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All Power Labs Power Pallet PP30 Operation Manual

Cogeneration system
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PP30 Cogeneration System

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Summary of Contents for All Power Labs Power Pallet PP30

  • Page 1 PP30 Operation Manual PP30 Cogeneration System...

  • Page 2: Table Of Contents

    Table of Contents 1. Technology Foundations 2. Power Pallet Crate Contents 3. Safety Procedures 4. Required Tools O&M Tool List (Required) Technician Tool List (Nice to Have) 5. Power Pallet Set Up 5.1. Facility Requirements 5.2. Connecting to Loads 5.3. Connecting to the Grid 6.

  • Page 3: Technology Foundations

    1. Technology Foundations Gasifier Supersystem (gasifier Module) The gasifier system Power Generation Supersystem Power generation system Combined Supersystem Power generation supersystem The gasifier supersystem 3 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)
  • Page 4 4 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)
  • Page 5 5 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)

  • Page 6: Power Pallet Crate Contents

    2. Power Pallet Crate Contents 1. Power Pallet Gasifier System 2. Power Pallet Generator System 3. Charcoal for first start of reactor 4. CO Monitor 5. Basic Tool Assortment 6. Set of Essential Spares 7. Miscellaneous supplies for maintenance operations 6 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)

  • Page 7: Safety Procedures

    3. Safety Procedures CAUTION: Operator must wear personal protective equipment when operating this machinery. ● Whenever filling or emptying feedstock or char a mask appropriate to protect against fine particulates must be worn. ● Read all instructions and documentation carefully before operating or servicing.

  • Page 8: Required Tools

    4. Required Tools O&M Tool List (Required) The following tools are required to perform regular Power Pallet O&M activities. ● Gas line wire brush ● 7mm wrenches ● 8mm wrenches ● ½” sockets and wrenches ● 9/16” sockets and wrenches ●...

  • Page 9: Technician Tool List (Nice To Have)

    Technician Tool List (Nice to Have) The following tools will allow more complex Power Pallet O&M activities. ● Pliers ● Needle nose pliers ● Wire strippers ● Crimpers (ABCDE kind) ● Wire cutters ● Timing Light ● Voltmeter ● Cables/dongles for connecting computer to PP to load firmware ●...

  • Page 10: Power Pallet Set Up

    1000m or less. The power pallet’s power output will be derated at higher altitudes. In case of different conditions, please consult ALL Power Labs. ● Install the PP30 out of direct sunlight. UV from sunlight will damage parts over time.
  • Page 11 11 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)

  • Page 12: Connecting To Loads

    5.2. Connecting to Loads Hook up the cam lock connections to an off load system you want to send • power to that is within the power pallet electricity load range. (5-25 kW) • Press Close Generator button to close the contactor and start sending power to an external load.

  • Page 13: Feedstock Requirements

    6. Feedstock Requirements For your gasifier to operate properly, you must use the correct biomass feedstocks which have been properly prepared and sifted. Certain material shapes and sizes flow better in solid material handling systems. For example, long stringy pieces, similar to toothpicks, do not flow well, as they get stuck in feeds.
  • Page 14 Feedstock Notes Wood Chips (e.g: Oak, Rubber, Use only chips; chunks or long shards can bind au ger Pine) or bridge in the reactor Nut Shells (e.g: Coconut, Walnut, Not all shells will work, please contact us to discuss Hazelnut) your particular feedstock Corn Cobs Must be broken to size and must not include husks.
  • Page 15 Municipal Solid Waste/Trash Slag risk; heavy metals; plastic content not suitable Coal Burns too hot, releases sulfur and heavy metals Plastics Melts and fouls auger/reactor Manure: Cow, Pig, Chicken, etc High slag, low energy density Tires Not chemically compatible 15 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)

  • Page 16: Operating Procedures

    7. Operating Procedures The following procedures assume that the Power Pallet has been assembled and installed correctly. Training by a certified APL trainer is recommended before operating the PP30 for the first time. For a list of all parts of the Power Pallet including a list of parts, definitions and all other useful information see the PP30 Component Reference document.
  • Page 17 Image Set 2 2. Check radiator coolant level and refill if needed (see PP30 Engine Check for fill instructions) WARNING: Do not open the radiator cap when the unit is hot Image Set 3 3. Check expansion tank fluid and refill if necessary (Image Set 4) a.
  • Page 18 Image Set 4 4. Check engine oil level and refill if necessary (See PP30 Engine Check for fill instructions) a. Pull the dipstick and clean it. Reinsert and pull it again and then check to see if the oil is between the marking on the dipstick b.
  • Page 19 Image Set 6 c. Physically check if the governor throttle plate moves freely (Image 7) When pressed all the way open the throttle plate should close all the way on its own with a snappy motion Image 7 d. If check fails, clean governor (see PP30 Engine Check for cleaning instructions) e.
  • Page 20 Make sure to clean gaskets of tar and dirt before installation by wiping them with a paper towel Ensure that the governor plug is facing downwards when you install it Image Set 8 6. Check Polishing filter (Image 9) a. Remove V-band clamp and sanitary clamp from lid and pull out the polishing filter Pliers can help with the removal of the filter element Image Set 9 b.
  • Page 21 3. You can not see sunlight through the element when pointed at the Image Set 10 c. If inspection fails - Replace with new filter. Record in Daily Operation Records. d. Remove the metal mesh flame arrestor from the bottom of the filter canister and check to see if it is dirty - it is dirty if it is covered in tar or soot and if you cannot see through it (Image 11) 21 of 41...

  • Page 22: Pp30 Gasifier Prestart Duties

    Image 11 Clean if necessary with alcohol e. Replace the flame arrestor, filter, and lid. Secure with V-band and sanitary clamps 7. Check and tighten any additional engine gas connections, bolts and sanitary clamps that were removed during this process. 7.2.
  • Page 23 2. Empty the “Ash Collection Vessel” (ACV) following site procedures (Image 2) a. CAUTION Before opening up the ACV make sure that the area is well ventilated and are wearing proper PPE b. Remove the sanitary clamp holding the ACV to the unit c.
  • Page 24 provided, use locally sourced charcoal (e.g. sifted ACV char). The correct size of the charcoal to use to fill the reactor is roughly that of the charcoal produced from the ACV. APL provides an initial bag of the correct size for starting the power pallet the first time.
  • Page 25 Image Set 4 Press adv once to advance from fuel auger to grate shaker (Image 5) Image 5 iii. Press mode twice to change from auto to on (Image 6) Image 6 Run for a few seconds, listen for the shaker functioning and then press 25 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)
  • Page 26 mode once so display reads auto (Image 6) Image 7 b. Ash auger function test Ensure status screen is on manual control (Image Set 8) 26 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)
  • Page 27 Image Set 8 Press adv twice to advance from fuel auger to ash auger (Image 9) Image 9 iii. Press mode twice to change from auto to on (Image 10) 27 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)
  • Page 28 Image 10 Leave on for one minute, visually confirm rotation by going around the back of the Power Pallet and looking at the gears that turn the ash auger, they are attached to the bottom of the cowling near the Reactor Access Door (Image 11) Image 11 Then press mode twice so display reads auto...
  • Page 29 9. Perform a Leak Down test (this is a test where we determine if there is an air leak in the system) (Image Set 12) a. Open the flare valve by turning it until it is vertical and close the valve to the engine by turning it horizontally b.

  • Page 30: Pp30 Gasifier-Engine Startup

    ● If the reactor pressure reading is near or >90, the reactor passes the first leak test ● If the pressure is <90, the test fails. It may be that the battery has insufficient charge, there is a significant leak, blowers need to be checked, or there is a large pressure drop in the system.
  • Page 31 Image Set 1 Image 2 6. Using a propane torch, light the ACV char in pipe tee (Image Set 3) 7. When char is glowing, slowly open the flare valve, letting the embers be sucked into the reactor 8. If any charcoal is stuck in the tree, light it if not glowing, and poke it into the reactor 31 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)
  • Page 32 Image Set 3 9. When the top of the flare stack starts to smoke (should take a several minutes depending on feedstock and weather conditions) the producer gas should ignite 10. If the flare stack does not smoke, and Trst on the PCU screen does not start to climb, repeat steps 4-7.

  • Page 33: Pp30 Shutdown

    elapse for about 1 minute. If the engine does not start, repeat the process up to 3 times. See Troubleshooting if engine still does not start 4. Once the engine has warmed up, the ‘Generator Available’ light (listed as 2 on the Four Configurable status LEDs table below) will turn on.
  • Page 34 Image 1 4. Put the PP30 in cool-down flaring mode (Image Set 2) a. Close the engine valve and open the flare valve b. Turn both the gas and air blowers to 6. Let the PP flare for 2 mins c.
  • Page 35 7. Return all PPE and documentation to the proper storage location 8. If the unit will not be used for longer than two weeks, remove the negative battery leads from the battery. 35 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)

  • Page 36: Refilling The Pp30

    7.5. Refilling the PP30 Recommended hopper fill schedule Fuel type Time between refills Amount to fill each refill Walnuts 2.5 hrs 100 L 2 hrs 100 L 1.5 hrs 100 L Woodchips 1.5 hrs 100 L 1 hrs 100 L .5 hrs 100 L Refilling Procedure...

  • Page 37: Maintenance Schedule

    Maintenance Schedule 100 hours Clean cyclone insides from base with scraping bar 100 hours Check/replace filter gaskets 125 Hours Check/replace reactor access door graphite paste 125 Hours Check/replace cyclone collection can gasket 125 Hours Check/Calibrate O2 sensor 125 Hours Clean air intake check valve 125 Hours Clean cyclone to producer gas heat exchanger gas line 125 Hours...
  • Page 38 500 hours Check/replace: graphite paste (PYR> DRK) 500 hours Replace engine coolant (12 qt fill) 500 hours Replace Engine Oil 500 hours Replace Ashok engine oil filter 500 hours Check/replace: 4" OD PTFE sani gasket for ACV clean out port 500 hours Check/Clean Battery Terminals 500 hours...

  • Page 39: Spare Parts

    Spare Parts APL has provided the following spare parts to minimize equipment downtime. PP30 Spare Parts List: 0–500 hrs ● 4× spare gas blowers ● White lithium grease ● 2× spare spring check valve springs ● 1× spare O sensor ●...

  • Page 40: Service Record Form

    10. Service Record Form 40 of 41 FILE-004209 - Power Pallet Operation Manual (PP30)
  • Page 41 DOCUMENT INFORMATION PP30 Operation Manual FILE-004209 DOCUMENT NO: REVISION: DATE RELEASED: 02/23/2023 CATEGORY: Procedure REVISION HISTORY Revision Description Date Author Updated text information, images, forms and necessary details pertaining to PP30 Operation 06/13/2019 Alejandro Manual. Updated text information and necessary details 06/28/2019 Juan M.

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