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The Rolls-Royce Trent Engine

The Rolls-Royce Trent Engine. Michael Cervenka Technical Assistant to Director - Engineering & Technology. 5 October 2000. Rolls-Royce Today. World No 2 in aero-engines World leader in marine propulsion systems Developing energy business Annual sales of over £4.5 billion

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The Rolls-Royce Trent Engine

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  1. The Rolls-Royce Trent Engine Michael Cervenka Technical Assistant to Director - Engineering & Technology 5 October 2000

  2. Rolls-Royce Today • World No 2 in aero-engines • World leader in marine propulsion systems • Developing energy business • Annual sales of over £4.5 billion • Orders of over £13 billion

  3. Equilibrium Reaction Action Newton’s 3rd Law MV Thrust = Mass x Velocity (MV)

  4. Propeller versus Jet Propulsion Propeller - moves LARGE MASS of air at low velocity Mvjet Mvaircraft Thrust = M(vaircraft - vjet) Thrust = m(Vaircraft - Vjet) Jet - moves small mass of gas at HIGH VELOCITY mVjet mVaircraft

  5. Jet Engine Layout Combustion Chamber Exhaust Nozzle Compressor mVaircraft mVjet Turbine Shaft

  6. Different Jet Engine Types Civil turbofan - Trent Military turbofan - EJ200

  7. Different Jet Engine Types - Mechanical drive Turboprop - AE 2100 Turboshaft - RTM322 Marine Trent Industrial Trent

  8. Air intake Exhaust Intermittent Compression Combustion Continuous Air intake Exhaust Piston Engine versus Turboprop Piston engine Jet engine driven propeller (Turboprop)

  9. Pressure and Temperature 40 Pressure(atmospheres) 0 1500 Temperature (degrees C) 0

  10. Axial Compressor and Turbine Operation

  11. Axial Compressor and Turbine Operation Compressor Stages Turbine Stages Rotating Rotor Row Rotating Rotor Row Rotating Rotor Row Rotating Rotor Row Gas flow Airflow Stationary Nozzle Row Stationary Nozzle Row Stationary Vane Row Stationary Vane Row

  12. Multiple Shafts - Trent 95,000 lbs Thrust LP System 1 Fan stage 5 Turbine stages >3,000 rpm IP System 8 Compressor stages 1 Turbine stage >7,500 rpm HP System 6 Compressor stages 1 Turbine stage >10,000 rpm

  13. Combustor Operation

  14. Combustor Operation Primary zone Dilution zone Intermediate zone Fuel spray nozzle

  15. Net 25% to 30% thrust 85% thrust 15% thrust Reverse Thrust

  16. New Product Introduction Process Stage 1: Preliminary Concept Definition Preliminary concept defined for planning purposes Product definition stages Stage 2: Full Concept Definition Full concept defined, product launched Stage 3: Product Realisation Product developed, verified and approved Stage 4: Production Product produced and delivered to customer Capability Acquisition Stage 5: Customer Support Product used by customer

  17. New Project Planning Process BUSINESS MODEL Units sold Unit Cost Selling Price Concessions Sales Costs Development Costs Guarantee Payments Spares Turn Spares Price MARKETING MODEL Market Size Selling Price Concessions Operating Costs Payload Range Maintenance Costs Fuel Burn Commonality ENGINEERING MODEL Safety Unit Cost Weight Noise Emissions Geometry Reliability Operability Performance

  18. 102 Million Hours of Service RB211 & Trent operating hours August 2000 -22B 26.7 million hours -524 48.5 million hours -535 25.4 million hours Trent 2.2 million hours 4260 engines ordered 3592 engines delivered 103 customers currently flying with RB211 or Trent engines Million hours 100 Trent 800 90 Trent 700 80 70 60 50 -535C 40 -524D -535E4 30 -524 -22 20 -524H -524G 10 0 1972 1974 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 Entry into service

  19. Range Fuel consumption Acquisition Cost Maintenance • Requires high: • - Overall pressure ratio • - Turbine entry temperature • - Bypass ratio • Simpler engine, hence moderate: • - Overall pressure ratio • - Turbine entry temperature • - Bypass ratio Three-Shaft Configuration Two-Shaft Configuration Why 3 Shafts? Long / Medium-Haul(40,000-100,000lbs thrust): Short / Medium-Haul(8,000 - 40,000lbs thrust):

  20. Fan diameter - in. Trent 900 Trent 800 Trent 8104 Boeing 777 110 Airbus A3XX 80,000lb 95,000lb 104,000lb Scaledcore Scaledcore Trent 700 Trent 500 Trent 600 Airbus A330 97.5 65,000lb 72,000lb 56,000lb Boeing 747 RB211-524G/H-T Airbus A340 86.3 60,000lb Boeing 767 Evolution of Trent Family

  21. Phase 5 low emissions combustor Single CrystalUncooled IP turbine blade Single crystal HPT Fan diameterincreased to 2.8m (110.3in.) Trent 800 Five-stageLP turbine Four-stageLP turbine Fan diameter2.47m (97.4in.) Area of significant commonality Area of main geometric change Trent 700 8 Stage IPC 3 Variables Trent 700 & 800

  22. Scaled IP & HP compressor 3D Aerodynamics Scaled combustor with tiled cooling HP & IP turbines have increased blade speedsHigh lift LP turbine blading Trent 500 Trent 700 Trent 500

  23. Material Strength Specific Strength Titanium Alloy Nickel Alloy Steel Aluminium Alloy Temperature

  24. Engine Materials Titanium Nickel Steel Aluminium Composites

  25. Wide-chord fan Clappered + 4% efficiency Fan Blade Technology

  26. 1st generation: 1984 2nd generation: 1995 Honeycomb construction DB/SPF construction Wide-chord Fan Technology

  27. Fan Section

  28. Swept Fans

  29. Compressor Aerodynamics

  30. Cold supporting wall Cast tile Thermal barrier coating Trent 500 Tiled Combustor • Tiles reduce wall cooling air requirements making more air available for NOx reduction • A significant cost reduction relative to conventional machined combustors is also achieved Large primary zone volume for altitude re-light Small total volume for NOx control Large airspray injectors for improved mixing and smoke control

  31. Improvements in Materials Equiaxed Crystal Structure Directionally Solidified Structure Single Crystal

  32. Turbine Cooling Cooling air Thermal Barrier Coating Single pass Multi-pass

  33. Performance Trends Lowbypass Mediumbypass Highbypass Straight jet 50 40 %sfc improvement(bare engine) Propulsiveefficiency 30 Cycle efficiency 20 Thermalefficiency 10 Componentefficiency Datum Avon1958 Conway1960 Spey1963 -22B1973 -524B4/D41981 -535E41983 -524G/H1988 7001994 8001995 5002000 RB211 Trent

  34. New Engine Architecture with reduced parts count, weight, advanced cooling, aerodynamics and lifing Pylon/aircraft mounted engine systems controller connected to engine via digital highway Generator on fan shaft provides power to airframe under both normal and emergency conditions Internal active magnetic bearings and motor/generators replace conventional bearings, oil system and gearboxes (typical all shafts) Electric Engine Concepts Air for pressurisation/cabin conditioning supplied by dedicated system All engine accessories electrically driven

  35. Compressor Weight Reduction Conventional disk & blades Blisk - up to 30% weight saving Bling - Ti MMC - up to 70% weight saving

  36. Metal Matrix Composites Specific Strength Titanium Metal Matrix Composite Titanium Alloy Nickel Superalloy Temperature (degrees C)

  37. Main Pilot Main Pilot Future Emissions Improvements Double-annular combustor Pre-mixed double-annular combustor

  38. Contra-rotatingfan Large diameter duct Gas generator Contra-rotating turbine Flying wing Future Aircraft Configurations Blended wing aircraft may offer up to 30% reduction in fuel consumption - 40% if combined with electric engine concepts

  39. Conclusion • The three-shaft concept is now recognised as a world leader • Customer-focused competitive technology is critical to its success • Success is a tribute to many generations of people • The RB211 & Trent family has a long and secure future

  40. Rolls-Royce

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