Mie
Sczestone
Work Instructions
SPV25 to Woodward Valve Upgrade Kit Installation —
Model C60 MicroTurbine
Purpose and Scope
This document describes the removal of the SPV25, related LIP components and
‘subsequent installation of the Woodward valve upgrade kit. See Figure 1
UFCB Controller
{chown wlth Proceure Transducer) (sros47
Figure 1. Woodward Upgrade Kit Components
Guidelines
This document presents information sufficient to allow an Authorized Service Provider
(ASP) to properly replace the Woodward valve and related components.
Conduct maintenance in a clean, well-lighted area using normal shop tooling to avoid
damage to delicate components.
Retain all parts removed for use at assembly, unless otherwise specified, Discard all
parts as noted in this document.
440128-001 Rev A (January 2006) je 1 of
iCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
Safety Precautions
‘Observe and adhere to the Safety Precautions listed below when servicing your
MicroTurbine. Read and become familiar with the General Safety Precautions and
Instructions contained within the MicroTurbine Users Manual (400001). Before
servicing:
a
a
‘Check to ensure that the inlet fuel supply is SHUT OFF and detached from the
NicroTurbine.
‘Always check to ensure that your MicroTurbine is disconnected from the utility
Isolate and lock out the utility (if applicable),
Isolate and lock out any ther sources of power to the MicroTurbine. For
example, connections to the solid state relays in the MicroTurbine
‘Communications Bay.
‘Open the Stand Alone battery circuit breaker, lock it in the OFF position, and
then unplug the battery cable.
Ensure above power sources have been tured off and the unit has been
disconnected for at least five minutes to reduce the risk of electrical shook.
Use a voltmeter to verify that no voltage is present on the DC bus.
Never work on energized equipment
Observe all safety precautions to prevent injury or death.
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perpen Si te in ert ure etre te eetCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
Material Information
The following parts comprise the Woodward Valve Retrofit Kit 610098-100.
Part Number Nomenclature
519347-100 | UFCB Controller Assembly, Natural Gas
518348-100 | Woodward Valve Assembly, Natural Gas
§19480-001 | Pressure Transducer
518908-002 | Filter, 12, Inline, Flaretess Tube Fitting
519345-100 | Tube Assembly, -8 Woodward Valve Qui-Manifold
519338-001 | Tube, -12, Shutoff ta Woodward Valve Inlet
519346-100 | Tube Assembly, -6, Fuel Vent Out
519937-001 | Tube, 12, Inlet to Shutoff
§19244-100 | Shutoff Assembly with Bracket
519341-001_| Bracket, Shutoff, Woodward Valve
518342-001 | Bracket, Shutoff, Inlet Tube
§19243-001 | Bracket, Anti-rotation J
512294-010 | Fitting. Bulkhead, -12 Tube x 1/2" NPT Male
=|+|+]=|=|=|-/=]-|3/3)-]=|=|=/=]8]8]-||-|=|=|-|»]-]-|-|- |+|-|-|-|8
518472.001 _| Filling. Male Connector, -12 Tube to ~12 Tube, NPT
518471-001 | Fitting, Male Adapter, -12 Tube to 12 NPT, M, SS
514037-063 | Bolt, Hex Head, MB x 16, Zinc
507750-001_| Washer, Flat 1/4.inch, 1/16 thickness, 1/2 GD
507874-001 | Washer. Splitock, 1/4 zine-platod
508430-013 | Nut Hex, KEPS, Ext-lack washer
514926-001 | Fitting. Bulkhead, -6 Tube to 1/4 NPT
516983-100 | CABA, C200, FCM Fuel Valve
§18875-100 | CABA, Ext C60 UFCB to Manifold
507274-002 _| Sealant, Pipe Tape, Natural Gas
506711-001 _| Locker, Thread (Locktite 242)
508106-001 | Washer, Flat, 1-inch (1.082 ID. 2.6 OD), Zine
514016-001 | Label, High Pressure, NG
510622.002 _| Seal, 37°, Conical -8, Crush Washer, NI
§10622-003 | Seal, 37°, Conical -€, Crush Washer, NI
513808-001 | Filter, Vent, % NPT, 4 cim
513592.008 | Nut, Tube, BZ, -8. CPI Fig, SS
§13592-012 _| Nut, Tube, BZ, -12, CPIFig. SS
513531-008 | Ferrule, Tube, TZ. -8. CPI Fig, SS
513531-012 _| Ferrule, Tube, TZ, -12, CPIFig, SS
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Sanna apie samen Sas ears ean outa Sanh ea laCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
Recommended Tools
Use the Capstone’s Recommended Tools (400003) or equivalent to perform
procedures listed in this document. Additional tools/materials required:
a
DooOoOoDDOoOeD
10-mmm socket and open-ended wrench
7i8-inch open-ended wrench
TI6-inch open-ended wrench
14/16-inch open-ended wrench
41/4 -inch open-ended wrench
13/16 -inch open-ended wrench
41 1/8 -inch open-ended wrench
Teflon pipe tape, U/L rated (No. 2598, Lab 501 or equivalent)
Gas leak detector (Snoop, soapy water, gas sniffer)
Torque wrench, adjustable, 0 — 980 Ibs
Hand Drill and bit set, commercial
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perpen Sei te in ert ure etre te entCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
Removal and Installation Procedure
1. Remove MicroTurbine side panels using a 10-mm socket wrench.
2. Unplug all of manifold/shutoff and intra hamesses connecting the SPV25 to
the shutoff valve. See Figure 2.
Outlet Fitting
Shutoff Valve
§) —— SPV25 Bolts (2)
sPv2s sPv2s
Inlet Fiting
sPv2s
Mounting Botts
(1of 4 shown)
Figure 2. SPV25 Removal (Underside shown)
SPV25 Removal (see 440028-001 for more details)
NOTE — Remove fitings siowly to reduce impact from line pressurization.
1. Open the inlet fiting on the SPV25 side of the tube using a 7/8-inch
wrench. Use a second 7/8-inch wrench to support the fitting in the SPV25
housing.
2. Open the outlet fitting on the shutoff valve side of the tube connecting to the
SPV25 using a 7/8-inch wrench. Support the insert using the 1 1/16-inch
wrench.
3. Remove the inlet tube. Tube will not be retained and may be discarded.
4. Open the outiet fitting to the SPV25 using a 7/G-inch wrench. Use the 1-
inch wrench to support the fing in the SPV25 housing. This line may be
pressurized: therefore, release pressure siowly to prevent damage to the
fitting
5. Remove the outlet tube. Tube will not be retained and may be discarded
Remove two 7/16-inch bolts securing the SPV25 valve to the bracket
7. Remove the SPV25 assembly by detaching four 7/16-inch mounting bolts
from the upper side of the fuel plate.
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perpen Sie in ert ure etre te eetCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
‘Shutoff Valve Removal (see 440032-001 for more details)
1. Remove the tube on the inlet side of the shutoff valve using a 7/8-inch
wrench, and an 111/16-inch backup wrench. See Figure 3.
Detach the outlet side of the filter tube using a 7/8-inch wrench, and a 1
1/4-inch backup wreneh. Tube will not be reused and may be discarded.
2
Inlet Side of
Shutoff Valve
Filter
Figure 3. Shutoff Valve Tube Removal
3. Remove the ground wire using a 7/16-inch socket.
4. Remove the shutoff valve by detaching two 7/16-inch mounting bolts.
Reiain the shutoff valve fer future installation. See Figure 4.
Shutoff Valve
Outlet Side of
Fuel Inlet Shutoff Valve
Fitter
aerviees ‘Ground Wire
Line
Figure 4. Shutoff Valve Removal
Filter Element Removal
1. Remove the service line trom the fuel inlet fiter using an 11/16-inch wrench
on the tube and a 1 1/d-inch wrench as backup on the fitting.
2. Remove the filter from the fuel plate by detaching two 7/16-inch bolts.
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‘Work instructions: SPV to Woodward Valve RetrofitKit installation
Woodward Valve Inst
1. Mark and dri 10 holes on top of the MicroTurbine turbine deck to mount
Woodward components (see Figure 5 and Appendix A for more details).
Hole Location
(of 10:shown}
Figure 5. Hole Drilling Locations (Top View of Turbine Deck shown}
2. Drill additional holes on lower rear panel to accommodate the vent valve
and anti-rotation valve (see Appendix B). Install vent tube fitfing (514928).
Vent Tube
Fitting (514928)
Figure 6. Vent Valve Installation
3. Disconnect the TET hamess from the underside of turbine deck to allow
access to Woodward component installation. See Figure 7.
Figure 7. Disconnect TET Switch
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‘Work instructions: SPV to Woodward Valve RetrofitKit installation
4. Secure Woodward valve with 10mm bolts and attaching hardware, See Figure 6.
Woodward
Valve
Mounting Hardware
Bolt (514037-063) — Qty 4
‘Washer (507750-001) - Qty 4
‘Washer (507874-001) - Qty.
Figure 8. Securing the Woodward Valve
5. Mount the UFCB controller (519347) with mounting hardware shown to the
underside of the turbine deck. See Figure 9.
UFCE Controller
(519347)
Mounting Hardware
Bolt (514037-063) ~ Qty 4
‘Washer (507750-001) — Qty 4
‘Washer (507874-001) — Qity 4
Figure 9. Mount Controller Assembly
6. Secure UFCB controller from the top of the enclosure with four 10mm bolts.
See Figure 10,
Figure 10.
‘440128-001 Rev A (lanuary 2008)Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
7. Install upper shutoff vaive (619344) and mount as shown with bolts (514037),
washers (507750) and nuts (508430). ‘See Figure 11
Upper Shutoff
Valve (519344) Mounting Bracket
‘Mounting Hardware
Bolt (514037-063)— Qty 4
Washer (507750-001)— Qty 4
Nut (508430-013) - Qty 4
Figure 11. Upper Shutoff Valve
8. Assemble the anti-rotation bracket (519343) to the inlet fuel line and install
on the rear of the MicroTurbine with mounting hardware. See Figure 12.
Anti-rotation
Bracket
Bulkhead Fiting
12294) ba
Washer (507750-001) — Qty 2
Nut (£08430-013)— Qty 2
Figure 12. Anti-rotation Plate
9. Install the bracket (519342) on the lower shutoff valve (519344) and install
into the bulkhead on the rear of the MicroTurbine. Mount as shown with
Shutoff Valve
Lower Bracket
(519342)
Fitting (519471) — Qty 1
F 12 Formule (513531-012) —Aty 4
Bhitoft ‘ +12 Nut (513592-012} — Qty 1
Figure 13. Lower Shutoff Valve
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perpen Sie in ert ure eer lg el eetCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
10. Attach the tube (519337) to the shutoff valve and secure fitting with a 1 1/8-
inch wrench. Attach the ground wire to the bracket. See Figure 14.
Lower Shutoff
‘Valve Tube
Fitting - "i (519337)
(519472)
Figure 14. Lower Shutoff Valve Tube Installation
111. Attach the other end of the tube (519337) ta the upper shutoff valve with a
1 1/8-inch wrench, and a 1 3/16-inch backup wrench on the fitting.
Upper Shutoff
‘Valve Tube
(519337)
Figure 15. Upper Shutoff Valve Tube Installation
12.\nsert the in-line fiter (518908) into the valve as shown. Install tube
(519338) from the shutoff valve to the Woodward valve, and secure with a
1 1/8-ineh wrench, and 1 3/16-inch backup on the fitting. See Figure 16.
Shutoff-to-Woodward
Install Inline Valve Tube (519338)
Filter (518508)
Inside Fitting
(not shown)
Figure 16. Shutoff-to-Woodward Valve Tube Installation
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perpen Sie in ert ure etre el eatCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
13. Install the hamess connection to the lower shutoff valve. See Figure 17.
Shutoff Valve
Hames
Figure 17. Lower Shutoff Valve Harness Installation
14, Install the harness connection to the upper shutoff valve. See Figure 18.
Shutoff Valve
Hames
Figure 18. Upper Shutoff Valve Harness Installation
16. Install all connector hamesses as shown on the UFCB controller. See Figure 19.
Pressure
Transducer
Intra Hames Manae
Manifold
Shutoff Harness
(518875) Valve Harness
(516993),
UFCB Controller
Figure 19. Woodward Valve Harnesses Installation
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‘Tigran noi Cp hey renee fe Sd ot ahCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
16. Install the UFCB hamess on the Woodward valve. See Figure 20.
Fee
Harness
Figure 20. UFCB Harness Installation
‘17. Install one end of the fue! manifold tube (519345) to the Woodward valve
with an *-8" crush washer (510622-002) and seoure with a 7/&-inch wrench.
See Figure 21
Fuel Manifold
Tube (519345)
“9” Crush Washer
(510622-902)
Figure 21. Fuel Manifold Tube Installation (Woodward Valve)
16. Secure tube connections on the fuel manifold end with a 7/8-inch wrench
Fuel Manifold
Tube (519345)
8 Ferrule (513531-008) — Qty 1
-@ Nut (513532-008)— Qty 1
Figure 22. Fuel Manifold Tube Con
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perpen Sie in ert ure etre te entCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
19. Install one end of the vent valve (519346) to the Woodward valve with a
*.6" crush washer (510622-003) and secure with an 11/16-inch wrench.
See Figure 23.
7
“.6" Crush Washer
(610622-003)
Figure 23. Vent Tube Installation (Woodward Valve)
20. Install the other end of the vent tube (519346) to the lower rear panel with
an 11/16-inch wrench. See Figure 24,
Vent Tube
(519346)
Figure 24. Vent Tube Installation (Lower Frame)
21. Place a vent filter (513808) into the (female) NPT fitting on the outside of
the rear panel
22. Reattach the TET connector hamess.
23. Install label (514016) to the rear of the MicroTurbine.
24. Tum power an, open the fuel supply and initiate an engine start
25. Check fittings for leaks using a leak detector (e.9. Snoop, soapy water, or
gas sniffer).
26. Test system for proper operation as detailed in the MicroTurbine User's
Manual (400001).
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perpen Sie in ert ure eet el eetCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
ity
It is the responsibility of Capstone to make these procedures available to the
Authorized Service Providers so they can successfully complete this task.
It is the responsibility of the Authorized Service Providers to read this document,
understand its contents, and effectively complete the replacement procedures.
Itis the responsiblity of the Authorized Service Provider to provide Capstone with
a Field Service Report when the replacement task is completed.
Responsi
Notifying Capstone Customer Service
Upon completion of the installation of the Woodward valve and related components,
complete a Commissioning Checklist, and submit the paperwork to Capstone
Technical Support. If you have additional questions, please contact:
Capstone Technical Sui
Toll Free Telephone: (877) 282-8966
Service Telephone: (818) 407-3600
Facsimile: (818) 734-1080
E-mail: service@capstoneturbine.com
Capstone Technical Support - Japan
Service Telephone: (818) 407-3700
Facsimile: (818) 734-1080
E-mail: servicejapan @capstoneturbine.com
440128-001 Rev A (January 2006) Page 14 of
peptone Sie in ert ure eer lg el entCapstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA
‘Work instructions: SPV to Woodward Valve RetrofitKit installation
Appendix A -
Drilling Hole Locations on MicroTurbine Frame
= 26.623 +
28.673 ——____~
2x R625 5.587
42.077 “4
Foes.
2x 925+ =
tant
|
-—— 12.836
@.000—b 7
le 14.086 4
Figure A-1, Drilling Locations on Turbine Deck (View from Bottom)
Legend (Hole Locations)
W- Woodward Valve
- UFCB Controller
Z- Shutoff valve
440128-001 Rev A (January 2006) Page A-t
perpen Sei ee i er are eer li te eensCapstone Turbine Corporation » 21211 Nordhoff Street « Chatsworth « CA.91311 + USA
Work instructions: SPV to Woodward Valve Retroft Kit Installation
Appendix B -
Drilling Hole Locations on MicroTurbine Lower Right Rear
Figure B-1. Drilling Locations on Lower Right Rear of MicroTurbine
Legend (Hole Locations):
X— Anti-Rotation Valve
440128-001 Rev A (January 2006) Page B-1
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