and Commissioning Checklists

Note – The personnel who are commissioning the system and filling out the checklists below may
be required to print out additional copies to guarantee all installed equipment has been inspected.

Appendix 1 – System Information

Appendix 2 – Installing Contractor Checklist

Appendix 3 – Commissioning Equipment Checklist

Appendix 4 – Instrumentation Commissioning Checklists

Appendix 5 – EcoFilter Commissioning Checklist

Appendix 6 – Damper Valve(s) Commissioning Checklist

Appendix 7 – Startup System(s) Commissioning Checklist

Appendix 8 – Flex Connector(s) Commissioning Checklist

Appendix 9 – GRP Ductwork Commissioning Checklist

Appendix 10 – Water Panel(s) Commissioning Checklist

Appendix 11 – Blower Commissioning Checklist

Appendix 12 – Pump Commissioning Checklist

Appendix 13 – Airflow Balancing Checklist

Appendix 14 – Airflow Balance Worksheet

Appendix 1 - System Information
Equipment Type: EcoFilter EF63 + EcoCarb EB7S
Total Design Airflow (m³/hr.): 2000 m³/hr (Normal), 4000 m³/hr (Maintenance)
H2S Design (ppm):
Daily Average: 400 ppmv
Transient Peak: 800 ppmv

Water Supply Source: Site Water Supply

Nozzle Design Flow Rate (LPM): 61 LPM

This above is listed properly and ready for commissioning:

Name: _____________________________ Date: ________________

Signed: ____________________________
Appendix 2 – Installing Contractor Checklist
BioAir will assure the installing Contractor(s) complete the following items prior to the BioAir
Commissioning Team traveling to the site for startup of the odor control equipment.

Mechanical Installing Contractor Checklist

Reactor(s) placed the appropriate location and fully assembled with all vessel sections,
roof, nozzle assemblies, etc. installed.
Pressure gauge and nozzle installed on nozzle assembly.
Construction or shipping-related smudges or stains, shipping notices, and tape removed
from vessels.
All drain lines completed including reactor to site drain.
All anchoring devices installed and tightened to appropriate tension.
Water and other instrument panels mounted on odour control pad.
Recirculation tank placed in appropriate location and all piping and wiring completed.
Confirm nutrient barrel and EcoGrow nutrients are present on site.
All water supply lines completed per P&ID, including:
1) TSE Tanks effluent water supply to water panel(s) flange.
2) TSE effluent water supply to vessel bottom (make-up water supply).
3) Recirculation pump (on startup system) discharge to water panel flange.
4) Water panel to spray nozzle(s) connection on each reactor assembly.
All drain water lines completed, including:
1) Reactor drain(s) to startup system.
2) Startup system piped to site drain.
All Sampling Couplings are closed out with a threaded NPT PVC plug.
All water sources are connected and ready for delivery to system.
All ductwork, dampers, and blowers connected to source foul air streams and reactor
inlet flanges per Contract Drawings and BioAir P&ID, GA, and Installation drawings.
All instruments mounted and connected as necessary and as given in Contract Drawings
and BioAir P&ID drawings.
Review Offloading and Installation Manual and ensure all items are completed in
accordance with these instructions.
Appendix 3 – Commissioning Equipment Checklist
Note – Safety is the top priority on site, and all local safety regulations shall be followed without
exception. Below is a checklist of equipment needed for commissioning of the system. Note
additional equipment may be required due to the site conditions. Some Items listed below will not
require a Model No.

Description Qty. Model No. Notes

Hot-Tip Anemometer 1
pH Paper 1
Standard tool set* 1
Hard Hat Per Person
Safety Vest Per Person
Steel Toe Boots Per Person
H2S Personal Safety Monitor Per Person
Respirator Per Person
Electrical Nose Plier & Vise 1
Grip
Personal protective 1
equipment
H2S Personal Safety 1
Monitor
Spanner set 1
Multimeter 1
Measuring tape 1
Screw drivers Set 1
Ratchet Set 1
Adjustable Wrench 1
Hammer 1
Toolbox with Padlock/Key. 1
4-20mA Loop Simulator 1
Portable pH or pH paper 1
Rubber gloves 1

This above is installed properly and ready for commissioning:

Name: _____________________________ Date: ________________

Signed: ____________________________
Appendix 4 – Instrumentation Commissioning Checklist
Tag No. Function Wired and Installed per P&ID

Differential Pressure Gauge (dP-1)

Pressure Gauge (PI-1)

H2S Inlet Sensor (AIT-01)

H2S outlet Sensor (AIT-02)

This above is installed properly and ready for commissioning:

Name: _____________________________ Date: ________________

Signed: ____________________________
Appendix 5 – EcoFilter Startup Inspection Checklist
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Appendix 6 – Damper Valve Commissioning Checklist
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Appendix 7 – Startup System(s) Commissioning Checklist

Item #: Description / Task STATUS

1. Open Makeup Water Valve and set flow to each system’s  - OK  - NOT OK
design minimum
2. Close Startup System Bypass ball valve  - OK  - NOT OK
3. Set Overflow piping vertically  - OK  - NOT OK
4. Set ALL Irrigation Valve Switches to AUTO  - OK  - NOT OK
5. Using Diaphragm valve, set flow rate for Reactor Vessel #1  - OK  - NOT OK
6. Using Diaphragm valve, set flow rate for Reactor Vessel #2  - OK  - NOT OK

This above is installed properly and ready for commissioning:

Name: _____________________________ Date: ________________

Signed: ____________________________
Appendix 8 – Flex Connector Commissioning Checklist
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 Appendix 10 – Water Panel Commissioning Checklist
Item #: Description / Task STATUS
1. Verify Water Panel ball valves are in the proper positions  - OK  - NOT OK
1. Rinse gun shutoff valve (BV-04) CLOSED
2. Water release valve (BV-03) CLOSED
3. Startup water supply shutoff valve (BV-01) OPEN
4. TSE supply shutoff valve (BV-02) OPEN
5. Common line shutoff valve (BV-02) OPEN
6. Verify no leaks at full pressure for 10 minutes  - OK  - NOT OK

This above is installed properly and ready for commissioning:

Name: _____________________________ Date: ________________

Signed: ____________________________
Appendix 11 – Blower Commissioning Checklist



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 Appendix 13 - Airflow Balancing Checklist
1. Using Hot-Top Anemometer, Verify Airflow at inlet of EcoFilter #1
2. Use Inlet Actuated Damper Valve to set airflow.
3. Record final Airflow Readings on Airflow Balancing Worksheet, Appendix 13.
4. Using Hot-Top Anemometer, Verify Airflow at inlet of EcoFilter #2
5. Use Inlet Actuated Damper Valve to set airflow
6. Record final Airflow Readings on Airflow Balancing Worksheet, Appendix 13.
7. Use Outlet Damper Valves to set airflow
8. Record final Airflow Readings on Airflow Balancing Worksheet, Appendix 13.
9. Use Outlet Damper Valves to set airflow
10. Record final Airflow Readings on Airflow Balancing Worksheet, Appendix 13.

This above is installed properly and ready for commissioning:

Name: _____________________________ Date: ________________

Signed: ____________________________
APPENDIX 14: AIRFLOW BALANCING WORKSHEET
Airflow Balancing Chart note multiple sheets may be required to complete Appendix 13.

LOCATION # ________________________________

AIRFLOW # ________________________________

Damper AIRFLOW MEASUREMENTS Airflow

Position 1 2 3 4 5 6 7 8 9 Average

This above is balanced properly and ready for commissioning:

Name: _____________________________ Date: ________________

Signed: ____________________________