Technical Service

Schmack Biogas > Technical Service

Technical service

The key to successful economic operation of a biogas plant is seamless performance. Consider that when compared to the investment costs, the running costs account for around 85 % of the overall costs in the lifecycle of a plant. 

At HZI Schmack, customer service begins long before any component wears out or needs replacement – through qualified advice, preventive maintenance and appropriate planning. With efficient spare parts logistics, our in-house service team will ensure reliable operation of your biogas plant.

Maintenance & repairs

Regular maintenance contract: high availability for your biogas plant

If you do not want to leave anything to chance in the operation of your biogas plant, it is best to conclude a regular maintenance contract. Having a contract in place will mean that the technical condition of your plant will be verified by a specialist at regular intervals. Technical deficiencies and safety risks can then be identified and rectified without lengthy downtimes. As part of the contract, Hitachi Zosen Inova Schmack GmbH will take care of the design, coordination and materials planning of all requisite materials on your behalf. Depending on your requirements, you can conclude a regular maintenance contract for the entire biogas plant or only for individual areas such as the CHP unit, gas upgrading or fermentation residue treatment.

Take advantage of these benefits

  • Reliably high plant availability
  • Avoidance of downtimes
  • Operational reliability
  • Original spare parts from well known component manufacturers

Individual inspection: your plant equipment in safe hands

We carry out individual inspections covering technology, operation and safety equipment. You can count on the experience and expertise of our service technicians for everything from an oil change to large-scale maintenance work and expert inspections. We keep a large number of spare and wearing parts in stock at all times for your plant. In the unlikely event that a part fails unexpectedly, we can also offer express delivery of parts we have in stock.

Take advantage of these benefits

  • Comprehensive technical support
  • High plant availability
  • Minimised downtimes
  • Advanced technology
  • Original spare parts from well known component manufacturers
  • Express delivery of spare parts

Recurring inspections

Responsibility and safety – what does that mean for you as a plant operator?

Recurring inspections are obligatory! To operate a plant safely and efficiently, there are many regulations you must comply with. We help you to satisfy statutory safety requirements with our many years of expertise. A number of safety regulations apply to operation of a biogas plant, and they are constantly being amended and expanded. One thing is quite clear – the safety level that a biogas plant needs to meet will only get higher.

As a plant operator, this will involve considerable effort on your part. We support you so that you can rest assured you are operating a safe and tested biogas plant. Putting your plant through its paces not only reduces hazards and risks to a minimum but gives you the opportunity to make operation more efficient. Take advantage of our 5-point check and ensure that your plant satisfies all the requirements.

Good reasons for a safety check:

  • Fulfilment of legally prescribed operator obligations
  • Potential for economic & technical optimisation of the plant
  • Responsibility for employees and the environment

How it works:

  1. Our qualified employees check your plant against the latest engineering standards. We pay particular attention to current jurisprudence.
  2. Once complete, you will receive comprehensive documentation of the safety check.
  3. We will also hold a detailed final meeting with you. This will allow you to identify deficiencies and risks promptly and avoid expensive consequential costs.

What you can expect from us

  • Checks with top-class equipment and diagnostic technology
  • Support with the implementation of the Germany Operational Safety Ordinance (BetrSichV)
  • Compilation of risk assessments

Fault management & automation

Checks are good, remote monitoring is better

As the operator of a biogas plant, you usually have more important things to do than constantly monitor its performance level. That’s where EUVIS remote monitoring comes in. We monitor all relevant figures and parameters of your biogas process, 24 hours a day, 365 days a year. Our system records all key figures for your plant and compares them with our data pool. This allows us to identify deviations from normal operation promptly. It also helps to maximise the availability of your plant.

Take advantage of these benefits

  • Early identification of process disruptions
  • Reliable, fault-free plant operation
  • Short response times
  • High plant availability
  • Avoidance of long downtimes
  • Security for operators and banks

Authorities & approval management

Navigate the legal jungle

Missing tests and documentation cost time and nerves. It is not uncommon for staff to have to compile documentation in addition to their main job. This utilises valuable resources. If you’d like to spend less time at your desk and more time outside on your biogas plant, we are here for you.

To make your everyday work easier, HZI Schmack offers the “Fit for purpose” service package. We constantly handle all current legal requirements for biogas plants (44th German Immissions Ordinance – BImSchV; new amendment to the German Fertilisers Regulation – DüV; TRAS 120, etc.) and deal with all legal and bureaucratic tasks for you.

Outsourcing authorities management and test documentation allows you to free up time for your core tasks. We advise on and support you with all aspects of plant safety to ensure the technically reliable and legally compliant operation of your plant.

Communication with authorities

  • Practical assistance and advice in correspondence with authorities
  • Coordination of interfaces including representing the operator at meetings with authorities
  • Support with all operating procedures and technical advice at hearings
  • Coordination of recurring tests
  • Support with the preparation and revision of legally prescribed plant documentation, e.g. explosion protection documents, plans of zones with potentially explosive atmospheres, operating instruction manuals, risk assessments, etc.

Benefits for you

  • You have a partner by your side with many years of experience and the requisite approvals in all relevant fields.
  • You receive all value added services for your biogas plant from a single source and have only one point of contact.
  • You have legal certainty for the entire service life of the plant.
  • You reduce the administration that you need to carry out for the required inspections.
  • You can work more efficiently.

“Fit for purpose” – for a sustainable future with industrial standards

What the law requires:

  • Preparation of a risk assessment
    Art. 3 German Operational Safety Ordinance (BetrSichV) – determination of the measures required for the safe provision and use of equipment, assessment of the hazards in the workplace and when handling hazardous substances.
  • Explosion protection document
    Art. 6 German Hazardous Substances Ordinance (GefStoffV), Art. 9 German Operational Safety Ordinance (BetrSichV) – determination of explosion hazards as well as definition and implementation of measures to ensure explosion protection when handling biogas. Hazards and measures must be recorded in an explosion protection document.
  • Regular safety training for employees
    Art. 12 German Operational Safety Ordinance (BetrSichV), Art. 12 German Occupational Health and Safety Act (ArbSchG), Art. 14 German Hazardous Substances Ordinance (GefStoffV) – recurring, certified and documented instruction of employees on hazards arising from the working environment and the equipment being used.
  • Recurring inspection of the biogas plant or equipment
    Art. 14 and Art. 16 German Operational Safety Ordinance (BetrSichV) – as plants within the sense of the German Operational Safety Ordinance, biogas plants must be inspected on a recurring basis to verify their safety. The nature, extent and intervals of these inspections should be determined using a risk assessment. Failure to test equipment promptly and failure to produce appropriate documentation is a breach of regulations in accordance with Art. 25 German Operational Safety Ordinance (BetrSichV).
  • Condition test
    Art. 5, 4, 7 German Operational Safety Ordinance (BetrSichV) – equipment must be suitable for the activities being carried out and for the conditions in the workplace. It must be consistent with current engineering standards and satisfy applicable regulations.