Dual-Filter Air Intake for Gas Turbines
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Solution Overview
Problem
Air intakes for plants, such as gas turbines, face issues with particle accumulation in filters leading to increased pressure drop, energy consumption, and potential particle intrusion, necessitating frequent filter replacements which can disrupt operations and incur maintenance costs.
Innovation Solution
A dual-filter system with a high-efficiency front filter unit and a lower-efficiency back filter unit arranged in series, allowing for the front filter to be replaced during operation without shutting down the plant, with the back filter protecting against particle intrusion during exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single high-efficiency filter is used in the air intake, then particle removal efficiency is improved, but the filter requires frequent replacement which causes operational disruption and maintenance costs
Solution Approach 1:
The filter system is divided into two separate filter units (first filter unit and second filter unit) arranged in series. The first filter unit can be removed and replaced independently without removing the second filter unit, allowing maintenance without complete system shutdown. This segmentation enables continuous operation while maintaining particle removal efficiency.
2Ease of manufacture
If the plant is shut down for filter replacement, then maintenance can be performed safely, but productivity is reduced due to loss of electricity generation output
Solution Approach 1:
The first filter unit is designed to be removable independently from the second filter unit. This allows maintenance personnel to access and replace the first filter unit without shutting down the plant, thereby maintaining electricity generation output while performing necessary maintenance.
Solution Approach 2:
The second filter unit acts as a protective intermediary during maintenance of the first filter unit. When the first filter unit is removed for replacement, the second filter unit remains in place to continue filtering particles, enabling safe maintenance without complete system shutdown.
3Productivity
If filter replacement is delayed, then operational continuity is maintained, but pressure drop increases and energy consumption rises
Solution Approach 1:
By segmenting the filter system into two independently replaceable units, the first filter unit can be replaced more frequently without affecting overall system operation. This allows optimization of replacement timing to balance operational continuity with energy efficiency, replacing the first unit before excessive pressure drop occurs while maintaining continuous plant operation.
4Duration of action of stationary object
If a rough pre-filter is added before the main filter, then main filter life is extended, but device complexity increases
Solution Approach 1:
The filter system is segmented into two functional units: the first filter unit (acting as pre-filter) and the second filter unit (main filter). This segmentation naturally extends the life of the second filter unit by having the first unit capture initial particle accumulation, while maintaining a relatively simple overall structure through the series arrangement of two standard filter units.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Extends the time between back filter replacements by ensuring continuous operation and reducing maintenance disruptions, as the front filter captures most incoming particles, thereby maintaining plant efficiency and reducing downtime.
Implementation Method 1
a particle filter assembly arranged in the air channel for removing particles from an air stream passing through the air channel
Implementation Method 2
the front filter unit has a higher efficiency and dust holding capacity than the back filter unit
Data Source
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AI summary
The invention relates to an air intake for a plant, the air intake comprising an air channel for an air stream passing through the air intake into the plant, and a particle filter assembly arranged in the air channel for removing particles from an air stream passing through the air channel, the particle filter assembly comprising a front filter unit and a back filter unit. The front filter unit is arranged before and in series with the back filter unit such that an air stream passing through the air channel passes through the front filter unit before passing through the back filter unit. The air channel is such constructed and the front filter unit is such arranged in the air channel that the front filter unit is removable and replaceable by a fresh front filter unit while the back filter unit remains in the air channel and while an air stream is passing through the air channel during operation of the plant. The front filter unit has at least equal efficiency and dust holding capacity as the back filter unit.