General

CO2 recovery plant

 Essential Reading

Haffmans BV is not responsible for any damage caused by the owner’s failure to follow the instructions given in this
manual. Haffmans BV is not responsible for print or translation errors in this edition of the manual. The specifications
and design of this product are subject of change without notice. All rights reserved. No part of this publication may be
reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior
written permission of Haffmans BV.

Art. no. : General CO2 - recovery plant

Release date : 03 August 2012
Version : 2009.0
 HAFFMANS General CO2 recovery plant

TABLE OF CONTENTS

1 GENERAL INFORMATION ................................................................................................ 7

2 COMPANY PROFILE ......................................................................................................... 9
3 CUSTOMER SERVICE ..................................................................................................... 11
4 PLANT DOCUMENTATION ............................................................................................. 13
5 GENERAL OPERATIONAL INSTRUCTION AND SAFETY RULES ................................ 15
5.1 BASIC OPERATION AND DESIGNATED USE OF THE PLANT ................................................. 15
5.2 WARNING SYMBOLS ..................................................................................................... 15
5.3 ORGANIZATIONAL ........................................................................................................ 16
5.4 BEHAVIOR ................................................................................................................... 18
5.5 PERSONAL PROTECTION .............................................................................................. 18
5.6 SAFETY EQUIPMENT ..................................................................................................... 18
5.7 PRESSURIZED EQUIPMENT ........................................................................................... 18
5.8 MATERIALS ................................................................................................................. 19
5.9 ELECTRICAL EQUIPMENT .............................................................................................. 19
5.10 GAS, DUST, STEAM AND SMOKE .................................................................................... 19
5.11 PNEUMATIC EQUIPMENT ............................................................................................... 20
5.12 OIL, GREASE AND OTHER CHEMICAL SUBSTANCES ......................................................... 20
6 TERMS OF GUARANTEE ................................................................................................ 21
7 LIST OF ABBREVIATIONS .............................................................................................. 23

General CO2 recovery plant Page 5 of 24

 HAFFMANS General CO2 recovery plant

Page 6 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

1 GENERAL INFORMATION

Project information
Project number Haffmans BV : 12.7369
Project number customer : XX.XXXX

Status : Provisional

Customer:
Name : Dashen Brewery S.C.
Address : XXXXX
City : Debre Birhan
Country : Ethiopia (ET)

Site address:
Name : Dashen Brewery S.C.
Address : XXXXX
City : Debre Birhan
Country : Ethiopia (ET)

Supplier:
Name : Haffmans BV
Address : Marinus Dammeweg 30
City : NL-5928 PW
Country : Venlo
P.O. Box 3150
NL-5902 RD VENLO
Tel.: (+31) 77 – 3232300
Fax.: (+31) 77 – 3232323
E-mail: info@haffmans.nl
Homepage: www.haffmans.nl

General CO2 recovery plant Page 7 of 24

 HAFFMANS General CO2 recovery plant

Page 8 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

2 Company profile
Pentair Haffmans is a market leader in state of-the-art technology and custom-made solutions
for the recovery and management of CO2. The company belongs to Pentair’s Global Business
Unit Filtration Solutions.

Pentair, Inc. is a global diversified industrial company

headquartered in Minneapolis, Minnesota. With 2010
revenues of $3.0 billion, Pentair employs over 14,000
people worldwide.

Pentair Haffmans was founded in 1947 and has its roots in

total carbon dioxide (CO2) and oxygen (O2) management
and quality control for the brewing and beverage
industries. Over the years our company has grown from a
supplier of raw material to developing, manufacturing and
servicing, focusing on quality control equipment, units for
carbonation, blending, de-aeration and of course, CO2
recovery.

Based on our long-term experience in the area of total CO2 and O2

management, Pentair Haffmans has succeeded to continuously expand
its existing market presence in the brewing and beverage industries and
successfully enter new markets like the wine and soft drink markets and
the bioethanol/distillery market.

The latest innovation is a solution for upgrading biogas into biomethane,

using a technique, which makes it possible to recover 100 % of the
methane and at the same time recover the CO2 by-product.

Pentair Haffmans is a multinational company, with a strong focus on

innovation and customer satisfaction, and a presence in more than 150
countries around the world. All of our company’s technologies are
designed with the same principles in mind: protect the environment and
reduce operating expenses at the same time. In other words: Do more
with less.

When it comes to customer satisfaction Pentair Haffmans continuously strives to realize a ‘best
of the best’ standard, not just meeting but anticipating and exceeding customers’ requirements.
We offer unparalleled customer service and technical support for all our products through
custom-made service plans that range from maintenance contracts to comprehensive service
level agreements. Our highly motivated and skilled team of specialists in The Netherlands is
supported by a worldwide professional network of agents, distributors and Sales & Service
Offices. To help you achieve maximum plant efficiency, our professionals provide 24/7 technical
support by phone, e-mail or remote service.

General CO2 recovery plant Page 9 of 24

 HAFFMANS General CO2 recovery plant

Page 10 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

3 Customer service
Haffmans BV provides comprehensive service opportunities for maintaining CO2 plants. In most
cases this maintenance is planned but in exceptional cases an experienced Haffmans service
engineer can be on-site at your plant within a few days if required. For details on Haffmans BV
extensive service contracts, contact Haffmans BV.

Utmost care is taken in designing, fabricating, commissioning and checking the CO 2-plant with
the aim of reliability of systems and convenience for operators.
If you nevertheless encounter troubles operating the CO2 plant please contact Haffmans BV at
NLVENService@Pentair.com

If spare parts are required please contact Haffmans BV at spareparts@haffmans.nl

When contacting Haffmans BV always mention the project number and if available the tag
number of the specific item. These can be found in chapter ‘03-Drawings P&ID’.

Haffmans BV
Marinus Dammeweg 30
5928 PW Venlo, The Netherlands

P.O. box 3150

NL-5902 RD, The Netherlands

T : (+31) 77-3232300
F : (+31) 77-3232323
E : info@haffmans.nl
I : www.haffmans.nl

General CO2 recovery plant Page 11 of 24

 HAFFMANS General CO2 recovery plant

Page 12 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

4 PLANT DOCUMENTATION

Chapter Table of contents

01 Manual text

02 Engineering list

03 Drawings P&ID

04 Drawings layout + foundation

05 Drawings General assembly

06 Drawings Turn-key

07 Drawings Electro

08 PLC Software

09 Documentation

10 Process data and set point list

11 Spare parts

12 Certificates

13 MSDS

Note: Documents are available only if they are part of the order.

General CO2 recovery plant Page 13 of 24

 HAFFMANS General CO2 recovery plant

Page 14 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

5 GENERAL OPERATIONAL INSTRUCTION AND SAFETY RULES

5.1 Basic operation and designated use of the plant
The plant has been built in accordance with state-of-the-art standards and recognized safety
rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or
cause damage to the machine and to other material property.

The plant must only be used in technically perfect condition in accordance with its designated
use and the instructions set out in the operating manual, and only by safety-conscious persons
who are fully aware of the risks involved in operating the plant. Any functional disorders,
especially those affecting the safety of the plant, should therefore be rectified immediately.

Using the plant for purposes other than those mentioned in the manual is considered contrary to
its designated use. Haffmans cannot be held liable for any damage resulting from such use. The
risk of such misuse lies entirely with the user. Operating the machine within the limits of its
designated use also involves observing the instructions set out in the operating manual and
complying with the inspection and maintenance directives.

Operating the plant within the limits of its designated use also involves observing the
instructions set out in the operating manual and complying with the inspection and maintenance
directives.

5.2 Warning symbols

Warning and safety symbols used in the manual have the following significance.

Note! Information about the correct and effective use of the equipment.

Warning Incorrect or careless use can cause serious damage to the

equipment

Warnings can be accompanied with symbols to clarify the danger. (Example given below)

General CO2 recovery plant Page 15 of 24

 HAFFMANS General CO2 recovery plant

5.3 Organizational
At least twice per year all safety instruments must be checked by simulating faults.

A health and safety plan must be implemented.

The electrical equipment of machines/plants is to be inspected and checked at regular intervals.

Defects such as loose connections or scorched cables must be rectified immediately.

The operating instructions must always be at hand at the place of use of the plant.

In addition to the operating instructions, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and
environmental protection.

These compulsory regulations may also deal with the handling of hazardous substances,
issuing and/or wearing of personal protective equipment.

The operating instructions must be supplemented by instructions covering the duties involved in
daily operation, supervising and special organizational features, such as job organization,
working sequences or the personnel entrusted with the work.

Personnel entrusted with work on the machine must have read the operating instructions and in
particular the chapter on safety before beginning work. Reading the instructions after work has
begun is too late. This applies especially to persons working only occasionally on the machine,
e.g. during maintenance.
See to it that those safety instructions and warnings attached to the machine are always
complete and perfectly legible.

Never make any modifications, additions or conversions, which might affect safety without the
supplier’s approval. This also applies to the installation and adjustment of safety devices and
valves as well as to welding work on pipelines and or pressure holding parts.

Spare parts must comply with the technical requirements specified by the manufacturer.

Never modify the software of programmable control systems.

Adhere to prescribed intervals or those specified in the operating instructions for routine
checks and inspections.

For the execution of maintenance work, tools and workshop equipment adapted to the task
on hand are absolutely indispensable.

The personnel must be familiar with the location and operation of fire extinguishers.

Observe all fire-warning and fire-fighting procedures.

Page 16 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

The user of the plant has to ensure that the personnel operating the plant are aware of, follow and
execute exactly the safety rules before beginning the installation and during the operation and
maintaining of the plant.

For the control of the plant, the user has to appoint specially trained personnel. These personnel
have to be well informed about the safety rules and this manual.

Take care that all walkways are kept clear of obstruction and that the emergency exits are clearly
marked.

A protocol must be in place to ensure that all organizational and safety measures mentioned in
the entire manual are implemented and adhered to.

The machine may be started up only by authorized personnel and only after pre-start checks have
been made.

Reliable personnel must execute any work on and with the plant only. Statutory minimum age
limits must be observed.

Employ only trained or instructed staff and set out clearly the individual responsibilities of the
personnel for operation, maintenance and repair.

Define the machine operator’s responsibilities giving the operator the authority to refuse
instructions by third parties that are contrary to safety.

The plant room has to be equipped with good lighting. It also has to be equipped with doors or
openings that are easy accessible. For safety reasons the plant room must be well vented.

For working at the machine and machine parts only suitable instruments may be used.

If maintenance is carried out suitable signs must be displayed and precautions taken to avoid
accidental starting of the plant.

Nameplates may never be removed, damaged or painted, to prevent legibility of the information
printed on it.

Do not allow persons to be trained or instructed or persons taking part in a general training
course to work on or with the plant, without being permanently supervised by an experienced
person.

Avoid any operational mode that might be prejudicial to safety.

Operate the machine only if all protective and safety-oriented devices, such as removable
safety devices, emergency shut-off equipment and soundproofing elements are in place and
fully functional.

Observe the adjusting, maintenance and inspection activities and intervals set out in the
operating instructions, including information on the replacement of parts and equipment. Skilled
personnel may execute these activities only.
General CO2 recovery plant Page 17 of 24
 HAFFMANS General CO2 recovery plant

Brief operating personnel before beginning special operations and maintenance work, and
appoint a person to supervise the activities.

In any work concerning the operation, conversion or adjustment of the machine and its safety
oriented devices or any work related to maintenance, inspection and repair, always observe the
start-up and shut-down procedures set out in the operating instructions and the information on
maintenance work.

Ensure that the maintenance area is adequately secured.

To avoid the risk of accidents, individual parts and large assemblies being moved for
replacement purposes should be carefully attached to lifting tackle and secured Use only
suitable and technically perfect lifting gear and suspension systems with adequate lifting
capacity. Never work or stand under suspended loads.

For carrying out overhead assembly work always use specially designed or otherwise safety-
oriented ladders and working platforms. Never use machine parts as a climbing aid. Wear a
safety harness when carrying out maintenance work at greater heights. Keep all handles,
steps, handrails, platforms, landings and ladders free from dirt, snow and ice.

5.4 Behavior
In the event of safety-relevant modifications or changes in the behavior of the plant during
operation; stop the plant immediately and report the malfunction to the competent authority/
person.

5.5 Personal protection

For reasons of security, long hair must be tied back. Or other garments must be close fitting and
no jewellery - such as rings - may be worn:

Use protective equipment and clothing wherever required by the circumstances or by law.
Observe all safety instructions and warnings attached to the plant.

5.6 Safety equipment

Safety protection and safety devices may not be removed.

Any safety devices removed for maintenance or repair purposes must be refitted and checked
immediately upon completion of the maintenance and repair work.

5.7 Pressurized equipment

Pipelines are subject to a quality check (pressure and visual examination) by the operator in
appropriate intervals even if no safety-relevant defects have been detected.

Work on pressurized equipment may be carried out by specially trained personnel only.

Observe any existing national regulations if work are to be carried out in narrow rooms.

Page 18 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

5.8 Materials
Ensure that all consumables and replaced parts are disposed of safely and with minimum
environmental impact.

5.9 Electrical equipment

The main power switch must be switched off during work at the plant.

Use only original fuses with the specified current rating switch off the plant immediately if trouble
occurs in the electrical system.

Work on the electrical system or equipment may only be carried out by a skilled electrician
himself or by specially instructed personnel under the control and supervision of such electrician
and in accordance with the applicable electrical engineering rules.

If provided for in the regulations, the power supply to parts of machines and plants, on which
inspection, maintenance and repair work is to be carried out, must be cut off. Before starting
any work, check the de-energized parts for presence of power and ground or short-circuit them
in addition to insulating adjacent live parts and elements.

Necessary work on live parts and elements must be carried out only in the presence of a
second person that can cut off the power supply in case of danger by actuating the emergency
shut-off or main power switch. Secure the working area with a red-and-white safety chain and a
warning sign. Use insulated tools only.

The main isolating switch must be switched off during working at the plant.

It is strictly forbidden to bridge contacts in the safety-circuit of the electrical control equipment.

5.10 Gas, dust, steam and smoke

Carry out welding, flame-cutting and grinding work on the plant only if this has
been expressly authorized, as there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding operations clean the plant and its
surroundings from dust and other inflammable substances and make sure that the premises are
adequately ventilated (risk of explosion).

General CO2 recovery plant Page 19 of 24

 HAFFMANS General CO2 recovery plant

5.11 Pneumatic equipment

Only persons having knowledge and experience with pneumatic systems may carry out work on
pneumatic equipment.

Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair
damage immediately. Penetrating compressed air respectively gases may cause injury and fire.

Depressurize all system sections and pressure pipes to be removed before carrying out any
repair work.

Compressed-air lines must be laid and fitted properly. Ensure that no connections are
interchanged. The fittings, lengths and quality of the hoses must comply with the technical
requirements.

5.12 Oil, grease and other chemical substances

When handling oil, grease and other chemical substances, observe the product-related safety
regulations.

Page 20 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

6 Terms of guarantee

This Haffmans BV guarantee supersedes all rights that the purchaser may already have with
respect to its supplier, based upon the contract of sale between the purchaser and the supplier
and based upon legislation.

Haffmans BV guarantees that the equipment supplied is fit for normal use and maintenance and
free from material and manufacturing defects. This guarantee applies for the period and
conditions stated in the Haffmans BV order confirmation.

The guarantee does not cover any re-calibration and/ or standard maintenance, which may be
necessary. The guarantee does not cover fuses, nor does it cover instruments or instrument
components which have been misused or modified other than in as specified in the directions
for use, or which have been exposed to abnormal working conditions or abnormal handling.

In the unlikely event that a defect occurs within the period covered by the guarantee, the nature
of the defect has to be notified directly in writing to Haffmans BV.

The defective component(s) will be replaced or repaired free of charge, provided the defect
involved has not been caused by the following:

• Use other than in accordance with the operating instructions

• Any unauthorized modification
• Failure to complete routine maintenance within the specified intervals
• Repair by third parties, not been trained or authorized by Haffmans BV
• Abnormal working or ambient conditions.

The labor costs associated with the disassembly and reassembly required to carry out the repair
work concerned will be charged to the buyer.

Not covered by the guarantee are liquidated and/or consequential damages due to loss of
production.

Parts that are replaced during the lifetime of the installation are guaranteed for 6 months,
provided they are mounted according to our instructions.

General CO2 recovery plant Page 21 of 24

 HAFFMANS General CO2 recovery plant

Page 22 of 24 General CO2 recovery plant

 HAFFMANS General CO2 recovery plant

7 List of abbreviations
ACF Active carbon filter
CE Committee European de normalization
CIP Cleaning In place
CO2 Carbon dioxide
CS Customer service
DI Direct injection
DIN German industry norm
DX Direct expansion
EMC Electro magnetic compatibility
EN European norms
HLP High low purity
HMI / OP Human machine interface / Operator panel
LO Low oxygen
MEB Active carbon filter drying material
MPS Motor protection switch
NC Non condensable
NC Normally closed
NEN Dutch normalization
NH3 Ammonia refrigerant
OEM Original equipment manufacturer
PBU Pressure building unit
R507a Refrigerant
R744 Carbon dioxide refrigerant (CO2)
QC Quality control
TWI Recovery plant
WI Work instruction

Systems / inline measurements

AGM CO2 content measurement

c-AGM CO2/O2 content measurement
CBR Carbon blender
CCR Carbo controller
CFU Cylinder filling unit
CO2-4U Unique, universally, upgrade unit
DPT Dew point tester
ESCR Energy scan CO2 recovery
HGB High gravity brewing
HRS Heat recovery system
KiO2 LiquiDive oxygen (O2) content measurement
MDS Membrane deaeration system
OGM Oxygen (O2) content measurement
OGM Gas Oxygen (O2) gas content measurement
WDS Water deaeration system

General CO2 recovery plant Page 23 of 24

 HAFFMANS General CO2 recovery plant

Page 24 of 24 General CO2 recovery plant