Biogas Technician Training Course
rural development and environment
Profile of Bio-gas Technician :
1.History and review of bio-gas technology, actual digestion process with gas composition and gas characteristics, controlling
2.The different designs like Floating Drum, Janata, Deenbandhu etc. with basic principles, designs and dimensions and comparative
study of plants ,construction requirements like site selection criteria, material types with quantity, quality and costing, critical
dimensions and post-construction measures
3.All the commissioning process like pipe / valve fitting, plumbing requirements, bio-gas stove connection, leakage testing, digester
filling, input requirements, gas pressure, air flow adjustments etc.
4.The problem identification and preparation of check-list useful for study of defective plants , the techniques required for undertaking
repairs of the plants in case of failure for various reasons .
5.The servicing and maintenance tips will be given to the bio-gas technician.
The bio-gas technician will be equipped with all the skills and the tools required to undertake servicing , repairs and basic
We propose to train 20 youngsters as ‘Biogas Technicians’ who will provide the maintenance &
repairs service to the rural households in the area.
Stipend to trainees:
20 x 75 days x Rs.20/-
plants of 3 types
tools & basic testing
Manuals, practical books
& audio-visual training
Travelling and study
Services of Biogas
Total Expenditure :
Biogas Technician Course
Assisted by AID,USA.
Progress Report - April 2001 to June 2002
1. Status Survey :-
The status survey was initiated in the following
villages. The prospective technicians / trainees were
identified from these villages. Total 12 participants were
selected after the individual interviews (See Annexure I).
The awareness campaign was organised for the
farmers who own the biogas plants. The charts and film on
biogas construction was also shown. The household visits to
identify the operational and defunct plants were made. The
reasons behind the nonfunctioning were noted. Thus the
status of about 130 plants were noted. Households willing
to adopt the technology were organised at a common place to
discuss the plan of action. From this, potential women /
farmers to be benefited were finalised. The viability
assessment of these plants was done on site.
2. Course Preparation :-
From the survey, the training needs were properly
identified in which the extent and nature of the defects
and difficulties in maintenance were noted.
The detailed discussions with experts in Open University,
Nasik, State Biogas Federation, BAIF, School of Energy
Studies in Pune University as well as individual experts
like H. N. Todankar, Dr. S. V. Mapuskar, Ravindra Desai
were arranged. The efforts made by other organisations
working in the same field like BAIF, RAIN, Bajaj Trust and
Centre of Sciences, Vardha were fruitful to know the
present situation and past experiences.
From these initial efforts the exact requirements of the
plant holders and the know-how required to fulfill the same
were crystallised. The sessions, syllabus modules and
proper training material were devised. Material in the form
of booklets, manuals were borrowed from the other
The selection of the candidates from 12 villages was done
after the individual interviews. The orientation session
was arranged to give background information and clarity
about the objectives of the course.
3. Training Methodology :-
The role of the biogas technician in the villages
will be social as well as technical. The economic aspect of
the situation is also necessary. The proper fault finding
is the key job. For this he should know the basics of the
technology, the development of plants and the real need for
the farmers. The field training including the hands on
experience in measurements and estimation will serve the
purpose. The planning of work schedule along with local
resources is also part of the training.
The above aspects were covered in the construction of 3
plants in 3 villages. The exposures to various stages upto
commissioning were planned for this batch of 12
technicians. The working drawings and the theory part were
also taught. From this exercise it was felt that continuous
training of minimum 10 days covering all the aspects should
be conducted for this batch. Thus, the idea was discussed
with Centre of Sciences, Vardha working in the field for
last 25 years. Together with Shrikant Karanjekar fron CSV,
the course content was designed.
4. Advance Training Workshop at Vardha :-
The above workshop was held between 24th December
to 2nd January 2002 at CSV, Vardha. The institute is having
complete experimental setup, laboratory, different types of
plants in the campus and the classroom training centre. The
course was conducted as per the syllabus (see Annexure I).
The participants were exposed to various demonstrative
plants, actual measurements in the field and the operation
of plant. They also studied latrine attached biogas plant
and slurry usage for productive agriculture. The actual
experience while participating in the construction of
plants in village Kunghada in block Charmoshi was much
enriching. The various stages as well as difficulties
during the commissioning were observed keenly by the
Along with the designed course the trainees also visited
the training centres in low cost housing, pottery, honey
collection, solar equipments, energy efficient devises and
had made paper products in the same campus. At the end of
the course the trainees acquired the skill regarding the
biogas plant construction, repairs and maintenance. The
written test and oral examination was conducted at the end
in which participants performed satisfactory.
5. Follow-up Programme :-
The monthly meeting of technicians is being
arranged at the Agro-technical School, Shivapur. The
villagewise action plan is chalked out together with
technicians. The detailed visits were made to the
households identified in the baseline survey.
The plant situation study was made with the family members.
The estimation of about 30 plants are completed. The
repairs are being taken up as per convenience. Total three
plants were repaired and brought into action in the last
quarter. This was the collective experience for all the
technicians. One new plant was constructed and commissioned
at village Ranze. The study visit was done to the village
Charholi, where the farmers use the gas and the slurry very
effectively. The slurry usage promotion for organic farming
is also being promoted as the complimentary activity.
6. Future Plan :-
The process of convincing the plant-holders for
taking up repairs will be continued. The estimates of the
plants owned by households - who are willing to operate are
being prepared by the technicians. The village wise-
repairing activity is planned after the monsoon.
Classification of defects will be done according to the
skill involved in maintenance.
The 2 more batches of technicians will be trained this
year. The courses are planned at Shivapur and Velhe. The
visit schedules to the functioning plants will be followed
to ensure the productive output. Some of the plants are
being maintained at much lower productivity. The survey of
such plants will be done to suggest the proper action.
These plants can be a good example for others to follow.
The effective awareness and training material for the
community is not available in local languages. The simple
material development is in process. The audio-visual
documentation of the plant-holders successfully running the
plant for more than 5 - 10 years is planned. The interviews
of women working on biogas in smoke free, clean kitchen
will be documented. The study visits within the district
will be arranged.
7. Other points :-
While the training of pilot batch was satisfactory,
the various difficulties were encountered during the
implementation. As the vocation is not familiar in the
villages, the initiative among the youth is very less as
compared to the conventional jobs. Also, due to failure of
the government programmes there is apathy among the
community about the technology and its viability. Therefore
more period is required to cross these barriers. But from
these pilot experiment experiences, it is proved that this
new artisanship can be a viable solution for the energy
problem in villages.
There was delay in starting the course due to the
above aspects of the project. Now, as the concept is
developed comprehensively the efforts will be more specific.
First batch of Trainees
Sr. No. Name Education Village/Block
1. Rahul M. Sanas 10th Std. Sanaswadi / Haveli
2. Kalidas H. Bhoite B.A. Sanaswadi / Haveli
3. Rajesh N. Chorghe 10th Std.
Rahatawade / Haveli
4. Pravin V. Chorghe 9th Std. Kolawadi /
5. Shivaji E. Marne 10th Std. Ketkawane /
6. Nilesh E. Kanade 12th Std. Kanhersar /
7. Mahesh C. Gaikwad 9th Std. Jogawadi /
8. Shivaji V. Bhor DCE Kamthadi / Bhor
9. Rishikish S. Khaire 9th Std. Naigaon /
10. Pradeep G. Khutwad 12th Std. Degaon /
11. Prakash B. Dhawale 12th Std.
Yangarwadi / Tuljapur
12. Rohidas B. Limhan DCE Vinzar / Velhe
§ JP representatives :
Madhav Deshpande - Project Head
Subodh Kulkarni - Coordinator
BIOGAS TECHNICIAN COURSE
1. History and review of biogas technology :-
* Some statistics, National scenario
2. What is biogas digester?
* About digestion process
* Gas composition, gas characteristics
* Controlling parameters
3. Different designs :-
* Floating drum, Janata, Deenbandhu
* Basic principles
* Design and dimensions
* Comparative study of plants
4. Construction requirements :-
* Site selection criteria
* Material types, quantity, quality, costing
* Various stages of construction, critical
* Curing, painting
5. Commissioning :-
* Pipe, Valves fitting
* Plumbing requirements
* Biogas stove connection
* Leakage testing
* Digester filling
* Input requirements
* Gas pressure, air flow adjustments
* A running plant - flame, input/output
6. Study of defective plants :-
* Problem identification
* Survey proforma and problem checklist
7. Plant defects and solutions :-
* Fixed dome plant - dome leakage, inlet and outlet
status, slurry discharge level, construction cracks,
* Floating drum - Rusting, Water chamber leakages, Wall
cracks, inlet / outlet status, floating action, painting.
8. Accessories'''''''' defects and solutions :-
* Pipeline and valve status
* Choking of pipeline
* Water removal system
* Biogas stove - burners, buttons, air adjusters
9. Operational defects and solutions :-
* Input status - quantity, quality, frequency
* Output status - free discharge, slurry analysis
* Gas pressure, scum formation, vapour formation,
temperature affecting / maintaining parameters
10. Maintenance tips :-
* Servicing card system
* Daily, weekly, monthly, annually, 5 yearly
Biogas Technician Course
Assisted by AID, USA.
Progress Report during the period - July 2000 to March 2001
The following activities in the project were completed
during the period - July 2000 to March 2001 :
1. Baseline Survey :
The survey was conducted in the four prospective village
clusters in Bhor, Haveli and Velhe block. The status report
on the existing plants and interviews with the households,
willing to adopt the technology were completed. From this,
the potential was assessed.
2. Construction of demonstrative plants :
The two types of plants having the capacities- 2cu.m and
3cu.m were constructed and commissioned during the period.
These plants were purposefully constructed in two different
clusters. The process drawings and guidelines for the
were standardised during the construction.
3. Training of prospective trainers and candidates :
While commissioning of the plants, the training regarding
the handling of tools, measuring instruments and the
precautions to be taken in maintaining the plant was
imparted to the prospective trainers as well as the
candidates for the course.
4. Developing the training material :
The syllabus and the course content was finalised after the
trials. The hand outs, booklet and few charts were prepared
in local language. Some resource material from other
institutions is being collected for training. The expert
faculty in the field is also involved in the process.
5. Orientation cum Publicity gatherings :
These gatherings are being organised in various clusters
using audio-visual aids to introduce the concept. During
these, the registration of plant-holders and the
participants is done.
First Quarter Planning ( April 2001 to June 2001)
· The practical lessons in the field are planned
before mansoon. The clusterwise gatherings will be
conducted. The candidates will be selected from the first
trial batch conducted.
· The multiple sets of training material and tools
will be prepared.
Jnana Prabodhini Apr2001
There is a severe problem of unemployment in the rural areas. Especially,for the youngsters who are not able to complete even their
school , this problem becomes more acute. Those who cross the threshold of school-ending exam, atleast stand some chances of
employment and further prestige in life. One cannot ignore that there is also a large number of youngsters who have completed their
education upto a degree or diploma in some or the other subjects, are still groping in the dark for want of jobs. For those whose
families hold some agricultural land, the option of engaging themselves to the farming operations remains open. However, the
psycological impact of pursuing formal education upto the 10th standard is aversive to getting down to the gray collard or un-collard
operations like farming. Such youngsters slowly turn into problematic persons for the families as will as to the society. Day by day
land owners are complaining that farm labour is felt to be very expensive with increasing daily wage rates and decreasing productivity.
This state of affair continues for long time even when there is a large number of youngsters loitering idle in the respective villages.
Need of re-vitalizing the bio-gas technology :
This undoubtedly efficient grass-root technology was developed to overcome the problem of non-availability of cooking gas in remote
villages. Besides saving the trees, which were used as the main source of energy for cooking, it also produces organic manure. This
technology is simple to use and maintain. But, today, this image is shadowed by non-functionality and poor performance of the
majority of plants in villages (National average — 66%). As this technology is enviro- friendly, the importance of which is increasingly
felt, there is a need to re-vitalize the technology.There are innumerable benefits such as efficient energy source. The by-product can
be used for soil conditioning and enrichment. More importantly, it gives hygienic environment and sanitation where latrine is attached.
Developing technical support team locally to take care of the bio-gas plants is an important task. A well-trained bio-gas
technician’s network undertaking regular servicing, maintenance, modification or repairs contract will definitely serve the
The project proposes to train 20 unemployed rural youth as biogas technicians. The bio-gas technician will be equipped with all the
skills and the tools required to undertake servicing , repairs and basic entrepreneurial capabilities. So, they will be able to help in
reviving the biogas technology in rural area, which may prove to be a solution to the energy and environmental problems in villages.
Creating New Vocations in the Changing Rural Scenario
(A Project Proposal from Jnana Prabodhini, Pune 411030, Maharashtra, India)
About the Organization:
Way back in 1962, Dr. V.V. Pendse, an educationalist par excellence, dreamt of an institute that will awaken intellectual, physical
and spiritual potential in our youth and develop them into integrated individuals committed to making positive contribution to the social
development. Over the past four decades, Jnana Prabodhini (JP) has evolved as a movement for motivating intelligence towards social
change. Jnana Prabodhini is now an ensemble of 4 schools; 4 research institutes; a computer training center; 3 other
training-cum-production units; a hundred-bed hospital, and a rural development program spread over from four adjoining blocks of Pune
About the present proposal
There is a severe problem of unemployment in the rural areas. Especially, for the youngsters who are not able to complete even their
school, this problem becomes more acute. Also, there exists a need of re-vitalizing the biogas technology. This undoubtedly efficient
grass-root technology was developed to overcome the problem of non-availability of cooking gas in remote villages. Besides saving
the trees, which were used as the main source of energy for cooking, it also produces organic manure. This technology is simple to
use and maintain. But, today, this image is shadowed by non-functionality and poor performance of the majority of plants in villages
(National average - 66%). Developing technical support team locally to take care of the biogas plants is an important task. A
well-trained biogas technician''''''''s network undertaking regular servicing, maintenance, modification or repairs contract will definitely
serve the purpose. So, JP has proposed to conduct a Biogas Technicians Training Program. The program aims at training 20
unemployed rural youths in construction, servicing and maintenance of different designs of biogas plants. The trainees will be
exposed to the theoretical as well as practical aspects of this technology. Major emphasis of the course will be on fieldwork (site
selection, construction & commissioning of plants, problem identification, undertaking repairs etc.). In short, the course will lead to
self-employment opportunities to the rural youth and also provide a much needed support structure for the environmentally benign
renewable energy source of biogas plants in rural settings.
Apart from this Biogas Technicians Course (which has been approved by AID-Pittsburgh chapter), Jnana Prabodhini has also
proposed two more activities viz. a Farm Operators Training Course and Formation of Farmer''''''''s Co-operative for Water Distribution.