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Gas Conditioning: A Key To Success In Turbine Combustion Systems Using Landfill Gas Fuels
Gas Conditioning: A Key To Success In Turbine Combustion Systems Using Landfill Gas Fuels
Presented by: Marty Schlotthauer, Senior Process Engineer, Technical Programs Waste Management of North America, Inc. and Reza Hashemi, Vice President, Technical Director Pall Corporation to the 14th Annual Landfill Gas Symposium, GRCDA/SWANA, March 27, 1991, San Diego, California
Background Analyzing Individual Turbine Failures Evaluating Process Design Specifications Reasons for Selecting a Pall Liquid/Gas Filtration System Post-Installation Report Ketema Gas/Gas Heat Exchanger Analyzing Project Savings and Payback Analyzing Life Cycle Economics Conclusion

Background
Waste Management of North America (WMNA) started generating electrical power from its landfill gas to electric facility at Omega Hills Landfill in Germantown, Wisconsin, during December, 1985. Initially two turbine/generator (T/G) systems were installed: each system consisted of a Hall fuel gas compressor (FGC) skid and a Solar Centaur turbine/generator set. On August 15, 1988, after 20,935 operating hours, turbine no. 1 failed when a hole burned through the combustor liner and housing. The plant operator actually observed a fireball coming out of unit no. 1 and immediately shut down the system. Turbine no. 2, with 20,562 operating hours, was also shut down because it had exhibited a deterioration in performance over the previous several months. Both units were eventually shipped back to the turbine manufacturer for a comprehensive examination and failure analysis.
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Analyzing Individual Turbine Failures

Unit No. 1 The combustor case exhibited a large protuberance with a central region, which had melted adjacent to an injector inlet (see Figure 1). The combustor liner was also thermally distressed with remnants of a small molten region on the cooling air louver near another injector boss. A fine, powdery red deposit covered all internal areas of the combustor. Examination of air blast tubes showed that all fuel injectors and air blast tubes were constricted to some degree with a hard black deposit (see Figures 2, 3, and 4). Figure 1 : Combustor housing failure in unit no. 1.

Figure 2 : Leakage of fuel mixture caused by deposits.

Figure 3 : Fuel nozzle locations.

Figure 4 : Nozzle constricted with hydrocarbons.

Chemical analyses of both black deposits found in the blast tubes and red surface deposits found on the turbine blades were performed (see Figure 5). The black deposit's composition was mainly carbon with small amounts of aluminum, iron, sulfur, and magnesium. Silicon was also detected (see Table 1). The red deposit was mainly comprised of silicon, typical of deposits routinely found in turbines operating in a landfill gas application (see Table 2). Metallurgical and structure analysis confirmed that all turbine components were designed and made to withstand normal operating conditions. The problem, however, was due to blockage of the aforementioned extended air blast tube. This forced the fuel to pass and ignite between the liner and the case rather than in the combustor. Also, the high temperature of combustion caused the combustor case to melt. Figure 5 : Contaminated turbine blade vs. clean.

Table I: Composition of black deposits found in blast tube orifices (wt%) A1 7.75 C 71.51 Ca 0.52 Fe 4.25 Mg 1.40 O 10.6 S 2.68 Si 1.29

Unit No. 2 Three of the first stage turbine blades had failures of varying degree in the blade airfoils. All turbine section gas path components were found to have a heavy coating of the red deposit. As with turbine no. 1, this unit's combustor liner air blast tubes were partially blocked with the same hard black deposit. Chemical analysis of the red deposit (see Table 2) revealed the presence of oxygen (in the form of oxides), silicon, iron, sulfur, tin, calcium, and aluminum; almost the same properties found in the red deposit from unit no. 1. Damage and deterioration of a combustion liner cooling air louver located downstream of the injector blast tubes were also observed. Table 2 : Composition of red deposits found in no. 1" turbine (wt%) A1 1.86 Ca 1.52 Fe 9.46 O 47.89 S 8.50 Si 26.51 Sn 4.26

* Red deposit in turbine no. 2 had the same composition.

Metallographic examination provided sufficient evidence to conclude that thermal stress rupture was the primary cause of blade failure. Similar to unit no. 1, the deposit of oil and condensate not only caused severe fuel mal-distribution but also interfered with the combustor aerodynamics, resulting in abnormal combustor exit temperature profile. Further buildup of these deposits caused pressure inside the blast tube to exceed combustor inlet air pressure resulting in leakage of the fuel/air mixture outside the combustor can and combustor housing. The turbine manufacturer strongly recommended that fuel gas compressor oil and condensate carryover be prevented from entering the engine fuel and combustion system. They also recommended routine boroscope inspections be performed every 1,000 hours on the injectors and injector boss air blast tubes.
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Evaluating Process Design Specifications

Based on the turbine manufacturer's failure analysis and WMNA's own investigation, it was agreed that the problem had been initiated by the inlet gas and not the turbines themselves. To thoroughly understand and resolve the oil carryover problem, WMNA conducted the following evaluations of the process system as it was configured at the time of failure. The items WMNA evaluated are as follows (refer to Figure 6): Performance of existing filter/separator (Fil/Sep). Pipe route from the fuel gas compressor to the turbine/generator (T/G). Temperature and pressure differential profiles. Quantities of oil carryover. Requirements for final filter/separator at the turbine inlet. Gas mixing versus gas to gas heat exchanger. Compressor operations and design. Effects of high ambient temperatures and high humidity on gas conditioning and turbine performance. Figure 6 : Power generation facility before process modifications.

Existing Filter/Separator Performance The existing filter/separator was removing particles 1 micron in diameter and larger. It was not designed, nor rated, to remove oil in the form of aerosols. The Fil/Sep unit would, however, prevent slugs of oil or condensate from entering the fuel system when properly installed and maintained. After consulting with major filter/separator manufacturers, WMNA concluded that improved filtration was required at the T/G inlet. The following design objectives were established as minimum requirements for a new system. Place a final filter as close to the turbine inlet as possible so that oil droplets and aerosols from the gas are captured before entering the system. Use a two stage, reverse flow, inside to outside filter element. Increase gas temperature above the dew point (after interstage cooling) so that oil, water, and emulsion can separate at the fuel gas compressor (FGC) skid. Based on technical and cost analysis, a Pall Process Filtration Company Liquid/Gas (LG) Coalescer filter unit was selected. Pall guaranteed removal of 99.98% of solid and liquid aerosols at 0.3 microns and above, with downstream concentration of 0.003 ppmw or less. Pipe Route from the Fuel Gas Compressor (FGC) to the Turbine Generator (T/G) The existing piping was routed underground between the FGC and T/G skids. Engineering calculation showed that the average heat loss underground and to the above ground portion was approximately 66,000 btu/hr. On cold, windy, and/or rainy days, this heat loss would exceed 70,000 btu/hr. Because the gas leaving the FGC skid was at or near its dew point, any cooling between the FGC and the T/G would result in substantial quantities of condensate forming inside the piping. WMNA determined that low points, fittings, and changes in direction should be minimized. Therefore, a new pipe with proper insulation was installed (see Figure 6). Temperature and Pressure Differentials The Chem ShareTM process simulator was used to evaluate the effects of temperature and pressure on the gas under normal operating conditions. The process scheme was simulated and dew point temperatures for inlet and outlet gas streams were calculated. The existing operating configuration mixed hot gas from the third stage compressor discharge bottle with cool gas directly from the air exchanger. The system was set up to maintain a gas temperature of 150F at the FGC skid before the gas went to the turbine building. By mixing hot gas with cool gas before any separation of free liquid from the cool gas, the effluent product gas would have a dew point of 144F. By the time the gas reached the turbine its temperature would drop to 130F, which was below the dew point temperature. Liquids would drop out between the FGC and T/G, setting up the possibility of slugging the filter at the turbine inlet. This predictable situation was verified by the amount of liquids that accumulated at the filter/separator (Fil/Sep) unit during normal operations. At times the levels in the upper section of the Fil/Sep would fill

unexpectedly, which indicated a slug of liquid had been carried over to the filter by the gas. The system was not effective in controlling condensation within the pipe between the FGC and T/G. A solution to control the dew point and a means of maintaining some superheat between the FGC and T/G was provided by a gas to shell and tube exchanger installed between the final separator and the T/G on the FGC skid. The hot gas from the third stage compression at 275F was used to reheat the cool gas. After the gas has passed through the fin fan cooler, liquids are removed in a filter separator vessel. The cool, dry gas then passes through the shell side of the gas to gas heat exchanger. The hot compressor discharge gas is used as the reheat media which passes through the tube side of the exchanger at 275F to heat the gas on the shell side (see Figure 7). Figure 7 : Power generation facility after process modifications.

The reheat via shell and tube would raise the final gas temperature by 20 to 30 degrees and would insure that no water condensed between the FGC discharge and the T/G inlet filter. Oil Carryover Quantities Each compressor used 1.1 to 1.5 gallons of lube oil per day. The existing Fil/Sep removed 25% to 50% of the contaminants depending on ambient conditions. The amount of suspended aerosols passing through the Fil/Sep and entering turbine no. 1 was 2 ppmw, which was equivalent to 110 pounds or 14.65 gallons of oil a year. Filter/Separator for the Fuel Gas Compressor (FGC) Since the gas entering the third stage discharge scrubber was above its dew point, the scrubber was not removing any liquid. Sizing calculations also indicated that the existing separator bottle was too small to effectively remove condensed liquids that were formed in the after-cooler section. The Fil/Sep was adequately sized and was surplus equipment. WMNA decided to relocate the existing Fil/Sep to a position downstream of the after-cooler (see Figure 6) in order to act as a pre-filter to the final liquid/gas coalescer. Gas Mixing Versus Gas to Gas Exchanger Gas properties and Chem ShareTM results indicated that reheating the gas after the Fil/Sep by injection was not appropriate. Instead, WMNA concluded that a gas to gas heat exchanger would be quite efficient (see Figure 7). Compressor Operation and Design The fuel gas compressor (FGC) had experienced valve plugging, emulsion formation, and piston failure, mostly due to poor pre-filtration. More efficient filtration was recommended. High Temperature and Humidity High temperature and humidity experienced during the summertime could contribute to the instability of T/G operation due to changes in gas quality. Higher rates of condensation along with poor liquid removal efficiency needed to be corrected to protect the T/G. A gas to gas heat exchanger and improved filtration would control the dew point and minimize the adverse effect of higher temperature and humidity on turbine performance.
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Reasons for Selecting a Pall Liquid/Gas Filtration System

Pall's Liquid/Gas Coalescer (see Figure 8) was selected based on its ability to remove both particulate and oil vapor from the gas stream. The filters were placed adjacent to the turbines using a minimum amount of piping between the filter and turbine fuel inlet flange. Pall filter housings and elements were selected competitively based on removal efficiency of particulate and aerosols, filter life expectancy, as well as price. Performance guarantees of the Pall system included the following: 99.98% removal of aerosols and particulates 0.3 microns and larger with downstream aerosol concentrations of less than 0.003 ppmw (3 parts per billion by weight). No re-entrainment of coalesced liquids. Low saturated pressure drop (less than 1.2 psi differential).

Long filter life (typically one year or longer). Filtration to remove both liquid and solid contamination to the levels specified (in the absolute terms).
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Post-Installation Report
As of May, 1989, the above modifications were completed. WMNA's first overall inspection after 90 days of operation revealed that the Pall LG system performed efficiently and effectively. On July 11th and 12th, the two turbine units were shut down and boroscoped, and the T/G fuel system and the Pall filter housings were opened and inspected. The most significant evidence of the effectiveness was seen in the fuel injector nozzles. They were exceptionally clean and free of any buildup. There was no evidence of oil carryover and only a slight discoloration on the injector tips. Other signs of effectiveness included dry fuel control valves and no evidence of residual oil or condensate. Also, the filter elements were clean; almost in a "like new" condition. No evidence of oil carryover was found downstream of the Pall housing either. Boroscope inspection of the turbine units showed no accumulation of oil or deposits on the blast tubes in the combustor. The internals of the combustor and turbine inlet nozzles actually appeared to be cleaner, as if the engine was being cleaned by the cleaner fuel. An oil carryover test was performed by Pall's field service team on July 26th. Results outlined in Table 3 confirmed that the Pall Liquid/Gas Coalescers were performing to guaranteed levels with particulate removal (absolute) of 0.3 microns with aerosol penetration at 3 to 5 parts per billion. The Pall filter cartridges, proving their long service capability, were replaced after one year. The elements were not exhibiting any excessive pressure drop and were replaced during routine maintenance. Table 3 : Liquid/Gas coalescer and filter/separator performance as measured in the field

Sampling Point Influent to Fil/Sep Effluent of Fil/Sep Influent to LG Effluent of LG (2)

(1)

Hydrocarbon Content (ppmw) 0.4536 0.1971 0.1745 0.0056

(1) All solid aerosols collected on the test membrane were below 25 microns in diameter. (2) All solid aerosols collected on the test membrane were well below 1 micron in diameter.
Further inspection of these elements was performed by removing a section, dissecting it, and examining the internals. The results: Pall filters were in excellent condition. Prior to installing the filters, fuel control valves were rebuilt quarterly and oftentimes more frequently due to contamination and condensation. Since Pall filters were installed, no fuel valve rebuilds have been required.
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Ketema Gas/Gas Heat Exchanger

The gas to gas heat exchanger was installed to use third stage discharge gas at 250F to 300F to reheat third stage filter/separator effluent to 30F above its saturated dew point. This eliminates the potential of condensation occurring between the fuel gas compressor and the turbine inlet. Each exchanger was designed to handle 6,300 lb/hr of gas and exchange 91,000 btu/hr. The delta T approach temperature at design conditions was 30F tube side and 27F shell side. The heat exchangers were performing at or above their performance specifications. During hot days and at reduced flow rates, the exchangers provided delta T approach in the range of 50F on both shell and tube sides. This is due to higher third stage discharge temperature and higher interstage cooling temperatures from the air cooled exchanger. Gas leaving the FGC skid was at 170F. Gas at the turbine inlet has been between 145F and 160F during the summer season. During winter months, interstage temperatures decrease and T/G inlet's temperature averages 120F. New exchangers are more efficient because fouling factors which were considered in design have not materialized. As fouling factors develop, efficiency and overall heat exchange rates will be reduced to within the specified limits. Figure 8 : Pall Liquid/Gas (LG) Coalescer assembly.

Figure 9 : Clean nozzle after 1,200 hours of operation with a Pall LG filtration system installed.

Results The gas/gas exchangers performed as specified. They provided a minimum of 30F reheat to maintain gas temperatures at the turbine above the dew point. Inspecting Turbines Post Installation Since completion of the process modification project and the start-up of the units in mid-May 1989, the results have been impressive. The purpose of the modifications was to protect the turbine from oil carryover and to prevent future failures. Inspection of the turbine conducted on July 11th and 12th, 1989, and in January, 1990, indicated the project had met or exceeded its objective in all respects. Boroscope inspection, performed during Omega Hill's quarterly maintenance shutdown, revealed that the fuel gas injectors were cleaner than any injectors inspected after 1,200 hours of operation. The following turbine areas were also boroscoped and/or visually inspected: Gas fuel manifold Fuel injectors Combustor liner and case Turbine section first stage nozzles and blades The fuel manifold had a dark oil deposit in the upper section at the end plate baffle. The volume of this oil deposit was similar to that observed in gas turbine fuel manifolds at other sites. Due to their cleanliness, not all of the injectors were pulled from the combustor section for inspection. The injectors had 1,200 hours operating time since process modifications were introduced (see Figure 9). Relocating Existing Filter/Separators The existing filters were previously located at the turbine inlet where the Pall filters have not been installed. The process review indicated that existing separators for the final stage after cooler effluent were undersized. Relocating existing filters to the new location provided more separation of condensate from the aftercooler, as well as efficient filtration of upstream gas from the gas to gas heat exchangers. This change enabled the gas/gas exchanger to operate with exceptional efficiency. Fouling after one year has been negligible. Results These relocated filters provided efficient coalescing of entrained liquids in the gas as it left the aftercooler section of the air cooler. Also, significant quantities of water, oil, and organics were removed from the system at this point. During winter months when the aftercooler was most effective, the filters

from the system at this point. During winter months when the aftercooler was most effective, the filters would remove large quantities of liquids which would otherwise remain in the gas and wind up in the piping and/or Pall LG Coalescer. Relocated Gas Piping Above Ground Relocating the gas piping from below ground to above ground and insulating it was necessary to insure that the gas would remain above its dew point. This would eliminate the possibility of liquids accumulating in low spots in the system. Further inducement was provided in that meter runs were required to measure the gas flow and provide samples to the gas chromatographs for record-keeping purposes. The below ground portion of the line was a huge heat sink, and reliable control of gas temperatures at the turbine was impractical as long as the below ground lines were used. Two gas lines were installed above ground, low points eliminated, meter runs with sample points installed, and insulation conserved heat. Results The temperature drop from the FGC to the turbine has been reduced from 30-60F down to 15-20F. The gas leaving the FGC final filter had been as low as 110F before the modifications. Temperature at the turbine now ranges from 145F to 160F providing a margin of safety of 25F to 40F. During the winter season, this margin will narrow due to increased heat transfer in the air cooler, but the gas at the turbine will still remain well above the dew point.
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Analyzing Project Savings and Payback

Not only is there a high possibility of injury to operating personnel as a consequence of mechanical failure, but the repair costs are also expensive. The total repair cost for failed turbines at Omega in 1989 was $477,000. This included freight and miscellaneous expenses to change out the failed units and install replacement units. Cost breakdown is summarized below: Repair cost of unit no. 1 Repair cost of unit no. 2 Removal, package, and freight to turbine repair shop $149,200 $235,200 $ 8,650

Freight, unpack, and install replacement turbines at $ 12,750 site Lost production and fixed costs during shutdown Administrative overhead and expenses TOTAL $ 55,400 $ 15,800 $477,000

In view of the high cost to replace a turbine and the expected long-term benefits which would accrue after the process modifications, the project expense was classified non-discretionary. Omega Hills process modifications have provided excellent system performance which can be quantified. To illustrate the economic incentive, a cost savings analysis follows: Project cost - all equipment, labor, etc. $(84,400) Return on investment Revenues - accrued to reduce maintenance, increased on-line time $105 x 2 units hr/turbine x 14.58 hrs. month x 12 months year = $ 36,740

Labor Savings - reduction in man-hours expended in maintenance and troubleshooting (350 hrs x $16.40/hr) = $ 5,740 Equipment Savings - reduction in material cost, to maintain engine systems (240 + 180 + 1,200 + 800) x 2 = $ 4,840 TOTAL ANNUAL SAVINGS $ 47,320

The payout period at 10% cost of funds is 24 months.

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Analyzing Life Cycle Economics

Life cycle economics were performed to ascertain the value to WMNA for proceeding with the process modifications on all existing and projected installations. Based on WMNA's experience the following costs were used. Numbers are per unit basis:

 Average cost to repair one turbine Average cost to implement process modifications and install new filters

$238,500 system $42,200

Average annual savings accrued from modifications $23,660 Expected turbine life (normal life cyclebetween changeout) Expected turbine life (without process modifications) Scheduled turbine changeout, includes cost of downtime 5 yrs 2.5 yrs $133,720

Cash Flow - Timetable present value analysis using 10% interest for ten years. The present value of the old system costs without the process modifications over ten years would be: PVold = 238,500 (.7889 + .6333 + .5038 + .4009 + .3186) = $630,950 The present value of the new system is calculated to be: PVnew = 23,660 + 133,720 (.5645 + .3186) = $141,748 Over a ten-year period, the present value difference is equal to: PVold - PVnew (630-950-141,748) = $489,200 per turbine WMNA has 25 centaur turbines in operation, which equates to a total company savings of: $12,230,000.00.
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Conclusion
As pointed out in the text and as illustrated in the photos, the improvement in turbine productivity and the reduction of O&M costs have justified the process modifications. The results have been so overwhelmingly conclusive that Waste Management has decided to install Pall filtration on all of its 27 turbine installations nationwide. All new projects will include gas conditioning using the process design criteria that were established at the Omega Hills facility during 1988. Waste Management is the nation's leader in landfill gas recovery. In fact, 14.5 billion cubic feet of gas were recovered from 16 facilities during 1990. Currently eight facilities are either in design or under construction and an additional ten sites are under consideration for development in 1991 and 1992. With the large number of turbine generator systems that will ultimately be in operation and the high initial investment costs, it becomes evident that gas conditioning plays a vital role in the overall success of using landfill gas as a fuel in turbine combustion systems.
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