x2 Panel Product - Frame 6 Users Groupframe-6-users-group.org/...Filter2x2ProductUpdate.pdf · x2 Panel Product GE 6B User s Group Scottsdale, Arizona ... Salt Retention Test According

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


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


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.


Case 2: Petrochemical Customer Texas

Gore H12 Turbine FiltersWith Coalescers


Compressor Efficiency

Power Load

Temperature

Frame 6B8,000+ hrsNo Wash

Case 2: Constant Power OutputPetrochemical Plant (GE Frame 6B - 35MW) - Texas


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


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


Case 3: LM6000 after >2 years with GORE® Turbine FiltersAfter 18500 hrs.

After 8500 hrs.

After 15075 hrs.


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


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


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


Elimination of Off-Line Washes


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


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


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


Filtration Efficiency: Wet & Dry Filters

GORE® H12/E12 Turbine Filter

Competitive F9Nanofibers Filter

DRY

WET


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.


Salt Retention Test Results for GORE® Turbine Filters

No Water was detected downstream of GORE filters after each cycle.



No Salt was detected downstream of GORE filters after each cycle.


Salt, water, and dust have hardly any effect on the filtration efficiency of GORE filters.E12 efficiency class is maintained throughout the test.



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



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


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


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


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!!!


Typical Clean Side Condition


Low Efficiency Media Clean vs Dirty Side

New filters – clean onboth sides of filter

Used filters showing particlepenetration on “clean side”


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


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


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


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


Some Filters Houses Will Not Accept 16 DeepFilters Due to Clean Side Obstructions

Support beams or water sprayheaders on the clean side can causeinterference


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


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


Layout

110 Vac12 Vdc

Tubing from sensors

Sensor Transducer Box Power Supply/Comm Box

Filter House WallInside Outside


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


Tested Range of Pre-filters

Lower MERV0% submicron efficiency0.26” P

Higher MERV50% submicron efficiency0.36” P


For High Bug Environments, G2 Bug FilterPrevents Pleat Bridging


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


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


Leakage Around Gasket - Clean Side View

Leakage


NA Vendors are Also Starting to Design NewSystems with Better Hold Downs


Additional Fixtures to Eliminate By-passes

450

Existing threaded rod

Additionalthreaded rod


Filter House Modification: Adding 4 HoldDowns in Corners of T-grids


Installing New Hold Down Brackets in 4 Corners


Special Bracket for Bottom and Side Rows


Additional Hold Downs for Square Tube FilterWalls


Gaskets Not Sealing Due to Poor Weld Jointsin Some House Designs


Joint Overlap Sealing


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


Full Installation of V-bank Panel with Pre-filter


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


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: [email protected]

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

mailto:[email protected]

http://www.gore.com

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x2 Panel Product - Frame 6 Users Groupframe-6-users-group.org/...Filter2x2ProductUpdate.pdf · x2 Panel Product GE 6B User s Group Scottsdale, Arizona ... Salt Retention Test According