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2) A bypass line was added to the LFG treatment skid to route excess landfill gas to the flare station. Regardless of load-following or full-load operation of the microturbine array, the same amount of LFG is extracted from the well field through the dedicated header. Based on previous experience, SCS decided to utilize an industrial compressor to pressurize the LFG. An oil- flooded sliding vane compressor was selected in order to achieve the desired 90 psi pressure increase in a single stage. A water/glycol chiller and heat exchanger provide enhanced moisture removal from the LFG. Initial siloxane samples were taken from the wells indicated that the total siloxane level was 1.9 mg/m3 or 200 ppb. A siloxane removal system consisting of stainless steel vessels and graphite-based material was installed to meet the Capstone fuel specification of less than 5 ppb total siloxanes. Carbon change out frequency is expected to be every six months. The fuel treatment equipment including all non-utility electrical and control equipment were designed and constructed on one skid by SCS Energy. This allowed for assembly and initial testing to be completed off-site prior to delivery. SCS Energy worked extensively with Capstone’s open- communications control protocols to develop and extend the PLC-based monitoring and control network to include external equipment, principally the compression and pre- treatment skid. Net of equipment donation by SCAQMD and state grants, total installed cost was under $400,000. Plant Operation and Maintenance The Calabasas microturbine plant began operation in mid-August, and has been operating for more than 3,500 hours with 98 percent availability. Some downtime consisted essentially of tuning the various fuel treatment components to provide the requisite fuel quality for proper microturbine operation: • Upgrading compressor operation to deliver higher flow at increased gas pressure. The oil- flooded sliding vane compressor system was originally intended for 80 psi output. The system was adjusted to provide 90 psi. The vane compressor appears to require a significant derating from manufacture specifications when using media other than air at atmospheric conditions. In the case of Calabasas, the compressor is used to pull a vacuum on the well-field. The derating was noted during the start-up by reviewing pressure and flow trends with a varied number of turbines operating. Once the required increase in flow was determined, the compressor capacity was increased by modifying the pulley sizing. • Compressor Maintenance. The compressor oil is replaced between each 1,000 to 1,500 hours of operation. During the oil change the complete system is shut-down and inspected. By sampling and analyzing the oil, the replacement frequency can be optimized. • Siloxane filter maintenance. The graphite media in the siloxane filters is expected to last six months before siloxanes break through at detectable levels. Complete carbon change out will take four hours. • Microturbine Review and Testing. Due to close proximity to Capstone’s offices, the ten Calabasas microturbines are utilized for review and testing of fuel pressure requirements, fuel system improvements, controls, and miscellaneous parts. Although minimized, these actions result in some downtime. Additional operational enhancements included: • PLC-based control system implemented with the installation of Modbus translators. The SCS- provided touchscreen PLC controller governs operation of the entire microturbine array and the fuel treatment system. Capstone products typically communicate using a RS-232 protocol through proprietary remote monitoring software. With the installation of Modbus translators in each of the units, a facility-wide control and monitoring system was implemented that includes the microturbines, the pre-treatment system, and the on-site power requirements. • Feedback for Fuel Treatment. Since the gas dryer is critical to the fuel treatment equation, it was considered critical that the microturbines and the pre-treatment system communicate. This would limit exposure to out-of-spec fuel input that could hamper operation reliability or potentially could negatively impact internal fuel system components. NEWLY COMMISSIONED AND UPCOMING At the Rutgers University EcoComplex shown in Figure 4 below, an array of microturbines is currently converting LFG into two energy forms being used at the center: electricity and heat. In addition to power, exhaust from the microturbines heats water that is used in hydroponics greenhouse, a desalinization unit, andPDF Image | MICROTURBINE OPERATING EXPERIENCE AT LANDFILLS
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