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Design Evolution, Reliability 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 734.7 of the U.S. Export Administration Regulations. As a result of this publication, this report is subject to only copyright protection and does not require any license agreement from EPRI.
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Design Evolution, Reliability and Durability of Rolls-Royce Aero-Derivative Combustion Turbines Pedigree Matrices, Volume 6 1004227 Technical Update, March 2006 EPRI Project Manager D. Grace ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1395 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ USA...
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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. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM: (A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR...
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This report describes research sponsored by the Electric Power Research Institute (EPRI). The report is a corporate document that should be cited in the literature in the following manner: Design Evolution, Reliability and Durability of Rolls-Royce Aero-Derivative Combustion Turbines: Pedigree Matrices, Volume 6, EPRI, Palo Alto, CA: 2006. 1004227.
The ultimate result of this report is a concise presentation of the design evolution of Rolls-Royce combustion turbines in the form of a pedigree matrix that allows risk to be assessed. The pedigree matrices identify design trends across all of a manufacturer's products that can be categorized as low, medium, or high risk.
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Whitney, Rolls-Royce, Siemens Power Generation, and Mitsubishi Power Systems. Approach The project team reviewed the design characteristics of the Rolls-Royce aero-derivative combustion turbine product lines (RB211, RB211 Uprate, and the Trent) to assess the technical risk associated with these advanced technology combustion turbine designs. Information was drawn from operations data and directly from the owners of machine fleet leaders operating in peaking, cycling or baseload service.
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Thanks to Ted Gaudette (formerly of Strategic Power Systems, Inc.) and to Ian Langham of Ian Langham & Associates Inc. for preparing the original report in 2002. Thanks to Rolls-Royce for welcoming EPRI attendance at the Turbine Operator’s Conference in Houston in 2005. Thanks to Dale Paul and Bob Steele at Strategic Power Systems, Inc.
Medium to High Risk ......................1-5 Other Risk Factors......................1-6 The Use of Advanced Technology for Peaking Duty.............1-7 Insurers and Lenders Perspective..................1-8 2 ROLLS-ROYCE AERO-DERIVATIVE COMBUSTION TURBINE BACKGROUND....2-1 Summary ..........................2-1 RB211 Background Information ....................2-1 RB211 Horsepower Ratings .....................2-3 RB 211 Maintenance Approach..................2-4 Turnaround Time and Costs ..................2-5...
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EPRI Proprietary Licensed Material RAM Assessment........................3-4 Conclusion ..........................3-4 4 BIBLIOGRAPHY ........................4-1 Literature Citations ........................4-1 A KNOWN ISSUES ........................A-1 B RB 211 MAINTENANCE SCOPE ..................B-1 RB 211 - 2,000 Hour Inspection ................... B-1 RB 211 - 8,000 Hour Inspection ................... B-1 RB 211 - Midlife Workscope....................
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EPRI Proprietary Licensed Material LIST OF FIGURES Figure 2-1 Industrial RB211: Gas Generator and Free Power Turbine........2-2 Figure 2-2 Industrial Trent......................2-8...
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EPRI Proprietary Licensed Material 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 ......3-2 Table 3-2 RAM Statistics for Roll-Royce Avon, RB211 and Trent Engines – All Duties ....3-3 Table 3-3 Additional RB 211 Operating Statistics..............3-4...
EPRI Proprietary Licensed Material INTRODUCTION The power generation market place and the combustion turbine market in particular are evolving at an ever-increasing pace. Market forces are driving the introduction of new technologies and advanced combustion turbines designs. The introduction of these technologies inherently involves risk.
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EPRI Proprietary Licensed Material Introduction turbines in combustion technology with dry low NO and CO levels that are several orders of magnitude lower and meet land based pollution requirements in many geographic areas. The enabling technology of today’s advanced frame machines lies with the computer codes and manufacturing processes developed by the aviation combustion turbine industry.
EPR Proprietary I Licensed Material Introduction Risk Trends Based upon the review of the designs from all of the manufacturers, several trends are readily apparent. These trends in the development of advanced designs involve incorporation of current industrial combustion turbine technology, transfer of aircraft engine technology to industrial combustion turbines, and new technologies developed specifically for industrial combustion turbines.
EPRI Proprietary Licensed Material Introduction abnormality in the flow path. Adoption of proven aviation technology has minimized leakage paths and has improved clearance control. These aviation to industrial transfer technology trends, which can be considered low to medium risk with respect to product reliability include: •...
• Staged combustion for high turndown capability *Highest risk technologies Rolls-Royce advanced aero technology is being applied to ALSTOM engines under a long-term technology transfer agreement (ref. Diesel & Gas Turbine Worldwide April 2002, p. 4). Very high temperature technologies, advanced aerodynamics, very high strength/high temperature materials and protective coatings will be applied to improve efficiency, power output and durability of ALSTOM’s heavy duty combustion turbines.
EPR Proprietary I Licensed Material Introduction • Single, large capacity units • Minimum resources applied to Monitoring, Diagnostic, and Prognostic Programs Original Equipment Manufacturers • Integration of systems • Competitive economics • Corporate downsizing • Sourcing compromises (country of sale or worldwide) •...
EPRI Proprietary Licensed Material Introduction efficiency advantage of the new technology combustion turbine might not offset the increased maintenance costs. It is a difficult equation to solve, especially when trying to predict changes over the 20 to 30 year life of a typical plant. Insurers and Lenders Perspective Technology risk is of interest not only to owners and operators but also to insurance companies and project lenders.
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EPR Proprietary I Licensed Material Introduction compensate for their losses. Some companies concluded they would no longer 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 premiums decreased on a relative basis. The insurance market appears to be fundamentally based on supply and demand of its “product”, with volatility somewhat decoupled from quantified technical risk.
TURBINE BACKGROUND Summary Rolls-Royce’s aero-derivative heritage goes back more that forty years with an active role in establishing the combustion turbine in marine application with such units and the Proteus, Gnome, Tyne Spey, and Olympus combustion turbine propulsion units. Rolls-Royce has more than 975 marine installations with over 6 million operating hours.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background seven-stage low pressure compressor (LPC), six-stage high pressure compressor (HPC) driven by a single-stage high pressure turbine (HPT), and a single axial stage, low pressure turbine (LPT) which drives the LPC via an inner coaxial shaft, for a total of 5 pre-balanced modules.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background for ease in maintainability. This unit also requires a reduction gearbox in electrical utility applications. Several significant upgrades are available for RB211-24C and -24G gas generators which are generally included in the RB211-24GT: •...
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background RT 56 – (Cooper Bessemer) 56” Diameter, two stage, Reaction Turbine. For the –22, -24A and –24C engines RT 62 - (again Coopers) 62” Diameter, two stage, Reaction Turbine. For the –24G and –24G DLE engines RT 61 - (based on the Trent 800 aero engine) 61“...
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background 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. Then, by use of the two cranes, the engine can be lifted into the vertical position and be placed nose down on the lifting fixture.
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EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background 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 machine injected, RTV 851 dampening medium. I.P. Stage 6 Stator: to Mod.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background stop the bearing cavity can see temperatures in excess of 400 degrees in the ninety minutes following a crash stop. Whereas, on a cool stop that cavity temperature only got up to just over 275 degrees. No oil in the world can stand the former temperature, without laying down some coke.
EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background controls water usage to meet emission levels for changes in power demand and ambient conditions. The 8-stage intermediate pressure compressor (IPC) and the 6-stage high-pressure compressor (HPC) are identical to the Aero Trent 800. The HPT and IPT are also single stages and identical to the Aero 800 Trent.
EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background The fundamental feature of the aero-derived turbine is its modularity. The industrial Trent consists of 6 prebalanced and interchangeable modules. A module can be removed and replaced with a module from the module pool and operations resumed without any other work being necessary.
100,000 hours. The standard turnaround time is 40 days. Pedigree Matrix for the RB211 and Trent 60 Engines This section provides a review of the Pedigree Matrix developed for the Rolls-Royce RB211 and Trent industrial combustion turbine product line currently relevant for new electrical generation projects.
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EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background RB211 – 6761 Trent 60 DLE Trent 60 WLE RB211 – 6562 Design (RB211-24GT Gas (Derivative of AERO 800 on (Derivative of AERO 800 on Reliability, Maintainability, Durability (RB211-24G Gas Generator...
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EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background RB211 – 6761 Trent 60 DLE Trent 60 WLE RB211 – 6562 Design (RB211-24GT Gas (Derivative of AERO 800 on (Derivative of AERO 800 on Reliability, Maintainability, Durability (RB211-24G Gas Generator...
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EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background RB211 – 6761 Trent 60 DLE Trent 60 WLE RB211 – 6562 Design (RB211-24GT Gas (Derivative of AERO 800 on (Derivative of AERO 800 on Reliability, Maintainability, Durability (RB211-24G Gas Generator...
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EPR Proprietary I Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background RB211 – 6761 Trent 60 DLE Trent 60 WLE RB211 – 6562 Design (RB211-24GT Gas (Derivative of AERO 800 on (Derivative of AERO 800 on Reliability, Maintainability, Durability (RB211-24G Gas Generator...
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EPRI Proprietary Licensed Material Rolls-Royce Aero-Derivative Combustion Turbine Background RB211 – 6761 Trent 60 DLE Trent 60 WLE RB211 – 6562 Design (RB211-24GT Gas (Derivative of AERO 800 on (Derivative of AERO 800 on Reliability, Maintainability, Durability (RB211-24G Gas Generator...
Data Analysis: Rolls-Royce Aero-derivative Engines This chapter provides statistical evaluation of the Reliability, Availability, and Maintainability (RAM) performance of the Rolls-Royce Avon, RB211, and Trent machines in power generation applications. The fleet is represented by units that report to the Operational Reliability Analysis Program (ORAP) managed by Strategic Power Systems (SPS).
Rolls-Royce engines. The following table summarizes the characteristics for the Rolls-Royce fleet as represented by the units reporting to ORAP. The statistics are for all units reporting that meet SPS criteria for inclusion in the database for a particular year. As such, they are a subset of Rolls-Royce entire operating fleet.
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EPR Proprietary I Licensed Material Reliability, Availability and Maintainability Table 3-2 RAM Statistics for Roll-Royce Avon, RB211 and Trent Engines – All Duties Model Availability Reliability Service Service Starting Average Forced Scheduled Unscheduled Mean Mean & Year Factor Hours/Start Reliability Load Outage Outage...
EPRI Proprietary Licensed Material Reliability, Availability and Maintainability Additional RB 211 Operating Statistics The following table provides average Reliability and Availability statistics for a limited number of RB 211 engines based on a one-year operational study. Statistical values are from sources other than ORAP and have not been verified.
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“repair by replacement”. The Rolls-Royce aero flight engines have a long history of being the world’s most powerful and reliable turbines. The industrial versions of these engines are continuing that tradition and are some of the world’s most powerful and reliable industrial turbines.
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 presented at Power-Gen Europe, Barcelona, Spain, May 2004.
EPRI Proprietary Licensed Material KNOWN ISSUES Table A-1 Listing of Known Issues for Rolls-Royce Units Issue Symptom Comments Ancillary Package Numerous Deficiencies Cooper Bessemer, now part of Rolls-Royce, Design packaged the unit as a Coberra 6256 and then, with the higher powered machines, the Coberra 6562 unit.
EPRI Proprietary Licensed Material RB 211 MAINTENANCE SCOPE RB 211 - 2,000 Hour Inspection • Carry out a soak wash of the engine’s compressor. • On completion of the above; − Inspect the Intake Flare for any cracks or damage −...
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope • 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 Maintenance Scope 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 airflow control system check. Chapter 7, paragraph 4 in the Maintenance Manual gives the full details.
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope • Visually inspect the remainder of the module in the bulk condition (i.e. Curvic Coupling, thrust bearings). • Electrically check the N2 Magnetic Speed Sensors and electrical connectors. • Fit the ‘POOL’ OGV Ring Assembly 04 Module: Prepare the 04 Module for shipping to Vendor.
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope 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 combustor. •...
EPRI Proprietary Licensed Material RB 211 Maintenance Scope Rebuild the Module to the Rolls-Royce overhaul specification, fits and clearances 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 Maintenance Scope RB 211 - Overhaul Workscope This overhaul workscope is conducted as schedule maintenance at approximately 50,000 Operating Hours, providing the engine had a midlife inspection repair at 25,000 hours. On Receipt of Engine •...
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope • Inspect VIGV’s, crack test, measure inner and outer journals. Inspect threads. • Measure and inspect inner and outer bushes. • Embody the following Repair Notes (RN): − RN 5002 – Wear of VIGV Trunnions and associated parts −...
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope Compressor Rotor IP (Section 1666) • Detail strip the Rotor. Wash, NDT, inspect and record/embody the following: − RN 5015 – Cyclic Lives of Critical Group A Components − RN 5016 – Engine Component Life Limitation Data −...
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope − MOD 1231 – Revised HP Speed Probes Compressor Intermediate Case (Sections 1661/1661A) • Detail Strip, Clean and Inspect. • Re-protect the Compressor Intermediate Case. • Replace Thread Inserts on the Starter Mounting Flange, Borescope Ports and BOV Mounting Flange.
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope − RN 5017 – Log Book Cyclic Life Information − RN 5024 – HP Turbine Blade Check Procedure − RN 5033 – Fatigue failures of Compressor, turbine rotor blades and stator vanes −...
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope 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. • Embody the following: −...
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EPRI Proprietary Licensed Material RB 211 Maintenance Scope − RN 5009 – Renew HP compressor bolts in Jethete material at every service strip. − RN 5020 - Reduced cyclic life of specific HP compressor rotor Stages 1 to 2 discs Assembly −...
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• Wash and inspect all pipes. • Visually and electrically inspect harnesses and thermocouple harness. • Overhaul the fuel burners in accordance with the Rolls-Royce Overhaul Standard. • Recondition all accessories as such IP and HP bleed valves and bleed valve controller.
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It is recommended to incorporate MODs 1135, 1136, 1164, 1078, 1054, 1071, 1124 and 1266 Non-Engine Components • Inspect transportation stand for serviceability. • Inspect transportation bag for serviceability. Engine Test Conduct performance test in accordance with Rolls-Royce CTS 1165. B-15...
EPRI Proprietary Licensed Material RAM TERMS AND DEFINITIONS Term Definition ⎛ ⎞ Availability (%) (Avail) Forced Outage Hours Scheduled Outage Hours ⎜ ⎜ ⎟ ⎟ − • ⎝ ⎠ Unit Period Hours where Scheduled Outage Hours = Maintenance Unscheduled Outage Hours + Maintenance Scheduled Outage Hours ⎛...
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EPRI Proprietary Licensed Material RAM Terms and Definitions The above equations adhere to IEEE Standard 762: Standard Definitions for use in Reporting Electric Generating Units Reliability, Availability, and Productivity Unavailability Types ® IEEE 762 Equivalent (1987) SPS ORAP System Forced Outage Types Forced Outage - Automatic Trip: While the unit was Unplanned Outage (UO) operating a component failure or other condition...
EPRI Proprietary Licensed Material INSTALLATION LISTS The following tables provide a representative listing of installation sites for Rolls-Royce RB211, Trent and Avon models in electrical generation applications. Mechanical drive and off-shore applications in the oil and gas industry are not included. For instance, there are over 240 units in mechanical drive applications (29,000 to 38,000 hp each), with over 40 having DLE combustors.
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Cogen 2004 6562 Electricidade de Portugal Fafen Energia RB211 SA (EDP) Camacari Brazil CC/Cogen 2003 Cogen 6761 EDP Energen Rolls-Royce Power Ventures (RRPV) Ankara Bilkent Ankara Turkey RB211 Cogen 2003 Rolls-Royce Power (University) Ventures Ltd E.ON AG UK/England Mersey Docks...
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EPRI Proprietary Licensed Material Installation Lists Cycle Number Company Site City State Country Model Fuel Type of CTs rating Statoil Heidrun OS Norway RB211 1994 AGIP SpA Tiffany OS RB211 1992 AGIP (UK) Ltd Bruce Field North Sea RB211 1992 Norsk Hydro A/S Oseberg A OS Norway...
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Type of CTs rating TransCanada Corp Bear Creek Grande Canada Trent CC/Cogen 2003 TransCanada PipeLines Ltd Cogen Prairie Rolls-Royce Power Ventures (RRPV) Croydon UK/England Croydon Trent 2001 Rolls-Royce Engineering Powre Facility & Wales Avedore Dk-2650 Energi E2 A/S Denmark Trent...
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EPRI Proprietary Licensed Material Installation Lists Table D-3 Avon Sites Cycle Number Company Site City State Country Model Fuel Type of CTs rating Pakchina Fertilizer Haripur Pakchina Haripur Pakistan Avon Cogen Unknown 1997 Schon Power Pakchina Haripur Haripur Pakistan Avon Unknown 1997 Generation Ltd...
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EPRI Proprietary Licensed Material Installation Lists Cycle Number Company Site City State Country Model Fuel Type of CTs rating Abu Dhabi Gas Bu Hasa United Arab Industries Ltd Abu Dhabi Avon Unknown 1981 (ADGAS) Emirates (ADGAS) General Electric Co Abu Kamash Libya Avon Unknown...
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EPRI Proprietary Licensed Material Installation Lists Cycle Number Company Site City State Country Model Fuel Type of CTs rating Fin-79620 Fingrid Oyj Huutokoski Finland Avon Unknown 1973 Huutokoski Power and Water Berrimah Darwin Australia Avon Unknown 1973 Authority Vattenfall AB Gothenburg Sweden Avon...
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EPRI Proprietary Licensed Material Installation Lists Cycle Number Company Site City State Country Model Fuel Type of CTs rating Vattenfall AB Gotland Vattenfall Gotland Sweden Avon Unknown 1971 Virgin Islands Water St. Thomas Charlotte Avon Unknown 1971 & Power Authority Australian Newsprint Boyer Boyer...
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EPRI Proprietary Licensed Material Installation Lists Cycle Number Company Site City State Country Model Fuel Type of CTs rating UK/England Shell Oil Co Carrington Shell Avon Unknown 1968 & Wales TXU Corp UK/England TXU Europe Group West Burton Retford Nottinghamshire Avon Unknown 1968...
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Electric Power Research Institute, Inc. Printed on recycled paper in the United States of America 1004227 ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1395 • PO Box 10412, Palo Alto, California 94303-0813 • USA...
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