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Design Evolution, Reliability and Durability of
Rolls-Royce Aero-Derivative Combustion Turbines
Pedigree Matrices, Volume 6
1004227
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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 800.313.3774 ▪ 650.855.2121 ▪ askepri@epri.com ▪ www.epri.com
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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, O
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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 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:
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PRODUCT DESCRIPTION Competitive pressures are driving power generators to exploit aviation combustion turbine technology to create more efficient and powerful generation plants at lower cost. However, the use of aero-derivative combustion turbines (third generation or "next generation") carry a degree of technical risk because technologies incorporated into their design push them to the edge of the envelope. This report reviews the design evolution and experience base of advanced Rolls-
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introductions as design changes go from the ‘drawing boards’ into production testing at a customer’s site early in the learning curve. The absence of long-term experience with the technology raises issues of reliability and durability. For specific models and components, chronic durability problems could result in insurability issues potentially undermining a project’s financial structure. Applications, Values & Use This report, along with EPRI’s previously published design evaluatio
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ACKNOWLEDGMENTS 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. for providing current reliability statistics for the Rolls-Royce engines reporting to the ORAP database. vii
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EPRI Proprietary Licensed Material CONTENTS 1 INTRODUCTION ....................................................................................................................1-1 Risk Trends ...........................................................................................................................1-3 Current Technology Trends Related to Industrial Combustion Turbines: Low Risk ........1-3 Applied Aero Technology Trends Directly Transferred to Industrial Combustion Turbines
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EPRI Proprietary Licensed Material RAM Assessment..................................................................................................................3-4 Conclusion ............................................................................................................................3-4 4 BIBLIOGRAPHY ....................................................................................................................4-1 Literature Citations ................................
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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 xi
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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 St
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EPRI Proprietary Licensed Material 1 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. The economic pressure of a market moving towards deregulation intensifies this risk of new technologies. Whereas in the past new products were
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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 x 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. The application of these processes is inevitable under the pressure of the power generation in
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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. The subsections below discuss these trends
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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: • Advanced compressor designed flow paths − Controlled diffusion airfoils − Multiple circular arc airfoils − Double circular arc airfoils − 2D and 3D aerodynamics
