gas turbine inlet air filtration - frame 6 users...

GAS TURBINE INLETGAS TURBINE INLETAIR FILTRATION 1AIR FILTRATION 1

FILTRATIONBASICS

Quality Air Filtration is designed to capture the largest amounts of solid or liquid particles contained in an air flow by fibrous material (media) along the path of the gas flow

Purposes of Air Filtration for Turbine Machinery

FILTRATIONBASICS

Micron Size Particle Overview

Dust Concentrations

Definitions of Harmful Effects

Fouling: A solid deposit on the compressor blades that alters the outline(Caused by particles less than 5 microns)

Erosion: Effects the wear on the metal(Caused by particles greater than 5 microns)

Corrosion: Alteration of metal surface due to chemical reaction. It occurswith (NaC1) – Sodium Chloride combustion sulphides and (Oxidation) H2O at high and low temperatures.

Low temperature (Wet Corrosion) High temperature (Salt & Sulphur)(Damage is irreversible)

TYPICAL PROBLEMS ASSOCIATEDWITH AIR QUALITY

Compressor Blade ErosionCompressor FoulingCompressor Corrosion

The 3 Greatest Problems to Compressors

New Blades

Fouling


Cooling Passage PluggingRotor ImbalanceLocking of Turbine Blade Roots

Causes and Solutions


“Salt is great sprinkled on French Fries but it’s no friend to Gas Turbines”…Jean Pierre Stalder

(Turbotect)

WORDS TOLIVE BY

•The biggest expense during the life of Gas Turbine is fuel cost•An 80 MW GT will consume $23 million+ in fuel a year•New frame 7’s & 9’s are 150-226 MW Turbines

ANNUAL ECONOMIC IMPACT OFGOOD FILTRATIONFuel Cost Expense

Just a decrease in pressure drop of 1.00” of W.G. is a savings of over $300,000 a year (150 MW GT)

(Based on a $0.05 cost per KWH)

ANNUAL ECONOMIC IMPACT OFGOOD FILTRATION

Average Annual Energy Cost Savings

ANNUAL ECONOMIC IMPACT OFGOOD FILTRATION

OEM Frame Size Examples

•FS7-FA 320 Filters•FS-5 150 Filters•FS7-EA 220 Filters•FS-6B 110 Filters•F-7 504 Filters

•V84.3A 375 Filters•V94.2 460 Filters•V94.3A 505 Filters•V84.2 320 Filters•501-F 320 Filters

•11N 280 Filters

Dirty compressors increasefuel consumption by up to 5%

A fouled compressor resultsin output drop of 10%

WHY GOOD AIR INLETFILTRATION IS IMPORTANT

Fuel Consumption & Output Drop

A 75 MW unit located in an industrial environment with air loading of 10ppm will ingest 594 lbs of particulate a day


Ingestion of Particulate


Protection of Equipment Cost Benefit

•Maintenance Labor•Unscheduled Downtime•High Gas Consumption•Preventable Work Orders•Business (Power) Interruption


Protection of Equipment Cost Benefit

•6-7% of the gross national product is required just to repair damage caused by poor maintenance to machines.•One out of every 3 dollars spent on maintenance is wasted

-Forbes Magazine

Efficiency (average)Pressure drop(Initial resistance)Dust holding capacityAverage arrestance

The Big Four Factors

THE MOST IMPORTANT FACTORS WHEN THE MOST IMPORTANT FACTORS WHEN CONSIDERING GT AIR FILTRATIONCONSIDERING GT AIR FILTRATION

Efficiency The ability of the air filter to remove particulate or gaseous material from the air stream (measured in percentages)(Final Filters are measured by Dust Spot Efficiency F4 Thru F9)

Test ASHRAE 52:1 and 52:2 (Merv Rating)0.3 to 1 microns1 to 3 microns3 to 10 microns

Definition of Terms



Pressure Drop (Resistance) The resistance of a device (filter) to flow air through it (measured in W.G.)

Dust holding capacity The amount of dust (ASHRAE) or (SAE) that a filter will hold when fully loaded to final resistance measurements

Definition of Terms


Arrestance A measure of the ability of an air filtration device to remove test dust from test air(Pre Filters are measured by Dust Weight Arrestance G1 thru G4)

Definition of Terms


The Difference Between Arrestance& Dust Holding Capacity

PRE FILTER(Dust Weight)

G RATINGS

FINAL FILTER(Dust Spot Efficiency)

F RATINGS

“Biggest misunderstanding among users”

Measurement of the ability of the filter to remove synthetic dust from the air. Measured in terms of weight. Large micron-sized particles.

Measurement of the ability of the filter to remove staining portion of atmospheric dust from the test air. Measured in terms of dust spotting. Small micron-sized particles.


Measurements Standards(ASHRAE, EN779, Eurovent, DIN)

ASHRAE – American Society of Heating, Refrigeration, and Air Conditioning Engineers. 52.1 Efficiency Ratings. 52.2 Minimum Efficiency Reporting Values (MERV)

EN779 – European standard for air filter testing

Eurovent – Fractional efficiency test

DIN 24183 – German standard for penetration values and integral efficiency

Ambient environmentDust type & characteristicsConcentrationsEffect on gas turbinesMean temperaturesAtmospheric conditions

FILTER SELECTIONFILTER SELECTIONCRITERIACRITERIA

How Your Operating EnvironmentPlays a Role

Coastal & Off-ShoreIndustrialTropicalDesertArtic


The Five Different Environments to Consider

FILTER SELECTIONCRITERIA

CELLULOSESpecial blend of select fibers designed to provide you with excellent efficiency and high air flow capacity. This media is extremely efficient at capturing fine dust.

Recommended for a wide variety of applications where excellent efficiency and low cost are essential.

SYNTHETIC BLENDA blend of premium synthetic and cellulose fibers for heavy-duty applications offers increased durability and efficiency.

Synthetic Blend Media is of great benefit in applications that have moisture related problems or use frequent pulsating (most popular brand).

SPUN–BONDED POLYESTERSpun Bonded Polyester is formed by thermally bonding continuous file-denier fibers. Along with its stiffness and very smooth surface, this fine fiber structure media makes a filter with excellent efficiency plus superior cake release.

The media is excellent for applications requiring abrasion, moisture or chemical resistance.

REQUIREMENTS OF GT AIR FILTRATION

Long filter life(At least 12 months between change-out)Final Filter elementHigh efficiencies (on small particulate)Low pressure dropEasy installationCost competitiveHigh reliability

Dry (Desert Type) Pulse Jet/ (Final Filters)

Industrial/Urban Rural Prefilter/Final Filter


Best Applications

High Humidity Coalescer/Final Filter

Arctic Pulse Jet

Tropical Coalescer/Final Filter


Best Applications

PlaceRain Louvers

/ Hood Coaleser Pre-filter High EfficiencyFilter 90 - 95%

Demister Coaleser Pre-filter High EfficiencyFilter 90 - 95%

Vane type Internal Filter Coaleser Pre-filter -

Demister Coaleser Demister -Demister Coaleser High Efficiency

Filter 90 - 95% -Rain Louvers

/ Hood Pre-FilterHigh EfficiencyFilter 90 - 95%

High EfficiencyFilter 90 - 95%

Rain Louvers / Hood Pre-Filter Coaleser -

Vane type Internal Filter Pre-Filter



Vane type Internal Filter Pre-Filter Coaleser -

Sol

.1

Pulse - Jet - - -

Sol

. 2 Vane type Internal Filter Pre-Filter

High EfficiencyFilter 90 - 95% -

Pulse - Jet - - -Pulse - Jet - - -

Arc

tic

With Sand Storms

Dus

ty

Des

ert

Dus

ty

Dry Snow

Coa

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- M

arin

eIn

dust

rial -

U

rban

Rur

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High Humidity

Without Sand

Storms

Sol. 1

Sol. 2

Scarce Humidity

Scarce Humidity

High Humidity

Off

Sho

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orm

alD

usty

Succession Of Filtering StagesEnvironment

Salt / Humidity

Mist / Sea Storms

Dusty


Specification Criteria

1980’s – Pocket (Bag) Filters

1990’s – Rigid Box

1995 to Current – V-Bank

TYPES OF GAS TURBINETYPES OF GAS TURBINEAIR FILTRATIONAIR FILTRATION

The History of GT Air Filtration

Pleated Panel (Pre Filters)Bag Filters (Pocket Type)Rigid (Box) FiltersV-Bank (Mini-pleat design)Pulse Cartridge


Discussion of Good and Bad Characteristics

Pulse – Cartridge (Self Cleaning)• High Efficiency• Low Pressure Drop• Single Stage Filtration• Extended Life

Mini – Pleat Design (Barrier)• High Efficiency• Low Pressure Drop• High Dust Holding Capacity• Moisture Resistant• Extended Life


New GT Filtration Technology

Pre Filter• High Efficiency• Low Pressure Drop• Disposable• Economical

Rigid Pocket (Bag) Filter• High Efficiency• Low Pressure Drop• High Dust Holding Capacity• Extended Life



Coalescer• Moisture Removal• Low Pressure Drop• All Plastic (Fully Disposable)• 100% Effective @ ≥ 3 microns

Polyester Foam Media• Different Porosities• Long Service Life• High Dust Holding Capacity• Washable / Reusable



Combined Filter Systems• Final Filter Combined with a

Pocket Pre Filter (fastening system)• All Plastic (Fully Disposable)• F8 Final Filter / G-4 Pocket Filter

HEPA Filters• High Efficiency Particulate Air• Extremely Efficient / Higher Pressure Drop• All Plastic (Fully Incinerable) • Up to 99.999% Efficient



FILTER MAINTENANCEFILTER MAINTENANCESTRATEGYSTRATEGY

Change Out Criteria

•Visual & Physical Inspection (Dust Load - Structural Integrity)•Hours in Operation•Pressure Drop•Exposure to Significant Climactic Events•Length of Time Installed


Life Cycle Cost Analysis

LIFE CYCLECOST ANALYSIS

FILTERS NEED TO BE CHANGED OUT ACCORDING TO

P (PRESSURE DROP)

Pre Filter Elements are normally changed at P of 1.5 inches w.g.Final Filter elements are normally changed at Pof 2.5 inches of w.g.Self-Cleaning Pulse cartridges are normallychanged at P of 2 to 3 inches w.g.(maximum operating P of 3”)


Pressure Drop Replacement


(RUL) Remaining Useful Life

•Time in Service (Installation

Date) + Number of Hours

•Visual Inspection

•Type and Granulometric

Sizes of Particles on Filter

•Pressure Drop

TYPES OF GT FILTERSTYPES OF GT FILTERS

Gasket on either sideDual phase fiber glass media Convex openings for better

air flowOne piece headerCompletely incinerable100% potted with

polyurethaneHeader and side pieces are

interlocked and sonic welded Bottom pieces are

interlocking

FINAL FILTER

•Filter classes F6 – F9 for compact cassettes•Standard Pre Filter: pocket filter G3 + G4 •Absolute stability at 100% relative humidity •Max. operating temperature up to 80 °C•Polystyrene housing, fully incinerable, no corrosion

COMBINED FILTER SYSTEM

MINIPLEAT FILTERBOX (HEPA)

Filter classes F6 – H14 according to DIN EN 779/DIN EN 1822 Absolute stability at 100%

relative humidity Max. operating temperature up

to 80 °C Leakage free casting of filter

media inside housingEndless foamed sealing Polystyrene housing, fully

incinerable, no corrosion

High efficiency pre-filter with low initial pressure dropHigh dust holding capacityExtended service life (the

Quality pleat can last up to 4 times longerthan standardpads or paneltype filters)

G-4 HIGH EFFICIENCY PRE- FILTER

ECONOMY PRE-FILTER

•Double wall beverage board frame•100% synthetic fiber media •Pleated media with expanded metal backing bonded to the frame•Filter media area not less than 27.4 Sq. Ft.•Maintained pleat shape and spacing•ASHARE 52.1 efficiency 90%

Remove airborne moisture100%, 3 microns & aboveGlass fiber media 2” reusable plastic frameDrain hole to allow drainage of

air stream moisture Environmental friendly

COALESCER(Mist Eliminator)

•High ageing•stability•Contains no•plasticizers •High ozone and•oxygen resistance •Temperature resistant up to•90 °C •CFC - free foaming process •Washable •Easy disposal by way of thermal recycling

PORET® ESTER(polyester foams)

HIGH EFFICIENCY MULTI–POCKETBAG FILTERSGalvanized steel provides strength and

resists corrosionNon-Carcinogenic synthetic media resists

microbial growthSpunbond scrim layers sandwich the

meltblown media to increase tensile strength and prevent tearing or puncturing

High dust holding capacityLow pressure dropEfficiencies - 45% to 95%Economical

RIGID POCKET FILTER

F5 – F6 RatedStability at 100%

Relative HumidityPlastic header (Polyurethane), Fully

Incinerable, Leak ProofSelf Supported Filter Pockets Stay

Rigid in the Air Stream Under High Turbulence (Spacer Channels In Pocket)Low Pressure Drop

CYLINDRICAL PULSE FILTER CARTRIDGES

Seamless rubber gasketCorrosion resistant zinc

coatingPleat separatorsAdhesive (fully sealed) to prevent bypassMetal supports to provide extra strength

Low pressure dropHigh efficiency (98%)High dust holding capacityLong service life

CONICAL PULSE FILTER CARTRIDGES

Low pressure dropHigh efficiencies (98%)Long service lifeHigh dust holding capacityHot spiral melt to provide extra

protection

Optimum protection for your gas turbineResistant to variable weather and

operating conditions

COMPOSITE CARTRIDGEFILTER (LM 6000)

2 stage protection systemfor your LM6000 unitLong service life with replaceable inner

filter linerDual element (inner/outer) for added

protection and filtration

High efficienciesLow pressure dropHigh dust holding capacity360 degree seamless gasket

PRE FILTER WRAPS

Low pressure dropHigh efficiencyExcellent dust holding capacity

Provides,protects, andprolongs the lifeof cartridgefilters

FLANGED REPLACEMENT FILTER

High efficiency mediaLow pressure dropHigh dust holding capacityHot spiral meltGalvanized metal end caps

Great filtration protection for your Farr-Tenkay-GT system

Long Service Life

TWIST–LOCK REPLACEMENT FILTER

Twist lock topGalvanized metal end capsLow pressure dropHigh dust holding capacityHigh efficiency

Excellent filtration protection for Pneuma-PulseSelf-Cleaning air filtration systems

from Pneumafil

Snap out lock edge holds clover leaf door in placeClover-leaf door holds filter pad

in place for efficient performance24 gauge steel "U" construction

for strength and durabilityTuck-in clover-leaf front door

has permanent hingeMitered corners - no protruding

edges

CLOVER LEAF PRE–FILTERHOLDING FRAME

POLYESTER PAD FILTERS

Economical and effective method of filtrationLong service lifeLow pressure dropExcellent dust loading

Gradient density with roughing layer for larger particles and fine layer for smaller particulate

SELF-CLEANINGPULSE SYSTEM

All components are moisture-resistant.

All medias are impregnated with a hygroexpansive resin (treatment)

Our filters are welded on the inside & outside of the expanded metal liner to provide extra strength and stability

A spiral hot melt bead is also applied on the inside and outside to provide proper pleat separation (embossing and pleat separation is utilized throughout the media)

$219,000.00$164,250.00$109,500.00$54,750.00$ 43,800.00$32,850.00$21,900.00$10,950.00$ 0.10

$197,100.00$147,825.00$ 98,550.00$49,275.00$ 39,420.00$29,565.00$19,710.00$ 9,855.00$ 0.09

$175,200.00$131,400.00$ 87,600.00$43,800.00$ 35,040.00$26,280.00$17,520.00$ 8,760.00$ 0.08

$153,300.00$114,975.00$ 76,650.00$38,325.00$ 30,660.00$22,995.00$15,330.00$ 7,665.00$ 0.07

$131,400.00$ 98,550.00$ 65,700.00$32,850.00$ 26,280.00$19,710.00$13,140.00$ 6,570.00$ 0.06

$109,500.00$ 82,125.00$ 54,750.00$27,375.00$ 21,900.00$16,425.00$10,950.00$ 5,745.00$ 0.05

$ 87,600.00$ 65,700.00$ 43,800.00$21,900.00$ 17,520.00$13,140.00$ 8,760.00$ 4,380.00$ 0.04

1.00”0.75”0.50”0.25”1.00”0.75”0.50”0.25”

Generator Size 50 MWDecrease in Resistance – In W.G.


Cost of

Power$ per KWH

EXAMPLES OF ENERGY SAVINGSwith High Efficiency Gas Turbine Filtration

Typical Annual Energy Cost SavingsWith GT Filters (based on Pressure Drop Differential 24-7 -365 Based Loaded Operation)

EXAMPLES OF ENERGY SAVINGSwith High Efficiency Gas Turbine Filtration

$657,700.00$492,750.00$328,500.00$164,250.00$438,000.00$328,500.00$219,000.00$109,500.00$ 0.10

$591,300.00$443,475.00$295,650.00$147,825.00$394,200.00$295,650.00$197,100.00$98,550.00$ 0.09

$525,600.00$394,200.00$262,800.00$131,400.00$350,400.00$262,800.00$175,200.00$87,600.00$ 0.08

$459,900.00$344,925.00$229,950.00$114,975.00$306,600.00$229,950.00$153,300.00$76,650.00$ 0.07

$394,200.00$295,650.00$197,100.00$98,550.00$262,800.00$197,100.00$131,400.00$65,700.00$ 0.06

$328,500.00$246,375.00$164,250.00$82,125.00$219,000.00$164,250.00$109,500.00$54,750.00$ 0.05

$262,800.00$197,100.00$131,400.00$65,700.00$175,200.00$131,400.00$87,600.00$43,800.00$ 0.04

1.00”0.75”0.50”0.25”1.00”0.75”0.50”0.25”



Cost of

Power$ per KWH

Typical Annual Energy Cost SavingsWith GT Filters (based on Pressure Drop Differential 24-7 -365 Based Loaded Operation)

ASHRAECERTIFICATION

NATIONAL AIR FILTRATION ASSOCIATIONCERTIFICATION

FINAL ANALYSISCOST OF STANDARD TURNKEYCOST OF STANDARD TURNKEY Combined Cycle orCombined Cycle or

Simple Cycle PlantSimple Cycle Plant++

OPERATING COSTS (FUEL)OPERATING COSTS (FUEL) 70% OF TOTAL PLANT 70% OF TOTAL PLANT EXPENDITURESEXPENDITURES

==AN INCREASING NEED FOR QUALITY GT AIR FILTRATIONAN INCREASING NEED FOR QUALITY GT AIR FILTRATION

THANK YOU

gas turbine inlet air filtration - frame 6 users...

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