All Power Labs PP30 Installation manual

PP30 Gasifier-Engine Startup
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
Collect the following items
1. ½” NPT Pipe tee for lighting port
2. Sifted ACV Charcoal
a. Sift ACV using a screen (wear proper PPE)
3. Propane torch
4. Small Pipe wrench
5. Heat protective gloves
6. Ear and eye protection
Gas-Making Supersystem
CAUTION Before starting up the Power Pallet sure that you are in a well ventilated
area and are wearing proper PPE
Ensure power is on (Image Set 1)
Remove cap from lighting port
Attach pipe tee to lighting port, a single turn is enough
Place a few grams of ACV charcoal in pipe tee
Close the flare valve and engine valve by turning it to horizontal and turn gas up to 11
(Image 2)
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FILE-004468 PP30 Gasifier-Engine Startup

Image Set 1
Image 2
Using a propane torch, light the ACV char in pipe tee (Image Set 3)
When char is glowing, slowly open the flare valve, letting the embers be sucked into the
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FILE-004468 PP30 Gasifier-Engine Startup

reactor
a. If any charcoal is stuck in the T, light it if not glowing, and poke it into the reactor
Image Set 3
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
b. If the flare stack does not smoke, and Trst on the PCU screen does not start to
climb, repeat steps 4-7. If Trst is climbing, and no smoke is seen, check that the
flare valve is open, and that Preac is a negative number
c. If trst is slow to climb the grate shaker can be activated to speed the process up
Once ignited, turn the air to 5. A loud roaring sound indicates that the PP is flaring
properly
Remove air intake plug (with wrench if needed)
d. Wearing heat resistant gloves, remove the pipe tee and reinstall the ½” NPT cap
on the lighting port and tighten lightly with the pipe wrench
Increase the air blower to 7 and continue to adjust to maintain a strong roaring sound
from the flare to allow the reactor to reach full operating temperature. This can take
10-15 minutes
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FILE-004468 PP30 Gasifier-Engine Startup

Once Trst (PCU - temperature at the restriction zone) is greater than 750°C and Tred
(PCU - temperature at the reduction zone) is greater than 300°C, the engine can be
started by the following steps (note: while the engine can be started at lower values, the
PP30 system will accumulate more tar and require more maintenance)
Power Generation Supersystem
Turn both the gas and air down to 0, close the flare valve, and open the engine valve
(turn it vertically)
On the generator controller, press Stop/Reset, then Manual Mode, then Start button to
start the engine
The status screen will confirm that the engine is running and count down timers will
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
Once the engine has warmed up, the ‘Generator Available’ light (listed as 2 on the Four
Configurable status LEDs table below) will turn on. Press the Close Generator Button
to close the connection to the generator and export power/energize loads
Image 5
Four Configurable status LEDs
1
Bus Live
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FILE-004468 PP30 Gasifier-Engine Startup

2
Generator Available
3
Contactor Closed
4
Power Export
GASIFIER-ENGINE STARTUP PROCEDURE COMPLETE
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FILE-004468 PP30 Gasifier-Engine Startup