400012A 2007-08 Capstone Gas Pack User's Manual
400012A 2007-08 Capstone Gas Pack User's Manual
400012A 2007-08 Capstone Gas Pack User's Manual
Capstone CORPORATION
Publisher
Capstone Turbine Corporation
21211 Nordhoff Street
Chatsworth • CA 91311 • USA
Telephone: (818) 734-5300
Facsimile: (818) 734-5320
Website: www.microturbine.com
TABLE OF CONTENTS
ABOUT THIS DOCUMENT ........................................................................................................... 5
SYMBOLS ...................................................................................................................................... 5
SAFETY INFORMATION............................................................................................................... 5
PRODUCT DESCRIPTION ........................................................................................................... 6
Gas Pack Block Diagram............................................................................................................ 8
PRODUCT INTERFACE DEFINITION ......................................................................................... 9
Control Panel Lights and Controls............................................................................................ 11
PRODUCT OPERATION............................................................................................................. 12
Normal Operating Procedures.................................................................................................. 12
System Start Up .................................................................................................................... 12
System Shut Down................................................................................................................ 12
Emergency Shutdown (Emergency Off)............................................................................... 13
Simple Troubleshooting Scenarios....................................................................................... 13
PRODUCT MAINTENANCE........................................................................................................ 15
Scheduled Maintenance ........................................................................................................... 15
REFERENCE DOCUMENTS ...................................................................................................... 16
CAPSTONE CONTACT INFORMATION ................................................................................... 16
Capstone Applications .............................................................................................................. 16
Capstone Service...................................................................................................................... 16
Capstone Technical Support................................................................................................. 16
Capstone Technical Support (Japan)................................................................................... 16
LIST OF FIGURES
Figure 1. Gas Pack Fuel Gas Booster and Inlet/Outlet Fuel Kits ........................................ 7
Figure 2. Gas Pack Block Diagram and Flow Schematic.................................................... 8
Figure 3. Installation Overview of 2 MicroTurbines, Gas Pack & Fuel Trains ..................... 9
Figure 4. Rear View of MT Showing High Pressure Fuel Inlet Fitting ................................. 9
Figure 5. Single MT Installation Showing Gas Pack and Fuel Trains ............................... 10
Figure 6. Dual MT Installation Showing Gas Pack and Fuel Trains.................................. 10
Figure 7. Gas Pack Control Console Panel ...................................................................... 11
Figure 8. MT Display Panel and Applicable Functions...................................................... 12
LIST OF TABLES
Table 1. Gas Pack Scheduled Maintenance – Gaseous Fuels......................................... 15
Table 2. Reference Documents ........................................................................................ 16
NOTES
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.
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.
PRODUCT DESCRIPTION
The Gas Pack (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,
MicroTurbine 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 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 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.
Part of MT
Frame
Gas Pack
Regulator
Isolation Valve
Fuel Strainer
Figure 1. Gas Pack Fuel Gas Booster and Inlet/Outlet Fuel Kits
Low Isolation
Pressure Sight valve
Gas Glasses
Oil
Cooling
Oil Fan Fan Inlet
Hi Temp Signal
Oil Filter
Fan
Air Outlet Hi Press Signal
Via Control Module Start/Stop Signal
Louvered
(In Upper Control
Front
Console Bay)
Panel General Fault Signal to C60/65 Aux In
Air In Air Out
MT #2 Gas Pack
Assembly
Outlet Kit -
One MT
Inlet Kit
Regulator
Regulator
Fuel Trains
Outlet Kit – Second MT
Figure 3. Installation Overview of 2 MicroTurbines, Gas Pack & 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
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
Gas Pack
Optional
Inlet Kit
Pressure Regulator
MT #2 with Gauge
Pressure Regulator
Outlet Kit – Second MT
with Gauge
(Optional)
Power On
Light On/Off
Switch
Run
Light
Run
Fault Timer
Light Reset
Button
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 Switch 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 User’s Manual (40001 or 40017) for additional information on
MicroTurbine startup.
Interlock Start & Enable
Button Buttons
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.
This action stresses the compressor and should not be done unless
CAUTION
absolutely necessary.
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.
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.
• Do not operate the system with the inlet gas supply off or allow the
unit to operate at a vacuum on the inlet side.
CAUTION
• 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.
Oil Replenish
Oil Filter Replace
Scroll Compressor Replace
20,000 hours
Oil Replenish
40,000 hours Heat Exchanger Replace
REFERENCE DOCUMENTS
Table 2 lists applicable Capstone reference documents.
Capstone Applications
Toll Free Telephone: (866) 4-CAPSTONE or (866) 422-7786
Fax: (818) 734-5385
E-mail: [email protected]
Capstone Service
Capstone Technical Support
Toll Free Telephone: (877) 282-8966
Service Telephone: (818) 407-3600 • Fax: (818) 734-1080
E-mail: [email protected]