Gore HEPA Turbine Filter Update - x2 Panel Product

Transcription

1 Gore HEPA Turbine Filter Update - x2 Panel Product GE 6B User s Group Scottsdale, Arizona June 9, 2011 By Steve Medvetz W.L. Gore & Associates

2 GORE HEPA Turbine Filters Dramatically Improve the Operation of Gas Turbines Simple retrofit Similar initial pressure drop Similar filter life

3 Presentation Agenda 1. Share results from multiple sites using filters in round form 2. Show results of 3 rd party salt & water penetration testing 3. Share status of 2 x2 panel installations and commercial status of Gore s products

4 Case 1: Constant Power Output Coastal Power Plant (RB211-30MW) - UK 3 off-line washings/yr. 0 off-line washings/yr. Power Variance from corrected target (MW) offline compressor washing offline compressor washing and filter replacement Days F9 standard filter GORE Turbine Filter

5 Case 2: Petrochemical Customer Texas Gore H12 Turbine Filters With Coalescers

6 Case 2: Constant Power Output Petrochemical Plant (GE Frame 6B - 35MW) - Texas 8,000+ hrs No Wash Frame 6B Compressor Efficiency Power Load Temperature

7 Case 2: Performance Data Petrochemical Plant (GE 6B 35MW) Texas GE Frame 6B 7,850 Hrs Power Load 34.4 MW (H12) 31.0 MW (F8) 3.4 MW Gain Compressor Efficiency 90.2% (H12) 87.6% (F8) 2.6% Gain

8 Case 3: Coastal Refinery/Petrochemical Plant (GE LM MW) Eastern Canada F9 H12 1,450 hrs 2,500 hrs Compressor section after 10,600 hours. No washing necessary. No power loss.

9 Case 3: LM6000 after >2 years with GORE Turbine Filters After hrs. After hrs. After 8500 hrs.

10 Clean GE LM6000 (44MW) Turbine in Refinery HP Compressor Section after 18,500 hours

11 Case 4: Clean Power Plant Turbine Oregon Mitsubishi 501G (265MW) after 2000 hours

12 Case 5: Clean Power Plant Turbine after 1 st 5 months (Alstom GT26: 290MW)

13 Elimination of Off-Line Washes

14 GORE Turbine Filters: High Efficiency (H12/E12) with Low Pressure Drop Pre-filter Layer removes Bulk of large Particles High Efficiency Membrane Removes Submicron Dust, Water, and Salt High Strength Backer Provides Burst Strength

15 Water Entry Pressure Test Measures the resistance of the filter media to liquid penetration by water under constantly increasing hydrostatic pressure. Sample Water AATCC 121 Water Pressure

16 WEP Test Time Lapse Pictures Water Pressure Ramp Rate 23.6 inches water/min Flooded in 15s 1 st Drop 2 min Left: Non-membrane Filter F9 Right: eptfe Filter H12/E12

17 Filtration Efficiency: Wet & Dry Filters DRY GORE H12/E12 Turbine Filter WET Competitive F9 Nanofibers Filter

18 Salt Retention Test According to GE Test Procedure The test filters are exposed to water mist with a defined salt concentration of 3.5%. Nine spraying tests are done, two with previous dust loading. The amount of water and salt is measured upstream and downstream of the filter after each spraying cycle.

19 Salt Retention Test Results for GORE Turbine Filters No Water was detected downstream of GORE filters after each cycle.

20 Salt Retention Test Results for GORE Turbine Filters No Salt was detected downstream of GORE filters after each cycle.

21 Salt Retention Test Results for GORE Turbine Filters Salt, water, and dust have hardly any effect on the filtration efficiency of GORE filters. E12 efficiency class is maintained throughout the test.

22 Salt Retention Test Results: Water penetration of F- Class (MERV) vs. GORE Turbine Filters Appearance of air duct downstream of the tested filters Conventional F9 filter after first spraying GORE Turbine Filter after nine sprayings

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24 Turbine Models with GORE Turbine Filters OEM Model MW Installed GE LM 2500/5000 LM /25 44 RR RB GE 6B 40 8 turbines 6 cylindrical 2 panels Siemens SGT GE 6F 70 GE 7E 85 GE 7FA 175 GE 9F 250 Mitsubishi 501G 265 Alstom GT26 290

25 All Results Shown Were for Gore s Round HEPA Filters Does Gore have 2 x2 v-panel filters? Can the same turbine protection be expected in the Gore HEPA v-panel form?

26 Upgrading Turbine Inlet Panel Filters Houses to HEPA Filters GORE HEPA Turbine Filters

27 Gore Has Developed Two HEPA Panel Filter Options V-panel (2 x2 x 16 deep), typical for NA installations Z-panel (mostly for 2-wall European filter houses). Filter extends 12 into the clean side of a filter house

28 Protecting the Turbine Proved same great protection with panel forms in field installations but one must address other filter house issues to achieve this performance Shortened filter life caused by high air flow per filter Panels houses under-designed compared to round to save capital Shortened filter life for standard and HEPA filters Bypass & leakage Around access doors, hatches and ductwork AROUND THE FILTERS poor filter wall designs!!!

29 Typical Clean Side Condition

30 Low Efficiency Media Clean vs Dirty Side New filters clean on both sides of filter Used filters showing particle penetration on clean side

31 Improvements Needed to Achieve HEPA Quality in Current V-bank Inlet Houses Not as simple a retrofit as round filters. Need to: 1. Address filter life Install more filter media area Improve pre-filtration 2. Address bypass & leakage Modify the filter frames/walls to eliminate bypass leak points

32 1. Install More Filter Media Area Example: Retrofitted several 6Bs with 450 cylindrical filters Similar 6B with only deep v-bank filters Panel install has roughly half the total media of round in this example Implication Shorter filter life

33 Options for Installing More Filter Media Area Build larger filter house Retrofit current house with filters with more media area than the 2 x2 x12 deep final filter size Industry trend to deep filters

34 V-bank Filter (2 x2 x16 ) With the Extra 4 Depth Protruding Into Clean Side Support wall 16 depth Standard 2 x2 x4 pre-filter Clean Side Dirty Side

35 Some Filters Houses Will Not Accept 16 Deep Filters Due to Clean Side Obstructions Support beams or water spray headers on the clean side can cause interference

36 Even With Deeper Filters, Still a Question on Filter Life Because Airflow/Filter is Still High Been running Fitness for Use tests with spectrum of pre-filters to improve life Tests gave us confidence to move to full scale trials in 6B and 7F machines in US

37 Ran 1 Year Test in 7F Turbine RD FLOOR x ND FLOOR Installed 20 filter/prefilter combinations 5 x ST FLOOR x I

38 Layout Filter House Wall Inside Outside Tubing from sensors Sensor Transducer Box 12 Vdc 110 Vac Power Supply/Comm Box

39 Filter Classifications Ventilation Ventilation Cleanroom Filter Class Efficiency Particle Size EN779 ASHRAE 52.2 EN /2009 Coarse Filters G1-4 MERV 1-6 OEM Pre- Filters MERV 7-8 F5 MERV 9-10 F6 MERV 11 MERV 12 Fine Filters F7 F8 MERV 13 MERV 14 OEM Final Filters F9 MERV 15 MERV 16 >85% MPPS H10/E10 HEPA Filters >95% MPPS H11/E11 >99.5% MPPS H12/E12 EPA/HEPA (High) Efficiency Particulate Arrestor

40 Tested Range of Pre-filters Lower MERV 0% submicron efficiency 0.26 P Higher MERV 50% submicron efficiency 0.36 P

41 For High Bug Environments, G2 Bug Filter Prevents Pleat Bridging

42 Key Test Results Pre-filters improve final filter life Demonstrated 1+ year life on v-bank with good pre-filtration Higher MERV rated filters can dramatically increase life of final filter Should upgrade beyond standard OEM G- class pre-filter. Higher efficiency pre-filters are a trade-off between collection efficiency, pressure drop and cost

43 2. Modify the Filter Frames/Walls to Eliminate Bypass/Leak Points Filters secured by only two attachment points Only all-threads at the 9 and 3 o clock positions assure corner leakage

44 Leakage Around Gasket - Clean Side View Leakage

45 NA Vendors are Also Starting to Design New Systems with Better Hold Downs

46 Additional Fixtures to Eliminate By-passes Additional threaded rod Existing threaded rod 450

47 Filter House Modification: Adding 4 Hold Downs in Corners of T-grids

48 Installing New Hold Down Brackets in 4 Corners

49 Special Bracket for Bottom and Side Rows

50 Additional Hold Downs for Square Tube Filter Walls

51 Gaskets Not Sealing Due to Poor Weld Joints in Some House Designs

52 Joint Overlap Sealing

53 Fitness for Use (FFU) Testing 1 Year Trial Worked with large fleet customer in US Worked on fit and product form Tested multiple pre-filters Got one year life on v-bank leaving them in for second year Based on results, the fleet customer converted entire 7FA filter house for trial

54 Full Installation of V-bank Panel with Pre-filter

55 Gore Path Forward for V-panel Have 3 full scale trials underway 1 year on 6B in Europe (Z & V-Panel combination in AAF Filter House) May 11 installed in 6B in Louisiana (Pneumafil Filter House) April 11 installed in 7FA in Florida (Braden Filter House) Will install more trials in US in fall 2011 If final filter life meets expectations, will offer commercial products in spring 2012 To date results look very promising

56 To Achieve Key Benefits Have to be willing to invest time and money during a shutdown to upgrade the inlet house to get HEPA performance Benefits vary by site. More Power Constant Heat Rate Reduced maintenance Higher on-stream time ROI ($$) is quantifiable

57 MORE POWER, LESS WEAR GmbH Wernher-von-Braun-Str. 18 D Putzbrunn Germany Phone: Fax: Inc. 101 Lewisville Road Elkton, MD USA Phone: Fax: GmbH Middle East - Abu Dhabi Al Niyadi Building Airport Road Abu Dhabi UAE Phone: Fax: INDUSTRIAL USE ONLY. Not for use in food, drug, cosmetic or medical device manufacturing, processing, or packaging operations.