Technology overview 18/03/99 009576/01 PPT

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

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

Combustion Systems 18/03/99 009576/03 PPT

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

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

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

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

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

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

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

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

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

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

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

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

Control Systems 18/03/99 009576/16 PPT

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

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

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

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

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

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

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

Materials 18/03/99 009576/24 PPT

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

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

Trent HP turbine blade Cross flow ribs View with top of shroud removed to show cooling passages Damper LP Cooling air HP 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

Integration 18/03/99 009576/28 PPT

Industrial RB211/Trent product family Aeroderivative heritage Aero RB211 / Trent 3 shaft flexibility Industrial RB211 Industrial Trent Common component flow 18/03/99 009576/29 PPT

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

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

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

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

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

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

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

Allison 601 gas generator

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

Allison 601 engine configuration 94.4 in (2396.9 mm) Est. Weight 3,000 lbs Introductory Engine Performance -Kx9 -Kx9 -Kx11 -Kx11 Natural Gas Diesel Natural Gas Diesel 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 40 inch Dia. (1000 mm) 122.6 in (3114.0 mm) Est. Weight 4,000 lbs

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

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

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

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

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

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