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
• 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 function 4
• 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 function 5
• 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 technology
6
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 SPIRAL
Inadequate 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 m 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
ParticlestoppingEfficiency
M6+F9+E12
F7+E10
50.00%
60.00%
70.00%
F6+F9
G4+F9
©CAMFIL2014-07-21
Microns
ParticlestoppingEfficiency
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.
©CAMFILFARR2014-07-21

Poweroutput
Poweroutput
Maintenance & power output
EPA/HEPA FILTRATION
Poweroutput
Time
Poweroutput
Time
Downtime for wash Downtime for wash
©CAMFIL2014-07-21

Poweroutput
Performance gain
EPA Filtration always best choice
Poweroutput
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.
Outputvalue
BA
E
High
process GT.
C. Typical PG peak
unit.
D. Typical PG unit.
E. Seasonal machine.
I.e. high value 8
months
Outputvalue
Need of GT output (time)
D
C
High
Low
©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

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

Poweroutput
Performance gain
Why EPA Filtration?
To Reduce Costs
Typical GT output cycles
Poweroutput
Time
Increased operation time
©CAMFIL2014-07-21

Why EPA filtration?
©CAMFIL2014-07-21
To reduce costs and improve efficiency
By 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 E10
Today 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
• RELIABILITY
Our fundamental business principle is based on trust and transparency,
the basis to build long-term relationships with our stakeholders.
• COMMITMENT
We 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
• TEAMWORK
Our 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 SATISFACTION
We 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 PRESENCE
We 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?
peter.dyment@camfil.co.uk
For process plant applications including GT
WWW.CAMFIL.CO.UK
©CAMFIL2014-07-21

Gas Turbines technology and the importance of air filtration

Recommandé

Recommandé

Contenu connexe

Tendances

Tendances (20)

En vedette

En vedette (14)

Similaire à Gas Turbines technology and the importance of air filtration

Similaire à Gas Turbines technology and the importance of air filtration (20)

Plus de Camfil UK

Plus de Camfil UK (20)

Dernier

Dernier (20)

Gas Turbines technology and the importance of air filtration