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Power Generation  Markets and Projects

A 20 page Weekly Alert provides the latest insights on the worlds fossil and nuclear fired markets plus project leads from the perspective of combust, flow, and treat suppliers. 41F Utility E-Alert

The latest 5 year forecasts for coal fired and nuclear power  in each country plus individual owner and plant analyses are provided in 42EI Utility Tracking System

44I Coal Fired Power Plant Decisions provides networking with purchasers of CFT products as well as ways to validate lowest total cost of ownership  The package with  42EI and 44I for 5 people is $ 3800

Gas turbine forecasts by country plus details on combust, flow and treat products at individual plants are  included in 59EI Gas Turbine and Reciprocating Engine Supplier Program

A package including 41F, 42EI, 59EI and one of the market reports e.g. valves, pumps, FGD, DeNOx, chemicals, precipitators, fabric filters, or IIoT (http://home.mcilvainecompany.com/index.php/markets) is available as a package for  just $ 6500/yr.

 

Mcilvaine Logo 1     Refinery Decisions Update
                                               No. 1   April 4, 2018

REFINERIES AND IIoT

The IIoT and Remote O&M report provides continuing analysis of the accelerating utilization of process management and data analytics in the refining industry.  The Industrial Internet of Wisdom (IIoW) will empower IIoT.  This refineries decision system is one example of IIoW. You can view a refining webinar as described below:

 

RefiningA small number of companies make the decisions relative to combust, flow and treat purchases for refineries. The refinery IIoT and Remote O&M market will rise from $18 billion in 2018 to more than $36 billion by 2024. Companies building new refineries are well aware of the benefits of using IIoT through pervasive sensing applications.  A typical modern facility will thus have about 50,000 inputs and outputs to and from control and monitoring systems, with all connections made through plant intranets, which replaces the Internet in these IIoT applications. But an older refinery will typically have closer to 20,000 inputs and outputs, with the 30,000 shortfall the root cause of much inefficiency, operational issues and safety incidents.  So, the IIoT potential at existing plants is bigger than for new plants. McIlvaine tracks all refinery projects daily. There are relatively few refining companies. Many of them also own chemical plants and or extract gas and oil.  A marketing program for refining combust, flow, and treat products and services will be discussed.

Recorded 41 Minute webinar on January 10, 2018
View YouTube Recording: 
https://youtu.be/N0CgrGcfMAU

 

FUGITIVE EMISSIONS AND PUMP SUMMITS

McIlvaine is on the steering committee and working with KCI to help make this conference and exhibition June 26 and 27 as useful to attendees as the one 2 years ago. We are also working with the management (KCI) to provide come continuity between the U.S. show, the Chinese Show, and articles in Valve World Americas, Valve World,  Pump Engineer, Stainless Steel World, and Hose and Couplings magazines.

One of the continuity streams will be on common versus better options.  All the speakers and exhibitors are being asked to provide one such example.

Here are entries we have received so far:

Person Affiliation Option description
Richard Bierman Chevron Phillips Common Analysis based on overall vibration
Better The use of trend based narrow ban envelope alarming

Jeff Ronseneder

Trey Gorfe

Emerson Common Non-resilient stem packing for ball valves
Better Resilient stem packing for ball valves to prevent fugitive emissions
Buddy Broerman

Southwest

Research Institute

common Pump vendor sizes dampener as a guestimate when installing plunger pumps
Better

Take advantage of an upfront pulsation/vibration analysis to avoid vibration issues and piping rework costs.

Ned Davis

Maui Innovation

Group

Common Employ low emissions valve packing
Better Hermetically seal valve enclosure and actuate valve with a magnetic coupling ensuring zero emissions over the entire life of the valve
Jean-Marc Fosseux TechnipFMC Common Use of conventional pump sealing systems for hazardous product (dual mechanical seals + auxiliaries)
Better

use of seal-less pumps when possible

If you are an exhibitor or speaker at the Summit and would like to submit a common and better option, or if you have comments about any of the options displayed by others just communicate them to Bob McIlvaine at 847-784-0012 ext 112 or This email address is being protected from spambots. You need JavaScript enabled to view it.

To learn more about the conference click on   https://fugitive-emissions-summit.com/

RECENT ARTICLES IN THE INTELLIGENCE SYSTEM

A valve manufacturer’s perspective for reducing fugitive emissions

This article in the July 2017 Valve World by Stan Allen of Bray examines the laws, industry stands, end user specifications, and engineering responsibility which shape decisions about the design of valves.  Choice of valve types is one of the subjects examined.

Valve operation types fall into two broad categories – (1) rising or rising and rotating stems, and (2) quarter-turn (part-turn) stems. Rising and rising and rotating stems normally are used in gate, globe, and rising stem ball valves. These designs are considered the most susceptible to stem leakage since the stem is exposed to the service fluid and then drawn through the packing during the valve operation. These valve designs are the most prevalent used in refineries. Quarter turn valves, which include most ball valves, double and triple offset butterfly valves, and plug valves, are often considered significantly less susceptible to stem leakage due to the short quarter-turn rotation and the service fluid not being drawn through the packing during the valve operation. However, if not properly designed, manufactured or maintained, quarter-turn designs are still possibilities for release of emissions. Quarter-turn valves are often used in applications with infrequent operation, such as for emergency shutdown application, but they may also be used in high cycle processes and control valve applications. It is not uncommon that engineering and operations personnel consider the operation type (favoring quarter-turn) as a factor in valve selection, as they evaluate other factors in valve selection. The design of the packing chamber, selection of packing, torque, and the other parameters are different for rising stem designs than for quarter-turn stem designs.

Bray will be an exhibitor at the Fugitive Emissions Summit and asked to provide a common option and a better option.  This article would indicate that the common option would be to consider only rising stem designs for control applications.  The better option would be to consider both rising stem and quarter turn designs where fugitive emissions will be a problem.

Revision Date: April 4, 2018

Locator refinery, oil, and gas, monitoring, valve

Tags: refineries, Bray. Valve World, fugitive emissions, valve, packing, regulations

US Potential Ban on Venezuelan Oil May Hit Valero Hardest

If the U.S. bans oil imports from Venezuela, Valero Energy Corp. and Chevron Corp. may end up paying the price. The U.S. is considering a ban on oil imports from Venezuela and exports of petroleum products, but is wary of the damage to American companies, Secretary of State Rex Tillerson said February 4. In addition to exporting oil to America, Venezuela’s state-controlled oil company Petroleos de Venezuela SA also exports jet fuel to the U.S., and imports Permian oil and diluent naphtha used to help Venezuelan oil transported by pipeline. Valero is the biggest buyer of Venezuelan oil, importing 207,800 barrels a day in November for its refineries in Texas and Louisiana. Chevron was the second-largest buyer. State-owned PDVSA’s U.S. refining arm Citgo Petroleum Corp. has been receiving less and less oil from its holding company as output slumps. "Although production is declining, refinery utilization is down in Venezuela and so it’s kind of keeping exports available to us," Gary Simmons, Valero’s vice president of supply, said February 1 on the company’s fourth-quarter earnings call. Back when shale oil wasn’t even on the map, refiners from Texas to Mississippi invested billions in equipment to process cheap, heavy oil from countries like Venezuela, Ecuador and Colombia. Just as Venezuela became dependent on demand from the U.S. Gulf Coast, home to one of the world’s largest clusters ofrefineries, American fuel makers grew to rely more on Venezuelan crude. It’s now the second-largest supplier of crude to Gulf Coast plants, after Mexico.

Revision Date:  3/13/2018

Tags:  324110 - Petroleum Refineries 石油精, PDVSA, Valero, Chevron, Import, Refining, Export, Venezuela, USA, USA


Petrobras to Sell Pasadena, TX Refinery

Brazil's state-controlled oil company, Petróleo Brasileiro SA, said on February 6 it had started taking steps to sell its refinery in Pasadena, Texas, an installation ensnared in Brazil's largest corruption scandal.

Revision Date:  3/13/2018

Tags:  324110 - Petroleum Refineries 石油精, Petrobras, Refining, Non-binding, Sale, Investigation, USA


Pemex Refinery Chief Looks to Deal with Mitsui to Spur Recovery

With its money-losing refineries producing the least fuel in 27 years and only a handful of private partnerships announced since Mexico’s energy reforms, sealing a $2.6 billion venture with Mitsui & Co. will come as a relief to Petroleos Mexicanos.

Revision Date:  3/13/2018

Tags:  324110 - Petroleum Refineries 石油精, Pemex, Mitsui & Co, Delayed Coking Unit, Safety, Infrastructure, Refining, Delayed Coking Process, Maintenance, Repairs, Investment, Competition, Revamp, Mexico


ADNOC Awards Ruwais Refinery-West Upgrade to Samsung-CB&I JV (08, T19)

Abu Dhabi National Oil Co. (ADNOC) has awarded the engineering, procurement and construction (EPC) contract for its US$3.1 billion Ruwais refinery upgrade to a joint venture between Samsung Engineering and CB&I, ADNOC announced February 7. “Enabling the Ruwais Refinery-West to process Upper Zakum, or similar, medium sour crude, in place of Murban light sweet crude, will allow us to extract greater value from our crude resources,” Abdulaziz Abdulla Alhajri, Director of ADNOC’s Downstream Directorate, said in a written statement. “It will mean we can maximize the benefit of price differentials to enhance refinery margins, improve the middle distillate products and release valuable Murban crude into the market.” Under its US$3.1 billion Crude Flexibility Project (CFP), ADNOC plans to add an atmospheric residue de-sulphurization (ARDS) unit so that the Ruwais Refinery-West complex can process up to 420,000 barrels per day of Upper Zakum crude or other similar crudes from the market, the company stated. It noted that ARDS technology is extensively used in upgrading medium to heavy petroleum oils and residues to more valuable clean environmentally friendly transportation fuels. Moreover, the company pointed out that ARDS partially converts residues from crude to produce low-sulfur fuel oil and hydrotreated feedstocks. ADNOC expects the refinery modifications, slated for completion by the end of 2022, to free up more valuable Murban crude for export sales.

Revision Date:  3/8/2018

Tags:  324110 - Petroleum Refineries 石油精, ADNOC, Samsung Engineering, CB&I, Desulfurization Unit, Contract, Technology, Refining, Desulfurization, Engineering, Procurement, Construction, Upgrade, Modification, Environmental Efficiency, UAE


Permian Basin Refinery Project Doubles in Capacity

The developer of a planned West Texas refinery has decided to increase crude oil processing capacity in the Permian Basin by one-third rather than one-sixth.

Revision Date:  3/6/2018

Tags:  324110 - Petroleum Refineries 石油精, MMEX Resources, Pipeline, Crude Distillation Unit, Capacity, Permitting, Crude Distillation, Construction, Production, Output, Refining, Pipeline, Expansion, USA


TechnipFMC Awarded the Bapco Sitra Refinery Expansion in Bahrain (08, T19)

TechnipFMC announced in December 2017 that, jointly with Samsung Engineering and Tecnicas Reunidas, it has been awarded a $ 4.2 billion USD contract from Bahrain Petroleum Company (Bapco) for the Bapco Modernization Program (BMP). The project is located on Bahrain’s Eastern coast and entails the expansion of the capacity of the existing Sitra oil refinery from 267,000 up to 360,000 barrels per day (BPD), improve energy efficiency, valorization of the heavy part of the crude oil barrel (bottom of the barrel), enhancing products slate and meeting environmental compliance. The project will be executed on engineering, procurement, construction and commissioning (EPCC) lump sum turnkey basis and is slated for completion in 2022. It includes the following main units: Residue Hydrocracking Unit, Hydrocracker Unit, Hydro Desulfurization Unit, Crude Distillation Unit, Vacuum Distillation Unit, Saturated Gas Plant, Hydrogen Production Unit, Hydrogen Recovery Unit, Sulphur Recovery Unit, Tail Gas Treatment Unit, Sour Water Stripper Unit, Amine Recovery Unit, Bulk Acid Gas Removal Unit, Sulphur Solidification Unit and Sulphur Handling Facilities. Utilities and offsites are also part of the scope. The BMP project will capitalize on the vast experience of the joint venture partners in Bahrain as well as in the Region. Nello Uccelletti, President of TechnipFMC’s Onshore Offshore business stated: “This award is one of the strategic “early engagement” achievement, following the successful completion by TechnipFMC of the FEED contract.”

Revision Date:  3/6/2018

Tags:  324110 - Petroleum Refineries 石油精, TechnipFMC, Samsung Engineering, BAPCO, Amine Recovery Unit, Sulfur Units and Facilities, Sour Water Stripper Unit, Tail Gas Treating Unit, Sulfur Recovery Unit, Hydrogen Production Unit, Distillation Units, Hydrodesulfurization Unit, Hydro-cracking Unit, Acid Gas Removal Units, Hydrogen Recovery Unit, Procurement, Engineering, Environmental Compliance, Refining, Energy Efficiency, Expansion, Commissioning, Construction, Bahrain

Hengli Petrochemical to Use Honeywell Advanced Flare and Burner Technologies to Control Emissions

Honeywell announced November 16, 2017 that Hengli Petrochemical (Dalian) Refinery Co., Ltd. will use Callidus advanced flares and low-nitrogen oxides (NOx) burner technology at its refinery and petrochemicals complex, one of the largest in China, at Changxing Island in Dalian City. Honeywell will provide a 5,000 ton-per-hour flare system that will be the largest in Asia. In addition, Honeywell will provide more than 1,400 Callidus® low-NOx burners to provide heat for refinery processes, as well as process design and procurement services, key mechanical equipment and instrumentation. "Callidus' advanced burner technology helps refineries and petrochemical plants reduce NOx emissions, better control carbon monoxide emissions and achieve higher fuel efficiency, while our low-VOC flare technology provides excellent combustion performance," said Henry Liu, vice president and general manager of Honeywell UOP China. "These technologies offer excellent economics and will help Hengli comply with stricter environmental regulations in China." Under the Chinese government's Emission Standard of Pollutants for the Petroleum Refining Industry, emissions of nitrogen oxides from industry furnaces are required to drop 33 percent, from 150 milligrams per cubic meter in 2015 to less than 100 this year. These pollutants are a primary cause of acid rain and increased surface ozone concentration, which have serious and direct impacts on public health and the environment. Honeywell UOP's Callidus low-NOx burner technology and customized burners will allow Hengli Petrochemical to reduce NOx emissions to half the limit prescribed under the new emission control regulation. The burners are customized to meet requirements of all types of applications at Hengli, including refinery heaters, reformers, ethylene crackers, and CCR (continuous catalytic reforming) and propane dehydrogenation process heaters.

Revision Date:  2/15/2018

Tags:  325110 - Petrochemical Manufacturing 石化产品生产, 324110 - Petroleum Refineries 石油精, Honeywell, Hengli Petrochemical (Dalian) Refinery Co, Flare System, Burner, Technology, Process Design, Procurement, Emissions Reduction, Fuel Efficiency, China

ARTICLES IN INTELLIGENCE SYSTEM ON FUGITIVE EMISSIONS

How a Refinery Significantly Reduced Fugitive Emissions

The BP refinery in Whiting, IN has 80,000 valves in its leak detection and repair (LDAR) program. There are approximately 20 process units in the refinery, on an average five-year-turnaround cycle and 200-300 valves on every turnaround work list. BP executed an EPA consent decree in 2012 and has been working on improvements around LDAR and emissions since 2011. There are several failure modes for valves, including bonnet and flange leaks, and leaks through the seat, but 77% of them are due to stem packing leaks. Other variables are valve life, surface finishing to minimize gaps and the bellow seals alternative. Valves now must be certified low-leaking valves or repacked with certified low-leaking packing. These are defined as “valves for which a manufacturer has issued either a written guarantee that the valve will not leak above 100 parts per million (ppm) for five years or a written guarantee, certification or equivalent documentation that the valve has been tested pursuant to generally-accepted good engineering practices and has been found to be leaking at no greater than 100 ppm.” Steve McJones and Rich Sobilo of BP reported in Valve Magaine thatEarly results have shown a 21% decrease in one unit’s valve leaks. There have been no bellows leaks. Previously, 20% of new valves leaked in the first year, but it has been reduced by 180 less leaks in one year in just one unit. The overall leak rate has decreased from over 30% between 2008 and 2013.

Revision Date:  12/21/2017

Tags:  324110 - Petroleum Refineries 石油精, 211111 - Crude Petroleum and Natural Gas Extraction 原油和天然气开采, BP, Valves, Repairs, Emissions Control, Refining, Leak Detection, USA


California refinery monitoring system

CARB has published details of the ambient monitors used for criteria pollutants, toxics and TsP used at each refinery location in California

Revision Date:  12/13/2017

Tags:  324110 - Petroleum Refineries 石油精, Thermo Scientific, Teledyne, Monitoring Devices, Fence Line


PerkinsElmer mass spectrometer cost effectively measures benzene and a range of VOCs and SVOCs

GC instrumental parameters are optimized so that VOCs, in addition to semi-volatile organic compounds (SVOCs), can be analyzed on the same instrumentation enabling enhanced throughput and laboratory efficiency. The instrumentation used in this study was a TurboMatrixTM Automated Thermal Desorber (ATD) and a Clarus SQ8TM GC/MS system. (Both from PerkinElmer Inc., Shelton, CT). It should be noted that the method allows for flame ionization detection (FID) or mass spectrometer (MS) detection. However, for this particular study, MS was used to reduce the possibility of false positives being reported. One of the criteria of this method is to meet the tuning specifications for the compound 4-bromofluorobenzene (BFB) This study has clearly shown that by optimizing GC/MS and TD instrumental parameters a suite of VOCs, in addition to other semi-volatile compounds can be analyzed on the same system, resulting in increased laboratory efficiency. This provides flexibility in allowing the analysis of 325 and Semi-volatiles in the same sequence. In addition, the data also demonstrates that by using the fast, resolved chromatographic approach, EPA Method 325 performance criteria can be achieved, while still maintaining high sample throughput.

Revision Date:  12/13/2017

Tags:  324110 - Petroleum Refineries 石油精, PerkinElmer, Mass Spectrometry, Benzene, Method 325


Refinery fence –line monnitoriing to impact petrochemical operators

Gary Daves is technical services director of air quality for Providence Engineering & Environmental Group LLC advises chemical plants emitting benzene near a refinery to imitate discussions with neighboring refineries to determine possible impacts and to conduct independent benzene monitoring studies to identify potential problems which could be revealed in the new method 325 fence line monitoring program which will be implemented by refineries (the full article is available in the intelligence system)

Revision Date:  12/13/2017

Tags:  324110 - Petroleum Refineries 石油精, Providence Engineering, Benzene, Fence Line, Method 325


Forestalling fugitive emissions with two critical valve concepts

For controlling fugitive emissions, perhaps the most crucial consideration in valve selection is the stem seal design. Although traditional packing options such as chevron (v-ring) or cup-and-cone styles can successfully combat most fluid leakage, those options alone won’t suffice in guarding against fugitive emissions of highly hazardous chemicals in volatile applications with extreme fluctuations in temperature and pressure. Therefore, processors needing valves for such services should carefully assess stem seal design and materials. While both rising-stem and quarter-turn valves can be susceptible to leaks, valve stem movement through the packing in rising-stem valves makes them a more precarious choice than their quarter-turn counterparts. To mitigate the leak potential with rising-stem valves, a bellows-sealed design has proven highly effective compared to alternatives. In selecting a bellows-sealed valve, users should look for the following design features pertaining to fugitive emissions control: • Two-part rising stem. This isolates the rotational movement of the stem and shields inner components from the effects of torque. • Full-size safety gland packing made of graphite or polytetrafluoroethylene (PTFE). A safety backup enables continued valve function, eliminating the need to shut down the plant in case of emergency or failure. • Bonnet gasket with tongue-and-groove bonnet flanges. A valve that utilizes a tongue-and-groove design focuses the force of the nuts and bolts on a smaller area. Therefore, the gasket doesn’t wear out or become dislodged due to temperature swings, helping achieve leak tightness in volatile applications. Despite the benefits of a bellows-sealed design forrising-stem valves, processors often opt instead for quarter-turn valves for fugitive emissions control to avoid potential leak paths created by the vertical movement of a stem through packing. In this case, valves with redundant seals and side-load protection offer the best defense against external leakage. Valve design, materials and function can vary greatly among different valve types; therefore, we’ll focus only on considerations for process ball valves.

Revision Date:  12/13/2017

Tags:  324110 - Petroleum Refineries 石油精, Crane, Fugitive Emissions, Valve


Refinery fence –line monitoring to impact petrochemical operators

Gary Daves is technical services director of air quality for Providence Engineering & Environmental Group LLC advises chemical plants emitting benzene near a refinery to imitate discussions with neighboring refineries to determine possible impacts and to conduct independent benzene monitoring studies to identify potential problems which could be revealed in the new method 325 fence line monitoring program which will be implemented by refineries (the full article is available in the intelligence system) US Environmental Protection Agency's (EPA) upcoming compliance deadline for refiners to measure and report ambient benzene concentrations at their fence lines will put petrochemical manufacturers with operations in close proximity to these refineries at risk for increased scrutiny and enforcement action. Although EPA's "Petroleum Refinery Sector Risk and Technology Review and New Source Performance Standards" (RTR) rule covers only sources subject to refinery maximum achievable control technology (MACT) regulations, the rule's fence-line monitoring provisions require refiners to collect samples that represent fence-line ambient benzene concentrations, which can include contributions from petrochemical units both on and off a refinery's property (OGJ, Oct. 5, 2015, p. 40). In promulgating the rule, EPA acknowledged these potential contributions from sources not subject to Refinery MACT requirements and included specific provisions for refiners to exclude contributions from these near-field interfering sources (NFSs) when calculating a refinery's reportable ambient benzene concentration. To exclude these NFS contributions, however, a refiner must submit a site-specific, fence-line monitoring plan in which it individually identifies excluded NFSs as well as quantifies their likely contributions to the refinery's ambient benzene concentrations. Given that refining and petrochemical operations frequently are sited in the same general part of a city or region, petrochemical plants inevitably will be targeted as primary NFSs of benzene concentrations excluded by nearby refineries. This article explores potential air-permitting and enforcement implications of the refinery RTR rule's fence-line monitoring requirements on petrochemical operations as well as considerations for operators that may be identified as NFS in refinery site-specific fence-line monitoring plans.

Revision Date:  12/13/2017

Tags:  324110 - Petroleum Refineries 石油精, Providence Engineering, Benzene, Fence Line, Method 325


Golden specialty provides complete program to meet EPA 325 fence line monitoring rquirements

Golden Specialty, Inc. has been in the air business for over 20 years delivering air and industrial sample analysis. The company offers a complete service to address fence line monitoring requirement 325.

Revision Date:  12/13/2017

Tags:  324110 - Petroleum Refineries 石油精, Golden Specialty, Benzene, Laboratory, Fence Line, Method 325


ACCESS TO REFINERY DECISIONS

There is 3 months free access to Refinery Decisions for everyone.  Thereafter it will be free to operators but others will need to pay a subscription fee.  To subscribe just make your request to This email address is being protected from spambots. You need JavaScript enabled to view it.

GAS TURBINE INLET FILTER UPDATES

March 2020

  • Recent Articles in IFN
  • FILTXPO 2020
  • GT Inlet Filter Coverage in Recent Utility E Alerts

______________________________________________________________________________

Recent Articles in IFN

McIlvaine, IFN and FILTXPO  have been busy lately pursuing true cost information on gas turbine inlet filters. This includes articles in the two most recent issues of IFN plus lots of activity at FILTXPO and a gas turbine inlet filter tour guide at Power Gen in New Orleans

The January – February IFN carried the McIlvaine summary of the air filtration market including gas turbine inlet filters which are a significant percentage of the total ambient air filter market.

pic1

The full article is on the IFN website https://online.publicationprinters.com/html5/reader/production/default.aspx?pubname=&pubid=8f10051d-cbac-483f-b50e-51073e0e59bf

The November-December IFN included  a true cost article on gas turbine inlet filters.  It includes a pre FILTXPO  guide to exhibitors with relevant media.  This is being expanded in the coverage below on the actual event

https://online.publicationprinters.com/html5/reader/production/default.aspx?pubname=&edid=36240e8f-387a-4851-816f-2c2974d323a5

 

FILTXPO 2020

Despite the snowy weather and no shows due to the coronavirus FILTXPO was a success. Many of the exhibitors displayed products for gas turbine inlet filters.  There were also some highly relevant speeches.

Air filtration is one of the many promising applications for nanofibers, according to Andrew McDowell, of NXTNO in his speech. For a given pore size, he said a nanofiber membrane can have two times the flux of a cast membrane. Nanofibers can be compoundable as hydrophobic, hydrophilic and other characteristics. Sterilization does not impact performance properties.

Filters are rated based on the particle size they are designed to remove from the environment. However, particles are not all spheres with the same specific gravity. During his presentation, R. Vijayakumar, president of Aerfil, highlighted this point by presenting graphs showing corrections for density and shape for use with optical particle counters.   Therefore we must look to more practical approaches for rating filters.

At the Blue Heaven Technologies stand, the company’s president Bob Burkhead, spoke about Blue Heaven’s new rating tool, which incorporates a simulated room with air recirculating through a filter. The performance is based on multiple passes rather than a single pass. Since this is the way HVAC filters are used, it makes sense to use this kind of measurement in decision making. There has been  a similar initiative at Donaldson. It utilizes a miniature fabric filter, which can be connected to a stack and determine actual  efficiency directly. McIlvaine Company  used a similar approach in developing a 1 cfm mini scrubber, which measures pressure drop needed to achieve a given emission level. 

For gas turbine inlet filtration a miniature multistage inlet filter side stream system could be operated for extended periods and the results over time compared to the original results. Since there is a big difference in ambient contaminant levels depending on whether it is a platform in the North Sea, a desert oil extraction location, or a polluted industrial environment it is important to  determine the right filter for a specific location.

At the show we talked to an exhibitor Jerry Douglas of Innovative Air Management.  He designed a cleanable HEPA filter using Shanghai Lingqiao media. The miniature test rig would be an ideal way for IAM to demonstrate the value of this new product.

There were over 100 FLTXPO exhibitors prior to Coronavirus travel bans.  However 22 Chinese companies were not able to participate. Nevertheless there were a number of exhibitors of filter media  for gas turbine intake filters.  They were segmented based on pre filtration versus final filtration and cleanable vs non cleanable

chart1

Ahlstrom, Hollingsworth & Vose had the largest stands.  All three are supplying media for gas turbines.

Ahlstrom:  A range of efficiencies for both static and pulsable filtration media were displayed. Cedric Vallet, filtration product manager explained the options.

Ahlstrom-Munksjö Trinitex® GTIs is a technology which offers filter media with excellent mechanical filtration efficiency and low pressure drop thanks to its unique 3-layer structure.  Each layer can be customized to deliver specific properties and an optimal combination of strength, mechanical particle removal efficiency (even at small particle sizes) and pressure drop. Trinitex® is easy to process on rotary and knife pleating lines.

Ahlstrom-Munkjö Trinitex® Advance GT includes Trinitex® Advance:  W3000 and W3200.

Ahlstrom-Munksjö Glass GT uses microglass technology to guarantee consistent efficiency in the final stage of air intake filtration – which ultimately protects the turbine. Microglass media is available in dual layer design, which provides increased dust holding capacity while maintaining the highest possible efficiency.  Microglass media is  purported to be the best option for static filter F7-F9 and HEPA filter applications.

Ahlstrom-Munksjö Nano GT consists of  cellulose-synthetic media coated with electrospun nanofibers on the upstream side. This structure results in excellent reverse-pulsing behavior and high mechanical efficiency at the lowest possible pressure drop. Nano GT can also be customized with value-added treatments such as fire retardancy.

Ahlstrom-Munksjö FineFiber GT combines the advantages of cellulose synthetic media and fine fiber meltblown technology.  It delivers a media with excellent reverse-pulsing properties as well as high dust holding properties for extended pulse cycles. 

Ahlstrom-Munksjö CellTech GT is a blended media and is available in different basis weight and cellulose-synthetic ratios.  It has good mechanical strength and pleating behavior on rotary machines and deep corrugation offers optimum pleat separation.

Ahlstrom-Munksjö Synthetic GT Is a based on the CellTech platform with a fully synthetic fiber composition and a hydrophobic treatment. The self-supported structure is designed for pulse-jet applications, combining  pleatability, excellent durability and very good performance for filtering coarse particles.

Hollingsworth & Vose:  We talked to Joh Ayers, Division President of Engine and Industrial on a range of subjects including gas turbines. A new line of NANOWEB®-coated filter media has been specifically designed to meet the growing needs in gas turbine/dust collector air filtration. NANOWEB technology offers 0.3 to 0.5 micron nanofibers. Unlike electrospun nanofibers, NANOWEB fibers are stronger and more durable so the nanofiber coating can withstand stringent pulse-cleaning forces.

The new NANOWEB filter media offers significantly improved fractional efficiency over untreated substrates (97% versus 90%) when tested against AC fine test dust. When tested with 0.3 to 0.4 micron of NaCl particles, which are similar to soot, NANOWEB coated media has 60% fractional efficiency as compared to 20% with standard untreated media. Not only does NANOWEB coating greatly improve equipment protection, it also extends filter life and service intervals.

The cleanable line of NANOWEB filter media is specifically designed to meet the stringent pulse-cleaning requirements. Unlike other fragile nanofibers, NANOWEB coating exhibits increased media adhesion and more durable nanofibers. These stronger nanofibers offer a significant increase in pulse lifetime compared to untreated substrates. The high surface area of NANOWEB coating also noticeably improves the dust cake release during cleaning.

Lydall:  We had multiple conversations with personnel including with Paul Marold, president of Lydall Performance Materials.  He was co-chair of the conference. Michael O’ Laughlin, vice president of Advanced Solutions in his speech talked about developing technology in gas phase and particulate collection.

Arioso® high performance air filtration composite media, according to the stand personnel, is ideally suited for gas turbine air intakes, where end users value high efficiency filtration for reduced cleaning, less downtime, and maximum energy output. Suitable for pulsed and static applications, Arioso media delivers E10 to E12 efficiency at low resistance. Arioso composites’ resistance to oil and hydrocarbon loading provide longer filter life than other available membrane technologies.

Exhibiting excellent dust release in a highly durable membrane, Arioso composites can be used in both pleated cartridges as well as sewn or welded bag applications. At half the pressure drop of microglass filtration media for a given efficiency, Arioso composites are said to deliver lower energy consumption in clean space applications.

GT Inlet Filter Coverage in Recent Utility E Alerts

Utility E Alert November 15, 2019  Pre-show Coverage of PowerGen -New Orleans

The McIlvaine Company is working with associations, media and suppliers to create true cost analyses of combust, flow and treat products and services. One such initiative is the “True Cost of Gas Turbine Inlet Filters.”

The true cost of a gas turbine inlet filter can be affected by a large number of factors. These factors are not constants but are changing. The filter purchaser is challenged to not only identify these factors but to keep up with the changes.

Large gas turbines are used to generate electricity by utilities. Smaller gas turbines, drive pumps and compressors in locations with extreme conditions such as desert dust, artic snow or sea spray on an oil rig. As turbines have become more efficient, they have become more susceptible to damage from contaminants in the combustion air. This ambient air from the surrounding environment can contain high dust loads. In California, with very tight emission standards, the particulate in the inlet air to the turbine can exceed emission limits. Thus, the gas turbine has to act as an air cleaning device.

The challenge for  gas turbine inlet fiber, media, and filter suppliers is to increase gas turbine availability in all environments with newer and more sensitive gas turbines. The newer turbine designs are negatively impacted by small particles. This has led to the use of HEPA filters with efficiencies classed as H10/E10 and higher. Studies show that turbine maintenance can be reduced with even higher efficiency E12-U17. One study showed that even if the cost of higher efficiency filtration were four times higher than lower efficiency filters, the true cost would be lower.

One can choose a system with non-cleanable filters. They are relatively inexpensive but require continuous filter replacement. By using a sequence of inefficient but inexpensive pre filters and a final high efficiency filter, the replacement cost can be minimized.

An alternative is to use a cleanable filter. Periodic air pulsing knocks off accumulated dust.  These systems are available from many suppliers if the F-9 efficiency is all that is desired.  Cleanable filters with H12 efficiency are available from only a few suppliers. On the other hand, there are many new developments which will expand the number of choices.

In terms of high efficiency dust capture mechanisms there is a choice between wet laid glass and synthetic nanofiber non-woven laminates or membranes. The traditional glass media for HEPA filtration has been used primarily in non-cleanable filters.

Quantifying the benefit is a balance between reduced fouling and increased pressure drop. The increased pressure drop can be estimated to restrict performance by approximately 0.4%, while cutting fouling provides a 1.2% improvement in output (empirical average). Therefore, the overall result is a potential efficiency improvement of 0.8%.

 http://www.mcilvainecompany.com/GTairTech/Subscriber/Default.htm

Alliance Pipeline believes that the E12 filters from Gore may allow Alliance to extend the interval between overhauls of its aero engines from 25,000 to as many as 50,000 hours (from three to six years).

The many factors and media choices impacting gas turbine inlet filter selection  have been discussed in a background document on display at 

 http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/DescriptionTextLinks/Gas_turbine_inlet_filter_decision_guide_april_26830.pdf

In the past the most efficient filters that were used on gas turbine inlets were rated F-9 with efficiency of more than 95% on particles 0.4 um diameter. The most penetrating particle size is about 0.2 um where the efficiency is much lower. Higher efficiency filters are rated based on the most penetrating particle size as follows:

chart2

Membrane laminates such as used for dust collection can meet efficiencies up to E12.  The question is whether this is sufficient?

There are a number of new filter and media designs, which need to be evaluated. Mann & Hummel Vokes introduced the Aircube Pro Power S, which utilizes a new synthetic base media with much higher resistance to mechanical stress than glass fiber media and a stable high efficiency during operation. It is water and salt repellent while being extremely robust.

DHA Filter has introduced a cleanable HEPA filter for gas turbine inlets, which it will be displaying at Power-Gen.

Utility E Alert November 8

DHA is  introducing a  New Gas Turbine Inlet Filter at Power-Gen As the costs and complexity of gas turbine generators increase, end users seek ways to both protect and maximize their investment. Many gas turbine operators have explored high efficiency options for their inlet filters. Switching to HEPA grade intake filtration greatly reduces the presence of contaminates in the turbine compressor. This helps extend turbine life and efficiency while reducing the costs in fuel and maintenance. There have been a few drawbacks to making the move to HEPA filters. One issue is that with a more restrictive filter media comes increased initial pressure drop. There have also been questions surrounding the long-term durability and lifespan of the HEPA filters.

 November 15 Gas Turbine Inlet Filter – True Cost Investigation

Speeches: None are directly applicable although Mitchell Krasnopoler of Kiewit will be speaking about air emissions and can address the fact that with HEPA filter gas turbine inlets the outlets are reduced below requirements in California where ambient air levels exceed emission limits.

Stands: The only stand displaying gas turbine inlet filters is DHA stand 1331. An open meeting at their stand is scheduled for 10:AM Wednesday but check updates for changes.

Issues to be Discussed:  DHA will be displaying a rugged cleanable HEPA filter. The debate has centered on whether the theoretical value of lower maintenance with the HEPA filter is worth the higher cost. The argument against the HEPA filter has been fragility.  (see separate analysis)

chart3 

As the costs and complexity of gas turbine generators increase, end users seek ways to both protect and maximize their investment. Many gas turbine operators have explored high efficiency options for their inlet filters. Switching to HEPA grade intake filtration greatly reduces the presence of contaminates in the turbine compressor. This helps extend turbine life and efficiency while reducing the costs in fuel and maintenance. There have been a few drawbacks to making the move to HEPA filters. One issue is that with a more restrictive filter media comes increased initial pressure drop. There have also been questions surrounding the long-term durability and lifespan of the HEPA filters.

The true cost of a gas turbine inlet filter can be affected by a large number of factors. These factors are not constants but are changing. The filter purchaser is challenged to not only identify these factors but to keep up with the changes.

Large gas turbines are used to generate electricity by utilities. Smaller gas turbines, drive pumps and compressors in locations with extreme conditions such as desert dust, artic snow or sea spray on an oil rig. As turbines have become more efficient, they have become more susceptible to damage from contaminants in the combustion air. This ambient air from the surrounding environment can contain high dust loads. In California, with very tight emission standards, the particulate in the inlet air to the turbine can exceed emission limits. Thus, the gas turbine has to act as an air cleaning device.

The challenge for  gas turbine inlet fiber, media, and filter suppliers is to increase gas turbine availability in all environments with newer and more sensitive gas turbines. The newer turbine designs are negatively impacted by small particles. This has led to the use of HEPA filters with efficiencies classed as H10/E10 and higher. Studies show that turbine maintenance can be reduced with even higher efficiency E12-U17. One study showed that even if the cost of higher efficiency filtration were four times higher than lower efficiency filters, the true cost would be lower.

One can choose a system with non-cleanable filters. They are relatively inexpensive but require continuous filter replacement. By using a sequence of inefficient but inexpensive pre filters and a final high efficiency filter, the replacement cost can be minimized.

An alternative is to use a cleanable filter. Periodic air pulsing knocks off accumulated dust. These systems are available from many suppliers if the F-9 efficiency is all that is desired.  Cleanable filters with H12 efficiency are available from only a few suppliers. On the other hand, there are many new developments which will expand the number of choices.

In terms of high efficiency dust capture mechanisms there is a choice between wet laid glass and synthetic nanofiber non-woven laminates or membranes. The traditional glass media for HEPA filtration has been used primarily in non-cleanable filters.

Quantifying the benefit is a balance between reduced fouling and increased pressure drop. The increased pressure drop can be estimated to restrict performance by approximately 0.4%, while cutting fouling provides a 1.2% improvement in output (empirical average). Therefore, the overall result is a potential efficiency improvement of 0.8%.

 http://www.mcilvainecompany.com/GTairTech/Subscriber/Default.htm

Alliance Pipeline believes that the E12 filters from Gore may allow Alliance to extend the interval between overhauls of its aero engines from 25,000 to as many as 50,000 hours (from three to six years).

The many factors and media choices impacting gas turbine inlet filter selection  have been discussed in a background document on display at 

 http://www.mcilvainecompany.com/Decision_Tree/subscriber/Tree/DescriptionTextLinks/Gas_turbine_inlet_filter_decision_guide_april_26830.pdf

In the past the most efficient filters that were used on gas turbine inlets were rated F-9 with efficiency of more than 95% on particles 0.4 um diameter. The most penetrating particle size is about 0.2 um where the efficiency is much lower. Higher efficiency filters are rated based on the most penetrating particle size as follows:

chart4

Membrane laminates such as used for dust collection can meet efficiencies up to E12.  The question is whether this is sufficient?

There are a number of new filter and media designs, which need to be evaluated. Mann & Hummel Vokes introduced the Aircube Pro Power S, which utilizes a new synthetic base media with much higher resistance to mechanical stress than glass fiber media and a stable high efficiency during operation. It is water and salt repellent while being extremely robust.

DHA Filter has developed a new line of intake filters that address many of these

concerns. DHA’s Duraweb™ Elite line features a new 3-layer media that combines high efficiency filtration with durability and breathability. The base layer is a 100% synthetic material that gives the media pack its strength and enable the filter to be pulse cleanable. The 2nd layer is a thin “relaxed” ePTFE membrane. The membrane is what gives the filter its high E11 efficiency while maintaining a low initial pressure drop. The physical properties of this membrane repel water and dust ensuring maximum filter life. Finally, a synthetic top layer adds dust holding capacity while protecting the membrane. The media is hydro- and oleophobic which helps it to perform in environments where hydrocarbons and/or high humidity are present. 

DHA’ Duraweb™ Elite line features a new filter media that uses 3 layers to prove HEPA grade inlet filtration:

pic2

1.    The fully synthetic top layer adds dust holding capacity and protects the membrane.  This layer is treated to be oleophobic and hydrophobic to repel hydrocarbons and moisture.

2.    A very thin “relaxed” ePTFE membrane gives the filter an E12 efficiency while maintaining a low initial pressure drop.  This membrane is applied with a proprietary process that ensures durability and maximum filter life.

3.      The synthetic base layer is made from a robust material that provides strength for the media pack.  This allows the filter to hold up over time even after going through numerous pulse cleaning cycles.

Boldrocchi is offering complete systems including gas intake filters.

pic3

Background Information In Gas Turbine Decisions  (Free To Operators)

Gas Turbine Intake Filters Webinar - Hot Topic Hour May 21, 2015  The session covered four route maps in the Gas Turbine Combined Cycle Air Treatment Guide 

Nonwovens in Gas Turbine Air Filtration Clarcor offers a full range of air inlet filters for gas turbine applications including panel, pocket V-cell and cartridge filters. This presentation addresses ways to improve inlet filtration to avoid fouling and corrosion of turbine equipment.

Gas Turbine Air Filter System Optimization Proper air filtration is critical to the overall performance and reliability of gas turbines. This article discusses various aspects of the air filtration and conditioning process including inlet cooling, filters and water wash cycles.

Gas Intake Filters: HEPA or Medium Efficiency Webinar - Hot Topic Hour May 15, 2014 A high level discussion attended by knowledgeable end users, consultants, fiber makers, media suppliers and filter manufacturers. 

EMW recommends HEPA filters for air intakes to reduce compressor cleaning A new trend is emerging in the sector of gas turbine inlet air filtration. Frequently, highest-efficiency (H)EPA filters are selected as the solution of choice for optimum protection of gas turbines. A leader in (H)EPA technologies for many years, EMW offers comprehensive product solutions to keep your gas turbine plant at the cutting edge.

HEPA Air Filtration Technology Keeps Compressor Blades Clean Combustion turbine operators generally experience turbine fouling from airborne particles passing through existing inlet air filters. Fouling can be caused by the particle capture limitations of conventional F-class (EN779:1998) or MERV-class (ASHRAE 52.2) filters. The consequence is reduced performance of the turbine operation. 

202I  Refinery Decisions

A decision system matrix for refineries provides purchasers with tools to buy based on lowest total cost of ownership for each type of combust, flow, and treat product or service.   Individual decision guides are being set up on many subjects. For example, fence line monitoring, fugitive emissions, process management software, automation, wireless transmitters, delayed coker valves, molecular sieve switching valves, FCC scrubbers,  etc. The system includes the 4 knowledge needs: Alerts, Answers, Analysis and Advancement. See a sample update at Click Here.  You can view an introductory webinar at: https://youtu.be/N0CgrGcfMAU

202I Refinery Decisions is free of charge to refineries. There is a 3 month free subscription for others after which there is the offer of a yearly subscription for $ 1600/yr to register for the free subscription Click Here to Order

 

Gas Turbines and Reciprocating Engines

Gas Turbine, Reciprocating Engine IIoT & Remote O&M Overview

Markets

  • Gas Turbine and Reciprocating Engine IIoT and Remote Markets for Components
  • IIoT is Creating New Market Paths to the $100 Billion Gas Turbine Repair, Replace and Service Market
  • Market Segmentation by Major Component
  • Valves and Pumps Lead Component Purchases
  • Drivers Impacting Product Markets
  • Regulatory Drivers
  • Gas Turbine Opportunities for Valve Companies Shaped by IIoT
  • Multiple Gas Turbine Valve Purchasers with IIoT
  • Inlet Air Filter Monitoring can be combined with Digitized Sourcing Programs

Support Program

  • Gas Turbine Product and Services Enhanced by IIoT
  • This Program will help You make the Paradigm Shift caused by IIoT and Remote Monitoring
  • Example of Bi Weekly GT Supplier Alert
  • Monthly GTRE Update
  • Projects Updated Every Few Weeks. Here is Update for November 26, 2016
  • Details on GTCC in Each Country
  • IIoT and Remote O&M Programs allow the Large Owners to Coordinate  Operations Across the Fleet
  • Lots of data relative to each component has to be gathered in a digital process management program.  If the owner already has that information, the cost of program implementation with be far less.
  • Operating ZLD Systems from McIlvaine GTCC Supplier Program
  • New ZLD projects from Mcilvaine GTCC Supplier Program

Software

  • AEP Monitoring with IBM Maximo and Siemens PrismMoni
  • ABB Symphony Plus DCS for Collection and Analysis of Plant Data
  • Schneider Electric is Providing Comprehensive Services for Power Plants
  • C3IoT Platforms used at all 24 ENGIE Business Units
  • AECC replaces CEMS with Predictive System for Seven Gas Turbines

Third Party O & M

  • Turbine Services Supports Sites with Different Make Turbines
  • ProEnergy is One of Many Third-Party O&M Firms and the Trend is Accelerating
  • IHI has Flexible Suite of O & M Services
  • NRG Energy Services can provide Digital Process Management and Remote Monitoring of its Own and Client Facilities
  • NRG Energy Services providing O&M to Golden Spread for Two Large Gas Turbine Plants
  • Wood

Remote Monitoring

  • Remote O&M, Data Analytics and Subject Matter Experts
  • Laborelec (ENGIE) has Remote Monitoring and Niche Expertise Capability
  • Ethos Energy operates Monitoring and Diagnostic Center
  • Siemens Monitors More Than 9,000 Turbines at its European Data Center
  • GE Gas Turbine Remote Monitoring Center
  • Ansaldo Remote Monitoring and Diagnostic Center
  • IHI Remote Monitoring Center for Gas Turbines
  • MHPS Supplies Records of Daily Activity and Insights on Performance and Availability
  • Parker has Condition Monitoring for Gas Turbines
  • Parker Condition Monitoring for Gas Turbines

Individual Company Opportunities

  • Braden
  • Berkshire Hathaway

Engine Applications

  • Diesel and Natural Gas Internal Combustion Generators by State
  • Drivers for the Growth in Use of Gas for Power Generation
  • Factors Favoring Growth in the use of Stationary Engines for Power Generation
  • Age of Gas
  • Natural Gas Production by Type
  • Developing Countries will have Greatest Growth in Consumption
  • Projected Number of New Stationary CI (Diesel) Engines per Year from 2011 through 2017
  • Distributed Power
  • Existing CHP Compared to On-Site Technical Potential by Sector
  • Total U.S. CHP Technical Potential Across All Facility Types
  • Existing Commercial CHP Capacity by Prime Mover
  • Remote Monitoring of Compressor Station Engines with Rockwell PlantPAx
  • Wärtsilä Condition Monitoring
  • Wärtsilä DMP Concept
  • CBM Way of Working
  • How Engine Health is Determined
  • Cummins CHP Systems provide up to 90% Energy Efficiency
  • CO2 Cleaned and Returned to Greenhouse to Gain 30% Plant Growth (600 ppm)
  • H&H SCR System Reduces NOx and delivers CO2 to the Greenhouse. System could be Remotely Monitored
  • Clarke Energy Greenhouse System
  • Biogas Engines

Power by Biogas ICEs vs. Central Power Plants