Rolls-Royce Avon 200 industrial gas turbine upgrade hits 100 000 hours

An upgraded Rolls-Royce industrial gas turbine, which incorporates advanced technologies used in the latest generation of Rolls-Royce aero engines, has achieved more than 100 000 hours of faultless operation.

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The Avon 200 life extension upgrade, which delivers increased power, efficiency and component life, was launched in 2007. Forty engine kits have been ordered by operators in nine countries, with 18 now delivered.

The industrial Avon is one of the most successful industrial aero-derivative gas turbines ever built, accumulating more than 60 million operating hours. It has established an unparalleled record for reliability and availability in the oil and gas and power generation industries.

Total orders exceed 1200 units, with more than 800 still in service worldwide. Avon 200 upgrades are suitable for Avon 1533, 1534 and 1535 models.

The Avon 200 can deliver 8.9 per cent more power and 4.4 per cent better thermal efficiency. It provides extended mean times between overhauls (from 30 000 hours to 36, 000 hours) if operated at the current base rating. In addition, improved mechanical design helps to reduce life-cycle costs. When operating at the enhanced or current base rating, significant reductions in CO and CO2 emissions can also be expected.

Robert Wallace, Sales and Marketing Director of the Energy Customer Service Business, said: “The newly upgraded Avon 200 is a significant new addition to our portfolio. It delivers value for Avon operators worldwide by setting new standards for power, efficiency, life cycle costs and environmental impact.

“Avon operators want their gas turbines to operate for longer periods before major maintenance is required and they also want to mitigate the effects of high cycle fatigue brought on by fuel quality issues. The Avon 200 delivers this and more.”

Petrobras were first to order an Avon 200 upgrade for one of their engines in service on the P18 platform offshore Brazil. In addition, half of the current Dubai Petroleum Avon fleet operating on offshore gas platforms in the Gulf will be upgraded.

Before entry into commercial service, a demonstrator Avon 200 performed a closely monitored endurance run at the Clarkson Valley natural gas compressor station on TransCanada Corporation’s Alberta, Canada System pipeline.

The same development engine also underwent hot weather trials in Dubai prior to the order from Dubai Petroleum.

Mitsubishi unveils 66.1 per cent efficient gas engine

Mitsubishi Heavy Industries, Ltd. (MHI) has developed and begun operational verification testing of the “MACH II-SI,” a new gas engine featuring enhanced energy efficiency and reliability.

The MACH II-SI was developed based on the company’s existing “MACH-30G,” which many units have been sold in Japan; but whereas the forerunner uses a “micro-pilot ignition” system, the new MACH II-SI adopts a spark ignition (SI) system that eliminates the need for auxiliary liquid pilot fuel such as light oil.

In developing MACH II-SI, MHI focused on further enhancement of the efficiency leveraging its abundant experience accumulated in its existing engines.

As a result, the new engine has achieved efficiency – combining power generation and heat energy recovery via steam – of 66.1 per cent (under the terms of ISO 3046 using gas with a methane number of 80), the world’s highest level among 6000 kW class engines, in which electric power generation efficiency has been improved by one percentage point. MHI expects the MACH II-SI series, which power output ranges from 3650 kW to 5750 kW, will significantly contributes to increasing needs for CO2 emission reduction.

To enhance overall efficiency, MHI focused on enhanced heat recovery in steam generation and effective utilization of exhaust gas energy. The company also has shortened lead-time to reach full load after engine start by 50 per cent, which contributes to enhance load-following capability.

In order to boost power generation efficiency, MHI redesigned the combustion chamber, including the cylinder cover and piston. By optimizing formulation of the fuel-air mixture, as well as improving the pre-chamber’s shape and fuel-air mixture ratio, the company has raised combustion efficiency and reduced thermal loss.

In developing the technology used to achieve these improvements, MHI applied results gained from “Development of Technology for Ultra High-efficiency Natural Gas Engine Combined System,” a joint development project under way since 2005 together with the New Energy and Industrial Technology Development Organization (NEDO) and the Japan Gas Association. Going forward, the new technologies employed in the MACH II-SI to enhance power generation efficiency will also be applied to existing MACH engines with the micro-pilot ignition system.

MHI conducted the testing of the actual MACH II-SI engine – to confirm start-up performance, engine performance and control system – last summer at the company’s Yokohama Machinery Works. As all targeted goals were achieved, the new engine has now progressed to the next stage of testing, including durability testing, toward final verification of its enhanced reliability.