GTG AIR FILTRATION SYSTEM

UPGRADATION
Proposed Solution
Background & Purpose
 The frequency of GTG compressor off line water washes have increased due to the
persistent issue of compressor fouling.

 Due to compressor fouling and frequent water washes, the LCPL has to bear the cost
difference between its own generation and power Import from K-electric.

 The Frequent water washes also results in suspension of Power Export to K-electric
causing loss of additional revenue.

 Due to compressor fouling, we are unable to operate the GTG with sprint during the
winter season.

 Also, this fouling can lead to unplanned downtime due to compressor stall.
Problems & Proposed Solutions

GTG Air Filtration

System

Increased
Decreased Filter
Compressor
Life
Fouling

Filter
Pre- Modification Improve Recovering lost
Filtration/ Eliminating any compressor
to avoid bypassing Filtration
Coalescer bypassing Class (EPA) efficiency
through Pre-
FILTER
Implemented
In Progress Implemented Not Implemented Implemented
1. Improvement in Filter efficiency/ Class
The filtration efficiency/ class was improved in year 2022.

The MERV rating was improved from 15 to 16

Turbo-Tek H2O Filter

Performance Data PulseMaster2500C F8E11 Media
(Existing)

EN 1882 Rating E11 F9 (EN 779)

ASHRAE 52.2 Rating MERV 17 MERV 16
Initial Resistance 1” WC / 250 Pascal 0.86” WC / 214 Pascal
Initial Resistance with
N/A 0.90“ WC / 225 Pascal
Pre-filter/ Coalescer
Media Type Synthetic Synthetic
Initial Efficiency >99 % 89%
1. Improvement in Filter efficiency/ Class
(Cont.)
Proposed Solution
 To mitigate the problem of compressor fouling, Eagle Filter Manufacturer has
suggested an upgrade to EPA class Filtration.

 The idea is to replace existing fine Conical-Cylindrical filter with EPA

Cylindrical-Cylindrical filter on the existing tripods with quick lock yoke

 G4 Pre-filter in weather hoods will be installed in combination with EPA

filters
1. Improvement in Filter efficiency/ Class
(Cont.)
Advantages
 This set-up has been proven in several power stations during many years of
operations

 The Panels G4 SG Pre-filter is easy to install and remove in the existing

weather hoods, even during online operations

 The Pre-filter can be washed according to instructions and can be reused

several times.

 The PulseMaster2500C F8E11 QLY EPA-filter fits perfectly on the existing

tripods and the washers are specifically designed for the quick lock yoke.

 Reduced number of offline water washes. ( 50% Reduction)

 Full warranty on 2 years of service life.

1. Improvement in Filter efficiency/ Class
(Cont.)

SAVINGS
COST SAVING
EPA Cylindrical Filter to be consumed in Two Year 224
Unit cost of EPA Filter 53300
Unit cost of Conical Filter 49918
Unit cost of Cylindrical Filter 38583
Two Year consumption of Conical Filter 672
Two Year consumption of Cylindrical Filter 672
Total Cost of EPA filter 11939200
Total Cost of Existing Filter 59472672
Total Saving Rs47,533,472.00
1. Improvement in Filter efficiency/ Class
(Cont.)
GE Aero-derivative Gas Turbine Using EAGLE Filters
2. Recovering Lost Compressor Efficiency
 As the GTG compressor fouls, some deposits/ scales are bonds on the blades surface
(specifically on later stages due to high temperature zones) and are hard to removed thru
regular offline water wash.

These deposits accumulates over time and further reduces the offline water wash
effectiveness.

Recommendation:

It is recommended to carry out manual cleaning of HP compressor rotor and stator
blades on annual basis to remove the accumulated hard scales and deposits.

Lost Power/ efficiency due to

hard deposits/ scales
HP Compressor
Efficiency

Offline water Manual Cleaning

wash

Time
Conclusion
Cost
Options Duration (PKR Units Constraints
Mn)

GE Engineering and
Improvement in filter
1 Short Term 16 per set Performance team approval is
efficiency/ class
required.

Recovering lost
per Additional maintenance cost
2 compressor Long Term 30
year every year
efficiency
Thank You