Advantages of Aero-Derivative Gas

Turbines in Industrial Applications:

Technical, Operational and Financial Considerations on Equipment Selection
By David Vyncke-Wilson (Rolls-Royce Canada)

Benjamin Moey
October 2013

2013 Rolls-Royce plc

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 upon 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.

Trusted to deliver excellence

Rolls-Royce Proprietary Information
Contents

Energy Market Drivers

Power Plants Investment Considerations

Available Generation Technologies

Gas Turbine Technology

Aeros vs Frames

Rolls-Royce Proprietary Information

Setting the global scene

Climate
Energy Energy
Economics Change
Security Stability
(Emissions)

Rolls-Royce Proprietary Information

Global Energy Drivers
Global Energy Mix
Energy Availability of Supply (Shale)
Security Energy Mix

Energy Renewables
Stability Supply-Demand Matching

Price Fluctuations
Energy Intensity
Economics Cost of Available Technologies
Energy Efficiency

Climate Emissions
Change Natural Disasters

Source: BP Energy Outlook 2013

Rolls-Royce Proprietary Information

The Asian Context
Asia - manufacturing hub of the world, continues to rapidly urbanising,
industrialising and is craving for more energy for sustained high growth

ASEAN: Projected Total Primary Energy Needs 2030

2020

30% increase

Total: 687 Mtoe Total: 899 Mtoe

Source: IEA2011
Little change in the energy mix but an overall 30% increase primary energy demands.

Rolls-Royce Proprietary Information

Key Investment Considerations: Power Plants
Available Sources of Power Generation
Capital Expenditure
Operational Expenditure (Cost of fuel, maintenance)
Build time - Leadtime to commission/operation
Policies
- Government Subsidies
- Environmental Regulations (Emissions level)

The current buzzword in the industry is

Distributed Generation

Rolls-Royce Proprietary Information

Available Sources of Power Generation
Clean Energy Fossil Fuels
High CapEx Ease of access
High Risk Emissions
Dwindling Supply
Electric LOC (est 18) Construction
Oil
Power US$/MWhr Period (Yr)
Coal-Fired 100.1 3
Nuclear Coal
Gas-Fired 67.1 2
Solar 144.3 0.5
Hydro 90.3 4-10
Power Nuclear 108.4 6-8
Wind Gas
Generation
86.6
Wind 2
221.5#
# denotes offshore wind

Tidal Solar Optimal Option?

Renewables
Hydro High CapEx
Instability
Rolls-Royce Proprietary Information
Industrial Application: Gas Turbine Technology
What are the common industrial applications

Combined Cycle Gas Turbine Plants (CCGT)

Co-Generation Plants (CoGen)

Simple Cycle Gas Turbine Plants (SC)

Combined Heat and Power Plants (CHP)

Rolls-Royce Proprietary Information

Gas Turbine Technology
Aero-Derivative Heavyweights/
Light Industrials Hybrid
Gas Turbine Frames

Siemens SGT750 GE LMS100 GE MS5002 Frame 5

Rolls-Royce Trent 60 WLE
(Courtesy Siemens) (Courtesy GE Energy) (Courtesy GE Energy)

Very high power density
Low weight & Small
footprint
High efficiency (significant
fuel savings)
High cycle flexibility
Fast start and transient
capability
Short downtimes for
maintenance
Designed to keep some of
the pluses in Frames/
Heavyweights such as
material cost and life, and
combine them with the
footprint and flexibility of
an aero-derivative
Uses an aero-derivative at
the heart of the machine
but adds on an industrial
compressor and
intercooling system for an
increase in power
High power output
High combined cycle
efficiency
Lower emissions
Lower initial capital
expenditure cost
Single shaft machines tend
to have quick reaction times
to large step load changes

Rolls-Royce Proprietary Information

Aeroderivative (Aeros) Gas Turbine

Trent 800

Trent 60

Aircraft Engine Industrial Gas Turbine

Intermittent operation over short period Continuous operation over long periods
Wide range of altitudes experienced Narrow range of altitudes experienced
Only high grade aviation fuels used Wide range of liquid and gas fuels used
High & cruise power used every flight cycle Base/part load operation over long period

Rolls-Royce Proprietary Information

Aeros vs Heavyweights/Frames
- Technology
Characteristics Typical Aeros Typical Heavy Aero Benefit
Skid Dimensions 395 ft2 515 ft2 30% less footprint
More transportable
Reduced foundation
requirements
Faster installation times
Thermal Efficiency 37 - 42% 28 34% High efficiency equates to
savings on fuel expenditure
Operational Multiple lower power Single high power unit Ability to split or share load
units whilst maintaining fuel
Flexibility efficiency
Driver Skid Weight 60 tonnes 120 tonnes Reduced foundation civil works
required
Single heaviest ~ 5 tonnes 10 15 tonnes Requires lower lifting capacity
onsite
maintenance lift

Rolls-Royce Proprietary Information

Aeros vs Heavyweights/Frames
- Operations
Characteristics Typical Aeros Typical Heavy Aero Benefit
Start-up Cold to full load in 10 Fast starts but with adverse Faster response times to
minutes without impact impact to cycle life customer power demands
on cycle life No fast start capability on larger Ability to break away large
Start with only ~350kw heavy weights levels of torque with small
Helper motors required starter motor
Acceleration Rapid Slower Accept load faster
Idle-to-full load in 2mins 10 15mins Standby turbine rapidly
to load online when required
Heavy can experience
critical dynamic thermal
stressing
Deceleration 5 15mins ~ 30 60 mins Ready for maintenance
quicker
Cooling Rapid (< 1hr) Requires 10 24 hrs Less downtime, and cost

Immediate re- Yes (dependent on If no restarted within 10mins, a Higher start availability
engine type) full machine cool down required Less idle time
start

Rolls-Royce Proprietary Information

Aeros vs Heavyweights/Frames
- Maintenance
Characteristics Typical Aeros Typical Heavy Aero Benefit
Hot section Through borescope holes Requires removal of fuel Faster inspections, less
for entire gas generator and nozzles and combustors. downtime and lower cost
inspection power turbine
Turbine Incorporated into annual Inspection in ~ 160 hrs not Faster inspections, less
inspection and is not a including cool down time downtime and lower cost
Inspection separate shutdown
(hot gas path)
Annual Takes ~ 30 hrs or 3 x 10 hr Takes ~ 6 -15 days depending Faster inspections, less
shifts. Heavy equipment not on the scope of work downtime and lower cost
Inspection necessary Less manpower required
Detailed Normally not required, just 10 days, may require heavy Less downtime and cost
borescoping sufficient lift equipment for non-in-situ resulting from loss of
Compressor re-blading availability
Inspection
Gas Generator Engine stop to full load in Very limited, 20-28 day Significantly less downtime
48hrs or 4 x 12 hr shifts shutdown. Large manpower and labour costs.
Change out requirement

Rolls-Royce Proprietary Information

 Trending towards Aero-derivative Gas Turbine
Technology
- Distributed Generation (at point of use)
Generation at the point of use
Transmission Losses
High Fuel Low
Efficiency Flexibility Maintenance
Supply-Demand Matching

Fast Installation
Aero-derivative High
Fast Start Fast Build
Gas Turbine Efficiency
Captive Power

Remote Location Small Optimal

Operational Low
Flexibility Emissions Footprint Size
Flexible Operations

Rolls-Royce Proprietary Information

Summary

Aero-derivatives offer the end user many advantages such as

availability, reduced maintenance, higher efficiency and operational
flexibility

Heavy-weights have advantages in its capability to burn low quality

fuels but comes at a cost of much reduced thermal efficiency and
increase lifetime fuel cost.

Distributed Power Generation is a growing trend in emerging global

markets, and the aero-derivative gas turbine technology is a strong fit in
this space.

Rolls-Royce Proprietary Information

 Better Power for a changing world

Contact information
Benjamin.Moey@rolls-royce.com

Rolls-Royce Proprietary Information