Filtration
Filtration
Filtration
A-61
FIG. A-48 Filters protected by a canopy. (Source: Altair Filters International Limited.)
A-62
FIG. A-49
It is almost universally agreed that stainless steel is the most cost-effective longterm solution for construction of the air-inlet system. The premium between
stainless steel over painted carbon steel can now be as low as 20%, whereas there
are no further painting costs and the life is infinitely longer.
The grade of stainless steel is also important. It is recognized that the lower
grades, such as American Iron and Steel Institute AISI 304 and AISI 321, do not
have sufficient corrosion protection, particularly if the material is work hardened.
AISI 316 is the most popular choice since it has up to 18.5% chromium, a metal
whose presence helps to build up a passive protective film of oxide and prevents
corrosion. Together with 10 to 14% nickel content, the steel has an austenitic
structure that is very ductile and easily welded.
It also can have a low carbon content (below 0.03%) as well as a molybdenum
content of between 2.0 and 3%, which increases its resistance against pitting.
Indeed, one operator has paid a significant premium in both cost and delivery time
by insisting that the molybdenum content be no lower than 2.5%.
Not only are the filter housings now constructed in AISI 316 but also almost all
of the items such as vane separators, door locks, hinges, and instrumentation are
supplied in this same material. These inlet systems will give a long life, and they
look good as well. A typical system is shown in Figs. A-64 and A-65.
FIG. A-50
A-63
The attention to detail is now evident. Figure A-65 clearly shows the elaborate
drain systems that are now installed. In addition, the stainless-steel housings are
carefully segregated in the manufacturing shop to prevent any cross-contamination
from any other ferrous materials, which includes tooling.
Figure A-66 shows a Brunei 4 platform where five of the engines had been
retrofitted with this system.
In summary the main requirements of a filtration system in a tropical
environment are
1. Protection against tropical rainstorms by vane separators
2. The inclusion of an integrated drain system
3. The selection of AISI 316 stainless steel as the material of construction
4. Protection against droplet carryover by a final stage vane separator
A-64
FIG. A-51
FIG. A-52
FIG. A-53
Water penetration through the inlet silencer. (Source: Altair Filters International Limited.)
FIG. A-54
A-65
A-66
FIG. A-55
FIG. A-56
FIG. A-57
A-67
A-68
FIG. A-58
FIG. A-59
Not only was it found difficult to produce consistent data, but other factors such
as ship speed, hull design, and height above water level had major effects. It became
apparent that predicting salt in air levels was as difficult as predicting weather
itself.
FIG. A-60
A-69
Since the gas turbine manufacturers had defined a total limit of the amount of
the contaminants that the turbines could tolerate, some definition of the
environment was essential to design filter systems that could meet these limits.
Many papers and conferences were held with little agreement, as can be seen in
Fig. A-67. However since the gas turbine industry is a conservative one, it adopted
the most pessimistic values as its standard, namely the National Gas Turbine
Establishment (NGTE) 30-knot aerosol (Table A-11). It was treated more as a test
standard rather than what its name implied. In the absence of any other data, this
was used to define the environment on offshore platforms, despite the fact that they
were much higher out of the water, and did not move around at 40 knots!
This then defined the salt in air concentration, but did not address any other
particulates. In hindsight, it now seems naive that the offshore environments were
originally considered to be clean with no other significant problems than salt. Many
A-70
FIG. A-61
FIG. A-62
A new filter housing awaiting installation. (Source: Altair Filters International Limited.)
equipment specifications were written at that time saying the environment was
dust free.
In the early 1970s there was also a lively debate as to whether the salt in the air
was wet or dry. One argument was put forward that if the salt was wet it would
FIG. A-63
A-71
Corrosion on the new housing shown in FIG. A-62. (Source: Altair Filters International
Limited.)
FIG. A-64 A stainless-steel filter housing. (Source: Altair Filters International Limited.)
A-72
FIG. A-65 A stainless-steel filter housing. (Source: Altair Filters International Limited.)
TABLE A-11
Microns
<2
24
46
68
810
1013
>13
0.0038
0.0212
0.1404
0.3060
0.4320
0.6480
2.0486
Total
3.6000
A-73
FIG. A-66
Brunei shell petroleum Fairley 4 platform, showing five new filter housings. (Source:
Altair Filters International Limited.)
FIG. A-67 Airborne salt comparisons. (Source: Altair Filters International Limited.)
require a further stage of vane separators as the final stage to prevent droplet
reentrainment from the filters. The opposing argument maintained that vane
separators were unnecessary and that a lower humidity resulted in evaporation of
the droplet, giving a smaller salt particle that required a higher degree of filtration.
Snow and insect swarms were largely ignored as a problem.
A-74
TABLE A-12
January
February
March
April
May
June
July
August
September
October
November
December
85
83
83
80
81
80
FIG. A-68
A-75
Flare carbon can cause problems. (Source: Altair Filters International Limited.)
FIG. A-69 Typical turbine damage. (Source: Altair Filters International Limited.)
A-76
FIG. A-70 Typical leak caused by a missing cable gland. (Source: Altair Filters International
Limited.)
By far the most serious of these problems was the erosion of compressor blading
that was experienced almost simultaneously on many platforms. This occurred
about three to five years after start-up, as this was the time that repainting
programs were initiated. Grit blast found its way into the turbine intakes either
through leaking intakes, bypass doors, or through the media itself. (See Fig. A-70.)
Since the airborne levels were high, the air filters quickly blocked up, allowing the
bypass doors to open. As filter maintenance is not a high priority on production
platforms, considerable periods were spent with grit passing straight into the
turbine through open bypass doors. Even where maintenance standards were more
attentive, there were usually enough leaks in the intake housing and ducting to
ensure delivery of the grit to the turbine.
It often seemed contradictory that the system designers would spend a lot of time
specifying the filter system, but would pay little attention to ensuring the
airtightness of the ducting downstream.
Since the grit was sharp, it sometimes damaged the filter media itself, reducing
the system efficiency dramatically.
Bypass doors were a major problem. Early designs failed to take account of the
environment or the movement in the large structures of the filter housings. Very
few of those initial designs were airtight when shut, and it was not uncommon for
them to be blown open by the wind.
Turbine corrosion could almost always be traced to leaky ducting or operation
with open bypass doors. Very few systems gave turbine corrosion problems if the
ducting was airtight. The few installations that did give problems were usually the
result of low-velocity systems operating with poor aerodynamics, so that local high
velocities reentrained salt water droplets into the airstream and onward to the
engine. (See Fig. A-71.)
Rapid compressor fouling was usually the prelude to more serious problems later,
since it was usually caused by the combined problems of filter bypass.
Compressor cleaning almost once a week was fairly standard for systems with
those problems.
As time progressed the marine environment took its toll on the carbon steel and
severe corrosion was experienced on the intake housing and ducting. (See Fig.
A-72.) In some cases, corrosion debris was ingested into the turbine causing turbine
failure. This again was accelerated by poor design, which allowed dissimilar metals
to be put into contact, leading to galvanic corrosion.
FIG. A-71
Inertial filters showing severe corrosion. (Source: Altair Filters International Limited.)
FIG. A-72
A-77
A-78
To prevent erosion
Erosion
Erosion is caused by particles impacting and wearing away the metal surfaces. The
high speeds of the rotating blades collide with the airborne particles and produce
a quite large change in energy, which results in fragments of metal being blasted
out of the blade surface. Even particles as small as 10 mm in diameter can cause
severe erosion. The composition and shape of the particle can also significantly
affect the erosion rate. Blade profiles are so carefully designed that even minor
abrasions can alter the profiles to such an extent that engine performance is
affected. Erosion is an expensive problem since it causes permanent damage and
the affected parts will require replacing. It is proportional to concentration and in
severe duties, such as gas turbinepowered hovercraft operated in desert
conditions, engine life has been reduced to as little as 6 hours.
Fouling
Dry particles, which range in size from 2 to 10 mm, could, on old engine designs,
pass through the engine causing little or no damage. However, on the new
generation of hotter engines, these particles can cause problems if their fusion
temperature is lower than the turbine operating temperature, since they will melt
and stick to the hot-metal surfaces. This can cause severe problems since this
molten mass can block cooling passages and cause thermal fatigue. The affected
surface is permanently disfigured and will need replacement.
A-79
Corrosion
The high temperatures of the gas turbine can also cause rapid acceleration of the
corrosion process. Even though the hot-metal surfaces are made of some of the most
sophisticated materials, corrosion can still be extremely rapid. Blade failures in as
little as 100 operating hours have been known, and failures within 2000 operating
hours are relatively common. Corrosion, however, can be completely prevented by
modern techniques, and yet it still occurs.
Normally, corrosion is produced by a salt, such as sodium or potassium, but lead
and vanadium are also common contributors. Since many gas turbines are based
either offshore or close to the sea, sea salt (sodium chloride) is the main offender.
In the cold parts of the engine it is the sodium chloride that does the damage,
whereas in the hot parts of the engine it is sodium sulfate (or sulfidization) that
creates most of the corrosion. Sodium sulfate is produced from the combination of
sulfur in the fuel and sodium chloride in the air.
It is important to recognize that the corrosion process is self-propagating, and,
once started, will continue even though the source problem has been cured.
The modern gas turbine therefore is a sensitive machine and needs to be protected
to provide an acceptable life cycle. For this reason, there are limits that are
recommended by the manufacturers in order to achieve this. There is not one
universal limit that is adopted by all manufacturers. Each has its own, which is
expressed in many different forms, either as an absolute limit or one that is time
dependent. However, all seem to work from the same premise.
Previously, it was often thought that providing a gas-turbine air-filter system was
well chosen; it could be used in almost any environment with equal effect. This has
proved to be a fallacy, as many operators have found at their cost.
A-80
FIG. A-73
giving a relatively wide pocketed bag filter capable of those higher velocities and
giving protection against the problem contaminants. By having a relatively high
loft to the media, protection against filter blinding was ensured, with a resulting
longer life. Testing showed the new HV2 filter to be over 99% efficient against the
damaging grit blast.
A cleanable prefilter bag of similar but less dense media was also quickly
designed. This PB1 prefilter bag was unique in that it was designed to be tucked
inside the final filter bag and so only took a further 25-mm installation depth.
The new filters were installed into a new stainless steel housing protected front
and back by vane separators and delivered on Christmas Eve 1983, just three weeks
after the initial problems were investigated; a record for which all those involved
have a right to be proud of. (See Fig. A-73.)
Shell was the next platform operator to experience similar problems, firstly on
the Avon gas turbines on its Brent Delta platform. In these installations it was
possible to fit the HV2 filters in an access space between the existing filter stages.
Shell undertook a bold and very correct decision to weld up the troublesome bypass
doors, having first revised the alarm and trip levels for the intake depression
pressure switches. This system was carefully monitored for a period of nine months
before the remaining 23 Avons on the Brent platforms were similarly converted.
Comparison of two adjacent engines, one with the original system and one with a
retrofitted system showed that over a three-month period the performance of the
retrofitted engine was unchanged, while the other engine showed a steady increase
in exhaust temperature for a given power output amounting to 30C at the end of
the period. Also, the requirement to change out the filters was reduced from 350
hours to, in some cases, over two years.
On Shell Leman BK platform, a similar comparison of two Avons was
investigated, with an air sampling program constantly monitoring the quality of
the inlet air over a period of one month. This showed the modified installation to
be 1014 times more effective, in terms of particle penetration.
It is not surprising that Shell has now retrofitted 78 installations worldwide. In
total this design has been selected for 212 new and retrofitted gas turbine engines.
Filter systems that were an operational irritation every 15 days or so are now
forgotten to such a degree that on some platforms the filters have operated, without
replacement, for up to three years.
A-81
A-82
FIG. A-74 Filter with water eliminator. (Source: Altair Filters International Limited.)
FIG. A-75 Pressure loss versus volume flow rate filter characteristic. (Source: Altair Filters
International Limited.)
semirigid construction, together with the fact that each pocket is divided into
smaller segments by means of a semipermeable shelving system, ensures the best
possible profile throughout all operating conditions. This produces an extremely
uniform flow distribution, leading to improved dust-holding capacity and
eliminating the likelihood of localized dust breakthrough.
A-83
FIG. A-76 Efficiency versus pressure loss filter characteristic. (Source: Altair Filters International
Limited.)
This feature conducts water and salt removal. The vanes, which are constructed
from corrosion-resistant marine grade aluminum (other materials are available),
are produced with a profile that allows the maximum removal of salt and water,
yet produces an extremely low pressure loss. This optimal profile has been achieved
by the very latest design methods, and in particular by utilizing a Computational
Fluid Dynamics (CFD) flow modeling system. Hydra also incorporates a unique and
novel method of separating water droplets from the air stream, and this has led to
improvements in bulk water removal compared with conventional methods.
Reference and Additional Reading
1. Tatge, R. B., Gordon, C. R., and Conkey, R. S., Gas Turbine Inlet Filtration in Marine Environments,
ASME Report 80-GT-174.
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