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  1. Technology overview 18/03/99 009576/01 PPT

  2. Industrial RB211 DLE gas generator 18/03/99 009576/30 PPT

  3. Key technologies for industrial engines • Combustion systems • Control systems • Aero / thermodynamics • Materials • Integration 18/03/99 009576/02 PPT

  4. Combustion Systems 18/03/99 009576/03 PPT

  5. Rolls-Royce aeroderivative gas turbines • DLE technology is incorporated across the product range Trent RB211 Avon Allison 501 and 601 18/03/99 009576/04 PPT

  6. 120 • 30 • 25 • 100 • 80 • 20 • CO emissions • ppm • NOx emissions • ppm • 15 • 60 • 40 • 10 • 20 • 5 • 0 • 0 • 1400 1500 1600 1700 1800 1900 2000 Influence of temperature on CO and NOx emissions • Combustion temperature K NOx CO 18/03/99 009576/05 PPT

  7. Industrial RB211 DLE combustion system • Objectives :- • 25 vppm NOx and CO simultaneously • Flexible operation - compliance over a wide load and ambient temperature range • No effect on performance (power output, fuel consumption, maintainability or • availability) • Retrofit capability - changes restricted to high pressure 04 module • On going programme to further advance low emissions technology • Minimum changes to site configuration at retrofit 18/03/99 009576/06 PPT

  8. Industrial RB211 DLE combustion system • Technology selected :- • Premix lean burn - Control combustion temperature • Fuel staging - Turndown over the load and • ambient temperature range • Series fuel staging - To provide flexible operation • with wide stability range 18/03/99 009576/07 PPT

  9. Industrial RB211 DLE combustion system • Benefits :- • Constant primary zone combustion temperature achieved by fuel scheduling only • - no airflow management • - no performance loss due to need for compressor bleed • - wide stability margin providing complete operational flexibility • Series fuel staging • - low CO over wide operating range due to substantial pre-heat • from upstream stage • Incorporates conventional diffusion flame • - proven starting reliability • - stable low power operation 18/03/99 009576/08 PPT

  10. Industrial RB211 - Comparative diagrams of conventional and DLE combustor systems • Single annular combustor • 18 off conventional fuel injectors • DLE • Conventional • 9 off pre mix • lean burn combustors 18/03/99 009576/09 PPT

  11. Secondary mixing duct Primary mixing duct Secondary zone premix Central diffusion injector Primary Secondary Fuel flow Primary zone premix Primary fuel Conventional combustion Secondary fuel Power Premix leanburn series staged combustor DLE fuel staging Industrial RB211 DLE combustion system 18/03/99 009576/10 PPT

  12. Torch igniter Injector Combustor DLE 04 module Airflow Pre-mix flow Combustor Cooling air Air transfer casing HP turbine Diffuser Discharge nozzle Industrial RB211 DLE combustion system 18/03/99 009576/11 PPT

  13. Industrial Avon - Comparative diagrams of conventional and DLE combustor systems • Conventional • 8 off combustors • DLE • Existing cannular arrangement retained • but with pre mix lean burn combustors 18/03/99 009576/12 PPT

  14. Secondary zone • fuel inlet • Secondary zone • Combustor casing • Primary • fuel inlet • Secondary • fuel • Primary • fuel • Primary zone • Pre-mix duct • Secondary zone • fuel feed Industrial Avon DLE combustion system • Power • Fuel flow • Dilution zone 18/03/99 009576/13 PPT

  15. Existing engine support system retained DLE design changes contained within this area Industrial Avon DLE • Low risk programme • Changes confined to combustion system only 18/03/99 009576/14 PPT

  16. Allison 601 Programme review • Dry Low Emissions system • DLE Features • RB211 DLE combustor applied to the 601-K • Three combustion liners adapted to the 601-K outer case • 601-KB11 airflow is 1/3 of RB211 • Pressure ratio and firing temperature virtually identical 18/03/99 009576/15 PPT

  17. Control Systems 18/03/99 009576/16 PPT

  18. Industrial RB211 DLE control system • Entered service 1994 • Joint Rolls-Royce EnTronic Controls Development Team • Same equipment standard installed at all Rolls-Royce test sites • Can be used for operation of conventional RB211 gas generator • Single bay Engine Electronic Control System • Electric fuel metering and distribution system • 18 channel ignition system 18/03/99 009576/17 PPT

  19. Existing unit control panel • Engine • sensors • 18 channel • ignition • system • Interface • Engine control unit • Fuel metering • units • Compressor control • Yard valves • Unit sequencing • Power turbine lube oil • DLE engine control system Engine control system • System integration requires minimal changes to existing UPC 18/03/99 009576/18 PPT

  20. Aero / Thermodynamics 18/03/99 009576/19 PPT

  21. Trent 8104 Trent 800 400 350 300 250 200 150 Power (MW) Power (MW) Trent 700 Future Trent 75 50 25 75 50 25 -524H Thrust (kN) -524G -524D4 Trent IFB -524C -524B RB211-24G Upgrade Trent -22B RB211-24G RB211-24C RB211-24A RB211-22 Evolution of the RB211 and Trent family 2000 and beyond 1975 1980 1985 1990 1995

  22. RB211-24G Upgrade Improved SFC and power 60 50 40 30 20 10 0 5 10 15 Improved component efficiency Improved materials Advanced cooling techniques % Power increase 24G 24C 24A -24A % SFC improvement -24C RB211-24G Upgrade -24G 1975 1980 1985 1990 1995 2000 Industrial RB211 performance 18/03/99 009576/21 PPT

  23. RB211-24G IP compressor • Current standard Upgrade standard 18/03/99 009576/22 PPT

  24. IP compressor 1st and 2nd stage rotor 18/03/99 009576/23 PPT

  25. Materials 18/03/99 009576/24 PPT

  26. 1600 • Turbine temperature capability • Cooling improvements • Coating developments • 1550 • 1500 • 1450 • Firing temp • 1400 • 1100 • 1350 • Firing temperature (oK) • 1050 • 1300 • 1000 • SC cast • alloys • Metal temperature (oC) • 1250 • 950 • DC cast • alloys • 1200 • Conventionally • cast alloys • 900 • 1150 • 850 • 1100 • Wrought alloys • 800 Turbine technology developments • Approximate year of availability • 1940 1950 1960 1970 1980 1990 2000 18/03/99 009576/25 PPT

  27. Forged • Conventional • casting • DS • casting • Single • crystal Industrial RB211 - HP turbine rotor blades • Aero -22B -524 -524G Trent • Ind -22 -24A/C -24G -24G Upgrade 18/03/99 009576/26 PPT

  28. Cross flow • ribs • View with top of shroud removed • to show cooling passages • LP • Cooling air • HP • Damper Trent HP turbine blade • Low pressure loss • cooling passages • Sophisticated '3D' shaped • film cooling holes • Advanced internal heat • transfer augmentation • Increased efficiency • trailing edge 18/03/99 009576/27 PPT

  29. Integration 18/03/99 009576/28 PPT

  30. Aero RB211 / Trent 3 shaft flexibility Common component flow Industrial RB211 Industrial Trent Industrial RB211/Trent product familyAeroderivative heritage 18/03/99 009576/29 PPT

  31. Power • turbine • New compressor • first stage • Power • drive • Basic aero engine RB211-524 • 222.4kN thrust (50,000lb) Derivation of industrial unit from aero engine • Aero based RB211 industrial unit - 30.78 MW 18/03/99 009576/31 PPT

  32. Industrial Trent derived from aero Trent 800 Aero Trent Modified power turbine Common IP and HP systems New compressor Modified casings Low emission combustion system New bleed duct Industrial Trent 18/03/99 009576/32 PPT

  33. 418 Kg • (922lb) • 504 Kg • (1110lb) • 366 Kg • (740lb) • 800 Kg • (1765lb) • 320 Kg • (705lb) • Air intake • Module 01 • IP Compressor • Module 02 • Intermediate • casing • Module 03 • HP system • Module 04 • IP turbine • Module 05 Industrial RB211 modular construction 18/03/99 009576/33 PPT

  34. Advantages of modular construction • High gas generator availability • Maximised repair by local labour ease of transportation • Reduced spares holding • Optimised use of capital equipment • Updating and uprating capability 18/03/99 009576/34 PPT

  35. RB211 Upgrade - Gas generator development • Performance objectives - • Build on basic Industrial RB211 experience • Boost performance from modest flow and temperature • increases • Incorporation of improved efficiency HP compressor • How - • Use latest aero technology to achieve performance objectives • at low risk • - Aerodynamics - IP compressor flow increase • - Components - HP compressor • - HP turbine • - Materials - IP turbine 18/03/99 009576/35 PPT

  36. HPC boroscope relocated Revised HP speed probe ESD air supply IPC OGV redesign Turbine casing cooling RVDT VIGV control Single panel turbine support Reliability/ maintainability features Performance enhancing features CMSX4 IPT blade CMSX4 HPT blade Optimised DLE combustion system Increased flow IP compressor Trent 800 HP compressor Gas generator development - Upgrade features 18/03/99 009576/36 PPT

  37. COBERRA 6761 • RB211-24G • Upgrade • RT61 18/03/99 009576/37 PPT

  38. Allison 601 gas generator

  39. 601-KB9/-KC9 601-KB11/-KC11 601-KF9 (Marine) 601-KF11 (Marine) 601-KB9D/-KC9D 601-KB11D/-KC11D Allison 601 engine series

  40. 94.4 in (2396.9 mm) 40 inch Dia. (1000 mm) Est. Weight 3,000 lbs 40 inch Dia. (1000 mm) Est. Weight 4,000 lbs 122.6 in (3114.0 mm) -Kx9 -Kx9 -Kx11 -Kx11Natural Gas DieselNatural GasDiesel Power, shp 9,000 8,765 11,000 10,500 Power, kw 6,715 6,340 8,200 7,830 Heat Rate, B/shp-hr 7,540 7,640 7,900 8,000 Introductory Engine Performance Allison 601 engine configuration

  41. Allison 601 program status • Rig Development Testing Combustion Rig Tests Complete Compressor Rig Test Complete Gas Generator Rig Testing Completed • Engine Development Testing Performed Instrumented Diagnostic and Component Tests Completed Functional Testing Performance and Operability Lubrication and Vent System Gaseous and Liquid Fuels • Engine Endurance Testing Completed 150 Hour Endurance Test Assembly of 2000 Hour Field Endurance Engine in Process

  42. Industrial Trent • The world's most powerful and most efficient aeroderivative gas turbine 18/03/99 009576/38 PPT

  43. Industrial Trent modularity Air intake casing Interturbine NGV Intercompressor duct Intermediate casing IP compressor LP compressor rotor Gearbox HP core and combustion system LP turbine 18/03/99 009576/39 PPT

  44. Benefits of modern aeroderivatives over single shaft machines • 2 Spool engines allows better compensation for in-service degradation • automatic aerodynamic re-matching between spools • Each compressor spool is short with good bearing support • no bowing of drum, excellent concentricity control • Short bearing centre allows close tip clearances, seal control • minimum performance loss, minimum degradation • Modular arrangement allows flexibility of maintenance • Single row variable compressor blading • No accessory drives 18/03/99 009576/40 PPT

  45. End of Technology overview Please press “Esc” to return to main menu 18/03/99 009576/01 PPT