Intake Systems for Industrial Gas Turbines

Marco Osvaldo Vigueras Zuniga Cranfield University

Abstract
The paper presents a description of the main components of Intake Air Systems for Industrial Gas turbines and examines the impact of using new technology and advances in maintenance service to provide the best possible efficient in this particular section of the engine. The principal components are: Intake House, Filtration System, Cooling Inlet, Fog Nozzle Array, Silencer and Duct. This system provides the working element (air) at the engine. Innovations and advances provided by technology avoid fails in the intake of air. Equipments and accessories life is increased for many years more and the maintenance is more simple, easy and fast than equipment using some years ago. Additionally industrial gas turbines have been provided by new equipment designed to recover losses produced for waste and pollution of the air accumulated in the intake air system by automatic operation. This new technology contributes to save money in the operation of the engine. The maintenance of them is easier and fast, the costs of maintenance and time are reduced for more than 50% than in the past, and the turbine can continue operate when the maintenance in this section is running.

1. Introduction
Use of monitoring systems for assessing the condition of a gas turbine and its components has helped to design new equipment and accessories for the engine. Intake Air for industrial gas turbine is a field very important for study. This study has developed equipment that saves money and time in operation and maintenance. With a correct selection, the customer can get the same output power for many years with low costs of maintenance and time. The quality and quantity of the air depends on two principal factors. First the environment, in specific the conditions of the air provided by the nature and second the selection of equipment. This last one (equipment), such as was mentioned before plays an important roll in the operation of the engine. In general industrial gas turbines are not designed for specific environments, so the only way to get the best output power for the engine is by the auxiliary equipment. However the equipment in the intake system can solve 90% of the problem for the environment (atmospheric condition changes, etc.) with a low cost. Industrial gas turbine maintenance is necessary and frequently, allowing the engine operates in optimal conditions. But this maintenance have a high cost and if the equipment was selected incorrect the consequences will be reflected in the total cost of production, in other words, the customer lost out power or has to invest again in a new equipment to supply his requirements. This work has be divided in two chapters, the first provide the description of the following intake air systems: (1) Intake House, (2) Filtration Systems, (3) Cooling Inlet, (4) Fog Nozzle, (5) Silencer, (6) Duct. The second part is focused for using advance technology in this section of the industrial gas turbine (Intake Air System). The Auto-Cleaning results are reflected in the output power of the industrial gas turbine by Intake Air System Equipment. The maintenance in these new products is lower and easier than the conventional systems.

2. Intake Air System Equipments

2.1. Intake House (Filter House) The intake air house is called like filter house, but the building not only allocates the filters, it contents all equipment necessary to satisfy the demands and quality of the air for the compressor. The intake house is a building made by steel, it is built in front of the intake air of the compressor, some times is pre-fabricated before and only is assembled there. The principal characteristic of the Intake house is the size of the cross section, which is calculated by two variables which are linked between them. The first is the quantity of the air demanded by the compressor requirements and the size of the filters cross and long section. The components are: Weather Hoods, Housing, Filters Panels and Connector. 2.2. Filtration System The air of the atmosphere presents many kinds of particles which damage or cause losses of power in the engine, such as salt, sand, dry particles, droplets or a combination of them. The Filtration System consists in many filters in series designed for specific application to avoid the pass of particles. Filtration System works in the following way: The dirty air income from the inlet hoods, and inside of the housing, if a moisture eliminator or some other inlet treatment is used, its effect is seen at this stage first. The incoming air is then directed through the pre-filter wrap (if used) that covers each of the primary filters. Here, most of the larger particles are removed before they can reach the primary filter pairs. The partiallycleaned air then passes through to the high efficiency filter pairs for fine filtration. A walkway behind the inlet hoods provides accessibility to the filters as well as to any inlet treatment accessories. Environment Harshness.- salt, sand, particles, pollution, and chemical products contaminants originate as droplets that become airbone from the breaking action of ocean waves, deserts, etc. Proprieties of Filters: (1) The pressure drop of a filter is simply its resistance to airflow, that is, the energy loss incurred moving air through the filter and is typically measured in mm of water or inches of water, the lower the better. The effects of high filter pressure drop are well understood: it reduces turbine output. (2) Filter efficiency defines the amount of contaminant that is removed from the turbine inlet air-stream, and is typically measured in terms of the number of particles removed as well as their size. A highly efficient filter, especially one that removes particles smaller than a micron in size, can improve turbine performance by minimizing compressor blade fouling. (3) Service life is the period of time the filter is in operation before it must be replaced because contaminant loading is causing pressure drop that exceeds the recommended level for the turbine. A filter with a long service life at low pressure drop results in a low mean operating pressure drop of the system over time, resulting in more turbine output over time. Filtration System classification is composed for two filters (Pre filters and Main Filters or called Panel Filters). The filters can be for two types: self cleaning filters or static filters. Self cleaning Filter is used when the particles stay on surface. The maintenance is possible changing the filter orientation and passing a stream air through filter, the particles are removed automatic outside of intake house. Static Filters are located in panels, but the maintenance implicate that they have to be changed for new filters by the staff, these filters are used to protect a turbine in a continuous harsher environment. Pre-filters, both wraps and panels have the job of extending the life primary filter by capturing larger particulate, such as seeds, leaves, airbone fibers, etc. They are made of low-cost, relatively low efficiency

materials, and designed to be changed more often than primary filters, and thrown away. (Cleaning and reusing them is never recommended). The filter media in the pre/filters are made of polyester fibers, air laid (aka dry laid) in randomly oriented fashion to form a web. The wrap is a high loft media, meaning it has quite a bit of air space between the fibers throughout the depth of the media mat. This enables good airflow through the wrap even after it has captured much particulate. Main Filters have to provide highly efficient air filtration for gas turbines operating in a variety of harsh environments. Main filters are selected in two large groups. The first are Self-Cleaner, their principal characteristic is that they are provided for the self-clean system, and now they are having a big demand in the market for this propriety. Static Filter (Panel filter) is the second group. Both filters consist in filter packaging technique combined with different materials, resulting in significantly increased filter performance for the existing turbine inlet air panel filtration system. They provide a longer filter service life and maintain lower pressure drop over their lifetime, which means improved turbine output. Self-Cleaning Systems are designed to help turbines & generators operate anywhere in dusty deserts, urban/factory areas, on the coast, in the frosty north. Because they are self-cleaning, they require little maintenance between filter change-outs. Panel filters (not self-cleaning) air filtration systems are most often chosen to protect inlet air on turbines and generators in urban, industrial, offshore, marine, and coastal environments. They do not need to replace very often, but when the time comes, no special tools are needed to replace they. The durable polymer frame makes lightweight and easy to handle, a convenience for the maintenance staff. Due to the superior structure of the fluted design, no metal screens are needs to keep the media in place. The metal frame model offers can be used at higher temperatures 150 F (66C). Special Filters When is necessary to remove corrosive salt particles from the air-stream. A second stage of filtration is used in conjunction with a conventional gas turbine air filter assembly. The first stage assembly can be either a static or pulse system. The Salt filter is placed down stream form the first stage filter and serves as a barrier to the immigration of salt. It has been very effective in removing salt from the air stream without regard to the shape, size, or phase of the salt contaminant. This array consists on a series of horizontally placed filter elements separated by a series of inclined baffles. The baffles serve several functions. Their primary function redirects to air flow passing vertically through the media. A secondary function collects accumulated salt droplets and redirects them to flow towards the front of the module, opposite the direction of air flow. Lastly, the baffles constitute a surface for contaminants to impact directly, providing a means for inertial separation of the larger droplets. This media employs several physical principles to prevent the migration of salt. One such feature is the pore size. The small pore size of this media ensures excellent performance on dry salt particles that may enter or form in the clean air plenum. 2.3. Cooling Inlet Cooling the turbine inlet air even by a few degrees, it can increase power output substantially. This is because cooled air is denser; giving the turbine a higher mass flow rate and resulting in increased turbine output and efficiency, even as much as 0.4% per degree Fahrenheit or about 0.7% per degree Celsius. There are two tried and true inlet air cooling methods. Evaporative cooling and chiller coils.

Evaporative coolers and chiller coil systems are currently cooling gas turbine engines all over the world, from Southern California to Saudi Arabia in hot and arid climates, hot and humid climates, and in places with seasonal heat. Design range in size from 25,000 cfm to 1,300,000 cfm, and are available with choices in media efficiency and materials. Chiller Coil System is typically positioned downstream of the air filters. This allows the coils, fins and parts to stay clean enough to function well for many years. On some systems where this positioning is impossible or undesirable for some reason, we recommend using pre-filters to ensure the cleanliness and functionality of the coils. As air flow passes through the chilled coils, the air is cooled through an indirect heat exchange with the cooling fluid. The air then passes through drift eliminator media and into the turbine. The coils are cold and therefore condensation is created. Condensate droplets are directed downward and collected in pans, then directed out of the system. Typically, all condensation is eliminated this way, but to ensure air dryness, mist eliminator panels are in place to remove any stray condensate droplets. Evaporative Cooler Module is recommended positioned downstream of the filter section. Minimum requirement in this equipment: highly reliable water control system to respond to water levels needs, low air pressure drop of 76-10 mm w.g. to 12-15 mm w.g. depending on media and material made corrosion resistant. It works when the filtered air passes through the saturated evaporative cooling media, water evaporates off the wet media. This evaporation is the process that reduces the air temperature. Excess water that does not evaporate is directed down wars so as not to be carried along with the cooled air. Cooled air then passes through the integral mist eliminator, where leftover water droplets are removed. Clean, cooled air is then directed into the turbine inlet. 2.4. Fog Nozzle The contribution, which engine faults make to the availability of assets, is not small. The lack of availability through unscheduled maintenance impacts significantly on OVERFOGGING. The fog system is designed so that the fog mist does not evaporate before reaching the first compressor stage. With this method, called "over fogging," excess fog is injected into the air stream so that it will evaporate inside the compressor. As the air temperature rises during compression, the excess fog evaporates, bringing the air temperature down and thereby making it easier to compress the air. This process continues up to the eighth compression stage. In this case, the system is designed so that 10 percent of the water evaporates before reaching the compressor, with the remainder evaporating inside the compressor. While the above actions considerably improved power output, also moved to reduce the parasitic losses with the turbine itself. Due to the pressure difference between the suction and pressure sides of the blades, the hot gases tend to flow over the tip of the blade to the back side of the aerofoil. The second stage blades include a shroud as part of the blade casting and each shroud has two parallel rails to reduce the hot gas flow over the tips. The shroud block is furnished with bronzed honeycomb material. The system install a cutter teeth on each of the stage two blade shrouds to cut grooves in the honeycomb to

further retard the leakage of hot gases around the blade tips. When the turbine is operating under full load, centrifugal forces, gas dynamic forces and differential expansion between the rotor on the housing force the tip of the cutter teeth into the honeycomb. Some companies supplied honeycomb with one manufactured which was selected for its ductility and resilience to hot corrosion attacks. The honeycomb is made by the stainless steel shroud block. 2.5. Silencer The inlet noise of a gas turbine contains mostly high-frequency noise. An absorptive silencer in series with the inlet filtration system is usually required to meet noise attenuation requirements. Although the inlet silencing requirements are usually less stringent than the exhaust requirements, it is critical that the inlet silencer be constructed to exacting criteria. This work in two ways first the silencer directs air flow at the gas turbine inlet through a series of parallel, small-diameter tubes that are surrounded by absorptive material to reduce the high-frequency noise. Silencer can work as well directs air flow at the gas turbine inlet through packed baffles. They have to cover a wide range of applications and provide economical solutions to a broad range of noise conditions. 2.6. Ducting The contribution, which engine faults make to the availability of assets, is not small. The lack of availability through unscheduled maintenance impacts significantly on KEEPING UP THE PRESSURE. To optimize system performance from the air intake through the duct, the pressure drops across the inlet air structure affect gas turbine performance, for this reason the duct has to be considered in the design of a complete Intake Air System. On this type of gas turbine a 40 mm reduction in inlet pressure drop increases base-load output by 0.6 percent and combined-cycle output by 0.5 percent, with a commensurate improvement in heat rate. This translates into significant annual fuel savings. The characteristic of duct in industrial gas turbines are very important, using a single shaft axial compressor, about half the turbine's power output satisfies compressor demands. The amount of work the compressor consumes depends largely on the ambient conditions such as air pressure, temperature and humidity. The turbine uses a constant volume of air, but the power generated depends upon the mass flow of the air. Warm moist air is less dense than cool dry air and so results in lower power output. In addition, warm air is much harder to compress than cool air, again leaving less available energy for turning the generator, for this reason the duct has to warranty the complete seal a long the duct, to avoid any kind of particles inside of it.

3.1 Keeping Filters House and Duct clean Significant to have low pressure ratio in the intake system the turbine output increases by approximately % for each 25 mm reduction in Pressure. In addition to boosting power output, also wanted to find ways to slow down the gradual power loss that occurs over time. Minute particles in the air, too small to be trapped by the inlet filters, enter the compressor and deposit on the compressor blades. This process is enhanced by oil mist from the bearings. Since these particles have almost no mass, the centrifugal forces are too small to overcome the particles' suction and so they stay on the blades. Over time these particles build up to the point where the added drag on the blades cuts the power output from each turbine generator. These particles can be avoided in the ducts and filters house installing a brand new non-metallic brush seal. For example on bearing #1 just before the compressor intake is used this seal, it serves to minimize the amount of dirty ambient air and oil mist entering the compressor from bearing #1.

3. Using appropriate technology (equipment) gives the best results.

The space just upstream of the first compressor disk is normally under slight vacuum that may be as high as twenty inches of water. This slight vacuum condition will encourage leakage of dirty and oily air into the compressed air path. This then leads to a light coating of oil on the compressor blades, which makes it easier for dirt particles to stick estimates that this paste on the blades produces enough drag to result in a loss of 6 MW on each turbine. 3.2 Self-Clean Filtration System (Low costs in maintenance) Self-Clean Filtration System: When the filters are Self Cleaning the system requires little maintenance because a reverse pulse of air back through the filters knocks off accumulated dirt, dust, larger particulate, and even frost. New material of the filters has to be necessary to install in this section of low pressure. General Electric says that the on the frame of pressure drop at the inlet costs 1.4% turbine output. That is why the material of the pre-filter use a fine fiber media technology inside, and filters keep performing and delivering higher turbine output through their 2 to 3 year (or longer) lifespan. Pre-filters have to offer a powerful filtration on even the smallest (sub-micron) particulate and lower average pressure ratio over the life of the filter. Depending on the environment where work the filter is the fiber classification: Synthetic.- Man-made fibers that are sturdy, durable, and moisture resistant. Duratek.- special blend of man-made and natural fibers that has superior dust holding capacity and moisture resistance. Cellulose.- natural fibers that stop a range of particulate sizes. Spider-Web.- a fine-fiber layer that caches very fine particulate before it reaches the media substrate. The diameter of the fiber and poro size depends on the environment such as desert, arctic/frost, urban, industrial, marine, etc. The smooth fibers provide low impedance to airflow helping to maintain low P . for the entire life of the filter. The average life of the fiber is 2 to 4 years, depending on the harshness of the environment. A concurrent benefit is that the pore size contributes to the resistance of the media to droplets of salt. The surface energy of the media has been designed to droplets of salt. These features working in combination prevent salt contaminant from migrating through the filter media as it cycles through varying humidity cycles. 3.3 Performance in the gas turbine by cooling air system. For maximum turbine performance, the design temperature of the air leaving the cooling system and entering the turbine is typically no less than 7C (45 F). The ambient temperature and the altitude at the site are the major factors used in sizing and designing a coil system. Cooling agents are usually either water or a water/glycol mix, depending on local ambient conditions. Electrical demand is highest during warm summer afternoons when the air is also the least dense. Cooling the air on warm days, therefore, results in denser inlet air and increased power output. Install a 200 gpm evaporative cooler. It soon found, however, that at that flow rate, water droplets were being carried by the inlet air through the inlet air filter and onto the compressor blades. The impurities in the water, as well as the submicron particles released in the air by the evaporative cooler, would then foul the compressor blades causing a considerable increase in the power demand for compressing a constant volume of air.

Installing the fogging system downstream of the silencers is preferable. Because fog wash the accumulated dirt off the silencers and carried it downstream, where it fouled the first stage compressor blades. A gas turbine generator with evaporative cooling system installed at a site having an ambient temperature of 37 C and a relative humidity of 30% could deliver up to 7.6% more power than a gas turbine without an evaporative cooler. Evaporative cooling typically can decrease inlet air temperatures by as much as -7 C to 1 C. depending on the ambient humidity. 3.4 Performance in the gas turbine injected fog. Fog technology works through a system of high-pressure pumps that pressurize desmineralized water as it flows through a network of stainless steel tubes to nozzles located in the inlet ducts of gas turbines. Each nozzle atomizes the water into trillions of ultra-fine fog droplets per second. The droplets evaporate quickly and cool the inlet air. Installations account for an estimated 2.5 GW of added capacity. The company's customers include Florida Power, Cinergy, Duke Energy, Entergy, Madison Gas and Electric, and Utilicorp. The benefits of fog power, users say, are increased efficiency, reduced nitrogen oxide (NO x) emissions, and lower costs. Cooling the inlet air of a 100-MW turbine by -7 C can produce about 10 MW more powercalled "fog watts"-thereby increasing the overall efficiency of the turbine by about 3 percent. Each extra fog watt is produced using about 30 percent less fuel than "non-fog watts." Because fog cooling increases humidity, it also reduces NO, emissions, the most significant emission from gas turbines. For instance, using fog cooling to cool the inlet air by -7 C results in 10 percent fewer NO emissions produced by the turbine than by the non-fogged turbine. 3.5 Technology applied in Silencers. The new silencer has to be compact and lightweight to make shipping and storage easier. It is manufactured with low-cost, corrosion-resistant materials. High-impact composite faceplates are mounted on the front and back, and the rugged, mild steel shell has two coats of paint. Inside, flow tubes are placed parallel to the air flow direction. Each flow tube has a spun-bonded polyester wrap to prevent pack migration. The highquality design and construction ensure low maintenance and long product life.

4. Conclusions
Gas turbines are not often installed in ideal environments. The turbine may face challenges from hot weather, cold weather, fog, sand storms, salt-laden air, and/or noise abatement regulations, to name few. Intake Air System (Filters House, Filters, Fog, Silencer and Duct) helps overcome these challenges and keep your turbine producing its optimum output. Turbine Air inlet filtration system, it means better turbine protection, which means less blade fouling, results in better turbine performance and means higher turbine output. Higher efficiency inlet air filtration is important because it reduces compressor blade fouling, which helps boost turbine output, improves heat rate and contributes to more efficient fuel consumption. The performance of a filter is defined by 3 main parameters, pressure drop, efficiency and service life, which have a direct impact on the performance of a combustion gas turbine. The best air filters provide all

three characteristics: low pressure drop, high efficiency, and long service life. Economic analysis shows that selection of a high performance air filter (one that optimizes its filtration performance for its operating environment) results in greater operating profit of a gas turbine system. Cooling the turbine inlet air even by a few degrees can increase power output substantially. To accomplish exact controlled cooling, turbine manufacturers choose evaporative coolers or chiller coils. Power-plants are using fog to produce more energy with less fuel and fewer emissions. Because gas turbines produce less energy as the ambient temperature rises. For this reason fog cooling systems have been shown to work better than refrigeration or other traditional evaporative media cooling systems. In fact, power-plants are using fog to produce more energy with less fuel and fewer emissions. Because gas turbines produce less energy as the ambient temperature rises, generators look for ways to cool intake air to boost gas turbine power. Fog cooling systems have been shown to work better than refrigeration or other traditional evaporative media cooling systems.
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