A New HEPA Solution For GT Inlet Air Filtration: Tom Kelmartin, PE W.L. Gore & Associates, Inc

A New HEPA Solution for GT Inlet
Air Filtration
Tom Kelmartin, PE
W.L. Gore & Associates, Inc.
June 18, 2013
Frame 6 Users Group

League City, TX
tkelmart@wlgore.com
1
Agenda
• The Problem
• What is HEPA Filtration?
• Gore’s HEPA Technical Approach
• Case Studies
 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

Tom Kelmartin 2
The Problem
• Gas turbines consume enormous amounts of air for

combustion
– GE 7FA: ~360 Billion Ft3/year
– GE 6B: ~115 Billion Ft3/year
• That air contains contaminants large and small

– Dirt, salt , moisture, sand, soot, insects, corrosive gasses….
• Dirty air causes lost efficiency and can ultimately

destroy a turbine
– Compressor fouling, blocked cooling passages, blade erosion,
low and high temp corrosion, foreign object damage

Tom Kelmartin 3
The Problem
• Inlet air filtration aims to reduce contaminants in the air
stream without imposing a large pressure drop penalty
• Conventional filters are very good at capturing large

particles
• Conventional filters are very inefficient at capturing sub-

micron particles and allow liquids and dissolved
contaminants to pass
• HEPA filters are better at capturing submicron particles,

but in the past have been challenged by relatively high
pressure drops and limited life
Tom Kelmartin 4
Overview
What is HEPA Filtration?
(High Efficiency Particulate Air)
5
Sub-Micron Distribution in Urban Air
Particle Distribution (urban)
0.9 100 times more 0.1μ particles than 0.5μ

0.8
0.7
0.6
Particle
Number 0.5
(normalized)
0.4
Visible particle = 40µ
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Particle Size [µm]

Tom Kelmartin 6
Particle Size Range of Current
Standards
(Don’t measure below 0.3µ)
Particle Distribution (urban) US Standard
EU Standard
1
0.9
0.8
EN779
0.7
0.6
Particle
Number (normalized)
0.5
ASHRAE 52.2
0.4
0.3
0.2
0.1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Particle Size [µm]

Tom Kelmartin 7
HEPA Standard EN1822 Addresses <0.3
Micron Issue
Particle Distribution (urban)
0.9
0.8
EN779
0.7
0.6
Particle
Number (normalized)
0.5
ASHRAE 52.2
0.4
0.3
0.2
0.1 EN1822
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Particle Size [µm]

Tom Kelmartin 8
To Capture the Performance of HEPA Filters,
Need a Different Test (EN1822) and Scale
MPPS*
GORE H12/E12 Minimum required for H12 rating

1 100
0.9 90
0.8
MERV15/F9 80
0.7 70
0.6 60
Particle
Nanofibers / Synthetic Particle
0.5 50 Capture
Number (normalized)
Efficiency [%]
0.4
Nanofibers / Cellulose 40
*Most Penetrating Particle Size

0.3 30
0.2
Cellulose 20
0.1 10
0 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Particle Size [µm]

Tom Kelmartin 9
Filter Classifications
Filter Class Efficiency Particle Size EN779 ASHRA EN1822

E 52.2 2005/2009
80% ≤ Em ≤90% 0.4μm/ F7

E1 < 0.3-1.0 avg. MERV
Fine Filters 75%
80% ≤ E ≤95% 0.4μm/ F8 13
m
75% ≤ E1 ≤85% 0.3-1.0 avg. MERV
95% ≤ Em 0.4μm/ F9 14
85% ≤ E1 ≤95% 0.3-1.0 avg. MERV
95% < E1 15
>85% MPPS MERV H10/E10
16
EPA/HEPA >95% MPPS H11/E11
Filters
>99.5% MPPS H12/E12

Tom Kelmartin 10
What is a HEPA Filter?
• Defined by EN1822 standard. Were called “H”, now “E”

ratings
• Rating is based on the minimum capture rate of the
Most Penetrating Particle Size (MPPS), typically
about 0.1 microns
HEPA Rating Efficiency at

MPPS
H10/E10 > 85%
H11/E11 > 95%
H12/E12 > 99.5%
Tom Kelmartin 11
There Are Different HEPA Ratings For a
Reason
14
29 lb/yr Representative pollutants which
12 pass through a 25 MW turbine
during one year of operation
10
Turbine will
Uncaptured
still foul
Pollutants 8
[kg/yr] 135X due to low
Best GORE®
6
12.3 lb/yr efficiency MERV Turbine
filters 15 Filter Filters
4 F9 E10
Filter Grade Filter Grade
(MERV 15)
2
X= 0.09 lb/yr
F9 H10 E12 GORE® Turbine Filter
Filter Grade

Tom Kelmartin 12
GORE® Turbine Filters: High Efficiency (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

Tom Kelmartin 13
GORE Membrane Technology
Waterproof Media Provides Water & Salt Retention
Salt dust, water, and aqueous salt

solutions are repelled
Air can pass

through the membrane

Tom Kelmartin 14
Panel Filter Case Study – BASF, Geismar
LA

Tom Kelmartin 15
LA
• Objective: Determine the

effectiveness and service
lifetime of an E12 HEPA inlet
filter system
– V-Panel style
• GE 6B, base loaded

• Heavy industrial, agricultural,
coastal (Mississippi River)
• 120 Gore “V-Panel” filters,
MERV12 pre-filter with a
disposable G2 coarse pad

Tom Kelmartin 16
LA
• On-line data collection for

filter flow and individual filter
stage DP
• Installed May 2011 and
continuing

Tom Kelmartin 17
LA
• On-line data collection for

filter flow and individual filter
stage DP
• Installed May 2011 and
continuing

Tom Kelmartin 18
BASF Geismar LA, Frame 6B
(Data Courtesy BASF/JC Rawls)
Compressor Efficiency
100 10.00
90 9.00
80 8.00
Inlet Temp °F
70 7.00
60 6.00
Eff%, DegF, Pwr MW
η comp
MW Predicted
DP Inch H2O
50 Predicted MW 5.00 MW Actual
T-Inlet
DP Inlet
40 4.00
30 3.00
Actual MW Inlet Filter DP
20 2.00
10 1.00
0 0.00
7/10/12 12:00 8/29/12 12:00 10/18/12 12/7/12 12:00 1/26/13 12:00 3/17/13 12:00 5/6/13 12:00 6/25/13 12:00
AM AM 12:00 AM AM AM AM AM AM

Tom Kelmartin 19
BASF Geismar Filter DP (Inch WG)
G2 Change
G2 Change
G2 Change Prefilter and G2 Total DP
G2 Change
Change
MERV12 Prefilter
G2 Change
+G2 Wrap
G2 Wrap
V-Panel
Continuing Ops
2 Years

Tom Kelmartin 20
G2 Wrap Change-out (Inch WG)
Change-out
Total DP
V-Panel
Prefilter + G2
G2

Tom Kelmartin 21
Observations from BASF-Geismar
• HEPA filter system has succeeded in

keeping the compressor efficiency and
power output steady
• Maintenance of pre-filters is effectively
protecting V-panels, extending lifetime
• Regularly scheduled off-line washes no
longer required, on-line washing
eliminated
• Filter replacement frequency reduced
Tom Kelmartin 22
Cartridge Filter Case Study
– Chevron, El Segundo CA

Tom Kelmartin 23
Cartridge Filter Case Study
– Chevron, El Segundo CA
• Objective: Determine the

effectiveness and service
lifetime of an E12 HEPA inlet
filter system
– Cartridge (cylindrical) style
• GE 6B, base loaded

• Heavy industrial, urban, coastal
(Pacific Ocean)
• 448 Gore cartridge filters with
coalescing wrap

Tom Kelmartin 24
Chevron El Segundo CA, Frame 6B
(Data Courtesy Chevron/Mike Wenschlag)
GT Upgrade
100 5
Filter Eff
Comp Approaching End of Service Lifetime
90 4.5
80 4
70 3.5
DP Inch WG
Comp Eff %
60 Filter Approaching End 3

GT Upgrade of Service Lifetime
50 2.5
40 2
30 1.5
20 DP 1
10 0.5
0 0
8/10/2010 2/26/2011 9/14/2011 4/1/2012 10/18/201 5/6/2013 11/22/201
0:00 0:00 0:00 0:00 2 0:00 0:00 3 0:00
2 Years Continuing Ops

Tom Kelmartin 25
Chevron El Segundo CA, Frame 6B
(Data Courtesy Chevron/Mike Wenschlag)
A-Train Raw MW

Tom Kelmartin 26
Observations from Chevron-El
Segundo
• Compressor efficiency and power output
steady
• 2 years+ HEPA filter lifetime achieved
• Need for off-line washes greatly
diminished
• Impact of moisture/fog on filter DP very
minor during first 2 years of operation
– Frequent DP spikes during fog events
indicates nearing end of filter service life
Tom Kelmartin 27
Coastal Petrochemical Plant (Texas)
(Courtesy ExxonMobil-Greg Polasek)
GORE® E12 Turbine

Filters With
Coalescers

Tom Kelmartin 28
Petrochemical Plant (GE Frame 6B - 35MW)
(Courtesy ExxonMobil-Greg Polasek)
8,000+ hrs
No Wash Frame 6B
Power Load
Temperature

Tom Kelmartin 29
Petrochemical Plant (GE 6B – 35MW) – Texas
(Data Courtesy ExxonMobil-Greg Polasek)
GE Frame 6B 7,850 Hrs
34.4 MW (GORE)
31.0 MW (F8)
Power Load 3.4 MW Gain
90.2% (GORE)
87.6% (F8)
2.6% Gain

Tom Kelmartin 30
Should I Invest in HEPA Filtration?
1. Compare power output versus previous experience.
Power output will be effectively constant. Will this
reduce the need to purchase power?
2. Quantify value of stopping off-line washes
(availability, cost of shutdown with no power output).
3. Quantify value of constant heat rate versus previous
increases, fuel savings
4. Compare reduced costs due to elimination of
extensive compressor section cleaning during
scheduled major maintenance
5. Measure blade or rotor corrosion rates over time.

Tom Kelmartin 31
Annual Power Replacement Cost
(8,000 Hours)
1800
1600 $80/MWHr
1400
1200 $60/MWHr
$1,000's
1000
800 $40/MWHr
600
400 $20/MWHr
200
0
0 1 2 3 4 5
MW Lost Between Washes

Tom Kelmartin 32
Annual Power Replacement Cost
(8,000 Hours)
1800
1600 $80/MWHr
1400
1200 $60/MWHr
$1,000's
1000
800 $40/MWHr
600
400 $20/MWHr
200
0
0 1 2 3 4 5
MW Lost Between Washes
For Example: 3MW loss at $40/MWHr replacement cost = $480,000 annual cost

Tom Kelmartin 33
Should I Invest in HEPA Filtration?
1. Compare power output versus previous experience.
Power output will be effectively constant. Will this
reduce the need to purchase power?
2. Quantify value of stopping off-line washes
(availability, cost of shutdown with no power output).
3. Quantify value of constant heat rate versus previous
increases, fuel savings
4. Compare reduced costs due to elimination of
extensive compressor section cleaning during
scheduled major maintenance
5. Measure blade or rotor corrosion rates over time.

Tom Kelmartin 34
New V-Panel design – resulted from customer feedback during trials

Tom Kelmartin 35
GORE HEPA Turbine Filters Eliminate
®
Compressor Fouling:
Simple retrofit
• Similar initial pressure drop
• Similar filter life

Tom Kelmartin 36
Acknowledgements
• JC Rawls
• Mike Wenschlag
• Greg Polasek/Jeff Gillis

Tom Kelmartin 37
Thank-you!
MORE POWER, LESS

WEAR
W. L. Gore & Associates GmbH W. L. Gore & Associates, Inc.

Wernher-von-Braun-Str. 18 • D-85640 Putzbrunn • 101 Lewisville Road • Elkton, MD 21921 • USA
Germany Phone: +1 410 506-3300 • Fax: +1 410 506-3494
Phone: +49 89 4612-2211 • Fax: +49 89 4612-2302
W. L. Gore & Associates GmbH Middle East - Abu
E-mail: turbinefilters@wlgore.com
Dhabi
www.gore.com Al Niyadi Building • Airport Road • Abu Dhabi • UAE
Phone: +971 2 4437749 • Fax: +971 2 4437748
38

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A New HEPA Solution for GT Inlet

Frame 6 Users Group

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• Gas turbines consume enormous amounts of air for

• That air contains contaminants large and small

• Dirty air causes lost efficiency and can ultimately

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• Conventional filters are very good at capturing large

• Conventional filters are very inefficient at capturing sub-

• HEPA filters are better at capturing submicron particles,

What is HEPA Filtration?

(High Efficiency Particulate Air)

0.9 100 times more 0.1μ particles than 0.5μ

Particle Size [µm]

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

GORE H12/E12 Minimum required for H12 rating

*Most Penetrating Particle Size

Particle Size [µm]

Filter Class Efficiency Particle Size EN779 ASHRA EN1822

80% ≤ Em ≤90% 0.4μm/ F7

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• Defined by EN1822 standard. Were called “H”, now “E”

HEPA Rating Efficiency at

F9 H10 E12 GORE® Turbine Filter

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

Pre-filter Layer removes

High Efficiency Membrane Removes

High Strength Backer

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

Salt dust, water, and aqueous salt

Air can pass

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• Objective: Determine the

• GE 6B, base loaded

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• On-line data collection for

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• On-line data collection for

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• HEPA filter system has succeeded in

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

• Objective: Determine the

• GE 6B, base loaded

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

60 Filter Approaching End 3

2 Years Continuing Ops

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

GORE® E12 Turbine

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013

 2013 W. L. Gore & Associates Frame 6B User’s Conference/June 2013