Gas Pack: User`s Manual
Contents
1. Simple Troubleshooting Scenarios If the system does not start 1 Verify that the inlet and outlet Isolation valves under the Gas Pack are open and that the red handle On Off Switch on the Gas Pack is on 2 If the MicroTurbines are operating in grid connect mode verify the correct utility power is available at the incoming circuit breaker or fused disconnect to the MicroTurbine s and that this main circuit protection device is turned on 3 Check the status of the Power On and Run lights on the Gas Pack If the Gas Pack is an AC version the orange Power On light on the Gas Pack should be illuminated as soon as external power is provided to it If the Gas Pack is a DC version the Power On light should illuminate as soon as DC power is available from the MicroTurbine In either case the Run light should illuminate as soon as the MT initiates a start sequence 4 Any fault may shut down both the Gas Pack and MicroTurbine s If the red Fault light in the Gas Pack is illuminated try clearing the fault by pressing the yellow Reset button on the Gas Pack console If the Gas Pack red Fault light extinguishes a normal MT restart will also bring up the Gas Pack If the MicroTurbine initiated the fault it must be cleared before attempting a system restart Refer to MicroTurbine Users Manual 400001 or 400017 for fault codes 400012 Rev A August 2007 Page 13 of 16 Capstone reserves the right to change or modify without notice th2. Outlet Kit Second MT Figure 3 Installation Overview of 2 MicroTurbines Gas Pack amp Fuel Trains Figure 4 shows the location and type of C60 C65 MicroTurbine inlet connector that interfaces with the Gas Pack fuel outlet plumbing Fuel Train MicroTurbine Rear View Without Gas Pack User Connection Bay UCB AC Power Connection Bay High Voltage DC Bus Bay Fuel Inlet 3 Male NPT Communications Bay 8 7 t Cable Interface Punch Outs Pen 6 1 Underside Figure 4 Rear View of MT Showing High Pressure Fuel Inlet Fitting 400012 Rev A August 2007 Page 9 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual Figures 5 and 6 show the closer views of the installed Fuel trains for single and dual MTs equipped with the pressure regulator s near the MT inlet Gas Pack Optional Inlet Kit Pressure Regulator with Gauge Outlet Kit One MT Standard Figure 5 Single MT Installation Showing Gas Pack and Fuel Trains Gas Pack Optional Inlet Kit Pressure Regulator MT 2 with Gauge 7 Outlet Kit One MT Standard Pressure Regulator Outlet Kit Second MT with Gaug
3. 2007 Page 4 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual ABOUT THIS DOCUMENT This document provides user instructions to operate and maintain the Capstone Gas Pack fuel gas booster This document is intended for user personnel who may not have specific training on the Gas Pack system Any required maintenance must be performed by Capstone Authorized Service Providers ASPs who have received rigorous training and have been certified to perform commissioning troubleshooting and repair of the MicroTurbine and the related systems User personnel who have not received certification of satisfactory completion of this training should not attempt any procedures other than those specifically described in this document SYMBOLS There are three very important symbols used in this document Warnings Cautions and Notes Warnings and Cautions alert you to situations and procedures that can be dangerous to people and or cause equipment damage Notes provide additional information relating to a specific operation or task WARNING A WARNING means that personal injury or death is possible CAUTION A CAUTION means that
4. Bus Bay via weathertight conduit directly to the Gas Pack Several Gas Pack configurations are available from Capstone to meet different application requirements Both external AC and internal DC power versions are offered The Gas Packs are provided as kits that include the required mounting hardware and a fuel outlet kit to connect to the MicroTurbine MT that the Gas Pack is mounted on For some applications a skirt is provided as part of the kit to protect the gas lines under the Gas Pack and to provide mounting space for a natural gas detector when local building regulations require it these Gas Packs are designed for use with MTs having an internal gas pressure regulator consult factory or your authorized Capstone distributor if needed to confirm which type of MTs are installed at a specific site Several optional accessories are also offered to simplify gas connections These include two fuel inlet kits one using a gas flame arrestor manufactured by Lisk and a second one using a Protego brand flame arrestor The Protego brand flame arrestor is certified to meet CE European Conformity requirements A fuel outlet kit for a second MT is also offered and allows one Gas Pack to provide fuel to two MTs This second MT fuel outlet kit option is not useable with MTs having an internal gas pressure regulator Installers can provide their own fuel inlet connections to the Gas Pack and also can provide their own fuel connections to
5. Manual 400017 Model C65 User s Manual 480028 Gas Pack Commissioning Procedure and Checklist CAPSTONE CONTACT INFORMATION If questions arise regarding the Capstone Gas Pack fuel gas booster please contact Capstone for assistance and information Capstone Applications Toll Free Telephone 866 4 CAPSTONE or 866 422 7786 Fax 818 734 5385 E mail applications capstoneturbine com Capstone Service Capstone Technical Support Toll Free Telephone 877 282 8966 Service Telephone 818 407 3600 e Fax 818 734 1080 E mail service capstoneturbine com Capstone Technical Support J apan Service Telephone 818 407 3700 e Fax 818 734 1080 E mail servicejapan capstoneturbine com 400012 Rev A August 2007 Page 16 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction
6. a second MT However they must ensure that the second MT has fuel inlet pressure between 75 and 80 psig by providing a suitable regulator and pressure gauge in their plumbing The Gas Pack Assembly without the optional inlet and outlet fuel kits weighs NOTE about 420 pounds Use appropriate equipment when positioning or moving the Gas Pack 400012 Rev A August 2007 Page 6 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual Part of MT Frame Gas Pack Gas Pack Outlet Kit One MT Standard Equipment with Gas Pack a Gas Pack Inlet Kit Optional Flame Arrestor Isolation Valve er Fuel Strainer Figure 1 Gas Pack Fuel Gas Booster and Inlet Outlet Fuel Kits 400012 Rev A August 2007 Page 7 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual Gas Pack Block Diagram Figure 2 s
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8. U Capstone JNN CAPSTONE TURBINE CORPORATION Wz CAPSTONE GAS PACK USER S MANUAL 400012 Rev A August 2007 Page 1 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual Copyright 2007 Capstone Turbine Corporation All Rights Reserved Publisher Capstone Turbine Corporation 21211 Nordhoff Street Chatsworth e CA 91311 e USA Telephone 818 734 5300 Facsimile 818 734 5320 Website www microturbine com 400012 Rev A August 2007 Page 2 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual TABLE OF CONTENTS ABOUT THIS DOCUMENT ks iieiea aea aae aaae ena aea T anea aaa ae aA E EEE 5 EDANE Wh E E E A E Sr eee cern E 5 SAFETY INFORMA T ON a rea suet tout ac otek a e a EEE Eaa E 5 PRODUCT DESCRIP HON cerien em a a r a e a oe eas ease A 6 Gas Pack Block Diag rA aeea a Teea aaee are aca E e oee EE A a
9. ch on the Gas Pack is on If the Gas Pack is an AC version switch on the external circuit protective device providing power to the Gas Pack the orange Power On light on the Gas Pack should now be illuminated If the Gas Pack is a DC version the power will be provided from the MicroTurbine s DC bus 3 Perform a MicroTurbine startup according to your specific system setup For example using the Display Panel shown in Figure 8 press the Interlock and the Start buttons simultaneously on the MT connected to the Gas Pack or on the Master MT if configured in a MultiPac Both the orange Power On and green Run lights on the Gas Pack will illuminate indicating gas compression has started The MT will automatically start according to its configured setup Consult the MicroTurbine Users Manual 40001 or 40017 for additional information on MicroTurbine startup Interlock Start amp Enable Button Buttons Stop amp Disable Buttons Figure 8 MT Display Panel and Applicable Functions System Shut Down Perform the following sequential steps to shut down the system 1 Perform a normal MicroTurbine system shutdown according to your specific system setup For example using the MT Display Panel press the Interlock Button and the Stop simultaneously to perform a normal system shutdown see Figure 8 The MT and Gas Pack will both shut down in a normal sequence 400012 Rev A August 2007 Page 12 of 16 Capstone reserves the right to chang
10. damage to the equipment is possible A NOTE clarifies instructions or highlights information that might be NOTE overlooked SAFETY INFORMATION The user must read and understand the Safety Information section of the Capstone MicroTurbine User s Manual 400001 for C30 C60 or 400017 for C65 before operation of the Gas Pack and related equipment Failure to obey all safety precautions and general instructions may cause personal injury and or damage to the equipment The user must also read and understand this manual before operation of the Gas Pack and related equipment It is the user s responsibility to read and obey all safety procedures and to become familiar with these procedures and how to safely operate this equipment Only Capstone Authorized Service Providers ASPs should open the MicroTurbine enclosure or the Gas Pack enclosure including panel removal or control console door opening due to the inherent danger of multiple power sources pressurized fuel gas and oil 400012 Rev A August 2007 Page 5 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual PRODUCT DESCRIPTION The Gas Pack
11. e Optional Figure 6 Dual MT Installation Showing Gas Pack and Fuel Trains 400012 Rev A August 2007 Page 10 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual Control Panel Lights and Controls Figure 7 shows the Gas Pack front panel control console with the associated functions described below ON OFF Switch The red handle rotating disconnect called the On Off Switch rotates counterclockwise to the Off position interrupting the main power to the Gas Pack The On Off Switch may be a circuit breaker or fused disconnect depending on the Gas Pack model and functions as both a manual disconnect as well as automatic circuit protection for the Gas Pack POWER ON Light An illuminated orange Power On light indicates the Gas Pack is energized However it does not indicate that the compressor is running RUN Light An illuminated green Run light indicates that the compressor is running and able to supply compressed fuel to the MicroTurbine Both the Run light and the Power On light should be on to indicate proper operation If the compressor is running and either light is off it means that indicator light is not operat
12. e design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual If the system stops during operation proceed as follows 1 Determine if the MicroTurbine s have shut down due to an electrical or other fault Refer to MicroTurbine User s Manual 400001 or 400017 for how to read fault codes If a MicroTurbine fault is present take actions to clear the fault condition The red Fault light in the Gas Pack may also be illuminated in the case of a compressor fault If so press the yellow Reset button on the Gas Pack console If the Gas Pack red Fault light extinguishes and all MicroTurbine faults have been cleared try restarting the system 2 Verify that electrical power is available at the Gas Pack and that the MicroTurbine is either connected to suitable grid voltage if operating in Grid Connect mode or is able to provide power in Stand Alone mode If the Gas Pack is an AC version the orange Power On light on the Gas Pack should be illuminated as soon as external power is provided to it If the Gas Pack is a DC version the Power On and light should illuminate as soon as DC power is available from the MicroTurbine If these conditions are met try restarting the system 3 Determine if the heat exchanger fan air in
13. e or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual 2 If shutdown is for an extended period of time the user may also a Turn the main circuit breaker or fused disconnect to the MicroTurbine s off If the Gas Pack is an AC version switch off the external circuit protective device providing power to the Gas Pack there is no need to turn the Gas Pack s On Off Switch off b Close the gas Inlet valve on the Gas Pack The red handle On Off switch should not be used to immediately stop a running compressor in a normal shutdown situation This action stresses the CAUTION compressor and should not be done unless absolutely necessary Under normal operating conditions a Gas Pack fault causes a normal Gas Pack shutdown which also shuts down the MicroTurbine Emergency Shutdown Emergency Off In the event of an emergency situation with the Gas Pack 1 Turn the red handle On Off switch on the Gas Pack console panel counterclockwise to the Off position 2 Close the Gas Pack Inlet gas isolation valve and then close the Gas Pack outlet gas isolation valve This action stresses the compressor and should not be done unless CAUTION absolutely necessary
14. hows a block diagram and flow schematic of the Gas Pack system Isolation Valve Low Pressure High Pressure Bypass Gas High Pressure Gas Primary Oil Separator High High Temp Press 2 Stage I I Oil Separator l l To C60 65 4 1 I Low ae f l Isolation I Pressure o Sight l valve 1 Gas it Glasses I l 1 A I i Oil 1 1 Scroll Oil Cooler I o Compressor l Io i I a I Cooling Io i Leg Fan Fan Inlet 1 Hi Temp Signal ot I a a t 3o Oil Filter l an Me re sa a ye a 4 i Air Outlet Hi Press Signal Via I Control Module g Start Stop Signal l ri l In Upper Control en ee ee ee ront I Console Bay Pe S Panel General Fault Signal to C60 65 Auxin 1 l sea Pe eee eee eee AC or DC Power Depending on Gas Pack Type Figure 2 Gas Pack Block Diagram and Flow Schematic 400012 Rev A August 2007 Page 8 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual PRODUCT INTERFACE DEFINITION Figure 3 shows an interface layout of 2 MicroTurbines Gas Pack and Fuel Trains MT 1 Gas Pack Assembly Outlet Kit One MT Inlet Kit Regulator Fuel Trains
15. ight to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual PRODUCT MAINTENANCE Maintenance by the user is limited to external cleaning since only an ASP can open panels and the Gas Pack console door for component checkout servicing and replacement A liquid leak detector kit soap solution brush is recommended for general external leak detection purposes around the Gas Pack and associated plumbing Any line tightening etc must only be done by qualified personnel e Only Capstone trained persons ASPs qualified to work with flammable gases and associated equipment plumbing high voltage electrical components and mechanical systems may perform maintenance service and testing on a Gas Pack e All fuel gases are flammable and some may be toxic System WARNING users are responsible for following proper associated safety and personnel protection measures e Follow all federal state and local regulations regarding energy isolation and maintenance including use of approved Lockout Tag and Try procedures e Maintain approved clearances from all electrical components e Do not operate the system with the inlet gas supply off or allow the unit t
16. ing properly FAULT Light An illuminated red Fault light indicates a fault has occurred which has caused the Gas Pack to shut down RESET Button The yellow Reset button resets the fault which has occurred so a Gas Pack MT restart may be implemented by the user RUN TIMER This indicator displays the accumulated Gas Pack run time in hours Power On Light On Off Switch By Run Fault _ oN _ Timer Light Reset ba Button Figure 7 Gas Pack Control Console Panel 400012 Rev A August 2007 Page 11 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual PRODUCT OPERATION Normal Operating Procedures The Gas Pack should already be installed and commissioned by a Capstone Authorized Service Provider Therefore the user operation need only follow the instructions below for normal startup and shutdown of the system System Start Up Perform a startup as follows 1 Confirm that the Inlet and Outlet valves on the Gas Pack are open and that the main gas line connection is also open 2 Make sure that the main circuit breaker or fused disconnect to the MicroTurbine s is on and that the On Off Swit
17. let and the air vents are restricted in any way This can cause excessive system temperatures resulting in an over temperature fault condition Clean or remove restrictions if present and restart the system 4 Verify that incoming gas pressure is within the system design specification Inlet gas pressure must remain steady within the range of 0 2 to 10 0 psig during startup and normal load operation Excessive inlet pressure produces excessive motor current and causes the inverter or circuit breaker to trip Insufficient pressure trips out the Gas Pack Low Pressure Switch shutting down the system Adjust inlet gas pressure to achieve steady operation within the required range if needed and restart the system If the system runs for a short period of time stops and indicates a fault that can be reset immediately it is likely that the fuel supply is insufficient for the NOTE application If the system inlet pressure falls below the minimum 0 2 psig the inlet pressure switch opens and the system stops When this occurs the pressure usually increases enough to reset the low pressure switch 5 If your Gas Pack system includes a regulator with pressure gauge at the inlet to each MicroTurbine ensure that pressure is between 75 to 80 psig during operation Consult your Authorized Service Provider if you are not able to resolve the problem using the steps above 400012 Rev A August 2007 Page 14 of 16 Capstone reserves the r
18. o operate at a vacuum on the inlet side CAUTION nee e Do not operate this unit in excess of its rated capacity or gas inlet pressure referenced on the nameplate 10 psig Scheduled Maintenance The Table 1 details the preventive maintenance schedules of the Gas Pack under normal environmental conditions This information is provided for your reference Only Authorized Service Providers are permitted to access Gas Pack components and perform these maintenance tasks Table 1 Gas Pack Scheduled Maintenance Gaseous Fuels Maintenance Component Maintenance Commenta Interval Action 8 000 hours Heat Exchanger Clean Contact your ASP to Second Stage Oil Separator Replace schedule service Oil Replenish Oil Filter Replace 20 000 hours Scroll compissee Hepiece Oil Replenish 40 000 hours Heat Exchanger Replace 400012 Rev A August 2007 Page 15 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual REFERENCE DOCUMENTS Table 2 lists applicable Capstone reference documents Table 2 Reference Documents Document No Document Title 400001 Model C30 C60 User s
19. see Figure 1 is a variable speed drive device that serves to boost the inlet supply pressure of low pressure natural gas The Gas Pack compresses pipe line quality natural gas from a low pressure source and delivers pressurized fuel gas to the fuel system of a Capstone Model C60 C65 Natural Gas MicroTurbine also referred to as C60 C65 Micro Turbine or MT in this document The Gas Pack can provide high pressure fuel gas for up to two MicroTurbines using separate outlet Fuel Train assemblies which include 75 psig regulators with pressure gauges The Gas Pack MT s and interface kit s can be configured for either a single or dual MT set The optional Gas Pack Inlet Kit interfaces the low pressure natural gas supply to the Gas Pack inlet If the user chooses to use their own plumbing for inlet and high pressure outlet care must taken to ensure the high pressure fuel delivered to the MicroTurbines is a steady 75 to 80 psig The Gas Pack operates external to the C60 C65 enclosure but is integrated by physical attachment to the rear of the C60 C65 enclosure The Gas Pack performs its intended functions through electrical power start stop and general fault communication connections Two versions of the Gas Pack are offered the AC version fed by local utility 480 V three phase AC and the DC version fed by the MT 760 Volt DC power connection located at the back of the MicroTurbine This DC power is fed from the Gas Pack attached MT High Voltage DC
20. teeaeeas 16 LIST OF FIGURES Figure 1 Gas Pack Fuel Gas Booster and Inlet Outlet Fuel Kits eeeeesseeeeeeeeeeeeeee 7 Figure 2 Gas Pack Block Diagram and Flow Schematic csceeeeseeesseeeeseeeesneeetenaees 8 Figure 3 Installation Overview of 2 MicroTurbines Gas Pack amp Fuel Trains 068 9 Figure 4 Rear View of MT Showing High Pressure Fuel Inlet Fitting eee 9 Figure 5 Single MT Installation Showing Gas Pack and Fuel Trains ceeeceeeeeeeees 10 Figure 6 Dual MT Installation Showing Gas Pack and Fuel Trains ccscceeeeeeeeeeeees 10 Figure 7 Gas Pack Control Console Panel ccccceeceesseeeeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeesaaeeees 11 Figure 8 MT Display Panel and Applicable FUNCTIONS cece eeeeeeeeeeeeeeeeeeeeeeeeeanaaes 12 LIST OF TABLES Table 1 Gas Pack Scheduled Maintenance Gaseous Fuels 15 Table 2 Reference Documents ccccececececececeeceeeeeeececeesecueecaeececeeeeeseeeneeeneeeneeenennaeennenes 16 400012 Rev A August 2007 Page 3 of 16 Capstone reserves the right to change or modify without notice the design specifications and or contents of this document without incurring any obligation either with respect to equipment previously sold or in the process of construction Capstone Turbine Corporation e 21211 Nordhoff Street e Chatsworth e CA 91311 e USA Capstone Gas Pack User s Manual NOTES 400012 Rev A August
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