Filson Fuel Gas Coalescer

Filson Fuel Gas Coalescer

Your Best Fuel Gas Coalescer Supplier in China

Fuel gas cleanliness requirements of turbine, engine and other significant equipment demands that the flowing gas must be kept clean, dry and free of liquids. Filson fuel gas coalescers are used to remove the solid and liquid particles from the gas stream.

Coalescing refers to “aggregate together”. It is a continuous process by which small aerosols contact with the fibers in filter media, uniting with other collected aerosols and growing to large droplets in downstream surface of media which is capable of being drained by gravity.

Filson fuel gas coalescers are widely used in downstream oil and gas operations and petrochemical industries for liquid-liquid or liquid-gas separation during product refining processes. In addition, they can also be used to protect refining equipment from corrosion.

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Fuel Gas Coalescer: The Ultimate FAQ Guide

Whether you want to learn more or import fuel gas coalescer, this guide answers all questions you have been asking about this filtration system.

From components, functions, installation to testing, you will find everything about this coalescing filament element here.

Take a look:

What is a Fuel Gas Coalescer?

It is a device that removes solid and liquid contaminants from gas fuel to provide clean and dry gas that meets the consumer requirements.

Fuel gas filter

What are the Functions of a Fuel Gas Coalescer?

The fuel gas coalesce removes solid and liquid contaminants from the gas fuel used to power engines, turbines, burners, and compressors.

They help deliver quality fuel gas specified by the OEM for the protection of injectors and other system components from damages.

Further, the presence of water in fuel gas will affect its combustion and delivery of the required amount of energy.

What are the Components of a Fuel Gas Coalescer?

A fuel gas coalescer comprises of the following components:

Fuel gas filter system

Ports: The inlet and outlet ports for directing dirty fuel gas in and clean fuel gas out

Housing: Consist of the bowl that contains the filter elements and the head which provides enclosure to the elements

Coalescing element Removes liquid and solid contaminants.

Sumps: Collect the coalesced liquid

Baffle plate: Act as a barrier to incoming gas, removing large liquid and solid droplets.

Drains: For releasing contents of the sump

What Kind of Industries and Applications require a Fuel Gas Coalescer?

You can use fuel gas coalescing filter in all applications that require clean and dry fuel gas.

These include:

• Power generation in mobile power units or traditional power plants
• Protection of engines and gas turbines and automobiles
• Protection of burners in the steam generator
• Protection of compressors
• Recovery of lube oil immediately after compressors
• Protection of turbo equipment

They are specifically useful in the following industries.

• Mining
• Oil and gas
• Processing of natural gas
• Pulp and pap
• Power generation
• Petrochemical etc.

What are the Features of a Good Fuel Gas Coalescer?

A good fuel gas coalesce should possess the following key features:

• Removal of aerosols measuring 0.3 microns and above at 99.9% efficiency.
• Meet all the regulatory industry standards and codes include ASME and PED pressure vessels codes
• Possess either manual or automatic drainage
• Local and remote level controls
• Easy access to elements through quick opening enclosures. You can select fuel gas coalescers with either blind flange, swing-bolt, or blind flange with davit type enclosure.
• Can either be mounted on a skid, presented as standalone or trailer mounted
• Duplex and simplex design configurations
• Sump are should be large to collect bulk coalesced liquid.
• Support a high flow capacity and system pressure.

What Factors should you Prioritize when Choosing a Fuel Gas Coalescer?

Selecting a fuel gas filter should be guided by your system requirements.

Efficient filtration highly depends on the type, model, and design of the fuel gas filter you select.

When choosing a fuel gas coalescing filter, you should consider the following:

• Operating temperature and pressure
• Flow rate of the system
• Material used for construction of the filter system
• Desired filtration efficiency
• Micron rating of the filter
• Characteristics of contaminants in the gas
• Characteristic of the fuel gas
• Availability of the replacement parts
• Overall configuration of the
• Type of fuel gas coalescer filter housing – you can choose simplex or duplex option
• Initial cost and subsequent maintenance cost

What is the Working Principle of a Fuel Gas Coalescer?

The fuel gas coalescer consists of the coalescing filter elements and the housing assembly.

The coalescing elements perform the actual filtration.

The elements comprise two layers.

The inside layer is constructed using finer mesh while the outer layer has course mesh.

When fuel gas passes through the elements, filtration takes place inside to outside flow.

The inner mesh traps any solid contaminants that are still suspended in the gas stream.

As the gas flow outwards, the droplets suspended in the stream hit the intersections of the mesh and stick.

The addition of more droplets as the gas stream drags the droplets outwards causes the drops to grow in size and form large droplets.

Furthermore, the large drops flow down the sump due to the action of the gravity force.

The coalesced liquid is stored on the sump and removed on intervals either through automatic drains or manually after each cycle load.

Sometimes, a baffle plate is installed at the inlets to remove slugs, large droplets, and solid before reaching the coalescing cartridges.

Where present, the plates remove large contaminants, usually 1 micron and above, through sharp-changing the direction of gas flow.

The momentum of large droplets and particles drives them into the plates.

In fact, the liquids coalesce to form a liquid film which captures the solid contaminants and retain them.

The film flows downwards due to the force of gravity and settles in the sump together with the solids.

Why should you Install a Fuel Gas Coalescer?

Fuel gas coalescing is mandatory for all applications which need clean and dry gas fuel for gas-powered production processes.

The contaminants present in the fuel gas can cause dire financial repercussions if not removed on time.

Specifically, liquid contaminants can freeze and block the supply lines bringing the production to a halt.

Wet gas fuel also enhances the rate of corrosion and damage to vital equipment in the system.

Using a fuel gas coalesce in conditions the gas fuel provide the following benefits:

Fuel gas filter

· The Device is available for Numerous Flow Capacities and Models

Diverse models help meet the filtration requirements over a wide range of fuel gas applications.

Different models configured in diverse designs using different materials readily meets the demanding fuel gas filtration requirements.

· Extension of the Service Life of Vital System Components

Removing liquid contaminants helps protect the sensitive system components such as turbines and burner nozzles, thus eliminating the risk of system failure.

It also helps eliminate the need for unscheduled and costly maintenance and downtime.

· Reduction of Downtime

When you use a high capacity fuel filter, you extend the interval of maintenance and cartridge replacement.

Similarly, a fuel gas coalescer which supports faster removal and replacement of cartridges also reduce the downtime costs.

· Maximum Operation Performance and Efficiency

High quality coalescing filters guarantees efficient removal of contaminants at the desired efficiency and micron rating.

This helps provide high-quality gas fuel which burns and provides maximum energy required for smooth system operation.

· Reduction of Costs of Maintenance and Operation

The overall cost of ownership of the filtration system is significantly lowered by sufficient filtration of the fuel gas.

Removal of materials that can potentially damage the system components eliminate the frequency of unplanned maintenance, repair, and replacement of costly components of the system.

What are the Types of Contaminants found in Fuel Gas?

Some of the contaminants found in fuel gas include pipe scales and dust, sand, clay, rust, iron sulfate, copper sulfide, iron, water, lubricating, and crude oil.

Other contaminants include glycols, ice, gas hydrates, construction debris, and calcium carbonate.

These contaminants find their way into the gas stream at the point of production, transportation and/or storage.

Water is one of the most common contaminants associated with fuel gas and purposefully removed using coalescing filters.

Other than the above-mentioned contamination routes, water can also contaminate the fuel gas through:

• Condensation of dissolved water
• Rainwater intrusion
• Pipeline leakage

Water will stall the engines, remove additives, reduce conductivity, fasten abrasive wear of system components and haul the production process.

What are the Best Materials for Constructing a Fuel Gas Coalescer?

Fuel gas coalescer filter element

You can use several materials for constructing a fuel gas coalescing filter element.

When selecting a material for constructing your filter media, you should consider the following factors:

Select a material that is best suited for your operation and can efficiently coalesce the contaminating liquid particles.

The material must not lose or reduce its effectiveness at different operating temperatures.

It should be compatible with your fuel gas, non-toxic, light in weight, and cost-effective.

Some of the best materials include:

• Micro glass borosilicate
• Fiberglass
• Polypropylene
• Stainless steel
• Polyester

You can treat the surface of the medium to enhance filtration at higher flow rates and allow for a reduction in the size of the housing.

Surface treatment also reduced the re-entrainment of coalesced liquid back into the fuel gas.

What are the Benefits of using a High-efficiency Fuel Gas Coalescers?

A high efficiency coalescing filter elements provide enhanced filtration of sub-micron aerosol.

It produces more efficient removal of contaminating liquids from the fuel gas compared to normal coalescing filters.

The design of a high-efficiency filter media optimizes the media thickness and pore size for maximum filtration of aerosols.

Also, the designs also ensure that there is no occurrence of re-entrained coalesced liquids.

Consequently, a high-efficiency filter has:

• A higher dirt holding capacity hence an extended service life
• Lower dirt penetration/maximum dirt removal efficiency
• Can remove aerosols with diameters of up to 0.1 microns
• They can achieve between 99% and 99.999%+ dirt removal at different micron ratings
• Have a very low saturation pressure drop on the filter elements

What Types of Fuel Gas Coalescer Filter Media are there?

There are two types of coalescing media.

They include:

· Pleated Coalescing Media

Pleated filters media are surface filters that are constructed using several sheets of medium material laid down in accordion-shaped pleat structures.

Pleated media have a higher surface area for the removal of contaminants compared to depth media.

Pleated media work best when your fuel gas has uniform size contaminants.

Once the surface is fully clogged, you have to replace them or wash and reuse them.

Pleated coalescing filters have the following advantages.

• Larger surface area
• Lower pressure drop
• No foaming because they lack binders and additives
• Longer service life increased dirt holding capacity
• Lower cost of filtration
• Enhanced particles and aerosols removal efficiency
• Support higher flow rate at a lower pressure drop

· Depth Coalescing Media

Depth coalescing filters remove contaminants through passing the fluid across a porous medium.

Depth filters are suitable when you are filtering fuel gas with very high contamination levels.

They can hold a higher quantity of dirt before getting fully clogged.

They are suitable for filtering fuel gas which has contaminants of different diameters.

Depth coalescing media directs the fuel gas through a torturous path.

Consequently, it removes different sizes of particles and aerosols depending on the grade of the medium layer.

You should select this type of filter media when removing shear sensitive solid impurities.

What Fuel Gas Quality Standards are there?

Duplex fuel gas filter

The fuel gas quality standards describe the number of permissible contaminants in the gas fuel.

These standards vary from one application to the other and from one country to the other.

For instance, in the USA, ASTM D 1835 specifications provide guidelines for allowable maximum contaminants in liquefied petroleum gases (LPG).

Most of the countries also draw their standards from specifications of ISO standards like ISO 4257 which specify the number of allowable contaminants in LPG.

Other standards like ISO 8973 and ISO 7941 outline specifications on how to test for vapor on the processed fuel gas.

Countries like Australia use standards that combine different standards like ASTM, ISO, JLPGA, and CEN in testing the quality of the fuel gas.

In Europe, the European Committee for Standardization (CEN) provides CEN standards EN 589 specifications which outline the quality parameters for LPG.

In Japan, the fuel gas quality standards must adhere to specifications of JIS K 2240:2013

In cases of GE powered gas turbines, the fuel gas has to meet the specifications of GEI 41040E.

These specifications require the removal of all liquid contaminants and particulates measuring 10 microns and above at the turbine inlet ports.

What are the Fuel Gas Coalescers’ Designs?

The design of a fuel gas filter can vary greatly depending on the process application requirements.

Several factors such as the fuel dirt capacity, system flow rates, pressure, desired level of separation all affect the design of the filter.

When designing a filter, you can choose between a vertical and horizontal design.

The preference will depend on the piping system configuration, flow rate, and available installation space.

You can also select between simplex and duplex designs depending on the type of your process application.

Duplex designs are best suited for a continuous process that cannot be terminated for cartridge replacement.

How does the Design of a Fuel Gas Coalescer Affect its Sizing?

The size of a filter depends on the fluid flow rate of fluid, and the size of filter cartridges.

Systems with a higher flow rate require bigger fuel coalescing filters to sustain appropriate pressure drop.

Duplex designs are bigger compared to simplex designs because of the double housing and other additional components.

Generally, horizontal filters also tend to occupy larger floor space compared to vertical housing.

The amount of liquid in fuel gas will significantly determine the size of a filter.

You will need a larger sump, which will increase the length of a vertical housing, to collect more coalesced liquids.

How can you Test the Efficiency of a Fuel Gas Coalescer?

You can test the efficiency of a fuel gas using either a DOP efficiency test or Liquid Aerosol Separation Efficiency (LASE) test.

Fuel gas filter system

· DOP Test

The test measures the efficiency of a filter to arrest the fine particles.

When performing the DOP test, you inject aerosols measuring 0.3 microns in the fuel gas stream through condensing the DOP vapor under a controlled environment.

You have to maintain a constant temperature for the fuel gas stream because it determines the size of the droplets.

Measure the concentration of the aerosols upstream and downstream using a light scattering photometer.

The DOP test has the following drawbacks:

• It does not measure the performance of the coalescing filter in a saturated condition. The test is performed on unsaturated and dry elements
• The test does not reflect the actual operating conditions in the field as it happens on a vacuum
• Testing the filters using aerosols sized 0.3 microns does not reflect the actual range of contaminants present in the field.
• The test does not address possible liquid re-entrainment into the fuel gas.

· LASE Test

LASE test measures three main aspects of a coalescing filter, that is, aerosol capture efficiency, medium drainage, and separation downstream.

You can manipulate the test conditions to represent the actual operating conditions expected in the field.

In this test, you will generate the aerosols using a Laskin nozzle.

The aerosols should range between 0.1 to 0.9 microns in diameters which give a better representation of contaminants range found in the field.

The fuel gas is then passed through the coalescing filter at the manufacturers’ recommended flow rate and pressure.

Measure the system pressure and temperature at the inlets.

Also, measure the pressure differentials across the filter assembly.

You should take the performance measurements only when the coalescer has reached the equilibrium.

Install a full flow sampler just as the filter is approaching equilibrium.

Monitor the pressure differentials during sampling and terminate the procedure at a pressure where oil breaks the membrane.

What Factors Influence how long the Fuel Gas Filter Cartridges Last?

The service life of a fuel gas coalescing filter depends on numerous factors.

Most if not all coalescing filters elements have a finite operating life.

Theoretically, a coalescing filter element can last indefinitely if the process gas fuel has no particulate contaminants.

However, this condition is impractical under normal operating conditions even if you install an upstream pre-filter.

Therefore, the fuel gas coalescing filter will only remain effective as long as it has not reached the recommended change-out pressure drop.

Similarly, the filter element must remain free of any damages during the entire operating life.

Some of the important factors which will affect the operating life of a fuel gas filter include:

· Presence of a Pre-filter

Installing an upstream strainer and particulate filter will remove large and excess solid contaminants.

Removing the majority of contaminants will extend the service life of the coalescing filter element.

· The Contamination Level of the Incoming Gas Fuel

Highly contaminated gas fuel has a high number of particulate impurities which will clog the pores of the coalescing filter faster.

You should consider installing an upstream pre-filter to remove the majority of the contamination or else the operation cost will be too high.

· Characteristics of the Contaminants

The type and size of suspended solid and liquid contaminants will also influence how fast the filter element will last.

Contaminants which are approximately the size of the medium pores clog the medium fibers faster than large or smaller solid particulates.

If you are using a pleated type medium, then particulate contaminants of varying sizes will facilitate faster clogging compared to depth type medium.

· System Flow Rate

The flow rate will determine the velocity of incoming contaminants and the number of suspended contaminants per unit volume of gas fuel.

Gas fuel with a higher flow rate contains a higher number of suspended solids compared to gas fuels with lower fluid flow.

A higher number of contaminants per unit volume will clog the element pores faster and accelerate the pressure drop across the filter cartridge.

Similarly, higher fluid flow also contains suspended particles that travel at a higher velocity.

With increased momentum, the particles will exert more destructive force onto the medium.

Henceforth, it will facilitate a faster deterioration of medium integrity, if the elements have a week support structure.

· Dirt Holding Capacity

The dirt-holding capacity of a cartridge is directly proportional to the service life of a filter.

A filter with a higher dirt holding capacity will last longer compared to a filter with small dirt holding capacity.

· Size of the Cartridge

The size of a cartridge affects the dirt holding capacity of a filter.

Bigger fuel gas coalescing cartridges can last longer and reduce the replacement intervals.

This will help you save on downtime and maintenance costs compared to smaller filter cartridges.

· Medium Configuration

The quantity, shape, size, and pore arrangement in filter elements affect the dirt holding capacity and operating life of a filter.

· Pore Size

Filter medium with smaller pore sizes clog faster and have a shorter service life.

Can you Clean and Reuse Fuel Gas Coalescers?

Yes. You can clean fuel gas coalesce that are constructed using 100% synthetic material and reuse them.

What are the Quality Standards for Fuel Gas Coalescers?

Fuel gas coalescers have to adhere to industry standards required for equipment used in processing compressed air/gases.

You should also test the efficacy of the equipment as provided for under ISO 16889 and ISO 2942

Moreover, the filters should adhere to major international and national standards such as ASME, NACE, and AD2000 standards.

Other operator requirements that you should also consider include STATOIL TRs, SHELL DEP’s ETC.

What is the Difference Between Free and Entrained and Dissolved Water?

Figure 7 Fuel gas coalescer filter element

Free water is excess water found in the fuel gas after it has absolved and dissolved water to maximum capacity.

You will not see free water in the form of haze until it has surpassed 30 to 40 ppm.

Entrained water is water that contaminates the fuel gas as an emulsion and occurs when the fuel and water are immiscible.

It forms a hazy appearance as discrete water droplets on the continuous fluid phase.

You can only remove this type of water by fuel gas coalescing filters.

Dissolved water is water that forms a perfect mixture with the fuel gas and cannot be visually identified.

The amount of dissolved water in the fuel gas is directly proportional to the temperature of the fuel gas.

In short, choosing a fuel gas coalescer filter can be an overwhelming task.

The best part, this guide has outlined all the vital aspects you need to know.

In case you have any questions about fuel gas coalescer filter element, you can contact FilSon team now.