RB211 Gas Turbines

for oil and gas applications

Rolls-Royce Industrial RB211 G a s Tu r b i n e Systems

Rolls-Royce industrial gas turbine systems have been supplied to the worldwide oil and gas industry for four decades. With more than 3500 gas turbine systems sold and over 135 million hours of operation, Rolls-Royce is a worldwide leader serving the oil and gas industry. Rolls-Royce provides the advanced aeroderivative gas generators, combined with proven power turbines, compressors and the packaging know-how to create RB211 gas turbine systems.

The RB211 gas turbine package

The RB211 gas turbine package matches a Rolls-Royce gas generator to either a Rolls-Royce RT56, RT62 or RT61 power turbine. Auxiliaries such as intake air filtration, acoustics, lubrication, starting and wash systems are all part of the Rolls-Royce scope of supply.

RB211 systems provide an ideal solution for todays applications. Application versatility provides yet another reason why RB211 gas turbines excel in the field. Simplecycle thermal efficiencies can be enhanced by adding heat recovery equipment to produce steam or hot water for local area heating, or to provide heat for refinery or petrochemical processes. Simple-cycle as complete aftermarket support. From worldwide parts inventory and skilled service technicians, to Long-Term Service Agreements and the ongoing development of performanceenhancing upgrades, the Rolls-Royce commitment to integrated solutions continues throughout the equipment life cycle.

Performance in the field

More than 411 RB211 gas turbine systems have been sold with over 15 million operating hours. Rolls-Royce gas turbine systems have been refined through experience, including remote and offshore applications where availability and reliability are of crucial importance. With superior performance retention and relative ease of overhaul,

units can be designed for ready conversion to combined-cycle at a later date. This approach minimizes initial capital expenditures without sacrificing long-term unit capabilities. A primary factor in the success of the industrial RB211 is the Rolls-Royce dedication to excelling in project management as well

Rolls-Royce RB211 Gas Generator

Trusted performance
The industrial RB211 is a twin shaft design derived from the aero RB211, with a performance lineage founded in Boeing 747 and Lockheed 1011 (Tristar) applications. Through continual engineering and development, the RB211 has become the most advanced, reliable, and easiest to maintain industrial gas generator available. The Dry Low Emissions (DLE) version of the RB211 offers the same reliability and maintainability as the Single Annular Combustor (SAC) RB211. Today the RB211 DLE is the most experienced aeroderivative low emission gas generator available. The industrial RB211 is less than 3 meters (10) long and weighs just over 2.5 metric tons (2.75 U.S. tons). The DLE version maintains the overall length of the standard engine so it fits into existing installations.

Maximum efficiency
A single row of variable position inlet guide vanes in the low speed compressor module, combined with bleed valves and the twin shaft design, allow for lower power starting and optimum performance over the engine speed range. Guide vane position is automatically adjusted to provide maximum efficiency.

Fuel flexibility and DLE option

The standard RB211 gas generator employs a single annular combustor fitted with multiple fuel injectors. The combustion system can be configured for gas, liquid or dual fuel capability. The combustion chamber is lined inside and out allowing for the introduction of air for cooling and dilutions.

The DLE combustion system is comprised of nine combustors spaced radially around the engine casing. Thanks to the RB211 modular design, the replacement of the 04 module is the only engine modification required to retrofit SAC engines to the DLE system. The DLE canister combustors also offer simplified maintenance of the combustion system. Each combustor can be removed individually in less than an hour for inspection or repair without removing the engine from its berth.

Modular construction simplifies maintenance

The RB211 gas generator is constructed of five pre-balanced modules that can be removed or replaced individually. The design reduces downtime and maintenance costs by allowing an individual module to be replaced on-site with a new or leased module while the original module is repaired or overhauled.

Low Emissions Technology

As the innovator of Dry Low Emissions (DLE) technology, Rolls-Royce has remained steadfast to the original design concept: lower emissions without sacrificing the respected RB211 reliability and ease of maintenance. Through a pre-mix, lean-burn series staged combustion system, the RB211 DLE lowers emissions while offering the proven dependability of the standard RB211. The Rolls-Royce En-Tronic fuel control system provides the precise fuel management necessary to ensure consistent lower emissions levels. This system includes only four fuel valves for fuel scheduling, assuring high reliability.

Low emissions over a wide operating range less than 25 vppm NOx and CO simultaneously Most experienced aeroderivative low emissions gas generator available, with over 2,000,000+ operating hours Designed for simple retrofit of existing non-DLE engines Replacement of only one module required for DLE system Same overall length to fit existing installations

The Power urbine Tu

The RB211 package includes RT56, RT62 or RT61 power turbines. The turbines are mature products that provide high efficiency over a broad range of operating conditions. The two-stage RT56 was developed in the early 1970s as a match for the first generation RB211 gas generator. In the mid 1980s the two-stage RT62 was introduced to take advantage of the higher power of the RB211 as it became available. The RT61 is the latest-generation high efficiency three-stage power turbine, designed to accommodate future growth of the RB211, offering the highest power and efficiency in its class.

Several trends in aerodynamic design have been central to the development to improve power turbine efficiency. They include:
Short bearing spans for maximum rotor stability. Optimum rotor diameter allowing favorable blade velocity and stage loadings. The gas generator is close-coupled at the optimum distance from the power turbine.

Mechanical design features in Rolls-Royce power turbines include:

By using a front support, flow impeding exhaust struts have been eliminated from the gas path. The exhaust diffuser is designed to optimize work extraction efficiency. Interlocking, shrouded blades with honeycomb tip seals. Rotor disk cooling. Overhung rotor of forged aerospace quality materials. High nickel, chromium and molybdenum content alloys in hot components. Optional integrated auxiliary drive for powering lubrication, seal and hydraulic oil systems.

Added Efficiency of Auxiliary Systems

Air intake systems
The air intake system provides a clean, uniform airflow to the gas generator. It is comprised of a filter assembly, silencer and flow direction geometry to properly maintain the incoming air. Careful site design assures that the filter house is located to minimize disruptions of inlet air flow. Gas turbine filtration systems are configured to suit the demands of specific operation environments, whether offshore, onshore or inland. Filtration requirements vary significantly with systems ranging from single to multiple stages. Self-clean pulse filter systems can offer an effective, low maintenance alternative for high dust load environments. High-efficiency, multi-stage systems are engineered to combat corrosion in offshore and coastal installations. In cold climates icing and frost conditions are controlled using a pulse type filter. In hot climates, evaporative intake cooler or intake chiller can be added to lower intake air temperatures for improved performance. The Rolls-Royce Radial Intake configuration enclosure is a standard feature which offers exceptional efficiency, including the cost savings of all piping and wiring being installed at the factory. After testing, the unit is shipped with all connections intact, allowing for simplified site installation and commissioning. Lighting, ventilation, fire safety system and access doors are pre-installed. This design also includes a maintenance hoist and large side doors, or removable roof panels, for equipment changeout.

The gas turbine enclosure

Acoustic enclosures are available to meet a wide range of requirements, from weatherproof outdoor structures to enclosures customized to fit within existing buildings. Construction features sound absorbent materials to meet occupational noise level requirements.

Lubricating oil systems

The gas generator uses synthetic oil, which is provided by an on-skid oil console, to lubricate the bearings and dissipate heat. The console incorporates two identical pumps, one for active and the other for standby duty. The power turbine, gear (where applicable) and driven equipment share a separate mineral oil lubricating system. This system can be placed within the skid or on a separate console. It provides low pressure oil to the power turbine and driven equipment bearings as well as high pressure oil to compressor seals when oil film seals are required. Oil cooling is accomplished with either a forced air radiator, plate coolers or shell and tube heat exchangers. Overcooling is avoided by using thermostatic controls that maintain proper oil temperatures by means of bypassing oil around the cooler.

Equipment coupling
Dry flexible couplings are the preferred method for transmitting power between the power turbine and the driven equipment. These couplings require no lubrication and do not impose excessive axial or radial loads on the power turbine or driven equipment. Torque metering couplings can be supplied as well. When applications require an increase or decrease of shaft speed that exceed the standard speed range, a gear is introduced into the power train to assure the output speed matches the requirements of the driven equipment.

Gas generator wash system

Wash systems prevent the build-up of contaminants in the gas generator compressor that could cause deterioration in performance. The wash system consists of storage tanks, pressure gauges, valves, piping and either a pump or compressed air supplied by others. The wash cycle can be run during either a starter driven crank soak cycle or during gas generator operation.

Gas turbine starting

Starting the RB211 requires only approximately 200 HP. Starting options include air, gas, and electro-hydraulic systems which are incorporated into the base. When self-sustaining speed is achieved, the starter is automatically shut-off.

Automation and Control Systems

The basis of the Flexitrend control system is a state-ofthe-art programmable logic controller technology and hardware along with a variety of communication options that provide reliable performance with ease of maintainability and flexibility. The system provides real time monitoring and Rolls Royce provides complete automation solutions for gas turbines utilizing our Flexitrend controls algorithms. Flexitrend agorithms are coded using programmable logic controllers with independent safety shutdown systems. With decades of experience in designing control systems, Rolls-Royce engineers are uniquely qualified to offer solutions for any size project i.e. from turbine compressor sets, turbine generator sets to complete station control systems. control of turbine critical functions including: sequencing, speeds, guide vane positioning, EGT limiting, dry low emission, water injection and data event logging. The gas turbine controls offer either local or remote modes of operation. Viewing of the operating parameters is available locally or remotely via an FT210 PC. Easy-to-use software allows programming for initial operation and provisions for future changes.

Factory Te s t i n g
Rolls-Royce has extensive test facilities in both North America and Europe to ensure that each unit conforms to exacting performance objectives. Each gas turbine undergoes an API mechanical running test prior to shipment. Optional API tests are available on request, including complete package full load string testing and ASME PTC22 testing using either liquid or gaseous fuel over the complete range of speeds and loads of the RB211 gas turbine family.

Te c h n i c a l Tr a i n i n g
From the first day of start-up, the expertise of operating and support personnel is central to the productivity of every major equipment installation. Through the years, Rolls-Royce has trained thousands of operators, mechanics, technicians, engineers and supervisory support personnel to achieve the safe and economical operation/maintenance of RB211 packages. Measurable benefits include reduced downtime, increased fuel savings, reduced liability risk and extended equipment life cycle. In addition to OEM expertise, our professional instructors offer the insight of real-world experience. A professional training consultant is also available to evaluate individual training needs and develop customized curriculum for application-specific training. Rolls-Royce dedicated training facilities feature fully-equipped classrooms, equipment models and control systems simulating working conditions for indepth, hands-on training. On-site training, based on the proven learning strategies used in our training facilities, is also available.

Worldwide Support
From the moment you become a valued Rolls-Royce customer, you enter into an ongoing partnership that is totally focused on maximizing your profitability and unit availability. Rolls-Royce has earned the reputation as a leading supplier capable of sustaining optimum performance as a result of our commitment to integrated solutions. Solutions are delivered through Rolls-Royce global resources to satisfy individual needs:

Rolls-Royce global resources,

including multi-national manufacturing facilities, ensure that tight delivery schedules are met. Installation and commissioning are carefully monitored so the proper people, tools and equipment are on-site when needed.

field modification as required. And our experienced instructors offer technical training for efficient and safe operations.

Quality replacement parts and expert maintenance service. Inventories of critical parts,
as well as skilled service personnel, are located among the worlds energy capitals to assure prompt service. Sophisticated tracking systems also provide access to complete part inventories worldwide.

Project management begins

with a detailed activity network and schedule to determine the critical path for project completion. A complete activity manual, updated through periodic project reports, keeps the customer informed of project status. Computer-based projections can accommodate unforeseen contigencies to keep activity on-track.

Long-term service agreements designed to control

your maintenance budget while increasing the availability of your equipment. Benefits include early problem diagnosis for lower maintenance costs, decreased fuel and lubrication oil consumption, increased availability and reliability, and extended unit life.

Experienced, highly trained, technical field personnel

backed by the worlds most respected engineering staff to provide expertise on unit design, application, repair and

Engineered solutions, including

upgrades based on comprehensive system history and key performance indicators established in our technical support networks. The result is a retrofit investment that improves the customers operation as promised!

financial resources to provide sustained, comprehensive service? At Rolls-Royce, we have demonstrated that the answer is yes. Most importantly, we are working today to increase the range and scope of customer service solutions in order to meet tomorrows challenges. A prime example of this commitment to the future is our on-line service community at www.energymanageronline.com which provides customers with access to our technical documentation every second of every day!

Technical training from

experienced instructors, based on proven hands-on methods, to assure operating and support personnel positively contribute to productivity. Perhaps the most important question, when making a choice among capital equipment suppliers, is Does the supplier have the commitment and

The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied, without the express written consent of Rolls-Royce plc. This information is given in good faith, based on the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.

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Note: Standard equipment, specifications and data are subject to change without notice. EO200NA-8/05-3M Copyright 2005 Rolls-Royce plc. Printed in U.S.A.