the magazine of power generation

Technical Digest

Maximizing Power
Plant Efficiency
Many power generation systems rely on liquid
fuel and oil. Clean, dry oil and liquid fuels
are essential to preserving equipment and
preventing shutdowns that could cost hundreds
of thousands of dollars. Proper filtration is
crucial to optimizing the performance of power
generation and emission control systems.
It reduces the cost of new oil purchases,
decreases disposal costs, reduces wear, cuts
downtime and mitigates environmental
contamination. Power plants operate more
efficiently using high-performance oil, gas,
sponsored by:

carbon and gearbox filters. Given the harsh

operating conditions of a power plant,
maintaining reliability can be challenging.
Contamination control solutions can mitigate
failures and save power plants money by
reducing downtime and maintenance costs.

Your Gen-Set Engine

Gas Turbine Air Filter
Keeping Fluid Systems
2 IsReady
11
26
or Not?
System Optimization
Clean
Reprinted with revisions to format from Power Engineering. Copyright 2015 by PennWell Corporation.

Originally published June 17, 2014

Is Your Gen-Set Engine

Ready or Not?
Ensure your diesel engine will respond at a moments
notice by focusing on preventive maintenance.
By Craig Purvis, John Deere Power Systems

enerator-set
diesel engines

are trusted to
keep the power on
through the strongest storms
and in the most remote
locations on earth. Whether
theyre protecting hospital
operating rooms or providing
distributed power, these
engines must be ready when
called upon.
Generator-set diesel engines are trusted to keep the power

Proper preventive
on through the most powerful storms and in the most
maintenance is critical to
remote locations on earth. Proper preventive maintenance
ensuring that gen-set diesel
is critical to optimizing the performance, reliability and
engines deliver reliable power durability of generator-drive diesel engines. Photo courtesy:
John Deere Power Systems
in standby or prime-power
applications. By carefully
following the engine manufacturers maintenance recommendations, you can
optimize the performance, reliability and durability of your engine. Neglecting
preventive maintenance can lead to inefficient operation, component failures or
permanent damage to the engine - potentially costly consequences.

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Is Your Gen-Set Engine Ready or Not?

Your gen-set engine features integrated components working together to

provide fast response for standby situations and excellent load recovery in all
applications. The fuel, lubrication, air intake, cooling and electrical systems
require maintenance at various intervals. Observing the detailed service
recommendations in your engine operators manual will help ensure that the
engine stays healthy and responds when you need it most.
Gen-set engine maintenance recommendations vary from manufacturer to
manufacturer. Its important that you adhere to all the service procedures
and intervals found in the operators manual for your specific engine. John
Deere Power Systems, which offers generator-set diesel engine models with
displacements from 2.9L to 13.5L and ratings from 31 to 563 kW (42 to 755 hp),
recommends the following system-by-system maintenance practices.
Before you buy
The first step in properly maintaining your generator-set engine isnt a procedure
performed at a given interval on a certain system. You can avoid many potential
service issues and promote longer engine life by appropriately sizing the engine
for the application during the selection process.
An oversized engine will operate inefficiently and could experience issues such
as slobbering unused fuel. If an engine is too small, it may overheat, stall or be
slow to respond to load changes, and have a shorter life. When choosing a genset, carefully assess your standby or prime power requirements and properly size
the engine to the load youll be running. John Deere recommends working closely
with the gen-set manufacturer to determine the appropriate engine size for your
application.

Standby gen-set engines should be properly loaded in exercise mode. To ensure

that your standby gen-set engine will deliver efficient performance when needed,
John Deere recommends running the engine at rated speed with 50 to 70 percent
load for 30 minutes every two weeks. The engine shouldnt be allowed to run for
extended periods of time with no load. John Deere advises that standby gen-set
owners work with the gen-set manufacturer to implement an automated solution
for appropriately loading the engine during exercise mode.

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Is Your Gen-Set Engine Ready or Not?

Lubrication system
The first hours of an engines life
are important in determining
its performance, reliability and
longevity. Its important to use the
right type of oil during this breakin period to allow the engine parts
to wear properly.
New John Deere engines are filled
at the factory with John Deere
Break-InTM Plus engine oil, which
is formulated to work with the
specific alloys and part tolerances
A PowerTech E 13.5L model, a standby engine. Photo
used in John Deere engines. During
courtesy: John Deere Power Systems
the recommended 100-hour breakin period, the engine should be
operated under various conditions, particularly heavy loads with minimal idling,
to help seat engine components properly. The use of 10W-30 John Deere Break-In
Plus engine oil encourages rings and liners to set correctly to ensure a good wear
pattern and longer life.
If the engine has significant operating time at idle and/or light-load usage, or
makeup oil is required in the first 100-hour period, a longer break-in period may
be required. The oil and filter should be changed between a minimum of 100
hours and a maximum of 500 hours during the initial operation of a new engine.
With the introduction of exhaust filters in engines used to meet U.S.
Environmental Protection Agency Tier 4 diesel emissions regulations, the type
of engine oil used can have a significant impact on the proper functioning and
ash service life of these devices. John Deere recommends using only engine oils
meeting API CJ-4 and ACEA E9 standards, such as John Deere Plus-50TM II. These
oils are refined with a lower trace metal content, which reduces ash accumulation
and increases exhaust filter service life.

4
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Is Your Gen-Set Engine Ready or Not?

Lab and field tests reveal that the superior anti-wear additives in quality engine
oils can significantly reduce engine wear, increasing the productive life of the
engine. They also extend drain intervals and reduce piston deposits, which leads
to a cleaner engine that will last longer and provide consistent power.
Lubricants should be clean. Even the best lubricants cannot function properly if
they are dirty. When maintaining the engine, be sure to:
:: Change oil when recommended.
:: K
 eep all lubricant containers covered in an area protected from dirt and
moisture.
:: R
 emove all dust and grime from both the container and service points before
performing lubrication service.
Unfortunately, all lubricants gradually lose effectiveness during operation due
to chemical and physical changes in the lubricant. The deterioration process is
accelerated by contaminants from external and internal sources. Thats why
following manufacturer-recommended lubricant change intervals for normal
operating conditions is so important.
More frequent oil changes are recommended when operating in extreme
environments, such as in very hot or dusty conditions, or at high altitudes. Oil
analysis can be performed to ensure that the recommended service interval is
adequate for your application. Regularly scheduled oil sampling and analysis can
pay for itself by detecting potential problem-causing conditions before they turn
into performance issues or costly downtime.
Fuel system
Gen-set engines meeting Tier 4 diesel emissions regulations require the use of
ultra-low sulfur diesel (ULSD) - diesel fuel with a sulfur content of less than 15
ppm. Using diesel fuel with a sulfur content greater than 15 ppm can damage
the exhaust filter used to reduce particulate matter, leading to early replacement.
Some Tier 4 engines also operate efficiently with biodiesel blends, providing fuelchoice flexibility.

5
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Is Your Gen-Set Engine Ready or Not?

John Deere recommends limiting biodiesel use with gen-set engines to primepower applications. Biodiesel is naturally biodegradable, and blends up to B20
should be used within 90 days of the date of biodiesel manufacture. Microbial
growth present in biodiesel used after 90 days could damage an engines fuel
system and result in the need for new components. Because standby generators
may not use a full tank of biodiesel fuel during a short time period, John Deere
recommends using only regular diesel fuel for standby gen-set applications.
To ensure the quality of regular diesel fuel in standby applications, John Deere
recommends replacing old fuel with fresh fuel every six months to a year.
If you opt to run biodiesel for your prime-power application, a 5 percent blend
(B5) is preferred, but a biodiesel concentration of up to 20 percent (B20) may be
used. Regardless of biodiesel blend level, verify with your fuel provider that the
biodiesel blend meets ASTM D6751 (U.S.) standards.
Regardless of which fuel you run, only fuel additives that are approved by the
engine manufacturer should be used. Frequent fuel sampling and analysis is a
sound practice that promotes engine performance, reliability and durability.
To help achieve an uncontaminated and unrestricted fuel flow, John Deere
recommends these practices when performing fuel system maintenance:
:: Check for leaks.
:: Check for bent, kinked or dented supply or return.
:: Inspect fuel filters for dirt, water or other foreign matter.
:: U
 se fuel that is not contaminated with water. Water in the fuel system is the
greatest cause of fuel injection system failure.
:: C
 heck for water in the fuel filter. Daily inspection of the fuel filter and draining
the water from the fuel filter water separator and fuel tank as required will
ensure that the fuel system is protected.

:: I nstall a fuel storage tank water-separating filter to further protect engines by

filtering out dirt, rust and scale. To service the tank filter, install a shutoff valve
between the tank and filter. The filter element should be changed annually or
more often if fuel flow becomes restricted.

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Is Your Gen-Set Engine Ready or Not?

Air-intake system
Making sure your engine receives an unrestricted flow of clean air is imperative
for proper operation and long life. For example, dust reaching your engine through
a leaking connector in the air-intake system - called dusting the engine can destroy an engine, even one with low hours of operation. Therefore, it is
important to:
:: I nspect the entire air-intake system for openings that could draw in unfiltered
air (loose clamps, cracked hoses, etc.).
:: I nspect dry element type filters and replace if clogged with dust or dirt.
Inspect for damaged seams and pleats. Replace if necessary. Cleaning the
elements with compressed air or by pounding them on a hard surface is not
recommended.
:: H
 ighly efficient filters, such as Donaldson PowerCore filters, cannot be cleaned
and must be replaced when restricted.
Cooling system
When performing maintenance on your engines cooling system, always use the
recommended class of coolant. Its important to be selective with antifreeze/
coolants because not all of them provide the protection needed to operate
efficiently under extreme pressures and temperatures.
John Deere Cool-Gard II, for example, is a fully formulated antifreeze/summer
coolant designed and extensively tested to protect wet-sleeve-liner diesel engines
from cylinder-liner cavitation erosion.
Engine cooling systems should be thoroughly flushed and cleaned with a heavyduty cleaner and refilled with clean coolant and inhibitors per the recommended
intervals in your operators manual. In addition, it is important to visually
inspect the radiator and thermostats for any signs of corrosion, debris or physical
damage.

7
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Is Your Gen-Set Engine Ready or Not?

John Deere highly recommends coolant solution analysis, which will verify
the chemical composition of your coolant and include a written report with
maintenance recommendations for the coolant and cooling system. Regular
coolant analysis is particularly important in standby applications because coolant
heaters can deteriorate additive packages.
Also, John Deere recommends these maintenance practices:
:: Replace radiator hoses that are cracked, soft or swollen.
:: C
 lean all dirt and trash from between radiator fins and around the radiator
itself.
:: Check for bent radiator fins and straighten as needed.
:: Ensure baffles and fan shrouds are in place and functional.
:: I nspect the fan blades for damage and the fan belts for excessive wear. Replace
as needed.
Electrical system
Maintaining the electrical system is often more complicated than maintaining
some of the engines other systems, so most electrical maintenance tasks should
be left to a certified mechanic. However, an engines electrical system is centered
on its battery, and it is always important to check the condition of your battery:
:: Verify batteries are fully charged and the electrolyte is at its proper level.
:: Remove battery cables and clean cable ends and posts.
:: Repair or replace the alternator if it isnt keeping the battery fully charged.
:: C
 heck all alternator wiring connections for tightness and corrosion. Correct as
needed.
:: Check all chassis grounding and bonding wires for corrosion and integrity.
:: Check condition and tension of alternator belt and adjust or replace as needed.
:: C
 heck all starting motor connections for tightness and corrosion. Correct as
needed.

8
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Is Your Gen-Set Engine Ready or Not?

Facilities and locations around the world depend on diesel-powered generator sets
to provide worry-free service, often at a moments notice. By diligently following the
engine manufacturers preventive maintenance recommendations, gen-set owners
can optimize the performance, reliability and durability of their gen-set engine.

Craig Purvis is a senior field service representative specializing in generator sets

at John Deere Power Systems. He has 16 years of industry experience, including
positions as an electronics technician, heavy-duty diesel engine wire harness
designer and quality engineer in production engine testing.

9
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As bulk material handling machinery designs become more powerful

and increasingly efficient, braking system designs must also progress to
satisfy the demand to control speed and stop machines in routine and,
most importantly, during emergency stopping events.
Brakes are no longer straightforward on or off mechanical devices.
Sophisticated Smart Brake deceleration controls with system status
monitoring, fault acknowledgement, and feedback are required to maintain system integrity under all stopping conditions.
This is particularly crucial on belt conveyor systems, where tension management and personnel safety are of paramount
importance.
With these considerations in mind, Hilliard has developed a line of power units capable of controlling braking systems for a
multitude of scenarios and applications.

MK Electrically Released Caliper Brakes

Powerful floating caliper design can be used on conventional disc or rail applications.
The compact spring-applied design provides easy installation and maintenance.
Spring force and air gap can be adjusted to match torque requirements. The patented
Hilliard MK Guide Rail Brake is designed for use on elevators,
conveyors, cranes, or other devices requiring a spring-applied
electromagnetically released brake. The
patented MK brake can be applied to a guide
rail or a brake disc.

BBH2: Railcar Positioners,

Wind Turbines, Cable
Winders, Escalators,
Overland/Underground
Conveyors
BBH3: Overland/
Underground Conveyors,
Conveyor Tension Winches,
Marine Towing Winches
BBH4: Grinding Mills such
as AG, SAG, and Ball Mills

Magna Torque (MT)

for Backstopping &
Indexing
Hilliards line of
overrunning clutches
is economically priced
and ideally suited for
backstopping and
gearbox applications.
Custom designs and
rapid prototyping are
available.

Magna Torque (MTR) for Clutch

Couplings, Dual-Drive & Turning Gear
Roller-Ramp design for increased
reliability and longer life.

An integral part of many Hilliard motion control

products is our roller-ramp design. The use of
hardened cams and precision-machined rollers
maximizes service life.
There is almost no wear during freewheeling operations because
rollers are free to rotate between the outer member and the
inner cam. When the rollers are engaged, the load falls at
random positions on the rollers. The result is superior service life
and reliability.The MTR is similar to the MT design except the
cam surface is reversed allowing it to be used in multi-speed/
dual drive applications.

Hilco Oil Reclaimers

Comprehensive
Contamination Control for
Hydraulic Systems

If your application involves oil with substantial amounts of water or volatile

contaminants, an oil reclaimer may be the most cost-effective
solution to your contamination problem. The addition of settling
and clean-oil holding tanks, filters and controls converts the
basic Hilco Oil Reclaimer into an extremely efficient reclamation
system. The reclamation process uses a combination of filtration
and vacuum distillation to purify the oil and return it to a
like-new condition. Other contaminants best removed by this
process include acids, solvents, dissolved gases almost any
volatile contaminant. Although most reclaimers are part of a
permanently installed system, they can be made portable for
the greatest flexibility in dealing with your application.

The Hilliard Corporation

Overrunning Clutches
Hilliards enclosed overrunning clutch
incorporates superior MTR design in a
totally enclosed package. Designed for
power transmission operations, this
clutch is totally contained in a stationary
housing for constant protection from
hostile environments or wash-downs.

Supplemental Protection for Other Locations

A particular set of operating conditions may require contamination

control in addition to that provided by the off-line loop. Examples
include pressure-line filters for in-line
protection of remotely mounted critical
components, and reservoir air-breather
filters to protect against
ingestion of airborne
contaminants in hostile
atmospheres. Hilco
products are available for
these special applications,
and Hilliard's applications
specialists can advise and
assist you in the selection
of such equipment for
supplementary locations.

100 West Fourth Street, Elmira, New York 14902-1504 USA

PH: 607.733.7121 | FAX: 607.737.1108 | hilliardcorp.com | hilliard@hilliardcorp.com

Originally published January 21, 2015

Gas Turbine Air Filter

System Optimization
By James DiCampli, P.E., and Jack Pan, GE Power and Water, and
Mark Arsenault, American Air Filter

roper air filtration is critical to the overall performance and

reliability of gas turbines. Fuel costs approach 80 percent of the life

cycle cost of electricity. Small gains in efficiency can mean huge
savings. With fuel costs of around $16.00/mmBTU and higher in certain
global regions, operational savings can be achieved through improved compressor
performance using High Efficiency (HEPA) air filters. Operators can see greatly
reduced maintenance costs as a result of a much cleaner engine, quantified
by less frequent inspections, fewer shutdowns, and higher availability. HEPA
filtration can maintain optimum GT efficiency throughout the life of the filter.
This article investigates the decision criteria required in selecting an optimum
air filtration solution, with the goal of maximizing gas turbine availability and
lowering operating costs. Through case studies and analysis, essential filter
parameters and their impact on gas turbine operations and maintenance are
reviewed.
Air Filtration and Conditioning Overview
Aeroderivative gas turbine ventilation and combustion air filter systems are
designed to protect the gas turbine, generator, and equipment compartments
from the effects of air-borne dirt, contamination and foreign objects. A number
of inlet conditioning options are also available to maximize gas turbine
performance.

11

GE Distributed Power gas turbines use a three-section inlet air filter that mounts
directly above the turbine enclosure, conserving space and providing compact,
low-pressure loss ducting to the turbine inlet. Figure 1 provides an illustrative
example.

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Gas Turbine Air Filter System Optimization

LM6000 Gas Turbine Generator Air Flow

Bolt-on Coil Section

Composite
Flter
Coil
Section Canisters

Generator Cooling
Air Exhaust
Enclosure
Generator
Ventilation Enclosure
Air Exhaust
Exciter

Generator

Turbine
Exhaust
Guard Filters

Combustion Air
Ventilation
Air

Drift Eliminator

Drift Eliminator

Ambient
Air In

Fan

Ambient
Air In

Fan

Enclosure
Ventilation
Air Exhaust

Turbine
Enclosure
Gear
Box

The ventilation and combustion air system consists of a filter house structure,
roof-mounted silencers, fans, and associated ductwork all located on the turbine
and generator enclosures. The filter house is comprised of weather hoods, filter
elements, chiller or anti-icing coils, and plenum chamber assembly. Air from the
plenum assembly is ducted to the turbine engine intake for combustion and to the
turbine and generator compartments for cooling and ventilation. An external ladder
and walkway with access doors to the air filter structure enables filter servicing.
A temperature element in the air filter house combustion air section provides
inlet temperature information to the control system. Relative humidity sensors
measure moisture in the air before it enters the filter housing and activates an
alarm if icing conditions exist.

12

Pressure transmitters sense the pressure difference between the outside air
and the combustion air inlet plenum. For example, on a GE LM6000, if the

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Gas Turbine Air Filter System Optimization

differential pressure reaches 5 in-Wg (-127 mm), the control system activates an
alarm, an indication of filter clogging. If the differential pressure reaches 8 inWg (-203 mm), the control system activates a load reduction. Another pressure
differential transmitter monitors total pressure drop at the ventilation air plenum
and activates an alarm if the pressure differential reaches -5 in-Wg (-127 mm).
Ventilation air is ducted from the ventilation plenum directly into the turbine
compartment. One of the two turbine compartment fan assemblies draws air from
the inlet air filtration system through the turbine compartment and expels it to an
air exhaust stack that is equipped with a silencer limiting the transmitted noise.
Component Description
Weather Hoods and Drift Eliminators
Air entering the filter house first passes through (optional) weather hoods, drift
eliminators and inlet screens. Weather hoods protect filters from rain, snow
and sun. Weather hoods are bolted to the inlet side of the left and right coil
assemblies (for dual inlet systems). Weather hoods prevent rain and snow from
entering the inlet filter house by drawing inlet air upward at lower velocities
than that of falling rain and snow. Snow hoods and tropical rain hoods are
available for snowy or tropical environments. Inertial moisture separators (vane
type separators) are also available to prevent heavy rain or heavy fog mist from
entering the filter house.
Filters
A multi-stage filtration system is available which includes a guard filter upstream
of the chiller coils and a set of composite canister barrier or panel-type filters
located downstream of the coils. The guard filters (also known as pre-filters)
keep the chiller coils clean for maximum heat transfer efficiency and provides
supplementary filtration to extend the service life of the composite fine filters.
The fine filter elements are mounted to the filter face of the inlet plenum and
extend into the clean air plenum. The elements have extended surface area, large
dirt-holding capacity and low-pressure drop.

13
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Gas Turbine Air Filter System Optimization

Air passes through the fine filters and enters the clean air plenum. This
fabricated structure is the center section of the inlet filter assembly and separates
ventilation air from combustion air. Combustion air flows through a transition
duct from the clean air plenum to the combustion air inlet silencer. Ventilation
air flows through transition ducts to the turbine and generator compartment. The
inlet silencer is a low-pressure-drop device located in the combustion air stream
before the inlet volute. The silencer attenuates noise from the turbine and helps
maintain the units low noise level.
Inlet Cooling and Heating
Air conditioning options include evaporative coolers or optional inlet air chiller
coils to maximize gas turbine performance on hot days. Conversely, coils can be
used for anti-icing and/or optimizing efficiency during partial power operations.
The evaporative cooling system uses the process of evaporation to create a
reduction in inlet air temperature. Water is pumped to a header that distributes
the water over media blocks that consist of corrugated layers of a fibrous
material. Air passing through channels comes into contact with the falling water
causing a portion of the water to evaporate, transferring heat from the air to the
water.
Static and Pulse Filter Options
The correct type of filter (pulse or static) should be used for the specific project
environmental conditions and specific contaminants.
In general, a pulse or self-cleaning type inlet air filter should be used when the
dust loading approaches 0.300 mg/m3 or higher, or when operating in conditions
where dust or sand storms can occur. The ambient air can be tested using a
direct read-out device, such as a laser photometer that counts particulates in the
air sample.

14

The American Air Filter ASC Pulse filter system utilizes a unique inertial
separation system that diverts over 90 percent of the dust particles from the gas
turbine inlet into a secondary air system, via negative pressure. The remaining
particles are captured on the surface of AAFs PanelPak filter element, which

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Gas Turbine Air Filter System Optimization

in turn is pulsed off the filters when required. The AAF system prevents reentrapment of the pulsed particles as they are expelled into the same separation
system during the pulse cycle. This allows for continuous operation of the GT
during the pulse cycle, while the design provides for a lower pressure drop of the
entire inlet system. AAF has over 900 of these units in operation to date, in many
industrial areas and locations with very poor air quality.
Pulse filters can and have been successfully used in very dusty environments,
such as steel mills, cement plants, Middle East environments, or areas where
sand or dust storms are prevalent, even with high humidity. The pulse controller
can be programmed to pulse as the loading requires (e.g., based on filter pressure
drop, ambient relative humidity, hourly, daily, or even continuously). For example,
a common recommendation for an installation in a cement factory, is to
minimize caking on the filters by automatically pulsing the filters whenever the
relative humidity is greater than 80 percent.
Pulse filters are also utilized when a turbine is being operated in an environment
with significant loading of snow or ice crystals. Although a static filter can be
used in these environments if there is a properly designed conditioning system
upstream (e.g., heating coils, bleed air or other hot air conditioning), pulse systems
are the most reliable for preventing filters plugging due to cold weather moisture.
Another advantage of pulse filter systems, particularly for peak loading turbines,
is that the filters can be pulsed when the unit is not in operation, which provides
maximum effectiveness to the pulse cleaning, so the filters can be cleaned and
ready for the next start-up.

15

Static filters can be fitted with inexpensive pre-filters that can be replaced and/or
cleaned to extend the life of the barrier elements. However, special pre-filters can
become a maintenance item and drive up costs over the life of the project. For
example, for areas with a high hydrocarbon loading or areas with cement dusts
and frequent high humidity, pleated composite type pre-filters, rather than the
more standard fibrous type, are often required to prevent short barrier filter life.
These pre-filters are less expensive and must be replaced (or possibly removed
and cleaned) at somewhat frequent intervals.

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Gas Turbine Air Filter System Optimization

Water Wash
Fouling deposits on gas turbine compressor airfoils reduce engine performance
output. The water wash system provides a mechanism for cleaning engine
compressor blades. The aim is to recover power output and heat rate performance
by restoring the compressors flow capacity and efficiency.
There are many types of compressor fouling. The type and rate of fouling depend
on the environment in which the gas turbine operates and the efficiency level of
the inlet filtration. Among the most common types of contaminants are dirt or
soil, sand, coal dust, insects, salt, oil, and even turbine exhaust gas.
Salt also causes corrosion of blading and ductwork and subsequent ingestion of
rust and scale. Oil increases the ability of contaminants to cling to compressor
passages and airfoils. The type of material that is deposited on the compressor
blading influences the method of its removal.
Keeping the compressor internals clean can alleviate a number of problems before
they ever become apparent. Besides the obvious benefits of enhanced efficiency
(increased power output, lower compressor discharge temperatures, etc.), keeping
the compressor clean will help blades survive longer.
If the compressor is dirty, additional weight is added to the airfoil and this
increases the cyclic stress. Also, dirt in the dovetail slots will add to the existing
friction loading at the dovetail/slot interface and between the two mechanisms
making a blade dovetail failure more likely. Performing thorough water washes
with high quality ingredients on a regular basis with help combat these conditions.
Washing utilizes liquid detergents, a concentrated solution of water soluble,
surface active agents and emulsifiable solvents produced primarily for cleaning
gas turbine compressors, where the intent is to restore performance by removing
fouling buildup from compressor components.
Methods of Detection

16

The best method for detecting a fouled compressor is visual inspection. This
involves shutting the unit down, removing the inlet plenum inspection hatch,

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Gas Turbine Air Filter System Optimization

and visually inspecting the compressor inlet, bellmouth, inlet guide vanes, and
early stage blading. If there are any deposits, including dust or oily deposits that
can be wiped or scraped off these areas, the compressor is fouled sufficiently to
affect performance. The initial inspection reveals whether the deposits are oily or
dry. For oily deposits, a water-detergent wash is required, followed by clean water
rinses. The source of the oil should be located and corrected before cleaning to
prevent recurrence of the fouling.
Another method for detecting a fouled compressor is performance monitoring.
Performance monitoring involves obtaining gas turbine data on a routine
basis, which in turn is compared to baseline data to monitor trends in the
performance of the gas turbine. The performance data is obtained by running
the unit at a steady base load and recording output, exhaust temperatures,
inlet air temperatures, barometric pressure, compressor discharge pressure and
temperature, and fuel consumption. The data should be taken carefully with the
unit warmed up. If performance analysis indicates compressor fouling, it should
be verified by a visual inspection.
The compressor cleaning operation is conducted after turbine shut down (cranksoak cleaning) or while operating (on-line cleaning).
A consistent gas turbine water-wash strategy pays for itself many times over
in power and efficiency improvement. A crank-soak wash is typically the only
means to remove most deposits, including oily or tarry deposits which bind dirt
to the blades. Because crank-soak wash cleans the suction (convex) side of the
blade it has the greatest influence on compressor efficiency.
There are no hard and fast rules for when to crank-soak wash because the
schedule must be tailored based on type of atmospheric contaminants,
temperature, operational frequency, gas turbine health, and site economics.
In the absence of this information a prudent strategy would be to crank-soak
(off-line), wash every 2 weeks. High concentration of oily deposits and dust will
require more frequent crank-soak washing.

17
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Gas Turbine Air Filter System Optimization

On-line washing serves primarily to maintain gas turbine performance between

crank-soak washes. The primary effect of on-line wash is to remove deposits
on the blade which adhere by impact. Also, dust and dirt are removed on the
pressure (concave) side of the blade but not on the suction side which has a lesser
influence on efficiency. For this reason, the use of water for on-line wash is often
as effective as a detergent solution. The higher the concentration of oil and tars,
the less effective on-line washing will be for improving performance.
In the absence of site-specific information, it would be beneficial to on-line wash
with water daily. Use of detergent should be based on testing which demonstrates
measurable benefits for the site. Visual inspection of the rinse water is effectively
used by some sites to set the wash schedule. If the rinse is mostly clear, the
interval can be extended.
Filter Classification
Filtration systems are optimized to minimize foreign contaminants entering
the gas turbine, and are largely based on the operating environment. Seasonal
pollutants, rain, ice and snow, sand, dust, local industry exhausts, and other air
contaminants must be taken into consideration.
Filters are generally classified by several standard rating methods:
:: U
 nited States: American Society of Heating, Refrigerating, and Air-Conditioning
Engineers (ASHRAE) in standard 52.2: 2007.
:: E
 urope: European Standards EN 779: 2012 and EN 1822: 2009
(Parts 1 through 5).

High Efficiency Particulate Air filters ((H)EPA) filters are generally defined as
having an efficiency greater than 85% for particles greater than or equal to
a filters Most Penetrating Particle Size (MPPS). The MPPS for a filter varies
depending upon the media, media velocity, configuration along with other factors,
but is primarily between 0.07 and 0.2 microns for filters used in gas turbine inlet
applications.

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Case Studies
Six General Electric Distributed Power Lm2X gas turbine sites were investigated.
The environment of these sites ranged from continental, relatively clean air to
heavy industrial sites with significant amounts of hydrocarbon aerosols and
particulates. The air filter configurations are listed in Table 1. The usage of high
efficiency filters as a 3rd stage was installed at two of these sites, both with very
poor air quality.
The following sections summarize each case.

Summary For Investigated Sites

Site Location

Environment

Engine Model

USA

Continental

Lm2500+G4

Russia

Continental
Industrial(Aerosol,
Particles)

Lm2500+G4

Continental

Italy
Belgium
China Site 1
China Site 2

Heavy Industrial
(Aerosol, Particles)
Heavy Industrial
(Aerosol, Particles)

Air Filter
Static Air Filter; Additional Filter: PreFilter, Weather Hoods, Guard Filter
Static Air Filter

Filter Type
Synthetic Panel
Synthetic Panel(F8)

Lm2500+G4

Static Air Filter; Additional Filter: PreFilter, Weather Hoods, Guard Filter

Synthetic Panel(F8)

Lm2500+G4

Static Air Filter; wAdditional Filter: PreFilter, Weather Hoods, Guard Filter

Synthetic Panel(F8)

Lm2500+

Static Air Filter: Pre-Filter, Duracel

Xl90, Hepa

G4, F8, H12

Lm2500+G4

Asc Pulse Filter, Hepa

F8, H12

U.S. Site
This site is an urban area with an interstate highway nearby. There are two filter
stages in this system, a pre-filter and the AAF Duracel XL90N. The operator
changed the pre-filters at 4,000 hrs and primary filters at 8,000 hrs. Online water
washing was completed 1-3 times/week as a proactive measure to minimize offline washes.
Off-line water washing has been performed approximately every 3 months,
equivalent to 2,000 hrs of operation. Offline washing takes about one 8 hour shift,
although it usually is performed in conjunction with other work to maximize
overall availability. The operational history has shown ~1 MW power loss after
the three month period.

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Russian Site
The plant has been operating since 2012 in a relatively clean environment and
uses only one stage filter, a static EU8.
Still, the HPC rotor blades and stator vanes have rust colored deposits on the
surface. Compressor residue samples should be taken and analyzed at a lab to
identify the corrosion mechanism. From this, changes to the filtration system
and/or wash detergent can be recommended.
Italian Site
This site is a small industrial area, but the air is generally clean. The unit is
running about half of the year.
There are 3 filter stages, two pre-filter stages and then the Duracel XL90N. The
pre-filter was changed at 7,000 hours because of high dP. Offline water wash is
performed every 3-4 weeks, or after 700-900 hours of operation.
The site does not perform any online water washing, but conducts off line water
washes frequently to keep the compressor efficiency high.
Belgium Site
The plant operates near a refinery. The refinery fumes can be ingested by the
gas turbine, causing oil contamination of the filters. Both pre-filters and fine
filters are changed every 18 months. Offline water washing is performed every 6
months unless the power loss exceeds 1MW, then an additional offline wash is
performed. On-line washing is generally performed every 2 days.
China Sites
The two China sites investigated are in areas with very poor air quality. The
particulate count and size are shown in Figure 2, taken at different times of the year.
The particulate count at the size level of 0.3um and 0.5um make up 99% of the
contamination. At this level the particulates are captured by the 2nd and 3rd
stage filters.

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Gas Turbine Air Filter System Optimization

There are 3 filter stages:

1st stage is a G4 prefilter, the 2nd stage is a
Duracel F8, and the 3rd
stage is a HEPA H12 filter.
The filter change cycles
and water wash cycle
are shown in Figure 3 for
Unit 2 at the site.

Particle Test Result at China Sites

1,200,000

Site 1 June 2011

1,000,000
Particle Count

China Site 1

Site 1 October 2011

Site 2 April 2011

800,000
600,000
400,000
200,000
0

0.3m

0.5m

0.7m
1.0m
Particle Size

3.0m

5.0m

Filter Change & Water Wash Data (Unit 2) China Site 1

10
9
8

Pressure Drop (Inch H20)

7
6
5
4
3
2
1
0

Sep- 11

Nov- 11 Jan- 12

Mar-12

May- 12 Jul- 12

PreFilter

Sep- 12

Nov- 12 Jan- 13 Mar- 13 May- 13

Duracel X90

HEPA Filter

Jul- 13

Sep- 13

Nov- 13

Jan- 14

Mar- 14

Water wash

The 1st stage pre-filter change cycle is 3-4 months from March through October,
then typically less than once/month from October through March. The 2nd
stage Duracel change cycle is 4-8 months (Mar-Oct), and from 1 week-2 months

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Gas Turbine Air Filter System Optimization

(Oct-Mar). This is because of poor air quality in the winter months. The 3rd stage
HEPA filter change cycle is quite stable, every 6-9 months. Offline water wash is
performed at every 4,000 hours and requires 8-10 hours to complete.
China Site 2
The plant has a pulse filter system, and there are 2 filter stages. The 1st stage is an
ASC Panel Pak element (F8), and the 2nd stage is a HEPA filter (H12). The filter change
cycle and water wash cycles are shown in Figure 4 (Three gas turbines on site).

Filter Change & Water Wash Data China Site 2

Pressure Drop (Inch H20)

7
6
5
4
3
2
1
0

Mar-13

Apr-13

May-13

Jun-13

Jul-13

Aug-13

Unit 1

Sep-13

Unit 2

Oct-13

Unit 3

Nov-13

Dec-13

Jan-14

Feb-14

Mar-14

Apr-14

Water wash

Both the pulsed filter and HEPA filter have not been changed, and have been
running almost one year.
Filter pulsing has proved very effective in removing particles. Offline water wash
is performed at every ~4,000-5,000 hours.
No on-line water washing has been conducted.

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Filter Change Cycle/ Water Wash Cycle Analysis

The filter change cycle and water wash cycle data is summarized in Table 2. Not
surprisingly, better air quality sites do not have to change the pre-filter as often.
The filters at China site 2 performed better than those in China site 1 due to the
effectiveness of the pulse cleaning mechanism. The water wash cycle, both onand off-line, at the site with no (H)EPA is more frequent, meaning more downtime
at the plant.

Summary For Filter Change Cycle & Water Wash Cycles

Project
Location

Filter Change Cycle

Water Wash Cycle

Pre-Filter

Static/Pulse

(H)EPA

Online

Offline

USA
Russia

5.5 months
No change

11 months
No change

No (H)EPA
No (H)EPA

1-3 times/week
No

Italy

9.7 months

No change

No (H)EPA

No

Belgium
China Site 1
China Site 2

every 18 months
1 week-4 months

every 18 months
2 - 8 months
every 12 months

No (H)EPA
6 - 9 months
every 12 months

Every 2 days
No
No

every 2-3 months

every 2 months
every 3-4 weeks:
700-900 hours
every 6 months
every 5.5 months
every 5.5 months

Conclusions
The site analyses showed that (H)EPA filtration results in cleaner compressors,
longer cycles between water washing, and subsequently higher compressor
efficiency and plant availability.

23

To illustrate the savings, costs are normalized, and assumptions are based on the
site data summarized in this article. It is assumed that there is a 14 percent filter
house cost adder for (H)EPA filtration, and a negligible power loss due to higher filter
differential pressure. Further assume a 3 percent efficiency drop occurs linearly
over a 2 month period (non-(H)EPA) or 6 month ((H)EPA). Base natural gas price is
$16/MMBtu (Asia) and power sells for $15/MW-hr. Using (H)EPA filtration, the loss
of compressor efficiency is a rate 1/3 slower than without. For a 32MW turbine, the
net present value is >$550k for a base-load machine for one year and $3.7M over
15 years, as shown in Table 3. That is, a net benefit for (H)EPA filtration. Another
$200k/year could be assumed for increased operating time due to infrequent offline water washing. (H)EPA filtration yields higher compressor efficiencies over a
longer period saving fuel costs compared to non-(H)EPA filtration systems.

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Fifteen Year Return For HEPA Filtration, Base Load

Variable Title
3% Efficiency loss to wash
Fuel mmbtu/hr
MW
Fuel $/MMBtu
Sell price,$/(MW-hr)
# years
rate of return
run time, hr/yr
NPV w/o Cost
Equipment Cost Adder
NPV/3

Variable Value
330.6
35.732
16
15
15
0.15
8000
$7,423,260
-$34,440
$3,694,409.86

Year
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Power Loss
Cashflow
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0
$0

3
Efficiency Raw
Cashflow
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504
$1,269,504

Net Adj Annual

Cashflow
$1,103,917
$959,927
$834,719
$725,843
$631,168
$548,842
$477,254
$415,003
$360,872
$313,802
$272,871
$237,279
$206,330
$179,417
$156,015

Proper filtration is essential for gas turbine peak performance. Selecting the
optimal filters and configuration is based on operating and environmental factors.
Subsequent data collected since the case studies shows 1 percent degradation
in power loss with HEPA over a years time. Improper filtration will degrade
turbine performance, including blade erosion, fouling, cooling passage plugging,
and corrosion. These and other factors should be discussed with your OEM
turbine manufacturer or filter supplier. Cost-benefit models for specific operating
environments can be applied and account for filter purchase price, fuel price,
power sale price, maintenance, inspections, wash cycles, power degradation, heat
rate increase, pressure loss, labor costs and down time.

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A Division of THE HILLIARD CORPORATION

For info. http://powereng.hotims.com RS#31

Originally published September 1, 2009

Keeping Fluid Systems Clean

Condensate and feedwater systems, turbine lube
oil systems, electro-hydraulic control systems
rely on fluid purity to operate optimally.
By Brad Buecker, Contributing Editor

our years ago I wrote about the very successful application of

microfiltration for makeup water pretreatment at a former utility.1 The

machine replaced an aging clarifier and sand filters, where it greatly
reduced operating costs and vastly improved the quality of water being
fed to a downstream reverse osmosis (RO) unit. Obviously, however, power
generating units have many other fluid systems in which fluid purity is also very
critical. These include the condensate/feedwater system, turbine lube oil system,
electro-hydraulic control (EHC) system, and others. This article examines fluid
purity issues in these systems.
Power plant chemists and other plant personnel typically are aware that
contamination which enters steam-generator condensate can potentially cause
severe corrosion in the boiler and carryover of contaminants to the steam.
Condenser tube leaks are the worst culprit, but impurities may come from other
sources. Regardless, corrosion mechanisms in a boiler are exacerbated by the
presence of porous deposits, which can serve as concentration sites for impurities
that then directly attack the base metal of waterwall tubes.

26

During normal steam generator operation, condensate/feedwater piping and

boiler waterwall tubes develop a layer of iron oxide, which, while being a
corrosion product, protects the underlying base metal against further corrosion.
Even in the normal course of operation, this corrosion layer will gradually
increase in depth, but during periods of chemistry upsets, thermal transients

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and forced outages, additional corrosion products are generated. And, during
the major work often performed at times of scheduled maintenance outages,
literally hundreds to thousands of pounds of loose particulates may lodge in the
condenser hotwell, condensate and feedwater systems.
Some plants have the capability to remove at least a portion of this debris at
start-up. But in many cases particulate removal is inadequate at best, where
perhaps the only method is to withdraw material through the drum blowdown.
Particulates that cycle through the waterwall tubes will, as the temperature
increases to normal load condition, deposit on the tubes. These porous deposits
will subsequently influence heat transfer. More importantly, they serve as sites
for possible under-deposit corrosion and premature tube failure. Thus, at some
plants, and particularly those with once-through steam generators, start-up holds
are used to allow debris to be cleaned from the system. These holds may last for
days following a particularly intense maintenance outage. As plant personnel well
know, any delay in start-up can cost a utility tens to hundreds of thousands of
dollars, or more, in lost power production.
An equipment investment that can pay for itself several times over with just
the first use is a condensate particulate filter. These straightforward mechanical
devices can be easily equipped with filter cartridges that remove particulates in
the single-digit micron range at very high efficiencies.
The common location for a particulate filter is just after the condensate pumps,
with the filter placed in a valved, bypass loop around the main condensate feed
line. The device need not be full flow, as at start-up the condensate circulation is
often restricted to half the full-load flow rate or perhaps even less. The devices
will remove iron oxide particulates and other crud within a short period of
time, allowing for potentially significant reductions in hold periods.
At one utility, we once started up a supercritical unit following a boiler chemical
cleaning. The only method to remove iron oxide and other particulates from the
condensate was filtration through the deep-bed condensate polishers. Not only
did this process significantly foul the polisher resin, but four days of filtration

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were required to reduce the solids, whose original concentration was greater than
1 part-per-million (ppm), to the relatively low parts-per-billion (ppb) concentration
necessary to fire the boiler.
To alleviate this difficulty, we ordered a condensate particulate filter designed to
handle half of the full-load flow for installation ahead of the condensate polishers.
Plant personnel installed the unit and equipped it with 6-micron (absolute) filter
cartridges. The filter was first used in 2008 at start-up following another chemical
cleaning. Again, the initial particulate concentration was very high. As it turned
out, two filter replacements were required during the particulate cleaning
process. But the critical point is that the filtration time was reduced from four
days to one day. An extra three days of operation on a large supercritical unit
paid for the filter, the extra cartridges and the labor costs to install it several
times over just after the first use.
Turbine Lube Oil
In simplest terms, both steam turbines and combustion turbines are many tons
of machinery rotating at 3,600 rpm. Very tight tolerances are required at journal
or roller bearings, which in turn requires high-purity lubrication oil to prevent
bearing wear and premature failure. The most common contaminant in lube
oil is water. Water may enter through leaking steam seals, heat exchanger tube
failures, condensation in the main lube oil tank or other sources. Water can
cause corrosion and microbiological fouling in the main lube oil tank and other
locations, where the corrosion impurities will then travel to turbine bearings and
control valves, piping and so on.
Past equipment that has been used to remove water include gravity precipitation
systems with filter bags and settling chambers and centrifuges, which as the
name implies, ue circular motion to separate oil and water due to the difference
in density.

28

Typically, these older systems were somewhat efficient at removal of free water
but did not effectively remove emulsified or dissolved water from lubricating oils.
A more modern process that is capable of removing free water and up to 80 or
90 percent of dissolved water is mass transfer vacuum dehydration. The unit is

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typically installed in a kidney loop on the main lube oil tank. It uses mild heating
of the oil slipstream followed by vacuum dehydration from a small, skid-mounted
unit to remove virtually all of the water in the oil. The tiny amount of dissolved
water that remains is at much too low a concentration to convert to free water in
the lube oil tank.
Varnish Removal
Varnish formation in oil is a subject of great importance at both conventional
steam plants and those with combustion turbines. Power Engineering magazine
reported on this issue in February 20082 with an article that outlined many of the
fundamental varnish removal technologies. However, I have spoken with or heard
reports from a number of utilities, in which these conventional technologies gave
widely variable results. A process that has been recognized for some time but is
now beginning to grab headlines is that of adsorption to remove varnish. Varnish
occurs when oil and its additives oxidize and polymerize due to stresses placed
on the fluid, which include heat transfer from the equipment, microdieseling, and
electrostatic energy transfer from particulate filters.
Varnish polymers can reach high molecular weights, and due to their oxidized
nature, will settle on internal components, including servo valves. The latter has
become a very troublesome issue in many combustion turbines.
While varnish is only slightly soluble in oil, the fact that it has even some solubility
allows it to be removed from systems without the expense and headaches of
periodic off-line cleaning. Adsorption is proving to be an effective technology.
Adsorption is a film-forming mechanism, where the compound to be removed
exhibits an electro-chemical affinity for the surface of the collecting media.

29

The varnish removal compartment contains multi-layer media, whose surface

has been prepared to be especially attractive to the oxidized varnish particles. As
varnish comes out on the media, deposits within the lube oil system gradually
dissolve and are subsequently removed. Progress of this or other technologies can
be tracked via the QSA (Quantitative Spetrophotometer Analysis) test offered by
Analysts Inc. based in Los Angeles. The procedure involves filtration of oil samples
on a special filter media that collects dissolved varnish to produce a distinct color.
The color intensity can be directly related to varnish potential in Table 1.
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TABLE 1

VARNISH POTENTIAL

Varnish Potential Rating (VPR)

Condition

<35

Normal

38-58

Active monitoring should be implemented

60-79

Abnormal

>79

Critical. Immediate action needed.

A well designed and functioning varnish removal system should reduce the VPR
to well below the normal value of 35.
Electrohydraulic Control Fluid
Electrohydraulic control (EHC) fluids will also accumulate debris and varnish. A
malfunction of turbine control valves due to contaminated control fluid can be a
serious issue. The most common compounds utilized as EHC fluids are phosphate
esters, for example, organic compounds where the phosphate addition improves
fire resistance. A common method for filtering EHC fluid is to pass a slipstream
through material such as Fullers Earth. However, this process introduces
hardness ions to the fluid, which in turn can react with degraded EHC to produce
tenacious deposits such as calcium phosphate.
A technology to combat hardness-based deposit formation is to install an
ion exchange column on the slipstream, where the exchange media removes
the hardness ions. Use of ion exchange for phosphate ester treatment allows
the operator to selectively target both acidity and resistivity of the fluid by
combining different concentrations of anionic and cationic resins. The flow
rate required for these systems is relatively small, resulting in minimal resin
volume requirements, where the resin may last for several months before a
change-out is needed.
References
1. B. Buecker, Membrane Magic; Power Engineering, pp. 26-30, September 2005.
2. F. Guerzoni, Eliminating Varnish, Power Engineering, pg. 50, February 2009.

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Brad Buecker is the Technical Support Specialist with AEC PowerFlow in Kansas
City, MO. He previously served as an air quality control specialist and plant
chemist for Kansas City Power & Light. Buecker has written many articles on
steam generation, water treatment, and FGD chemistry, and he is the author of
three books on steam generation topics published by PennWell Publishing. He
has an AA in pre-engineering from Springfield College in Illinois and a BS in
chemistry from Iowa State University. He is a member of the ACS, AIChE, ASME,
and NACE.

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Company Profile
Founded in 1905, The Hilliard Corporation proudly marks its 110th anniversary
in 2015. From the first product of the company, a friction disconnect clutch, to
manufacturing oil reclaiming machines in 1925, Hilliard has continually evolved
into becoming a leader in motion control and industrial filtration technology.
HILCO has supplied thousands of liquid fuel filters, coalescers, and systems to
OEM turbine and engine manufactures to maintain fuel cleanliness to their
specifications. HILCO is able to offer our customer a customized and optimized
solution to their liquid fuel filtration application that will ensure equipment
reliability.
The Hilliard Corporation
100 West Fourth Street
Elmira, NY 14905
JImpson@Hilliardcorp.com
607-733-7121

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