Sub Project 1 Whole Engine Integration Andrew Rolt, Rolls-Royce plc. European Engine Technology Workshop Warsaw,
SP1 Whole Engine Integration Introduction and Objectives Development of the four advanced cycle concepts Specification of turbofan engines for 2020 using the NEWAC technologies Performance modelling, aero and mechanical design studies Optimisation of concept engines using NEWAC technologies Intercooled Recuperative Core Intercooled Core Active Core Flow Controlled Core Techno-Economic and Environmental Risk Assessment (TERA2020) Global CO2 and NOx emissions assessments Assessment of costs and benefits of individual NEWAC technologies Comparisons with reference engines, some of which are identical to the VITAL SP1 study engines while others are new or scaled designs Combining NEWAC and VITAL technologies to meet ACARE targets 2
SP1 Whole Engine Integration Assessment of Benefits and Impact Technical approach: - Study engines are sized for one or two sets of thrust requirements defined by Airbus for future long-range and short-range aircraft - 2 aircraft configurations and 4 engine configurations - Specify and assess based on traditional, detailed approach - TERA2020 software to conceive and assess engines with - - minimum global warming - lowest cost of ownership Typical flight cycle Short Range Long Range - Assessment of the 4 engine configurations to meet ACARE 2020 objectives - Novel combinations of NEWAC and other emerging technologies BPR = 10 BPR = 12 Parametric studies BPR = 14 3
SP1 Whole Engine Integration Work Packages Work Package 1.1 - The NEWAC baseline study engine cycles are specified and their performance and mechanical designs are being assessed and compared with reference study engines from earlier EU programmes such as ANTLE, CLEAN and VITAL, to identify costs and benefits of NEWAC technologies Work Package 1.2 - New combinations of NEWAC and previous EU funded technologies have been defined and the new concept engines are being examined and assessed to see if the overall ACARE targets can be met Work Package 1.3 - The baseline NEWAC engines have been modelled using the TERA2020 software developed in the NEWAC, VITAL and DREAM programmes - The software is facilitating sensitivity studies and optimisation studies - TERA2020 is extending the scope of the SP1 whole engine assessments by providing a tool for the rapid evaluation of variant engine designs 4
SP1 Whole Engine Integration Partners in SP1 WP1.2 Integration & Optimisation WP1.1 Specification & Assessment Airbus Rolls-Royce Deutschland Techspace Aero Turbomeca AVIO MTU Aero Engines Rolls-Royce plc Snecma Volvo Aero Cranfield University WP1.3 TERA2020 Chalmers University of Technology Technical University of Athens University of Stuttgart 5
SP1 Whole Engine Integration Intercooled and Recuperated Engine Technologies Researched in NEWAC IRA engine incorporates geared fan from VITAL engine study Improved centrifugal compressor Installation of recuperator modules optimised Concept assessed at the larger engine size for the longrange aircraft application Alternative compressor designs Lean Premixed Pre-vapourised combustor 6
SP1 Whole Engine Integration Intercooled Core Technologies Bypass duct offtake and cooling air inlet ducting Intercooler modules HP compressor aerodynamics Lean Direct Injection (LDI) combustor Direct drive singlerotation fan Concept assessed at two engine sizes for long-range and short-range aircraft applications New intercase structure HP inlet and outlet ducting for intercooler HP compressor tip injection and tip clearance control 7
SP1 Whole Engine Integration Active Core Technologies Smart Compressor - Active Surge Control System Improved Sensors Active Cooling Air Cooling with new heat exchangers, valves and combustor case Active core engine also incorporates geared fan from VITAL engine study Assessed at two engine sizes for short-range and long-range aircraft applications PERM or LDI combustor Active tip clearance control system 8
SP1 Whole Engine Integration Flow Controlled Core Technologies Counter-rotating fan and LP turbine design from VITAL programme Aspirated blading Advanced HP compressor design Concept assessed at two engine sizes for short-range and long-range aircraft applications Tip flow control Improved rotor path lining material PERM or LDI combustor Active stall control 9
WP1.3 Techno-Economic and Environmental Risk Analysis - TERA2020 Software and Engine Modelling Structure and Flow Chart P main BPD Examples - Performance Modelling and Results: 1.05 CAC Tin T main BPD BPR 1.10 1.00 OPR SFC FN T/O TOC MCr +/-2% CAC Pin 0.95 Fan Mass Flow CAC Mass Flow 0.90 Fan OD PR W HPC exit Fan ID PR HPC Mass Flow HPC PR HPC Tin HPC Pin LPC PR LPC Tin LPC Pin 10
TERA2020 Organisation European Engine Technology Workshop SOPRANO Turbomatch SOPRANO Sky Simulation Turbomatch PROOSIS Sky Simulation PROOSIS VITAL VITAL SPs SPs NEWAC SPs NEWAC SPs DREAM SPs DREAM SPs CU Engine Performance CU Aircraft Performance Engine Performance Aircraft Performance Global Maintenance warming potential cost Maintenance cost Emissions (NEWAC & DREAM) USTUTT Unit Cost Unit Cost CHALMERS Engine Layout Layout Engine Weight ISAE Noise (VITAL & DREAM) Noise (VITAL & DREAM) Emissions (VITAL) NTUA Emissions (VITAL) Engine Performance (NEWAC) Global warming potential Emissions (NEWAC & DREAM) USTUTT CHALMERS ISAE NTUA Engine Performance (NEWAC) VITAL NEWAC DREAM VITAL NEWAC DREAM 11
SP1 Whole Engine Integration Conclusions and Outlook Each of the four concepts shows some benefits at the whole engine level Final WP1.1 assessments will be made in 2010 As part of WP1.2, three further new engine concepts have been proposed, each incorporating a wider range of NEWAC and VITAL technologies these will be assessed to see if they can beat the ACARE targets TERA2020 is being demonstrated as an effective tool for preliminary design sensitivity and optimisation studies in WP1.3 12