Gas Turbines technology and the importance of air filtration

Gas Turbines technology

and

Clean air solutionsClean air solutionsClean air solutionsClean air solutions

and

Why air filtration is so important!

© CAMFIL2014-07-21

Why EPA filtration?

Clean air solutionsClean air solutionsClean air solutions © CAMFIL2014-07-21

Why EPA filtration?

• What are the operator needs and why?

• Reliable efficiency = saves money (output

and maintenance)

• Pressure loss (dP) = costs money (output)

• Turbine life = less stops = saves money

Clean air solutionsClean air solutionsClean air solutions

• Turbine life = less stops = saves money

(more output hours)

• Turbine life = less maintenance = saves

money.

• RISK = consequences and possibly

guarantees = insurance

© CAMFIL2014-07-21

Gas turbine technology and function4

• Single cycle operation has an efficiency up

to 40% for the most efficient GT on the

market. (Mainly used for peak demand,

standby units, offshore units)

VERSUS

• combined cycle operation (Mainly used for

base load, landbased or cycling units

lately)

1. Combined power generation (Gas


1. Combined power generation (Gas

turbine + Steam turbine) �

Efficiency up to 60% efficiency

available now

2. Combined power with steam for

other chemical processes (cracking

etc.) � Efficiency > 70%

3. Combined heat and power (District

heating) � Efficiency >70%

© CAMFIL2014-07-21

Gas turbine technology and function5

• Generator drive versus Mechanical drive � Energy versus product

• Heavy industrial type GT versus Aeroderivative type of GT � Now split is less

obvious as technology has been transferred to heavy industrial GT.


• Single shaft versus multiple shaft turbines � split of LP turbine from HP turbine

• Cold end drive versus hot end drive units� defines where the load (Generator

or pump, compressor) is positioned in relation to the turbine section.

© CAMFIL2014-07-21

1. Single cycle efficiency increases

• Compressor ratio is increased

• Turbine inlet temperature is increased

2. Emissions and Carbon footprint become more

important every day

3. Power demand keeps increasing due to emerging

markets (lead times need to be reduced)

Gas turbine technology6


4. Maintenance requirements to be limited as units

become installed in more remote locations

5. Installation/erection/commissioning time to be

reduced

6. Prevention is better than reaction

7. Flexibility of systems as environment and demand is

continuously changing

8. Increased availability and reliability required

© CAMFIL2014-07-21

Air Filtration purpose

• Protection against erosion from “heavy” particles > 5 micron. Mainly

in compressor blades and guide vanes.

• Protection against fouling from small particles < 2 micron. Builds up

on blades and guide vanes resulting in reduced compressor

efficiency.

Risk for plugging of cooling holes in power turbine


Risk for plugging of cooling holes in power turbine

• Protection from corrosion in both compressor and hot gas

passages. In turbine section sulphidation and oxidation can occur

when airborne NaCl and fuelborne S during high temperature attack

hot gas parts. © CAMFIL2014-07-21

Gas Turbine efficiency losses due to:

1. Inlet pressure drop

2. Ambient temperature and humidity

3. Fouling of compressor

4. Hot corrosion in Turbine section


© CAMFIL2014-07-21

Gas Turbine performance is partly recuperated by:

1. Online washing sequence (2 and 3)� only minor recuperation effect as dirt is

pushed further into the compressor. Only slows down the effect of fouling.

2. Offline washing sequence (1)� more or less full recuperation from fouling possible

BUT other degradations take place which cannot be recuperated. (like e.g. hot

corrosion, plugged cooling holes, ageing, erosion etc.)


© CAMFIL2014-07-21

Erosion

• Maintaining optimum airfoil shape is critical to compressor and turbine efficiency

• Tight blade tip clearances is critical to minimise stage leakage losses

• Small changes in component efficiencies make major changes to overall cycle efficiency.

• Modern filtration systems can eliminate erosion by airborne particles

NON-RECOVERABLE

BY WASHING


• Modern filtration systems can eliminate erosion by airborne particles

© CAMFIL2014-07-21

Hot section corrosion

If the filtration system allows NaCl to enter the combustion air while sulphur is

present in fuel or in the air; chemical reaction will occur in the hot section of

the gas turbine

Two types of Hot End Corrosion:

NON-RECOVERABLE

BY WASHING


• Type-1 hot corrosion at 815-925oC removes blade coatings and causes

surface oxidation and inter-granular attack in the turbine section

• Type-2 hot corrosion at 595-760oC leads to scaling of turbine airfoil surfaces

© CAMFIL2014-07-21

Compressor fouling

• For engine that run continuously, fouling is the major problem. Many new high

performances gas turbines are inadequately protected against fouling

• Compressor fouling modifies effective airfoil shapes and increases drag.

• The fouling rate is a function of the concentration of submicron particles in

ambient air.

• The life of cooled airfoils is very dependent on effective heat transfer in the

PARTLY RECOVERABLE

BY WASHING


• The life of cooled airfoils is very dependent on effective heat transfer in the

internal cooling passages (NON-RECOVERABLE)

BUT BETTER TO PREVENT FOULING ALL TOGETHER

by using an

EPA FILTER SYSTEM

© CAMFIL2014-07-21

Compressor washing• Most turbine manufacturers do not recommend online washing for extreme

duty application where sulphur is in the fuel and H2S in the air.

• If fouling is not too severe an off-line water wash can restore most of the lost

compressor performance but maybe frequently required.

• Compressor washing has no remedial effect on fouling of internal heat transfer

surfaces of cooled airfoils

• Off-line washing takes a turbine out of service for at least 8 hours which can


• Off-line washing takes a turbine out of service for at least 8 hours which can

have a significant economic cost

© CAMFIL2014-07-21

THE TURBINE DEATH SPIRALInadequate micro-particle filtering

Turbine fouling / corrosion

More fuel to maintain power

Overheating damage


Power loss/failure

Expensive service/renovation stop

BEST SOLUTION IS TO PREVENT

FOULING ALL TOGETHER

by using an

EPA FILTER SYSTEM

© CAMFIL2014-07-21

Gas turbine filtration challenges

A GT filter must withstand:

1. Humidity and wet conditions

2. Turbulence

3. All kinds of particles, i.e.:- salt and other hygroscopic


- salt and other hygroscopic particles- dry dust- sticky hydrocarbons

4. High pressure drop without any air bypass

Erosion, Corrosion & Fouling

Air Filtration purpose

• Protection against erosion from “heavy” particles > 5 micron.

Mainly in compressor blades and guide vanes.

• Protection against fouling from small particles < 2 micron. Builds

up on blades and guide vanes resulting in reduced compressor

efficiency.


efficiency.

Risk for plugging of cooling holes in power turbine = permanent

• Protection from corrosion in both compressor and hot gas

passages. In turbine section sulfidation and oxidation can occur

when airborne NaCl and fuel borne S during high temperature

attack hot gas parts.

Air Filter Performance

Higher filter class

�Less particles penetration

�cleaner engine

�Longer service intervals

�Higher availability/reliability

�Lower operating costs

17


�Lower operating costs

Penetration on 0.4 µm particles is typically reduced from 25% for an F8 filter to less than 0.15% with an E12 filter

OR approximately 150 times better protected.

Combined filter particle efficiencies, F9 to E12

80.00%

90.00%

100.00%

F6+F9+E12

F7+E10

Particle stopping Efficiency

M6+F9+E12

F7+E10


50.00%

60.00%

70.00% F6+F9

G4+F9

© CAMFIL2014-07-21

Microns

Particle stopping Efficiency

M6+F9

G4+F9

Low versus High dust concentration environment (20µg/m³) (120µg/m³)

0 kg/yr

50 kg/yr

100 kg/yr

150 kg/yr

200 kg/yr

250 kg/yr

Dust Penetration, PM10


0 kg/yr

50 kg/yr

100 kg/yr

150 kg/yr

200 kg/yr

250 kg/yr




0 kg/yr

10 kg/yr

20 kg/yr

30 kg/yr

40 kg/yr

50 kg/yr

60 kg/yr

70 kg/yr

F9 - 95% E10 E11 F9+E11 F9+F9+E12


0 kg/yr

10 kg/yr

20 kg/yr

30 kg/yr

40 kg/yr

50 kg/yr

60 kg/yr

70 kg/yr

F9 - 95% E10 E11 F9+E11 F9+F9+E12


© CAMFIL2014-07-21

Energy savings

• Filters

Labour (installing and replacing)

Energy consumption

Cleaning/maintenance

Downtime

Disposal of used filters


Disposal of used filters

= LCC

The cost of clean air is not the cost of replacement filters

BUT how much energy the filters use during their working life.

© CAMFIL FARR2014-07-21

Power output

Power output

Maintenance & power output

EPA/HEPA FILTRATION


Power output

TimePower output

Time

Downtime for wash Downtime for wash

© CAMFIL2014-07-21

Po

wer

ou

tpu

t

Performance gain

EPA Filtration always best choice


Po

wer

ou

tpu

t

Time

Increased operation time

© CAMFIL2014-07-21

A high performance engine

Clean air solutionsClean air solutionsClean air solutions Needs a high performance filter

© CAMFIL2014-07-21

WOULD YOU

SETTLE FOR

SECOND BEST?

WHEN BUYING

SERVICE PARTS

FOR YOUR ENGINE

Clean air solutionsClean air solutionsClean air solutionsClean air solutions

SECOND BEST?

© CAMFIL2014-07-21

Efficiency

Cost (GT degradation)

General common rules ”common sense”

RiskAvailability

Pressure drop

Cost (loss)1 2

3 4


Strength

Risk

Filter stages

Availability 3 4

© CAMFIL2014-07-21

What is the value of GT output?

A. Typical pipeline GT,

always one in

standby mode.

B. Typical LNG

process GT.

Output value

BA

E

High


process GT.

C. Typical PG peak

unit.

D. Typical PG unit.

E. Seasonal machine.

I.e. high value 8

months

Output value

Need of GT output (time)

DC

HighLow

© CAMFIL2014-07-21

What is the value of fouling?• Below is one example of the cost for output losses due to dP and fouling in

comparison with the cost for the filter elements.

2,000,000 €

2,500,000 €

3,000,000 €

Cost dP

Filter cost

Cost Fouling

Total cost

£ 2,400,000

£ 2,000,000

£ 1,600,000


Total costs for a PGT 25+ in industrial

environment for 10years.

0 €

500,000 €

1,000,000 €

1,500,000 €

F7 F9 E10 E11 E12

CamGT

3V-600

© CAMFIL2014-07-21

£ 1,200,000

£ 800,000

£ 400,000

£ 0

28

CamGT 3V-600- Non stop performance



- Non stop performance

What is the value of a pressure loss (dP)?

• Considering an output value for PG of £0.05/kWh and £0,10/kWh for O&G, the

output loss due to dP will have different impact.

120.0 Pa

140.0 Pa

160.0 Pa

180.0 Pa

200.0 Pa

PG (low)

PG (High)

O&G (low)

O&G (high) 65-90Pa difference

justifies a £200 price

difference for PG


0.0 Pa

20.0 Pa

40.0 Pa

60.0 Pa

80.0 Pa

100.0 Pa

120.0 Pa

0 € 50 € 100 € 150 € 200 € 250 € 300 € 350 € 400 € 450 € 500 € 550 € 600 €

difference for PG

10-15Pa difference

justifies a £40 price

difference for O&G

© CAMFIL2014-07-21

£0 £40 £80 £120 £160 £200 £240 £280 £320 £360 £400 £440 £480

EPA filtration with focus on User benefits

Key Features User benefits

High constant efficiency

(no discharge)

Prevents fouling – and reduces maintenance and need for GT washing

(On- and off-line). Maintenance is expensive!

Loss due to fouling of 5% is not abnormal. Up to 20% is possible!

Low stable pressure drop Saves fuel, increases power output! (1000Pa < 2% output loss)

Large media area and smart

design for long life

Longer life diminishes downtime and cost for filter change

Downtime = loss of output.


design for long life Downtime = loss of output.

Lower pressure drop and higher DHC means increased GT output and

GT availability.

Vertical pleating and open hot melt

ensures quick water drainage

Low pressure drop and to prevent corrosion since salty/dirty water is

quickly drained away instead of left to slowly migrate through the media.

EPA tight frame No bypass air keeps engine clean which means higher GT output!

Robust construction Value of no risk? No damage on element if compressor surges.

© CAMFIL2014-07-21

Medium velocity barrier system: 3 stages

Weather Hood alt.

Weather Louvre

Vane Pre-filter Cam-Flo XMGT

M6, F7,F9

High efficiency filter

CamGT F7-F9, E10-E12


Face velocity: 2.5 – 3.9 m/s

Media velocity: 0.35 – 0.54m/s


Media velocity: 0.05 – 0.07 m/s

© CAMFIL2014-07-21

Medium velocity barrier system: 4 stages

Weather Hood alt.

Weather Louvre

Vane Pre-filter Cam-Flo XMGT

M6, F7,F9


CamGT F7-F9


CamGT E10-E12



Media velocity: 0.35 – 0.54m/s


Media velocity: 0.05 – 0.07 m/s

© CAMFIL2014-07-21

Po

wer

ou

tpu

t

Performance gainWhy EPA Filtration?

To Reduce Costs

Typical GT output cycles


Po

wer

ou

tpu

t

Time

Increased operation time

© CAMFIL2014-07-21

Why EPA filtration?


To reduce costs and improve efficiencyBy paying attention to the individual plant details.

Camfil GT filter testing

Further testing relevant for GT applications:

Humidity testing

• A clean filter installed in a test duct is exposed to a relative humidity

that varies from 90-100%.

• The filter is exposed to a number of cycles to determine if or how the


• The filter is exposed to a number of cycles to determine if or how the

clean filter media reacts to humidity .

This is a realtively easy and quick test to make sure that media is

hydrophobic and the wet stiffness of the media is at acceptable levels.



Strength test

• A GT filter must withstand harsh environments and continuously

changing ambient conditions. To determine how strong the filter is and

when and how it breaks is the purpose of this test.


when and how it breaks is the purpose of this test.

• This should preferably be done in wet conditions. The filter will be

exposed to a gradually increasing dP until it breaks or severe bypass is

observed.

Not to be compared to blast wave testing. Blast wave testing is to simulate

compressor surge conditions.



Salt test

• Salt is enemy no. one for a GT since it causes permanent corrosion –

consequently a GT filter must be able to handle salt and moisture.


consequently a GT filter must be able to handle salt and moisture.

• Salt water (3.5%) is slowly sprayed onto a clean filter in operation.

• Approx. 4-5 liter/h is continuously sprayed on the filter for several hours

then let to dry. This procedure repeats for several cycles.

• This to determine dP development and how much salt that penetrates

the filter over time – regardless if it is in liquid or solid state.

CamGT

Box type

CamGT

3V-600

Opakfil

GT Std

Opakfil GT

Premium

CamGT

4V-300

CamPulse

Cam-Flo

XMGT

CamClose


GT Std

TurboPac

CamPulse

CamPulse

Tenkay

Media alternatives:

Polytech, Polytech

NFR, Polyteh HE, GTC,

GTD, CamBrane

30/30 GT

© CAMFIL2014-07-21

Reliability

Strongest filter on the market

guarantees a risk free operation.

Environments

Market leader. Optimal for all environments, incl

harsh humid and off-shore environments.

TOP OF THE CLASS


Efficient

Market leader with stable efficiency F7-F9, E10-E12 and H13 and no bypass.

Pressure loss / Air resistance

Market leader with lowest dP on the market

Life time

Market leader with optimized amount of media.

guarantees a risk free operation.

© CAMFIL2014-07-21

Key benefits

Less maintenance stops

Lower fuel consumption

Extended turbine life


Extended turbine life

Optimal for all environments

Reduced Total Cost of Ownership

© CAMFIL2014-07-21

CamGT Air resistance 3V-600 vs 4V-300

260 Pa

310 Pa

360 Pa

CamGt 3V-600 E12

CamGT 3V-600 E11

CamGT 3V-600 E10

CamGt 3V-600 F9

CamGt 3V-600 F8

CamGT 4V-300 E12

CamGT 4V-300 E11

CamGT 4V-300 E10

CamGT 4V-300 F9

CamGT 3V-600 CamBrane

Today E10 to E10Today E10 to E12 or membrane


60 Pa

110 Pa

160 Pa

210 Pa

3,400 m³/h 3,650 m³/h 3,900 m³/h 4,150 m³/h 4,400 m³/h

∆∆∆∆70Pa ≈ £175

© CAMFIL2014-07-21

Our Core Values

• RELIABILITYOur fundamental business principle is based on trust and transparency,

the basis to build long-term relationships with our stakeholders.

• COMMITMENTWe are committed to do our best in all situations. As a responsible company, we consider

global citizenship as part of our philosophy and also adhere to the values and principles of

sustainable development.

• TEAMWORK


• TEAMWORKOur strength and competitive advantage is, and will always be, people. We encourage cooperative

efforts and knowledge sharing across all our activities and at every level of the company, to make

every workday a fulfilment for our employees, as well as to provide the best service possible to

our clients.

• CUSTOMER SATISFACTIONWe permanently strive to improve the quality of our products and services. We also provide filtration

solutions to help our customers meet their own sustainability objectives.

• LOCAL PRESENCEWe encourage local people employment and seek to adapt to local stakes by respecting the culture

and environmental concerns of communities.

© CAMFIL2014-07-21

Questions?


Questions?

[email protected]

For process plant applications including GT

WWW.CAMFIL.CO.UK

© CAMFIL2014-07-21

Gas Turbines technology and the importance of air filtration

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Transcript of Gas Turbines technology and the importance of air filtration