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Gore® HEPA Turbine Filter Update -x2 Panel Product
GE 6B User s GroupScottsdale, ArizonaJune 9, 2011
By Steve Medvetz W.L. Gore & Associates
W. L. Gore & Associates
GORE® HEPA Turbine Filters Dramatically Improvethe Operation of Gas Turbines
Simple retrofitSimilar initial pressure drop
Similar filter life
W. L. Gore & Associates
Presentation Agenda
1. Share results from multiple sites usingfilters in round form
2. Show results of 3rd party salt & waterpenetration testing
3. Share status of 2 x2 panelinstallations and commercial status ofGore s products
W. L. Gore & Associates
Case 1: Constant Power OutputCoastal Power Plant (RB211-30MW) - UK
3 off-line washings/yr.
-5-4-3-2-1012345
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400
Days
Pow
er V
aria
nce
from
corr
ecte
d ta
rget
(MW
)
F9 standard filterGORE Turbine Filter
offline compressorwashing and filter
replacement
offlinecompressor
washing
0 off-line washings/yr.
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Case 2: Petrochemical Customer Texas
Gore H12 Turbine FiltersWith Coalescers
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Compressor Efficiency
Power Load
Temperature
Frame 6B8,000+ hrsNo Wash
Case 2: Constant Power OutputPetrochemical Plant (GE Frame 6B - 35MW) - Texas
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Case 2: Performance DataPetrochemical Plant (GE 6B 35MW) Texas
90.2% (H12)
87.6% (F8)
34.4 MW (H12)
31.0 MW (F8)
7,850 Hrs
Compressor Efficiency
Power Load
GE Frame 6B
3.4 MW Gain
2.6% Gain
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Compressorsection after10,600 hours.No washingnecessary.No power loss.
F9 H12
1,450 hrs 2,500 hrs
Case 3: Coastal Refinery/Petrochemical Plant(GE LM6000 - 44MW) Eastern Canada
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Case 3: LM6000 after >2 years with GORE® Turbine FiltersAfter 18500 hrs.
After 8500 hrs.
After 15075 hrs.
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Clean GE LM6000 (44MW) Turbine in RefineryHP Compressor Section after 18,500 hours
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Case 4: Clean Power Plant Turbine OregonMitsubishi 501G (265MW) after 2000 hours
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Case 5: Clean Power Plant Turbine after 1st 5months (Alstom GT26: 290MW)
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Elimination of Off-Line Washes
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Pre-filter Layer removesBulk of large Particles
High Efficiency Membrane RemovesSubmicron Dust, Water, and Salt
High Strength BackerProvides Burst Strength
GORE® Turbine Filters: High Efficiency (H12/E12)with Low Pressure Drop
W. L. Gore & Associates
Water Entry Pressure Test
Measures the resistance of the filter media to liquid penetration bywater under constantly increasing hydrostatic pressure.
Water
Sample
Water PressureAATCC 121
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WEP Test Time Lapse Pictures
Left: Non-membraneFilter F9
Right: ePTFE FilterH12/E12
Water Pressure Ramp Rate 23.6 inches water/min
1st Drop 2 min
Flooded in 15s
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Filtration Efficiency: Wet & Dry Filters
GORE® H12/E12 Turbine Filter
Competitive F9Nanofibers Filter
DRY
WET
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Salt Retention Test According to GE Test Procedure
The test filters are exposed to water mist with a defined salt concentration of 3.5%. Ninespraying tests are done, two with previous dust loading. The amount of water and salt ismeasured upstream and downstream of the filter after each spraying cycle.
W. L. Gore & Associates
Salt Retention Test Results for GORE® Turbine Filters
No Water was detected downstream of GORE filters after each cycle.
W. L. Gore & Associates
Salt Retention Test Results for GORE® Turbine Filters
No Salt was detected downstream of GORE filters after each cycle.
W. L. Gore & Associates
Salt, water, and dust have hardly any effect on the filtration efficiency of GORE filters.E12 efficiency class is maintained throughout the test.
Salt Retention Test Results for GORE® Turbine Filters
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Appearance of air duct downstream of the tested filters
Conventional F9 filter after first spraying GORE® Turbine Filter after nine sprayings
Salt Retention Test Results: Water penetration of F-Class (MERV) vs. GORE® Turbine Filters
W. L. Gore & Associates
W. L. Gore & Associates
Turbine Models with GORE® Turbine Filters
6 cylindrical2 panels
265501GMitsubishi
2509FGE
290GT26Alstom
1757FAGE
857EGE
706FGE
50SGT800Siemens
8 turbines406BGE
30RB211RR
15/25
44
LM 2500/5000
LM 6000GE
InstalledMWModelOEM
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All Results Shown Were for Gore s RoundHEPA Filters
Does Gore have 2 x2 v-panel filters?
Can the same turbine protection beexpected in the Gore HEPA v-panel form?
Upgrading Turbine Inlet PanelFilters Houses to HEPA Filters
GORE® HEPA Turbine Filters
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Gore Has Developed Two HEPA Panel Filter Options
V-panel (2’x2’x 16” deep) , typicalfor NA installations
Z-panel (mostly for 2-wallEuropean filter houses). Filterextends 12” into the clean sideof a filter house
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Protecting the Turbine
Proved same great protection with panel forms infield installations but one must address otherfilter house issues to achieve this performance
Shortened filter life caused by high air flow perfilter
Panels houses under-designed compared to round to save capitalShortened filter life for standard and HEPA filters
Bypass & leakageAround access doors, hatches and ductworkAROUND THE FILTERS poor filter wall designs!!!
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Typical Clean Side Condition
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Low Efficiency Media Clean vs Dirty Side
New filters – clean onboth sides of filter
Used filters showing particlepenetration on “clean side”
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Improvements Needed to Achieve HEPAQuality in Current V-bank Inlet Houses
Not as simple a retrofit as round filters. Need to:
1. Address filter lifeInstall more filter media area
Improve pre-filtration
2. Address bypass & leakageModify the filter frames/walls to eliminate bypass leakpoints
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1. Install More Filter Media Area
Example:Retrofitted several 6Bs with 450 cylindrical filters
Similar 6B with only 120 -12 deep v-bank filters
Panel install has roughly half the total media ofround in this example
Implication Shorter filter life
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Options for Installing More Filter Media Area
Build larger filter house
Retrofit current house with filters withmore media area than the 2 x2 x12 deepfinal filter size
Industry trend to 16-17 deep filters
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V-bank Filter (2 x2 x16 ) With the Extra 4Depth Protruding Into Clean Side
Support wall
16” depth
Dirty Side
Standard2’x2’x4”pre-filter
Clean Side
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Some Filters Houses Will Not Accept 16 DeepFilters Due to Clean Side Obstructions
Support beams or water sprayheaders on the clean side can causeinterference
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Even With Deeper Filters, Still a Question onFilter Life Because Airflow/Filter is Still High
Been running Fitness for Use tests withspectrum of pre-filters to improve life
Tests gave us confidence to move to fullscale trials in 6B and 7F machines in US
W. L. Gore & Associates
Ran 1 Year Test in 7F Turbine
5 x 20
5 x 20
6 x 20
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1
3RD FLOOR 2
3
4
5
6
2ND FLOOR 7
8
9
10
11
12
1ST FLOOR 13
14
15
16
Installed 20 filter/pre-filter combinations
I
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Layout
110 Vac12 Vdc
Tubing from sensors
Sensor Transducer Box Power Supply/Comm Box
Filter House WallInside Outside
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Filter Classifications
MERV 1-6G1-4Coarse Filters
MERV 7-8
MERV 9-10F5
MERV 11
MERV 12
F6
>99.5%
>95%
>85%
Efficiency
MERV 15
MERV 16
F9
H10/E10MPPS
H11/E11MPPSHEPA Filters
H12/E12MPPS
MERV 14F8Fine Filters
MERV 13F7
EN18222005/2009
ASHRAE 52.2EN779Particle SizeFilter Class
EPA/HEPA (High) Efficiency Particulate Arrestor
Vent
ilatio
n
Vent
ilatio
n
Clea
nroo
m
OEMFinalFilters
OEMPre-Filters
W. L. Gore & Associates
Tested Range of Pre-filters
Lower MERV0% submicron efficiency0.26” P
Higher MERV50% submicron efficiency0.36” P
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For High Bug Environments, G2 Bug FilterPrevents Pleat Bridging
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Key Test Results
Pre-filters improve final filter lifeDemonstrated 1+ year life on v-bank with goodpre-filtrationHigher MERV rated filters can dramaticallyincrease life of final filter
Should upgrade beyond standard OEM G-class pre-filter. Higher efficiency pre-filtersare a trade-off between collectionefficiency, pressure drop and cost
W. L. Gore & Associates
2. Modify the Filter Frames/Walls to EliminateBypass/Leak Points
Filters secured by only two attachment pointsOnly all-threads at the 9 and 3 o clock positions assurecorner leakage
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Leakage Around Gasket - Clean Side View
Leakage
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NA Vendors are Also Starting to Design NewSystems with Better Hold Downs
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Additional Fixtures to Eliminate By-passes
450
Existing threaded rod
Additionalthreaded rod
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Filter House Modification: Adding 4 HoldDowns in Corners of T-grids
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Installing New Hold Down Brackets in 4 Corners
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Special Bracket for Bottom and Side Rows
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Additional Hold Downs for Square Tube FilterWalls
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Gaskets Not Sealing Due to Poor Weld Jointsin Some House Designs
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Joint Overlap Sealing
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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 themin for second year
Based on results, the fleet customer convertedentire 7FA filter house for trial
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Full Installation of V-bank Panel with Pre-filter
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Gore Path Forward for V-panel
Have 3 full scale trials underway1 year on 6B in Europe (Z & V-Panel combination in AAFFilter House)May 11 installed in 6B in Louisiana (Pneumafil FilterHouse)April 11 installed in 7FA in Florida (Braden Filter House)
Will install more trials in US in fall 2011If final filter life meets expectations, will offercommercial products in spring 2012To date results look very promising
W. L. Gore & Associates
To Achieve Key Benefits
Have to be willing to invest time and moneyduring a shutdown to upgrade the inlet house toget HEPA performance
Benefits vary by site.More Power
Constant Heat Rate
Reduced maintenance
Higher on-stream time
ROI ($$) is quantifiable
MORE POWER, LESS WEAR
INDUSTRIAL USE ONLY. Not for use in food, drug, cosmetic ormedical device manufacturing, processing, or packaging operations.
W. L. Gore & Associates GmbHWernher-von-Braun-Str. 18 D-85640 Putzbrunn GermanyPhone: +49 89 4612-2211 Fax: +49 89 4612-2302E-mail: turbinefilters@wlgore.com
www.gore.com
W. L. Gore & Associates, Inc.101 Lewisville Road Elkton, MD 21921 USAPhone: +1 410 506-3300 Fax: +1 410 506-3494
W. L. Gore & Associates GmbH Middle East - Abu DhabiAl Niyadi Building Airport Road Abu Dhabi UAEPhone: +971 2 4437749 Fax: +971 2 4437748
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