GAS TURBINE EFFICIENCY IMPROVEMENT THROUGH AIR FILTER ...

POWERGEN ASIA 2010 SINGAPORE

2ND – 4TH NOVEMBER 2010

GAS TURBINE EFFICIENCY IMPROVEMENT

THROUGH AIR FILTER OPTIMIZATION

1

Gelugor Power Station

CONTENTS

1. AIR INLET SYSTEM

2. GT1 INLET FILTERS PROBLEM STATEMENT

3. GT1 INLET AIR HIGH DP SOLUTION

4. RESULTS

5. FILTER ELEMENT MODIFICATION DETAILS

6. COST COMPARISON

7. CONCLUSION

2


GELUGOR CAPACITY

3

Gelugor

CCP

GT1 110 Gas/Distillate John Brown MS9171E(GE) Dis 95

GT2 110 Gas/Distillate Nuovo Pignone MS9171E Oct 00

ST 110 Steam Fuji Electric System May 03

T. Ewa GT10 34 Distillate GEC Alsthom Frame 6 Jan 97

GT11 34 Distillate GEC Alsthom Frame 6 Jan 97

TOTAL CAPACITY UNDER GELUGOR POWER STATION

MANAGEMENT: 398 MW


CONTENTS

1. AIR INLET SYSTEM



4. RESULTS


6. COST COMPARISON

7. CONCLUSION

4


AIR INLET SYSTEM

• Air inlet system provides filtered air

to the gas turbine for combustion

•Configuration of GPS GT1 air filter

system:

• 1st stage weather louvers

• 2nd stage Pre-filter

• 3rd stage High Efficiency Filter

(Cartridge)

•Quality & quantity of the air being

drawn into the GT for combustion is a

major factor in determining its

performance and reliability.

5


AIR INLET SYSTEM

GT1 air inlet filter house is made up of a 4 matrix modules

type. The arrangement of the module is separated by 2 upper

and 2 lower floors and arranged in between a central plenum.6


AIR INLET SYSTEM TECHNICAL DATA

7


AIR INLET SYSTEM cont…

8

Factors that influence the performance of gas turbine :

• Ambient temperature

• Sufficient amount of clean air

• Level of humidity


CONTENTS

1. AIR INLET SYSTEM



4. RESULTS


6. COST COMPARISON

7. CONCLUSION

9


GT1 INLET FILTERS PROBLEM STATEMENT

10

• Increase in differential pressure (DP) of GT1 inlet air system

within a period of 3 to 4 months after initial replacement of the

filter elements.

• Major factors contribute to high DP:

• dry weather

• construction activities

• vehicle activities

• forest/illegal burning activities



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• DP increase exponentially after 9 mbar• Alarm at 11 mbar & shutdown at 14 mbar

• Manual replacement needed to run back

• Previous practice : regular 3-4 months shutdown toreplace the pre filters


Combustion Inspection Planned outage

-2.00

0.00

2.00

4.00

6.00

8.00

10.00

12.001

2-A

pr-

08

1-J

un

-08

21

-Jul-

08

9-S

ep

-08

29

-Oct-

08

18

-De

c-0

8

6-F

eb

-09

28

-Ma

r-0

9

17

-Ma

y-0

9

Dp

(mb

ar)

Date

Dp Across Pre & Fine Filter Dp Across Pre Filter (Left)

Dp Across Pre Filter (Right) Dp Across Fine Filter (Left)

Dp Across Fine Filter (Right)

GT1 DP FROM MAY 2008 TO APRIL 2009)

12

Planned outage



•Through experience, it required about 6 hours (permit to permit) to remove and replace all chocked pre filter

elements.

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CONTENTS

1. AIR INLET SYSTEM



4. RESULTS


6. COST COMPARISON

7. CONCLUSION

14


GT1 INLET AIR HIGH DP SOLUTION

• Proposal to change pre filter element type

• normal cartridge type filter to the pocket type air filter

• will last at least for 12 months

• Pocket type filter element

• more dust trapping surface area of 220% & dust holding capacity

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CARTRIDGE TYPE

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POCKET TYPE AIR FILTER ELEMENT

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POCKET TYPE AIR FILTER ELEMENT

• Heavy duty with high range efficiency

• Material 100% polyester fibers, laid on a polyester

scrim carrier material

• The seals are designed to withstand high pressure

• Dust holding capacity for is 1.5kg

• Initial dP can reach up to 5.0 mbar

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CONTENTS

1. AIR INLET SYSTEM



4. RESULTS


6. COST COMPARISON

7. CONCLUSION

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RESULTS (DP FROM MAY 2009 TO FEBRUARY 2010)

-1

0

1

2

3

4

5

6

7

28

-Mar-

09

17

-May-0

9

6-J

ul-

09

25

-Aug

-09

14

-Oct-

09

3-D

ec-0

9

22

-Ja

n-1

0

13

-Mar-

10

Dp

(m

bar)

Date

Dp Across Pre & Fine Filter Dp Across Pre Filter (Left)

Dp Across Pre Filter (Right) Dp Across Fine Filter (Left)

Dp Across Fine Filter (Right)

GT1 CI09 GT1 HGPI10

20


RESULTS (DP FROM MAY 2009 TO DECEMBER 2009)

• Maximum Dp across Pre & Fine filter : 6.5 mbar

• Maximum Dp across Pre filter : 3.1 mbar

• Maximum Dp across Fine filter :3.4 mbar

• Overall Dp is about 6-7 mbar across 1 year period

• Result: Filter replacement requirement extended

• from April 2009 until March 2010

• other concern : surrounding environmental condition

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CONTENTS

1. AIR INLET SYSTEM



4. RESULTS


6. COST COMPARISON

7. CONCLUSION

22


FILTER ELEMENT MODIFICATION DETAILS

Shutdown date 24 – 30 April 2009

Outage type Planned Outage

Type of last outage Combustion Inspection

Date of last outage December 2008

• Minor modification work of the filter element bracket at

filter house was carried out by GPS

• The duration of the total work ~ 7 days.

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MATERIAL & COST FOR INSTALLATION OF POCKET FILTER

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OVERALL COST :

• Pocket Filters : RM 37, 000.00

• Modification : RM 5, 000.00

Total overall cost (1 time) : RM 42, 000.00


GT1 POCKET FILTER INSTALLATION WORK

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GT1 POCKET FILTER INSTALLATION

Angle stainless steel to act as a

stopper to prevent filters from yank out

during operation

Filters attached to

base plate

26


GT1 POCKET FILTER INSTALLATION

The condition inside filter house after

pre filters installation27


CONTENTS

1. AIR INLET SYSTEM



4. RESULTS


6. COST COMPARISON

7. CONCLUSION

28


COST COMPARISON

• Pre-filters replacement cost in 12 Months:

Cartridge type (old): 3 times/year RM 31,000.00

Pocket type (new): 1 time/year RM 37,000.00

Difference: RM 6,000.00

• Modification cost (1 time) RM 5,000.00

• Total costs for replacement RM 11,000.00

(Incremental cost)

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COST COMPARISON (cont…)

• Total costs for replacement RM 11,000.00

(Incremental cost)

• Savings/extra income & values for

• Extra sales (due to no shutdown) = RM millions

• Extra capacity payment > RM 1.0 million

• Station’s reputation priceless…..

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CONTENTS

1. AIR INLET SYSTEM



4. RESULTS


6. COST COMPARISON

7. CONCLUSION

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SUGGESTION & RECOMMENDATION

Further actions:

• Knowledge-sharing between similar plants in TNB

• Incorporate filter replacement during major shutdown

• Study on the impact of performance & heat rate to

gas turbine upon using the pocket type filters

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THANK YOU


We’ve got the power, to serve, to strive and to deliver

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GAS TURBINE EFFICIENCY IMPROVEMENT THROUGH AIR FILTER ...

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