V004t10a009 84 GT 39
V004t10a009 84 GT 39
ABSTRACT INTRODUCTION
Industrial gas turbines swallow air at a Air inlet filtration systems are used
rate of approximately 14 to 16 kg/kWh. Even to protect the gas turbine against fouling,
in clean environments the amount of solid erosion, corrosion and foreign object
particle ingestion is significant. A damage.
70.000 kW gas turbine operating in a typical
residential area could ingest 1.3 to 1.5 kg Fouling
of solid contaminants in a 24 hour period.
The same gas turbine operating in a typical Fouling is the degradation of efficiency
mining or oil field region could ingest 33 to and flow capacity caused by the adherence of
39 kg of solid contaminants in a 24 hour particle matter/contaminants to the surface
period. Depending on the composition, size, of the turbomachine blading. Fouling, which
quantity and condition (wet, dry, sticky) of can normally be reversed by cleaning, can
the ingested particles, performance loss, occur in the compressor and/or turbine. The
due to the fouling of the compressor and/or contaminants that cause compressor fouling
turbine and hardware deterioration, due to enter the gas turbine with the inlet air.
erosion, corrosion and/or foreign object The contaminants that cause turbine fouling
damage, can be experienced. can enter the gas turbine with the inlet
air, the fuel, fuel additives or NO x control
To protect against performance loss and injection fluid.
hardware deterioration, industrial gas
turbines are normally equipped with air All compressors are susceptible to foul-
inlet filtration systems. However, the ing with the degree and rate of fouling de-
effectiveness of the filtration system pending on the type and condition of the
depends on how well it is matched to the airborne contaminants, the site environment
contaminants and site conditions. Matching and climatic conditions. Compressor fouling
the filtration system to the contaminants is generally caused by particle matter of
and site conditions is usually a judgement 5 ism in diameter or less. Whether turbine
decision based on experience and available fouling, if it should occur, is caused by
information. This paper was written in an airborne contaminants,depends on the ability
effort to enhance the equipment selection of the airborne contaminants to reach the
process by reviewing BBC's experience with turbine section and on the ability of these
air inlet filtration systems. contaminants (together with fuel ash) to
adhere to the turbine blading.
ACHIEVABLE RESULTS
2. Reduction in erosion.
The elimination of foreign object damage Recently, use has been made of self-
and erosion are the only absolute gain that cleaning filters, referred to as pulse fil-
can be achieved with air inlet filtration. ters. In addition to high efficiency separa-
All other gains are less than absolute be- tion, these filters are reported to have
cause existing air inlet filtration systems longer life expectancy than other air inlet
are not able to eliminate 100 % of the air- filter systems.
borne contaminants.
Electrostatic filters have also been
used successfully in the past. BBC employed
HISTORICAL OVERVIEW electrostatic filters on gas turbine in-
stallations burning low BTU blast furnace
The effect of fouling of an axial com- gas.
pressor was first measured in 1936. A coating
of about 0.1 mm was applied to the blading
of a relatively small machine. The reduction ELEMENTS OF THE AIR INTAKE SYSTEM
in flow capacity was found to be about 10
and the reduction in compressor efficiency Figure 2 schematically shows the most
about 5 %, very similar to current experi- important elements of the air intake system
ence. for stationary gas turbines. Normally the
weather shield and inlet silencing baffles
The first air filters used on gas turbine are always included.
installations were stationary oil-coated The screen element should also be in-
elements. They required a great deal of main- cluded to protect against bird ingestion
tenance and a shift was soon made to oil- and other large foreign object ingestion.
coated endless rotating belts of metal The bypass arrangement is used when there
elements. Contaminants are removed from the is a danger of icing or filter clogging. If
filter elements and the oil coating replaced there is a threat of icing, the inlet air,
by the rotating oil bath filters. wherever possible, is preheated before it
reaches the filtration system i3I. In certain
In conjunction with the development of cases evaporative cooling, not shown in
plastics, the next generation of filters figure 2, is used to reduce the inlet air
introduced were the moving media roll-type. temperature.
These filters consist of two reels. One reel
containing the unused rolled filter media
and the other reel, the take-up reel, con- THE EFFECT OF HUMIDITY
taining the used media. The filter media ad-
vances as a function of the pressure drop A high relative humidity can accelerate
registered across the media. the process of fouling. In front of the first.
Inertial filters were developed in rotating row in the compressor, the air is
parallel with the roll-type filters. The accelerated to about 200 m/s, which entails
primary purpose of these filters is to remove a reduction in static temperature of about
large, 10 um or greater, particles from the °
20 C f31.
air stream to reduce the possibility of
erosion.
1 23 4 5 z0
airborne dust,
0
0,01 0,1 1 10 µm
Figure 3 shows the change in the static particle size
air temperature, T as , at the entry into the
compressor blading. Figure 3 also shows the
change in the saturation temperature of the
air, T s , with various relative humidities
before the compressor. As an example, when
the relative humidity of the air, 0, is 0.6, Fig. 4 Dust Particle Distribution in the
the air temperature, T as , is lower, shaded Two Stage Filtration System
zone of figure 3, than the saturation tem-
perature T s , and this can cause condensation
of the water vapor. When this happens, the
dust particles serve as nuclei for conden- r-borne dust
sation, and become damp, which speeds up the z0
dust separation
process of forming deposits. During the course n prefilter
I
compressor islet
r 10
MULTI-STAGE FILTRATION
a
If a high degree of dust removal is
called for, two or three stages of filtra-
0,01 0,1 1 10 'lm
tion provide advantages with regard to oper- particle size
ating costs. The first filter stage is of a
sturdy structure, and is designed to remove
coarse particles of dust. The high efficiency
filter that follows is designed to remove
fine dust particles. Figure 4 shows the Fig. 5 Particle Surface Distribution in
filtration effect of the two filters as a the Two Stage Filtration System
function of the size of the particles.
If all the operating conditions are tion of an air filtration system are dis-
taken into consideration when evaluating cussed below.
various types of filters,the array of para-
meters becomes too large. Several parameters
can be grouped to define typical ambient
conditions to simplify performance compari-
sons. One such grouping is given in Table I. C
In addition to the climatic conditions, '.
to
Poole 1 :;ro.nprrw of ;,.,mot•c Con0.tions
I. __
Selection; Recommended Areas of
C 501 0 20/80 much /0l coarse small smell
fine Application
D 50/20 70/90 011001 fine small -rn-I
1. High efficiency filters
2. Roll and mat type filters
Aggressivmty reloimve ccmporson e g cement dust. N 0 1. `- 9 ,- ._ _.,, 3. Pulse and bag filters
Amount of miscellaneous mater / eq insects, fotmoy-rornimonO.,„ .._ 4. Oil bath filters
particles that re00ily adhere 5. Electrostatic filters
6. Inertial separators
7. Wet separators
Table I Grouping of Climatic Conditions Past experience tells us that when there
is fouling of the compressor, the gas turbine
process behaves in a manner similar to when
Figure 6, which conforms to BBC prac- there is an increase in the pressure drop in
tice,demonstrates a method of selecting the air inlet system, i.e., with a loss in
filters for air filtration systems. Two power output of Ap/p = 1 %, the specific
examples are indicated on the figure. Both heat rate Aw/w increases by 0.5 0.
result in the selection of a two stage fil- To justify the use of air filtration,
tration system. Point A has been selected as the additional costs that arise due to the
the initial condition for the first example. installation and maintenance of the filters
According to Fig. 6, an inertial separator should be less than the capitalized losses
can be selected as the first stage filter. due to fouling, erosion and corrosion.
The amount of dust in the inertial separator
will be reduced to Point B. It can be seen It is not yet possible to calculate the
that a dry filter is quite suitable for the losses in power output and efficiency due to
second stage. In the second example, the fouling of the compressor for a given flow
air is relatively moist. The initial condi- and composition of dust. Experience tells us
tion is located at Point C. A wet separator that a large flow of dust, a high humidity,
or an oil-bath filter would enter into con- and a high percentage of fine dust parti-
sideration for the first stage filter. The cles encourage fouling. The measurement of
amount of dust in this filter will be re- dust at the site [2J and operating experience
duced to Point D. An electrostatic filter with regard to losses due to compressor
would be advantageous for the second stage. fouling, figure 7, can be used as an example.
In reference 2, the measured dust flow, on
In addition to selecting the filtration an average, was 0.048 ppm. Assuming a grain
system for optimum operation, consideration size distribution similar to that in figure
must also be given to the customer's specific 4, and filter efficiency of 70 % a dust flow
situation, such as, the availability of of about 0.015 ppm is obtained after the
trained personnel, economic constraints and first filter. The compressor was washed
the planned duty cycle for the gas turbine. about every 5000 hours with practically a
The economic aspects involved in the selec- 100 a recovery in power output. Attempts
were also made to clean the compressor in
f"
ing on the quality of manufacture and main- 100
tenance, especially when using high effi- r
P
ciency filters it is important to seal all
leaks. 90
10 15
10. Disposal of the used filter pads or
elements, and of the sludge from oil troughs operation time 103h
11. Filter units have to be taken out Fig. 8 Power and efficiency losses as a
and replaced after fairly short time inter- function of time and loss recovery
vals, particularly when they are in a corro- by different methods
sive atmosphere and there is inadequate
maintenance. Good upkeep, e.g., by restora-
tion of painted surfaces and replacement of 3. A gas turbine plant in a desert area
worn parts, is necessary. with frequent sandstorms was equipped with
an inertial separator inlet filter which was
elevated 10 meters above ground level. After
EXPERIENCE - SPECIFIC about 70.000 hours in operation, only very
little erosion was observed on the compressor
1. In BBC-Review February 1979, Pages blades.
97-103 L21, there are reports on the studies
of the air in the environment of a gas 4. A gas turbine for a cement plant in a
turbine plant. The gas turbine was equipped tropical area with a very heavy amount of
with a roll-type filter. In spite of the air airborne dust was initially equipped with
filtration, a loss in power output was meas- roll-type filters and inertial separators.
ured. The use of these filters produced poor re-
sults. Cement dust, together with humidity,
2. BBC Review, December 1980 [11, showed formed a hard crust on both types of filters.
how the losses changed as a function of time, In addition, the roll-type filters clogged
Figure 8. The compressor was cleaned in because of the fine cement dust. Based on
various ways during operation and while at good experience obtained 30 years earlier in
a standstill. Figure 8 also shows the effect the use of oil-bath rotating filters, oil-
of these cleanings. It also illustrates bath rotating filters were installed. Because
that for this plant, dry cleaning in opera- of the very large amount of dust involved,
tion results in only a small recovery of special precautions had to be taken to remove
losses. Washing at very low rotary speeds the oil sludge from the trough. The oil-bath
is very efficient. Installing a last stage rotating filters resolved the filtration
high efficiency filter could be recommended problems.
as an improvement with respect to the foul-
ing of the blades. Because there is a 5. A gas turbine plant on an island, using
danger, of icing, particularly in winter, fuel contaminated with salt water, displayed
preheating of the inlet air also had to be high temperature corrosion on the turbine
employed. blades. In addition to the dust from the
environment, the air also contained salt in
a dry form. Installing high efficiency filters
with coarser pre-filters has produced good
success with respect to the reduction of the
compressor fouling. In addition, the filter
system, in conjunction with a fuel additive,
has successfully reduced the corrosive attack
on the turbine blades. The life expectancy
of the high efficiency filter is 12.000 to
16.000 hours.