02_fs_international_2014_seite_03-98__ 21.05.

14 20:12 Seite 85

Highlights 2013

Semi-automated Gas Turbine

Inlet Filter testing according
ARAMCO standard or for
performance optimization
D. Renschen*, J. Schamberg*, N. Guttenbrunner**, N. Schneider**

There is a growing demand for improved gas turbine air filters with regard to the energy efficiency in operation and
filtration efficiency in view of the increasing demands of modern gas turbine for inlet air quality. Therefore, supported by
DMT as air filter testing specialist, Bilfinger Gerber set up a special test rig for testing semi-automatically gas turbine
inlet filters according to ARAMCO standard (32-SAMSS-008) which describes a harsh gas turbine filter testing program.
The process measuring and control technology allows an automatic run of the different test phases as required by the
ARAMCO standard. Only for dust sampling for the determination of the filtration efficiency manual support is needed. This
facilitates the sequential tests of different air inlet filter types e.g. for optimization of the filter performance within R&D.

1. Introduction
New construction plus the growing
replacement market were supposed to
boost turbine inlet air filter sales to over
$400 million in 2013. This segment would
account for 6% of the $7billion air filter
market, as claimed by the McIlvaine
Company in its Air Filtration and
Purification World Markets report. There
is a growing demand for improved gas tur-
bine air filters with regard to the energy
efficiency in operation and filtration effi-
ciency in view of the increasing demands
of modern gas turbine for inlet air quality.
A lot of the existing and future gas turbine
power plants are erected in arid or semi-
arid zones with potential high dust expo-
sure.
Usually air inlet filter for gas turbine
applications are tested for classification
according EN 779.This gives a clear indi-
cation about performance in view of initial
pressure drop behavior and efficiency
against DEHS and ASHRAE test dust. But
this standard gives no information about
behavior about cleanable filter systems
and its performance within operation espe-
cially under severe operation conditions.
For the filter media of such air inlet fil-
ter pretests can be made by the VDI 3926-
1 (“Testing of cleanable filter media” or
ISO 11057) to receive information about
the ageing behavior and performance
against test dust from the application.
The so called Saudi Aramco DeskTop
Standard “32-SAMSS-O08” is a “Materials
System Specification” including a test
specification. The purpose of the “Speci-
* D. Renschen, J. Schamberg,
DMT GmbH & Co. KG
Product Assessment Refrigeration & Air Quality
Am Technologiepark 1, D-45307 Essen / Germany
** N. Guttenbrunner, N. Schneider
Bilfinger-Gerber GmbH, D-44379 Dortmund / Germany
fication” is to ensure the ability of an inlet
air filtration system for combustion gas
turbines to withstand the rigid environ-
mental conditions in a high ambient dust
desert area, with relative humidity ranging
from zero to 100% (coastal zones). The
intent of such an inlet air fi ltration system
is to limit the ingestion of airborne conta-
minants such as sand, dust and alkali metal
salts (sea salt aerosol) so as to prevent gas
turbine compressor erosion, fouling, cool-
ing air passage blocking and hot corrosion
of the turbine section components. The
system specifi ed is intended for continu-
ous duty, high effi ciency air fi ltration.
Therefore, the air fi ltration systems cov-
ered by this specifi cation are limited to the
automatic pulse-jet self cleaning type.
For other environmental conditions
with much less dust like in Central Europe
the test standard “Air intake filter systems
for rotary machinery - Test methods - Part
1: Static filter elements” (ISO/DIS 29461-
1:2010) was just developed for filter which
are not cleanable.
DMT as air filter testing specialist and
third party testing institution supported
Bilfinger Gerber in setting up a special test
rig for testing semi-automatically gas tur-
bine inlet filters according to the Saudi
Aramco Material System Specification 32-
SAMSS- 008 (ARAMCO standard).
Appendix II of the Aramco Specification
describes a test procedure for a harsh filter
testing program divided in several phases
to detect the capability of resistance
against desert sand storms.
2. Test Standard
Saudi Aramco Material System
Specification 32-SAMSS-008
(Aramco Standard)
Most chapters of the specification are
dealing with material and system require-
ments for an inlet air filtration system for
a gas turbine installed in a filter house. It
includes requirements for the filter ele-
ment (structure). Further on the specifica-
tion describes requirements for the system
performance, mechanical and electrical
instrumentation and the filter house itsself.
In the appendix information about protec-
tive coatings are summarized and a quali-
fication and performance tests for materi-
als e.g. against salt fog is defined.
For planning a test (rig) it is important
to consider the requirements for the pulse
air system (Chap. 5). All other important
figures for the test equipment, test materi-
als (test dust), test conditions and the test
procedure of filter elements and the report-
ing of the results are included in Appendix
II (Filtration Testing Requirements).
3. Test Rig Design and Validation
In spite of the requirements and descrip-
tions for the appropriate equipement for
the test rig according appendix II of the
Aramco Standard a lot of details had to be
fixed. By the target to set up a semi-auto-
matically working test rig further require-
ments had to be defined especially for
process measuring and control technology
devices and the software for data aquisi-
tion and control.
Other requirements resulted from the
necessity to set up a test system which
generates data which are valid in view of a
certification of filter elements which shall
be tested by means of this system (DIN
EN ISO/IEC 17065). Therefore, all these
measurement devices, which are integrat-
ed in the test rig, must have a precise spec-
ification and be able to be calibrated.
After finalization the test rig as com-
plete testing system has to be validaded
(EN 45002 “General criteria for the
assessment of testing laboratories”). The

F & S International Edition No. 14/2014 85

02_fs_international_2014_seite_03-98__ 21.05.14 20:12 Seite 86

Highlights 2013

Tab. 1: Survey of measurement points within the Aramco standard test rig validation test method characterizes the
method features of the Aramco Standard
test procedures. The further target of vali-
dating the test rig and the test procedure
(by DMT) is to ensure that testing of gas
turbine filter cartridges (which is per-
formed at a testing site of Bilfinger
Gerber), is according to the Aramco
Standard. For certification of tested filter
types the validated test procedure has to be
secured even against manipulation within
data acquisition. DMT acts as mandated
neutral evaluation service. Bilfinger Gerber
as testing laboratory. Therefore, DMT has
to ensure the integrity of the measured
data when measured in the external labo-
ratory.
Tab. 2: Basic modules of the Aramco standard test rig
The testing procedure of filters accord-
ing the Aramco standard is diveded in six
phases during which sets of different para-
meters and measurements are carried out.
Essentially, for the Aramco test proce-
1 dures (phases 0-5), the following data have
to be measured continuously:
Intermediate - Differential pressure on the Wilson flow
Compresso compressed
grid (volume rate test duct – up to
with air drier air tank
12750m3/h): Δpflow grid
- Ambient pressure (0 – 1100 mbar):
pbarom.
- Ambient temperature: Tambient
- Relative humidity: ϕambient
2
- Differential pressure inlet air filter (3
pressure transmitters: I 0 to 300 Pa, II 0
to 1000 Pa, III 0 – 10000 Pa): Δpfilter
Compressed air tank with diaphragm valves,
blow tubes connection and manometer Pressure regulator valve - Compressed air vessel pressure (up to
10 bar): pcomair
- Valve opening time (is adjusted to the
specified value, not measured)
- Volume rate at sampling point 1 (Mass
·
3 flow controller 0 – 200 l/min): V PN1
Controller
- Volume rate at sampling point 2(Mass
·
blow tube flow controller 0 – 200 l/min): V PN2
diaphragme - Dust concentration raw gas (upstream,
Diaphragme valve valve
via dust generator, gravimetric dosage,
balance 0 to 50 kg): m· test dust
The data acquisition and transmission
of measured values to the central comput-
er (control station) have to be ensured. All
4 measurement parameters are summarized
in table 1.

2 blow tubes with 4. Semi-automatically gas turbine

6 outlet nozzles (each)
inlet filters test rig
The new test rig of Bilfinger Gerber is
composed of several different modules
which are suitable for a testing according
the technical specifcation “32-SAMSS-
5 O08”.
+ The test setup is divided into 10 modules:
6
1) Compressor (supply) for compressed
Test duct air tank (vessel)
Section for 2) Compressed air tank
dust sampling 3) Diaphragm angle valve

86 F & S International Edition No. 14/2014

02_fs_international_2014_seite_03-98__ 21.05.14 20:12 Seite 87

Highlights 2013

4) Blow tube/pipes Tab. 2: Basic modules of the Aramco standard test rig
5) Test duct
6) Test section for dust sampling/dust
sampler system
7) Dust Injection System (ejector)
8) Differential pressure measurement 6
system (for the filter)
9) Fan (suction mode) Mass flow
10) Steam vaporizer for humidification controller
Dust sampling system (dust sampl.)
The different modules are shown in the
table 2 (below) in more detail.
All components of the resulting test rig
are connected to the central control com- Test dust
puter. The software program aquires all containment
data and controls different components 7
like the frequency controlled fan for auto-
matic adjustment of the volume rate to the
specified value. Further on test dust gener-
ation, pressure pulsing and sampling of the Dust injection system (nozzels) Controller unit
dust on the upstream side (clean gas) of
the test filters is done automatically within
one test phase according the Aramco stan-
dard. Only the change of the sampled fil-
ters for the gravimetrical determination of 8
the test dust in the clean gas has to be done
manually at the defined time intervalls by
Differential
the operator. pressure
By the central computer the measured transmitter Measuring points
data are controlled against special limits
(for instance upper pressure drop). If this
limit value is reached the test is stopped
automatically and the operator is informed
by an alarm signal. A picture of the screen
of the software control program is shown 9
in figure 1.
Radial fan unit
5. Validation of the test rig and
axial-flow fan Ventilation flap with actuator unit
the test procedure
To ensure a correct test procedure as
base of a certification the whole test rig
was thoroughly examined. The examina-
tion was performed in particular with
regard to the measuring sensors, in order 10
to inspect the proper positioning and cali-
bration of the measuring equipment.
Steam vaporizer Humidity and temperature sensor
First the status of calibration of the dif- (front outside of test chamber) (inside of test chamber)
ferent measurement devices was con-
trolled. This means as part of the test rig
validation, the calibration certificates were
checked and included in a test rig manual. The data measured by the different sen- the test bench at Bilfinger Gerber was
All sensors of the test equipment have to sors in the test bench are acquired by the accompanied by a test engineer of DMT.
be calibrated periodically according to the central control computer at a rate of about Within this test method validation fol-
requirements of the agreed quality control 5/min. A resulting table is arranged to a lowing work packages have been made by
system (tab. 1). By testing inlet air filters continous time scale to which the data of DMT:
according to ARAMCO standard under each sensor are included in the according - Definition of the requirements for this
supervision of DMT the validity of the cal- columns. The data are broken down by external certification testing
ibration certificates will be inspected. each of the five test phases and stored in a
“csv-file”, which is transferred into an - Definition of the validation procedure for
For the dust generation system the mass the test method
flow of dust was examined by DMT and “Excel” file-format which can easily be
edited for the following data analysis. - Round Robin test between DMT and
the system calibrated accordingly a inter-
To validate the semi-automated filter Bilfinger Gerber
nal QC procedure. The quality of dust dis-
persion of the dust generation system was test procedure adapted according the stan- - Check of the integrity of the raw data and
examined by measurement with a DMT dard 32-SAMSS-O08, two equal tests for the data transfer
modified Berner type impactor in compar- the same type of an inlet air filter were This whole validation process was full-
ision with the particle size distribution of carried out at the DMT and at the Bilfinger filled by Bilfinger Gerber successfully.
the used test dust (fig. 2). Gerber test rig. This first validation test on

F & S International Edition No. 14/2014 87

02_fs_international_2014_seite_03-98__ 21.05.14 20:24 Seite 88
Fig.1: A picture of the screen of the software control program
Fig. 2: Comparison particle size distibution of the test dust with the dispersed test dust sampled
from the raw gas in the test rig
6. Testing and Certification of
inlet air filter elements
The testing of filter cartridges accord-
ing the Aramco standard at the new test rig
will be performed at the site of Bilfinger
Gerber. Nevertheless, the test results will
be certified by DMT. This assumes that
88
Bilfinger Gerber and DMT closely cooper-
ate in the examination of filter perfor-
mance for other customer. Therefore, the
cooperation is based on a secrecy agree-
ment between both parties which secures
confidentiality of all information within
third party testing.
Highlights 2013
DMT gains access to the acquired data
at the external test rig within an ongoing
measurement and to complete data sets
after completion of the tests. The intrusion
by DMT on the computer system of the
external test rig is made via Internet access
about the program “TeamViewer”. Thus, it
is possible during the experiments to mon-
itor the current operating state. By com-
paring data documented during monitor-
ing via “TeamViewer” with the raw data
set after finshed testing validity of data can
be verified.
7. Capabilities of this unique
test system
The semi-automated “Aramco” test rig
of Bilfinger Gerber provides results which
are plausible and trustworthy. It is
designed appropriately for the inlet air fil-
ter test procedure within the specification
32-SAMSS-O08. By this semi-automated
filter system testing can be done much eas-
ier and with less man-power.
Beneath these basic features the test rig
also incorporates a steam humidification
and an air circulation system. Therefore,
different other testing options are possible
due to an “open” air inlet which is inte-
grated in a special test room.
This test rig facilitates the sequential
test of different air inlet filter types (not
only pulse filters) and is suitable for opti-
mization of the filter performance within
R&D. Therefore, beneath the testing
options according the standard further
tests can be made like optimization of the
distance between blow pipe and filter car-
tridge or of the consumption of com-
pressed air, determination of the efficiency
of coalescer filter for mist elimination etc..
Literature:
/1/ 32-SAMSS-O08, Materials System Specification for
Inlet Air Filtration Systems for Combustion Gas Turbines,
Saudi Aramco, 2008
/2/ DIN EN ISO/IEC 17065, “Conformity assessment -
Requirements for bodies certifying products, processes
and services”
/3/ EN 45002, “General criteria for the assessment of test-
ing laboratories”
/4/ ISO/DIS 29461-1:2010, “Air intake filter systems for
rotary machinery - Test methods - Part 1: Static filter
elements”
/5/ VDI 3926-1, “Testing of cleanable filter media -
Standard test for the evaluation of cleanable filter
media”
F & S International Edition No. 14/2014