Post on 06-Feb-2018
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
TYPICAL PROBLEMS ASSOCIATEDWITH AIR QUALITY
Cooling Passage PluggingRotor ImbalanceLocking of Turbine Blade Roots
Causes and Solutions
TYPICAL PROBLEMS ASSOCIATEDWITH AIR QUALITY
“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
WHY GOOD AIR INLETFILTRATION IS IMPORTANT
Ingestion of Particulate
WHY GOOD AIR INLETFILTRATION IS IMPORTANT
Protection of Equipment Cost Benefit
•Maintenance Labor•Unscheduled Downtime•High Gas Consumption•Preventable Work Orders•Business (Power) Interruption
WHY GOOD AIR INLETFILTRATION IS IMPORTANT
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
THE MOST IMPORTANT FACTORS WHEN THE MOST IMPORTANT FACTORS WHEN CONSIDERING GT AIR FILTRATIONCONSIDERING GT AIR FILTRATION
THE MOST IMPORTANT FACTORS WHEN THE MOST IMPORTANT FACTORS WHEN CONSIDERING GT AIR FILTRATIONCONSIDERING GT AIR FILTRATION
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
THE MOST IMPORTANT FACTORS WHEN THE MOST IMPORTANT FACTORS WHEN CONSIDERING GT AIR FILTRATIONCONSIDERING GT AIR FILTRATION
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 MOST IMPORTANT FACTORS WHEN THE MOST IMPORTANT FACTORS WHEN CONSIDERING GT AIR FILTRATIONCONSIDERING GT AIR FILTRATION
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.
THE MOST IMPORTANT FACTORS WHEN THE MOST IMPORTANT FACTORS WHEN CONSIDERING GT AIR FILTRATIONCONSIDERING GT AIR FILTRATION
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
FILTER SELECTIONFILTER SELECTIONCRITERIACRITERIA
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
FILTER SELECTIONFILTER SELECTIONCRITERIACRITERIA
Best Applications
High Humidity Coalescer/Final Filter
Arctic Pulse Jet
Tropical Coalescer/Final Filter
FILTER SELECTIONFILTER SELECTIONCRITERIACRITERIA
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
High EfficiencyFilter 90 - 95%
High EfficiencyFilter 90 - 95%
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
stal
- M
arin
eIn
dust
rial -
U
rban
Rur
al
High Humidity
Without Sand
Storms
Sol. 1
Sol. 2
Scarce Humidity
Scarce Humidity
High Humidity
Off
Sho
reN
orm
alD
usty
Succession Of Filtering StagesEnvironment
Salt / Humidity
Mist / Sea Storms
Dusty
FILTER SELECTIONFILTER SELECTIONCRITERIACRITERIA
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
TYPES OF GAS TURBINETYPES OF GAS TURBINEAIR FILTRATIONAIR FILTRATION
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
TYPES OF GAS TURBINETYPES OF GAS TURBINEAIR FILTRATIONAIR FILTRATION
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
TYPES OF GAS TURBINETYPES OF GAS TURBINEAIR FILTRATIONAIR FILTRATION
New GT Filtration Technology
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
TYPES OF GAS TURBINETYPES OF GAS TURBINEAIR FILTRATIONAIR FILTRATION
New GT Filtration Technology
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
TYPES OF GAS TURBINETYPES OF GAS TURBINEAIR FILTRATIONAIR FILTRATION
New GT Filtration Technology
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
FILTER MAINTENANCEFILTER MAINTENANCESTRATEGYSTRATEGY
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”)
FILTER MAINTENANCEFILTER MAINTENANCESTRATEGYSTRATEGY
Pressure Drop Replacement
FILTER MAINTENANCEFILTER MAINTENANCESTRATEGYSTRATEGY
(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.
Generator Size 10 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”
Generator Size 150 MWDecrease in Resistance – In W.G.
Generator Size 100 MWDecrease in Resistance – In W.G.
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