POWERGEN ASIA 2010 SINGAPORE
2ND – 4TH NOVEMBER 2010
GAS TURBINE EFFICIENCY IMPROVEMENT
THROUGH AIR FILTER OPTIMIZATION
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Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
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Gelugor Power Station
GELUGOR CAPACITY
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Gelugor
CCP
GT1 110 Gas/Distillate John Brown MS9171E(GE) Dis 95
GT2 110 Gas/Distillate Nuovo Pignone MS9171E Oct 00
ST 110 Steam Fuji Electric System May 03
T. Ewa GT10 34 Distillate GEC Alsthom Frame 6 Jan 97
GT11 34 Distillate GEC Alsthom Frame 6 Jan 97
TOTAL CAPACITY UNDER GELUGOR POWER STATION
MANAGEMENT: 398 MW
Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
4
Gelugor Power Station
AIR INLET SYSTEM
• Air inlet system provides filtered air
to the gas turbine for combustion
•Configuration of GPS GT1 air filter
system:
• 1st stage weather louvers
• 2nd stage Pre-filter
• 3rd stage High Efficiency Filter
(Cartridge)
•Quality & quantity of the air being
drawn into the GT for combustion is a
major factor in determining its
performance and reliability.
5
Gelugor Power Station
AIR INLET SYSTEM
GT1 air inlet filter house is made up of a 4 matrix modules
type. The arrangement of the module is separated by 2 upper
and 2 lower floors and arranged in between a central plenum.6
Gelugor Power Station
AIR INLET SYSTEM TECHNICAL DATA
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Gelugor Power Station
AIR INLET SYSTEM cont…
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Factors that influence the performance of gas turbine :
• Ambient temperature
• Sufficient amount of clean air
• Level of humidity
Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
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Gelugor Power Station
GT1 INLET FILTERS PROBLEM STATEMENT
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• Increase in differential pressure (DP) of GT1 inlet air system
within a period of 3 to 4 months after initial replacement of the
filter elements.
• Major factors contribute to high DP:
• dry weather
• construction activities
• vehicle activities
• forest/illegal burning activities
Gelugor Power Station
GT1 INLET FILTERS PROBLEM STATEMENT
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• DP increase exponentially after 9 mbar• Alarm at 11 mbar & shutdown at 14 mbar
• Manual replacement needed to run back
• Previous practice : regular 3-4 months shutdown toreplace the pre filters
Gelugor Power Station
Combustion Inspection Planned outage
-2.00
0.00
2.00
4.00
6.00
8.00
10.00
12.001
2-A
pr-
08
1-J
un
-08
21
-Jul-
08
9-S
ep
-08
29
-Oct-
08
18
-De
c-0
8
6-F
eb
-09
28
-Ma
r-0
9
17
-Ma
y-0
9
Dp
(mb
ar)
Date
Dp Across Pre & Fine Filter Dp Across Pre Filter (Left)
Dp Across Pre Filter (Right) Dp Across Fine Filter (Left)
Dp Across Fine Filter (Right)
GT1 DP FROM MAY 2008 TO APRIL 2009)
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Planned outage
Gelugor Power Station
GT1 INLET FILTERS PROBLEM STATEMENT
•Through experience, it required about 6 hours (permit to permit) to remove and replace all chocked pre filter
elements.
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Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
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Gelugor Power Station
GT1 INLET AIR HIGH DP SOLUTION
• Proposal to change pre filter element type
• normal cartridge type filter to the pocket type air filter
• will last at least for 12 months
• Pocket type filter element
• more dust trapping surface area of 220% & dust holding capacity
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Gelugor Power Station
CARTRIDGE TYPE
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Gelugor Power Station
POCKET TYPE AIR FILTER ELEMENT
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Gelugor Power Station
POCKET TYPE AIR FILTER ELEMENT
• Heavy duty with high range efficiency
• Material 100% polyester fibers, laid on a polyester
scrim carrier material
• The seals are designed to withstand high pressure
• Dust holding capacity for is 1.5kg
• Initial dP can reach up to 5.0 mbar
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Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
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Gelugor Power Station
RESULTS (DP FROM MAY 2009 TO FEBRUARY 2010)
-1
0
1
2
3
4
5
6
7
28
-Mar-
09
17
-May-0
9
6-J
ul-
09
25
-Aug
-09
14
-Oct-
09
3-D
ec-0
9
22
-Ja
n-1
0
13
-Mar-
10
Dp
(m
bar)
Date
Dp Across Pre & Fine Filter Dp Across Pre Filter (Left)
Dp Across Pre Filter (Right) Dp Across Fine Filter (Left)
Dp Across Fine Filter (Right)
GT1 CI09 GT1 HGPI10
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Gelugor Power Station
RESULTS (DP FROM MAY 2009 TO DECEMBER 2009)
• Maximum Dp across Pre & Fine filter : 6.5 mbar
• Maximum Dp across Pre filter : 3.1 mbar
• Maximum Dp across Fine filter :3.4 mbar
• Overall Dp is about 6-7 mbar across 1 year period
• Result: Filter replacement requirement extended
• from April 2009 until March 2010
• other concern : surrounding environmental condition
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Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
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Gelugor Power Station
FILTER ELEMENT MODIFICATION DETAILS
Shutdown date 24 – 30 April 2009
Outage type Planned Outage
Type of last outage Combustion Inspection
Date of last outage December 2008
• Minor modification work of the filter element bracket at
filter house was carried out by GPS
• The duration of the total work ~ 7 days.
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Gelugor Power Station
MATERIAL & COST FOR INSTALLATION OF POCKET FILTER
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OVERALL COST :
• Pocket Filters : RM 37, 000.00
• Modification : RM 5, 000.00
Total overall cost (1 time) : RM 42, 000.00
Gelugor Power Station
GT1 POCKET FILTER INSTALLATION WORK
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Gelugor Power Station
GT1 POCKET FILTER INSTALLATION
Angle stainless steel to act as a
stopper to prevent filters from yank out
during operation
Filters attached to
base plate
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Gelugor Power Station
GT1 POCKET FILTER INSTALLATION
The condition inside filter house after
pre filters installation27
Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
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Gelugor Power Station
COST COMPARISON
• Pre-filters replacement cost in 12 Months:
Cartridge type (old): 3 times/year RM 31,000.00
Pocket type (new): 1 time/year RM 37,000.00
Difference: RM 6,000.00
• Modification cost (1 time) RM 5,000.00
• Total costs for replacement RM 11,000.00
(Incremental cost)
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Gelugor Power Station
COST COMPARISON (cont…)
• Total costs for replacement RM 11,000.00
(Incremental cost)
• Savings/extra income & values for
• Extra sales (due to no shutdown) = RM millions
• Extra capacity payment > RM 1.0 million
• Station’s reputation priceless…..
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Gelugor Power Station
CONTENTS
1. AIR INLET SYSTEM
2. GT1 INLET FILTERS PROBLEM STATEMENT
3. GT1 INLET AIR HIGH DP SOLUTION
4. RESULTS
5. FILTER ELEMENT MODIFICATION DETAILS
6. COST COMPARISON
7. CONCLUSION
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Gelugor Power Station
SUGGESTION & RECOMMENDATION
Further actions:
• Knowledge-sharing between similar plants in TNB
• Incorporate filter replacement during major shutdown
• Study on the impact of performance & heat rate to
gas turbine upon using the pocket type filters
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THANK YOU
Gelugor Power Station
We’ve got the power, to serve, to strive and to deliver
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