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Design Evolution, Reliabi lity and Durability of Rolls-Royce Aero-Derivative Combustion Turbines Pedigree Matrices, Volume 6 1004227 Effective December 6, 2006, this report has been made publicly available in accordance with Section 734.3(b) (3) and published in accordance with Section 734.
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EPRI Project Manager D. Grace ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1395 ▪ PO Box 10412, Pal o Alto, California 94303-0813 ▪ USA 800.
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC.
iii CITATIONS This report was prepared by Electric Power Research Institute 3420 Hillview Avenue Palo Alto, CA 94304 Principal Investigator D. Grace This report describes research sponsored by th e Electric Power Research Institute (EPRI).
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v PRODUCT DESCRIPTION Competitive pressures ar e driving power generators to exp loit aviation combustion turbine technology to create more efficient and powerful generation plants at lower cost.
vi introductions as design changes go from the ‘d rawing boards’ into production testing at a customer’s site early in the learning curve. The absence of long-term experien ce with the technology raises issues of relia bility and durability.
vii ACKNOWLEDGMENTS Thanks to Ted Gaudette (formerly of Strategic Power Systems, Inc.) a nd to Ian Langham of Ian Langham & Associates Inc. for preparing the orig inal report in 2002. Thanks to Rolls-Royce for welcoming EPRI attendance at the Turbine Operat or’s Conference in Hous ton in 2005.
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EPRI Proprietary Licensed Material ix CONTENTS 1 INTRODUCTION .................................................................................................................. .. 1-1 Risk Trends .......................................................
EPRI Proprietary Licensed Material x RAM Assessment ................................................................................................................. .3 - 4 Conclusion ...................................................................
EPRI Proprietary Licensed Material xi LIST OF FIGURES Figure 2-1 Industrial RB211: Gas Generator and Free Power Turbine...................................... 2-2 Figure 2-2 Industrial Trent .............................................................
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EPRI Proprietary Licensed Material xiii LIST OF TABLES Table 2-1 Pedigree Matrix: Rolls-Royce RB211-6562, RB211-6761, Trent 60 (DLE and WLE) Engine Design Characteristics ............................................................................... 2-11 Table 3-1 RAM Statistics: Fleet Characteristics for Avon, RB211, and Trent .
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EPRI Proprietary Licensed Material 1-1 1 INTR ODUCTION The power generation market place and the combusti on turbin e market in particular are evolving at an ever-increasing pace. Ma rket forces are driving the in troduction of new technologies and advanced combustion turbines designs.
EPRI Proprietary Licensed Material Introducti on 1-2 turbines in combustion technology with dry low NO x and CO levels that are several orders of magnitude lower and meet land based polluti on requirements in m any geographic areas.
EPR Proprietary I Licensed Material Introducti on 1-3 Risk Trends Based upon the review of the designs from all of the m anufacturers, seve ral trends are readily apparent.
EPRI Proprietary Licensed Material Introducti on 1-4 abnormality in the flow path. Adoption of pr oven aviation technology has m inimized leakage paths and has improved clearance control.
EPR Proprietary I Licensed Material Introducti on 1-5 − Multi-pass serpentine cooling schemes − “Shower-head” cooling schemes • Advanced materials − Directionally solidified alloys − Sin.
EPRI Proprietary Licensed Material Introducti on 1-6 development programs and is entering commercial use. Advanced industrial technology trends which are considered medium to high risk with re spect t.
EPR Proprietary I Licensed Material Introducti on 1-7 • Single, large capacity units • Minimum resources applied to Monitori ng, Diagnostic, and Prognostic Program s Original Equipment Manufacture.
EPRI Proprietary Licensed Material Introducti on 1-8 efficiency advantage of the new technology com bustion turbine might not offset the increased maintenance costs. It is a difficult equation to so lve, especially when trying to predict changes over the 20 to 30 year life of a typical plant.
EPR Proprietary I Licensed Material Introducti on 1-9 compensate for their losses. Some companies co ncluded they would no l onger participate due to the perceived risks, while others entered the market due to improving margins. In 2004 and 2005, the market again became “softer” and prem iums decreased on a relative basis.
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EPRI Proprietary Licensed Material 2-1 2 R OLLS-R O YCE AERO-DERIV A TIVE COMBUSTION TURBINE B A CKGR OUND Summary Rolls-Royce’s aero-derivative h erita ge goes back more that forty years with an ac.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-2 seven-stage low pressure compressor (LPC), si x-stage high pressure compressor (HPC) driven by a sin.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-3 for ease in maintainability. This unit also re quires a reduction gearbox in electrical utility applications.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-4 RT 56 – (Cooper Bessemer) 56” Diameter, two stage, Reaction Turb ine. For the –22, -24A and –24C engines RT 62 - (again Coopers) 62” Diameter , two stage, Reaction Turbine.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-5 Once the engine is removed from the berth, it can be placed on its transportation stand . At this point the I.P. Turbine assembly can be uncoupled from its curvic coupling and removed.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-6 I.P. Stage 5 Stator: to Mod. 1205. This will put hard facing on the vane feet and the assembly will be re rubbered with m achine injected, RTV 851 dampening medium .
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-7 stop the bearing cavity can see temp eratures in excess of 400 degrees in the ninety minutes following a crash stop. W hereas, on a cool stop that cavity temperature only got up to just over 275 degrees.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-8 controls water usage to meet emission leve ls for changes in power demand and ambient conditions. The 8-stage intermediate pressure compressor (IPC) and the 6-stage high-pressure co mpressor (HPC) are identical to th e Aero Trent 800.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-9 The fundamental feature of the aero-derived tu rbine is its modularity.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-10 The 17 stage gas generator provides a compressi on ratio of 8.8:1 and is driven by a 3 stage turbine. The 2 stage power turb ine drives a 4-pole generator at 1500-1800 rpm, sim ilar to the RB211.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-11 Table 2-1 Pedigree Matrix: Rolls-Royce RB211-6562, RB2 11-6761, Tren t 60 (DLE and WLE) Engin e De.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-12 Design Characteristic RB211 – 6562 (RB211-24G Gas Generator with RT62 Power Turbi ne) RB211 – 6.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-13 Design Characteristic RB211 – 6562 (RB211-24G Gas Generator with RT62 Power Turbi ne) RB211 – .
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-14 Design Characteristic RB211 – 6562 (RB211-24G Gas Generator with RT62 Power Turbi ne) RB211 – 6.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-15 Design Characteristic RB211 – 6562 (RB211-24G Gas Generator with RT62 Power Turbi ne) RB211 – .
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Co mbustion Turbin e Backgr ound 2-16 Design Characteristic RB211 – 6562 (RB211-24G Gas Generator with RT62 Power Turbi ne) RB211 – 6.
EPRI Proprietary Licensed Material 3-1 3 RELIABILITY , A V AILABILITY AND MAINT A INABILITY Data Analysis: Rolls-Roy ce Aero-deri vative Engines This chapter provides statistical evaluation of th e Reliability, Availabili ty, and Main tainability (RAM) performance of the Rolls-Royce Avon, RB 211, and Trent machines in power generation applications.
EPRI Proprietary Licensed Material Reliability, Availability and Maintainability 3-2 Generation area, Strategic Generation Options an d go to Newsletters/ Program Updates under the Research Area Updates secti on in the left sidebar.
EPR Proprietary I Licensed Material Reliability, Availability and Maintainability 3-3 Table 3-2 RAM Statistics for Roll-Royce Avon, RB 211 and Trent Engines – All Duties Model & Year Availabilit.
EPRI Proprietary Licensed Material Reliability, Availability and Maintainability 3-4 Additional RB 211 Operating Statistics The following table provides ave rage Reliability and Availab ility statistics for a limite d number of RB 211 engines based on a one-year operational study.
EPR Proprietary I Licensed Material Reliability, Availability and Maintainability 3-5 The review of the frame pedigr ee matrices in a previous EPRI Report TR-114081, “Gas Turbine Design Evolution and Risk” clearly shows a high degree of commonality between the d esign of a frame unit and an aero-derivative unit.
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EPRI Proprietary Licensed Material 4-1 4 BIBLIOGRAPHY Literature Citations • “New applications for Trent”, Turbomachinery International , Sept/Oct 2005, pp 9-12. • T. Scarinci and C. Barkey (Rolls-Royce Canada), “Dry Low Emissions Technology for the Trent 50 Gas Turbine”, paper p resented at Power-Gen Europe, Barcelona, Spain, May 2004.
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EPRI Proprietary Licensed Material A-1 A KNO WN ISSUES Table A-1 Listing of Known Issues for Rolls-Royce Units Issue Symptom Comments Ancillary Package Design Numerous Deficiencie s Cooper Bessemer, now part of Rolls-Ro yce, packaged the unit as a Coberra 6256 a nd then, with the higher powered machin es, the Coberra 6562 unit.
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EPRI Proprietary Licensed Material B-1 B RB 21 1 MAINTENANCE SCOPE RB 211 - 2,000 Hour Inspection • Carry out a soak wash of the engine’s compressor.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-2 • Conduct a full internal borescope examination of the engine. Refer to the M/M Volume 1, Chapter 6. for reference and allowable limits of any nicks, dents or other foreign object damage found.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-3 instructions. These instructions and checks are to be found in the Maintenance and Parts Manual, off-engine parts, Volume 1A, Part 1A, Chapter 3 and Chapter 3 of Part 2A. • On re-start of the engine, carryout an airflo w control system check.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-4 • Visually inspect the rem ainder of the module in the bulk condition (i.e. C urvic Coupling, thrust bearings). • Electrically check the N2 Magnetic Speed Sensors and electrical connectors.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-5 Compressor Rotor HP (Section 1664) • Inspect the HP compressor rotor path linings and incorporate modifications 1115 and 1189, if required. Reprotect if necessary. • Incorporate Mod 1167 - Improved bolt material on com bustor.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-6 Rebuild the Module to the Rolls-Royce overhaul spec ification, fits and clea rances etc. and ship back to the Customer or replace in the ‘POOL’. 05 Module: • Carry out dimension check of IPT Rotor setting.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-7 RB 211 - Overhaul Workscope This overhaul workscope is conducted as sc hedule maintenance at approximately 50,000 Operating Hours, providing the engine had a midlife inspection re pair at 25,000 hours.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-8 • Inspect VIGV’s, crack test, measure inne r and outer journals. Inspect threads. • Measure and inspect in ner and outer bushes.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-9 Compressor Rotor IP (Section 1666) • Detail strip the Rotor. Wash, NDT, in spect and record/em b ody the following: − RN 5015 – C.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-10 − MOD 1231 – Revised HP Speed Probes Compressor Intermediate Case (Sections 1661/1661A) • Detail Strip, Clean and Inspect. • Re-protect the Compressor Interm ediate Case. • Replace Thread Inserts on the Starter Mounti ng Flange, Borescope Ports and BOV Mounting Flange.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-11 − RN 5017 – Log Book Cyclic Life Information − RN 5024 – HP Turbine Blade Check Procedure − RN 5033 – Fatigue failures of .
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-12 Combustion Outer Case (Section 1090-1090/A) • Detail strip, clean and inspect. • Re-protect the outer casing with Sermetal “W” coating Combustion Liner (Sections 1092-1092A-1092B) • Detail Strip, Clean and Inspect.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-13 − RN 5009 – Renew HP compressor bolts in Je thete material at every service strip.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-14 • Detail Strip, Clean and Inspect. • Embody the following: − RN 5018 – HP/IP support intern al pipe inspection/test − RN 502.
EPRI Proprietary Licensed Material RB 211 Mainte nance Scope B-15 • Visually inspect starter or as advised by customer. • Visually inspect all remaining com ponents and recondition as necessary.
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EPRI Proprietary Licensed Material C-1 C RAM TERMS AND DEFINITIONS Term Definition Availability (%) (Avail) 100 1 • + − ⎟ ⎟ ⎠ ⎞ ⎜ ⎜ ⎝ ⎛ Hours Period Unit Hours Outage Scheduled Hou.
EPRI Proprietary Licensed Material RAM Terms and Definitions C-2 The above equations ad here to IEEE Standard 762: Sta ndard Definitions for use in Reporting Electric Generating Units Reliability, Ava.
EPRI Proprietary Licensed Material D-1 D INST ALLA TION LISTS The following tables provide a representative li sting of installation s ites for Rolls-Royce RB211, Trent and Avon models in electrical generation applications. Mechani cal drive and of f-shore applications in the oil and gas industry are not included.
EPRI Proprietary Licensed Material Installation Lists D-2 Table D-1 RB211 Sites Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD PT PLN Persero Jakarta Jakarta Area J.
EPRI Proprietary Licensed Material Installation Lists D-3 Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD Statoil Heidrun OS Norway RB211 SC 3 NG 56 1994 AGIP SpA AG.
EPRI Proprietary Licensed Material Installation Lists D-4 Table D-2 Trent Sites Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD TransCanada Corp TransCanada PipeLine.
EPRI Proprietary Licensed Material Installation Lists D-5 Table D-3 Avon Sites Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD Pakchina Fertilizer Ltd Haripur Pakchi.
EPRI Proprietary Licensed Material Installation Lists D-6 Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD Abu Dhabi Gas Industries Ltd (ADGAS) Bu Hasa (ADGAS) Abu Dh.
EPRI Proprietary Licensed Material Installation Lists D-7 Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD Fingrid Oyj Huutokoski Fin-79620 Huutokoski Finland Avon SC.
EPRI Proprietary Licensed Material Installation Lists D-8 Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD Vattenfall AB Gotland Vattenfa ll Gotland Sweden Avon SC 2 Unkno wn 116 1971 Virgin Islands Water & Power Authority St.
EPRI Proprietary Licensed Material Installation Lists D-9 Company Site City State Country Model Cycle Typ e Number of CTs Fuel MW rating COD Shell Oil Co Carrington Shell UK/England & Wales Avon SC 1 Unknown 14 1968 TXU Corp TXU Eur ope Group plc West Burton Retford Nottinghamshire UK/England & Wales Avon SC 4 Unknown 72 1968 E.
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ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1395 • PO Box 10412, Pal o Alto, California 94303-0813 • USA 800.
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