The Gas Turbine Electrical

The Gas Turbine Electrical
Power Generation Market
Product Code #F646
A Special Focused Market Segment Analysis by:

Gas Turbine Forecast
Analysis 3
The Gas Turbine Electrical Power
Generation Market: 2007-2016
Table of Contents
Table of Contents .....................................................................................................................................................1
Executive Summary .................................................................................................................................................2
Introduction................................................................................................................................................................3
Format and Methodology........................................................................................................................................5
Trends and Competitive Environment ................................................................................................................7
Manufacturers Review.............................................................................................................................................8
Market Statistics .....................................................................................................................................................16
Table 1 - The Market for Gas Turbine Electrical Power Generation
Unit Production by Headquarters/Company/Program 2007 - 2016 ...............................................20
Value Statistics by Headquarters/Company/Program 2007 - 2016 ................................................27
Figure 1 - Gas Turbine Electrical Power Generation
Unit Production 2007 - 2016 (Bar Graph) ..............................................................................34
Value of Production 2007 - 2016 (Bar Graph)........................................................................34
Unit Production % Market Share by Headquarters/Company 2007 - 2016 ...................................35
Value Statistics % Market Share by Headquarters/Company 2007 - 2016 ....................................37
Unit Production % Market Share by Headquarters 2007 - 2016 (Pie Chart) ...........................39
Value Statistics % Market Share by Headquarters 2007 - 2016 (Pie Chart)............................39
Conclusion ...............................................................................................................................................................40
* * *
©
2007 August 2007
Product Code F646 The Gas Turbine-Powered Electrical Power Generation Market
PROGRAMS
The following reports are included in this section: (Note: a single report may cover several programs.)
Heavy Gas Turbines (11,185 kW and Larger)

Alstom GT 8/11/13
Alstom GT24/GT26
GE LM1600
GE LM2500
GE LM6000
GE LMS100
GE Model 5000
GE Model 6000
GE Model 7000
GE Model 9000
General Electric GE-10
Hitachi H-25
Kawasaki L20A
Mitsubishi MF-111
Pratt & Whitney Power Systems FT8
Rolls-Royce Industrial Avon
Rolls-Royce Industrial RB211
Rolls-Royce Industrial Spey
Rolls-Royce Industrial Trent
Siemens SGT-400
Siemens SGT-500
Siemens SGT-600/700
Siemens SGT-800
Siemens SGT5-2000/3000/4000
Siemens Westinghouse SGT6-3000/5000/6000
Solar Titan
Heavy Industrial & Marine Gas Turbine: Design and Development
Light Gas Turbines (Up to 11,185 kW)

Daihatsu DT Series
Dresser-Rand KG2
General Electric GE-5
Kawasaki M1A/M1T Series
Kawasaki M7A
Kawasaki S1/S2 Series
MAN TURBO THM 1200/1300
Mitsui SB5
Optimal Radial Turbine OP16
Pratt & Whitney Power Systems ST6
Pratt & Whitney Power Systems ST18/ST40
CONTINUED ON NEXT PAGE
©
2007
Rolls-Royce 501-K
Siemens SGT-100
Siemens SGT-200
Siemens SGT-300
Solar Centaur/Taurus
Solar Mars
Solar Saturn
Turbomeca Makila TI
Vericor ASE8
Vericor TF/ASE 40/50
Light Industrial & Marine Gas Turbine: Design and Development
©
2007
Introduction
Not too long ago, America woke up and realized that it machine installations, there is a positive side to
was running out of electrical power. With a growth in concerted conservation efforts in established markets.
population, a multifold increase in power-hungry First, it helps build credibility with the customer when
electronics, Western droughts reducing the output of you show concern for overall efficiency, not simply
hydroelectric power, and a long cycle of hot summers immediate profit. While many OEM’s are entering into
followed by winters so warm that people in some long-term operations and maintenance contracts, they
regions of the country needed to use their air must be realizing that steady, base-loaded machines and
conditioners year-round, demands on the providers of unencumbered transmission and distribution lines are
electrical power grew astronomically. These electrical favorable when it comes to maintenance costs and
power providers had long believed that if we all overall financial performance.
practiced energy economy, they would not have to add
Fuel cells (despite their immense appeal, due to their
new capacity in the form of power plants. Conspicuous
“relocation” of harmful emissions) are still considered
consumption continues and few people worry that every
to be in the demonstration stage, but we believe they
100-watt videogame left plugged in year-round adds
will be abundant from about 2008. Wind power, while
$140 to their annual bill. Compact fluorescent lights
commercially available, is not available everywhere; its
reduce energy consumption and are gaining acceptance,
overall efficiency is about 50 percent, and it is
but a good low-voltage LED system outshines them
expensive in the near term on a dollar-per-kilowatt-hour
without the mercury footprint. As a result, energy
basis. Nuclear power and hydroelectric plants are very
shortages in California caused problems ranging in
expensive and require a long period of hearings,
severity from brownouts and rolling outages all the way
followed by attempts to obtain financing and approvals,
up to complete blackouts. Environmentalists have
and finally, construction. Solar power is very
campaigned against new nuclear power plants, while
appealing, but shares the drawbacks of wind power – it
urging gas turbine power plants to further reduce
is not available everywhere, electrical power storage
emissions and use air-cooling as opposed to
technology is immature and cannot handle the capacity,
water-cooling. Even the indefatigable hydroelectric
and it too is expensive on a dollar-per-kilowatt-hour
power is not very effective after a warm winter with
basis.
meager snowfalls. The power need now spans all
phases of generation, from baseload to peaking to The viable alternatives are few. Above the level of
standby. microturbines, whose efficiencies range from 20-28
percent, are what we consider to be true gas turbine
When the need becomes critical, new electrical power
machines that range in power output from 200-250 kW
generation capacity can come from several sources:
at the low end to the super-high-power machines of
fossil-fuel-burning machines such as gas turbines
350+ MW. Today, gas turbine machines have
(including microturbine machines of under 250 kW) and
simple-cycle efficiencies of at least 35 percent, with
the new wave of gas engines and diesels; hydroelectric,
some approaching 45 percent, while some are advertised
nuclear, solar, and wind power; waste-to-energy plants
as already having a 60 percent efficiency in combined-
(which burn paper/wood, scrap, food waste, and
cycle.
bagasse); and exotic means such as geothermal energy,
ocean currents, and fuel cells. What does past performance predict? While gas turbine
machines continued to be ordered and fabricated for
Lack of storage capability is the major drawback of
electrical generation for their usual end uses (continuous
intermittent sources of energy, such as wind and solar.
duty, standby duty, and peaking duty), the lower-
Batteries and fuel cells are one area where development
powered gas turbine machines, those up to 3.5-4 MW,
is lagging. In the 1950s, Buckminster Fuller proposed a
have traditionally been employed in standby duty. As
Global Electrical Grid around the North Pole to transmit
we move up the power spectrum, the normal-use shift
solar energy from the day side to the night side of the
toward continuous duty becomes more noticeable at the
Earth. Not immediately practical, developments in high-
power level of 20-30 MW. At 120-125 MW and larger,
temperature superconductors may make this a long-term
virtually all gas turbine machines have been/should be
possibility. It is far more likely that this will not happen
ordered for use in continuous generation duty.
until all of the undeveloped petroleum reserves near the
Arctic Circle have been depleted. Given the current need for new baseload capacity, as
well as for power plant capacity additions, Forecast
One source of electrical power, which many dismiss for
International believes that the worldwide demand for
initially appearing to be fiscally unproductive, is
Continued…
conservation. Though it may slow the demand for new
©
20 07
GE Model 6000
Outlook Unit Production Forecast

• Flexible power plant package seen as an excellent means 2007-2016
30
of addressing the worldwide demand for electrical power
25
• Frame 6FA continues to attract attention for its 20
combined-cycle performance for gas turbine machines of
15
its size
10
• More mechanical-drive orders are expected to arise in the 5
decade
0
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Units
• Several associates, most notably Bharat in India, are Units 11 15 20 24 26 24 25 26 25 24
expected to garner sales in the decade, especially for

Frame 6B model
Orientation
Description. The Frame 6 is a single-shaft, simple- Price Range. Genset prices (estimated in 2007 U.S.
cycle, axial-flow, 50-Hz/60-Hz heavy-duty industrial dollars) are as follows:
design gas turbine in the 40-75 MW class. The
Machine Model Genset Price
Model 6000 is also referred to as the Frame 6; its GE Electrical Generation
designation is MS6001. Frame 6B $11-$13 million
Sponsor. The Frame 6 was privately developed by Frame 6C $12-$14 million
the prime manufacturer. The current prime contractor is Frame 6FA $19-$21 million
identified in the Contractors section below. Mechanical Load Drive
Frame 6B $10-$12 million
Power Class. The approximate power output of the
Frame 6 is as follows: For electrical generation (simple-cycle), the genset price
Machine Model Power Output covers a single-fuel skid-mounted gas turbine, electric
Electrical Generation
generator, air intake with basic filter and silencer,
Frame 6B 42.1 MW
exhaust stack, basic starter and controls, and
Frame 6C 42.3 MW conventional combustion system.
Frame 6FA 75.9 MW For mechanical drive, the price covers a gas-fired gas
Mechanical Load Drive turbine (without driven equipment) with gearbox, skid,
Frame 6B 58,380 shp enclosure, inlet and exhaust ducts and exhaust silencer,
basic turbine controls, fire protection, starting systems,
Status. The MS6001B, MS6001C and MS6001FA are and conventional combustion system.
in production for electrical generation; the MS6001B is
in production for mechanical load drive duty. Competition. The Frame 6B’s main competition is
the Siemens SGT-800. The Frame 6FA fits between the
Total Produced. At the start of 2007, at least 1,000 Siemens SGT5-4000F and the GE 7EA. In the
GE-design Frame 6 machines had been installed in 75 mechanical load drive market, the Frame 6 fits into the
countries and territories worldwide. power band between GE’s own LM5000PC and
Application. Utility and industrial electrical LM6000PA.
generation, including cogeneration installations, in
50-Hz or 60-Hz operating mode; various mechanical
load drive duties.
©
2007 June 2007
Page 2 Gas Turbine Forecast
GE Model 6000
Contractors
Prime
GE Energy http://www.gepower.com, 4200 Wildwood Pkwy, Atlanta, GA 30339 United States,
Tel: + 1 (770) 859-6000, Fax: + 1 (678) 844-6690, Prime
Bharat Heavy Electricals Ltd http://www.bhel.com, BHEL House, Siri Fort, New Delhi, 110049 India,
(BHEL) Tel: + 91 11 26001010, Fax: + 91 11 26493021, Email: etr@bheltry.co.in, Licensee
Subcontractor
American Air Filter International, http://www.aafintl.com, PO Box 35690, Louisville, KY 40232-5690 United States,
AAF International Tel: + 1 (800) 477-1214, Fax: + 1 (502) 637-0321 (Intake Filter System & Evaporative
Cooler)
BHS Getriebe GmbH http://www.bhs-getriebe.de, Hans-Boeckler-Strasse 7, Sonthofen, 87527 Germany,
Tel: + 49 8321 8020, Fax: + 49 8321 802685, Email: info@bhs-getriebe.de (Auxiliary
Gear)
Howmet Castings, Corporate http://www.alcoa.com, 145 Price Rd, Winsted Industrial Park, Winsted, CT 06098 United
Machining States, Tel: + 1 (860) 379-3314, Fax: + 1 (860) 379-4239 (Blade, Stage 1)
Sermatech Power Solutions http://www.sermatech.com, 155 S Limerick Rd, Limerick, PA 19468-1699 United States,
Tel: + 1 (610) 948-5100, Fax: + 1 (610) 948-1712, Email: info@sermatech.com (Sermaloy
1504 Coating - Stage 2 Nozzle)
Stork H&E Turbo Blading Inc http://www.he-machinery.com, 334 Comfort Rd, Ithaca, NY 14850 United States,
Tel: + 1 (607) 277-4968, Fax: + 1 (607) 277-1193, Email: info@StorkHE.com
(Compressor Blade)
Vogt Power International Inc http://www.babcockpower.com, 1000 W Ormsby Ave & 10th St, PO Box 1918, Louisville,
KY 40201-1918 United States, Tel: + 1 (502) 634-1511, Fax: + 1 (502) 637-7344 (HRSG
- Gujarat Fertilizer; through BHEL)
Wood Group Fuel Systems Ltd http://www.woodgroup.com, Wellshead Industrial Ctr, Dyce, Unit 22, Aberdeen, AB21
7GA Scotland, United Kingdom, Tel: + 44 1224 771 133, Fax: + 44 1224 725 275 (Fuel
Nozzle)
Comprehensive information on Contractors can be found in Forecast International’s “International Contractors” series. For a detailed description,
go to www.forecastinternational.com (see Products & Samples/Governments & Industries) or call + 1 (203) 426-0800.
Contractors are invited to submit updated information to Editor, International Contractors, Forecast International, 22 Commerce Road, Newtown,
CT 06470, USA; rich.pettibone@forecast1.com
Technical Data
Design Features. The GE MS6001B and nozzles and wheelspaces and bearings and for surge
MS6001FA have the following design features: control during startup.
Intake. The machine features an annular air intake via MS6001FA has an 18-stage, axial-flow compressor with
skid-mounted ducting system. modulating inlet guide vanes (IGVs). Stages 1-2 are of
transonic design. Pressure ratio is 14.5:1. Interstage air
Casings. All casings are split on the horizontal
extraction is used for cooling, and sealing air is used for
centerline with through-bolted horizontal and vertical
turbine nozzles, wheel spaces and bearings, and for
joints to facilitate maintenance.
surge control during startup.
Compressor. MS6001B has a 17-stage, axial-flow
Combustor. MS6001B combustion system is the
compressor with variable inlet guide vanes (VIGVs).
reverse-flow type and includes 10 combustion chambers
Pressure ratio is 12.2:1, while air mass flow is 141.1
equipped with liners, flow sleeves, transition pieces, and
kg/sec. Casings are in A395 ductile cast iron or A46
crossfire tubes. Its cylindrical, slot-cooled Hastelloy X
cast iron; blades and vanes of 403 stainless steel; discs
liner is plasma-coated with a ceramic thermal barrier to
are of Ni-Cr-Mo-V or Cr-Mo-V steel. Air extraction is
reduce metal temperature and gradient. Two combustion
employed for turbine cooling, and sealing air for turbine
systems are available: a standard combustion system
June 2007
Gas Turbine Forecast Page 3
GE Model 6000
and a dry low NOx combustion system. Both are cast from GTD-222. Stage 1 buckets have a DS grain
capable of multifuel operation. Dual igniters are used. structure with turbulated serpentine cooling passages
and tip and trailing edge bleed. Stage 2 has turbulated
The MS6001FA combustion system is composed of six
radial cooling holes. Stage 3 is uncooled. The last two
chambers that are similar in design and operating
conditions to the GEPS MS9001FA. It also uses a head stages have integral Z-lock shrouds. The cooling design
and components (including nozzles, swirlers, caps, and of the MS6001B allows operating gas temperatures
end covers) that are common with the 9FA. The 6FA entering the turbine to be higher than 2,085°F
features the integral Stage 1 nozzle vanes with the (1,140°C).
combustors. A dry low NOx (DLN) combustion system
Controls. GE SPEEDTRONIC™ Mark V or Mark VI,
is standard. The MS6001FA combustor liner cap
a microprocessor-based turbine control with distributed
incorporates multiple fuel nozzles.
processor design/redundant architecture.
Turbine. Three stages (axial-flow) have air-cooling to
Starting. A diesel engine coupled to a torque converter
all three nozzle stages and the first two bucket stages.
is used for starting; an electric motor is an option.
The Stage 2 and 3 buckets of the MS6001B were
designed with integral tip shrouds. For the MS6001FA, Bearings. Tilting pad journal and thrust bearings
the turbine buckets use GE’s GTD-111 alloy. Stage 1 provide rotor stability and load distribution.
nozzles are cast in FSX414; Stage 2 and 3 nozzles are
Dimensions. The approximate dimensions and weight of a 60-Hz Frame 6FA (PG6111 [FA]) gas turbine machine
in a packaged power plant configuration are as follows:
Metric Units English Units
Length 28.95 m 95 ft
Width 20.11 m 66 ft
Height 10.36 m 34 ft
Weight 362,877 kg 800,000 lb
Performance. The MS6001B (PG6581B) in simple-cycle duty has the following performance parameters:
ELECTRICAL GENERATION MECHANICAL DRIVE
Metric Units English Units Metric Units English Units
Output 42.1 MW 56,450 shp 43.5 MW 58,380 SHP
Heat Rate 11,227 kJ/kWh 10,642 Btu/kWh 10,821 kJ/kWh 7,650 Btu/shp-hr
Pressure Ratio 12.2:1 12.2:1 12.0:1 12.0:1
Mass Flow 141.1 kg/sec 311 lb/sec 140 kg/sec 309 lb/sec
Turbine Speed 5,163 rpm 5,163 rpm 5,111 rpm 5,111 rpm
EGT 548°C 1,019°F 544°C 1,012°F
The MS6001B in combined-cycle duty has the following performance parameters:

MS6001B: COMBINED-CYCLE PERFORMANCE
S106B S206B S406B
Output 64.3 MW 130.7 MW 261.3 MW
Heat Rate 6,960 kJ/kWh 6,850 kJ/kWh 6,850 kJ/kWh
Net Efficiency 49.0% 49.8% 49.8%
The MS6001C for electrical generation has the following performance parameters:
PG6591C: SIMPLE-CYCLE MS6001C: COMBINED-CYCLE
Metric Units English Units S106C S206C
Output 42.3 MW 56,725 shp 62.8 MW 136 MW
Heat Rate 9,930 kJ/kWh 9,410 Btu/kWh 6,667 kJ/kWh 6,618 kJ/kWh
Pressure Ratio 19:1 19:1 not specified not specified
Mass Flow 117 kg/sec 258 lb/sec not specified not specified
Turbine Speed 7,100 rpm 7,100 rpm not specified not specified
EGT 574°C 1,065°F not specified not specified
Net Efficiency >36.3% >36.3% 54.0% 54.4%
©
2007 June 2007
GE Model 6000
The MS6001FA (PG6111FA) for electrical generation has the following performance parameters:
50 Hz SIMPLE-CYCLE DUTY 60 Hz SIMPLE-CYCLE DUTY
Output 75.9 MW 101,781 shp 75.9 MW 101,781 shp
Heat Rate 10,300 kJ/kWh 9,760 Btu/kWh 10,330 kJ/kWh 9,795 Btu/kWh
Pressure Ratio 15.6:1 15.6:1 15.7:1 15.7:1
Mass Flow 202.76 kg/sec 447 lb/sec 203.66 kg/sec 449 lb/sec
Turbine Speed 5,231 rpm 5,231 rpm 5,254 rpm 5,254 rpm
EGT 603°C 1,117°F 604°C 1,118°F
The MS6001FA in combined-cycle duty has the following performance parameters:

MS6001FA: COMBINED-CYCLE PERFORMANCE
50 Hz Operation 60 Hz Operation
S106FA S206FA S106FA S206FA
Output 117.7 MW 237.9 MW 118.1 MW 237.5 MW
Heat Rate 6,582 kJ/kWh 6,508 kJ/kWh 6,593 kJ/kWh 6,550 kJ/kWh
Net Efficiency 54.7% 55.3% 54.6% 54.9%
IGCC. GE Energy makes available a wide range of gas turbine machines that can be efficiently incorporated into
Integrated Gasification Combined-Cycle (IGCC) plants.
The power output of the Frame 6 for IGCC plant applications is as follows:
FRAME 6B INTEGRATED WITH IGCC PLANTS
GE Turbine Syngas Power Rating IGCC Model Net Plant Output Power
Frame 6B 40 MW (50/60 Hz) 106B 60 MW (50/60 Hz)
GE MS6001FA (Frame 6FA)

Source: GE Energy
June 2007
GE Model 6000
Variants/Upgrades
MS6001A. The MS6001A was the initial production MS6001C. The MS6001C is the latest evolution of the
model of the Frame 6 series. It incorporated the 40-MW-class gas turbine technology; it builds on the
two-bearing configuration and 5,100-rpm shaft speed of experience and performance of the Frame 6B. The
the MS5001 design. Frame 6C was introduced in June 2002. The PG6591C
develops 42.3 MW at 7,100 rpm. ISO baseload exhaust
MS6001B. The MS6001B, also known as the PG6001,
flow is 117 kg/sec, with an exhaust temperature of
was introduced in 1978. Compared to the MS6001A, it
574°C.
has a higher turbine inlet temperature (TIT) and air
mass flow at peak load rating. One of the latest MS6001FA. The MS6001FA is the largest machine in
versions, the PG6581B, develops 42.1 MW at 5,163 the Frame 6 line; it was introduced in May 1993.
rpm. ISO baseload exhaust flow is 141.1 kg/sec, with Having gone through a series of power output upratings,
an exhaust temperature of 548°C. it has a current rating of 75.9 MW.
For mechanical load drive duty, the Frame 6B is rated at
58,380 shp.
Program Review
Background. Design of the GE MS6001 (also Frame 6 and Water Injection. Water injection is
referred to as the Model 6000 and Frame 6) began in the method of choice for controlling NOx emissions
January 1976 as a program to develop a family of from simple-cycle gas turbines. GE’s calculations are
industrial gas turbines utilizing the best features of the that for each 1 percent injection, the performance of an
MS5001 and MS5002 (Frame 5) and MS7001 (Frame 7) MS6001B increases by 3 percent power and fuel-flow
series. Close attention was paid to cost reduction in increases by 4.8 percent. The gas turbines ordered by
manufacture and operation. Three Frame 6 prototype Jersey Central Power & Light as part of a turnkey
units were built, with two going to actual customers for contract in June 1988 utilize water injection for NOx
testing/operation in typical environments, and the third control.
under test at GE. The prototypes were conservatively
Steam Injection. Steam injection (STIG™) is a
rated at 33,150 kW peak rating with a Tf of 1,066°C.
method for controlling emissions from gas turbines
Once parameters had been established and met,
applied to cogeneration and combined-cycle systems
temperatures were incrementally increased to 1,100°C
because of the availability of steam at appropriate
for production models.
conditions and the substantial improvement in gas
In June 1991, GE announced that it had received a $600 turbine heat rate that is achievable. GE has estimated
million contract to supply four MS6001B gas turbine/ that for each 1 percent injection, the power of an
compressor trains to ARCO Alaska Inc. The equipment MS6001B increases by 2.9 percent and fuel-flow
was to be used to increase oil recovery on Alaska’s increases by 1.5 percent. (STIG is a trademark of
North Slope, the first use of Frame 6 gas turbines for General Electric Company USA.)
mechanical drive purposes. Each of the four gas
Emissions Reduction. In November 1993, GE
turbines drives one tandem compressor string at
Power Systems reported on its dry low NOx (DLN)
ARCO’s Central Gas Facility. The compressor train
combustion program, with reference to the Frame 6
consists of Dresser-Rand 66-5B8 and 37-3B4/4
machine. It reported that an MS6001B DLN combustor
centrifugal turbocompressors in a tandem arrangement.
at Jersey Central Power & Light’s Forked River Station
The four compressor trains are used to re-inject up to
had achieved single-digit NOx emissions and less than
2.4 billion SCF/D (67.9 million SCM/D) of natural gas
20 ppmv CO at ISO (International Standards
(NG) into the Prudhoe Bay oil field at 4,200 psi
Organization) conditions.
(28,959 kPa) to facilitate increased oil recovery.
Emissions Levels. For the MS6001B, the emission
Frame 6B and Frame 7EA gas turbines offer significant
level achieved with the existing DLN-1 combustion
power density advantages over other gas turbines
system is 15 ppmv NOx on natural gas. MS6001FA gas
currently used for mechanical drive applications. A
turbines employ DLN-2 combustion technology that can
Frame 6B has roughly the same footprint as an MS5002
achieve NOx emissions of 25 ppmv or less on NG.
machine, but is 1.333 times as powerful.
©
2007 June 2007
GE Model 6000
China Participation in Frame 6. In 1985, GE the new machine is particularly well suited for the
announced that two MS6001 heavy-duty gas turbines, burgeoning markets for major projects in cogeneration
two rotors, and other parts worth $28 million had been and combined-cycle installations. GE and initial FA
ordered by China. The sale was GE Schenectady’s first customer Sierra Pacific announced that the first
direct sale to China. One of the gas turbines was for use MS6001FA gas turbine-generator would be in com-
in a repowering project in Karamay in northwest China, mercial operation by the end of 1996 at Sierra Pacific
and the other was for a STAG 109 combined-cycle Power Company’s Piñon Pine Integrated Gasification
cogeneration plant in Daqing in northeast China. Combined-Cycle (IGCC) power plant near Reno,
Nevada.
GE also entered into a manufacturing agreement with
the Chinese Ministry of Machine Building Industry’s Order for First Frame 6FA. When the Frame 6FA
Nanjing Turbine Works. Under the agreement, major was introduced in 1996, GE and Sierra Pacific
stationary parts for gas turbines would be manufactured announced that the first MS6001FA gas turbine-gener-
in China, and rotating parts for all GE industrial gas ator would be in commercial operation by the end of
turbines ordered for installation in the Asian nation that year. Part of the effort was funded by the U.S.
would be made in the United States. The initial two gas Department of Energy under the Clean Coal
turbine machines, however, would be built completely Technology IV Program. The Frame 6FA at the IGCC
in the U.S. site is site-rated at 61 MW on syngas, 66.9 MW on
natural gas, and 68 MW on propane.
EGTL in China. The VEGA combined-cycle systems
made by (then) European Gas Turbines Ltd (EGTL) The IGCC project uses an air-blown, fluidized bed
consist of standardized plants using a number of gas tur- KRW gasifier designed by the M. W. Kellogg
bines (from one to four), followed by one steam turbine. Company. Foster Wheeler Corporation’s Foster
The most popular VEGA plant is the VEGA 206, which Wheeler USA unit handled the project engineering,
is based on two Frame 6 machines and a steam turbine, procurement, and construction.
for an ISO rating of 110 MWe. Four VEGA 206 plants
6FA Uprating. Continuing the evolution of its “F”
have been ordered from EGT by China for installation
technology to meet customer requirements for higher
at Shantou (2 plants), Shenzhen (1), and Zhuhai (1).
efficiency and lower life-cycle costs, GE Power
The More Powerful 6FA Systems introduced an uprated version of the
Frame 6FA gas turbine in May 2002. Designated the
In May 1993, GE introduced the MS6001FA, intended PG6111FA, the uprated machine offers an output
for electric utility, industrial, and cogeneration appli- increase of 9.2 percent and a heat rate improvement of
cations in the 70- to 110-MW range. The machine has a 2.7 percent. The 6FA joined the “F” technology fleet in
rating of 75.9 MW for 50-/60-Hz applications and, since 1993.
it is a geared machine, is available for 50-Hz
applications. Optimized for combined-cycle and heat- The 6FA currently offers an output of 75.9 MW and 35
recovery applications, the Frame 6FA’s output in percent efficiency in simple-cycle applications. In
combined-cycle operation is 117.7-118.1 MW, depend- combined-cycle service, the machine has an output of
ing on frequency cycle. 117.7 MW/118.1 MW and 54.7 percent and 54.6
percent efficiency. Those advances add up to a 2.8
Combined-Cycle Systems. The MS6001 gas turbines percent improvement in the cost of electricity for these
are utilized in combined-cycle power systems that can machines. The first PG6111FA became available in
provide a solution to energy conservation problems by 2003.
offering a combination of the best features of gas and
steam turbine generation technologies. In combined- All design improvements to the 6FA were made incre-
cycle installations, the net efficiency ranges between mentally, based on proven materials and operating
49.0 and 54.9 percent. experience. The primary factors leading to the improv-
ed performance of the 6FA include a 40°C increase in
Data pertaining to the MS6001B and MS6001FA in firing temperature to 1,327°C (2,420°F), a 3 percent
combined-cycle performance are provided above. For increase in airflow, and a higher pressure ratio of 15.6,
both charts, the data reflect all models with a three- compared to the previous 14.6. Those enhancements
pressure reheat steam cycle, ISO base rating (LHV), and were achieved by directly scaling GE’s current
fueled by natural gas. Frame 7FA gas turbine, applying the design and the
Hitachi of Japan has participated in the scaling of the operational experience of the Frame 7 machine to the
Frame 7FA as a work-share partner on the 6FA project 6FA. The increase in firing temperature for the 6FA
to create the new machine. GE and Hitachi believe that was achieved through improvements in component
June 2007
GE Model 6000
materials and cooling, and by elevating the pressure for the combined-cycle plant. The gas turbines were
ratio. Also critical to the upgrade was the expanded use delivered to the site in early 2004.
of film cooling and thermal barrier coating for turbine
The Frame 6C has a simple-cycle net efficiency of
nozzles and buckets.
>36.3 percent, with an output of 42.3 MW. Optimized
The enhanced 6FA features GE’s advanced DLN-2.6 for heat recovery applications, the new machine can
combustion system, capable of 9 ppmv NOx on the 7FA achieve 54.0 percent efficiency and 126.7 MW of output
and designed to achieve 15 ppmv NOx on the 6FA. The in a GE S206C configuration (two gas turbines, two
Frame 6FA machines are manufactured in GE Power heat recovery boilers, one steam turbine). The turbine
Systems’ facility in Belfort, France. can limit NOx emissions to 15 ppmv on natural gas.
Frame 6B in IGCC Plants. Integrated Gasification With its high efficiency and reliability, the Frame 6C is
Combined Cycle technology is increasingly important in designed for cost-effectiveness. Key applications for the
the world energy market where low-cost-opportunity new machine will be industrial cogeneration, process
feedstocks such as coal, heavy oils, and pet coke are the industries, municipalities (district heating), combined
fuels of choice. In addition, IGCC technology produces heat and power, and mid-sized combined-cycle projects.
low-cost electricity while meeting strict environmental
Frame 6C development has been fully supported by
regulations.
GE’s Six Sigma quality initiative. The new gas turbine
The IGCC gasification process takes “clean” heavy will be manufactured in GE’s facilities in Europe, and
fuels and converts them into high-value fuel for gas will serve both 50-Hz and 60-Hz markets worldwide.
turbines. Pioneered by GE almost 30 years ago, IGCC
Power Barges. In mid-2001, Waller Marine took
technology can satisfy output requirements from
delivery of two 30-MW power barges from Friede
10 MW to more than 1.5 GW, and, says the manu-
Goldman Offshore shipyard and immediately loaded the
facturer, can be applied in almost any new or
vessels on the M/V Smit Express for their dry tow to
repowering project where solid and heavy fuels are
Lagos, Nigeria. The 60 MW of power can be connected
available.
to other, similar vessels.
For each gasifier type and fuel, there are a vast number
Each power barge was designed by Waller to ABS
of technical possibilities. IGCC systems can be
River Rule standards; each has a Frame 6B, a generator
optimized for each type of fuel as well as site and
set, controls, switchgear, a main transformer, and
environmental requirements. Using knowledge gained
associated equipment.
from successfully operating many IGCC units, GE has
optimized system configurations for all major gasifier Affiliates. Note that the following firms have been or
types and all GE gas turbine models. are currently affiliated with GE on the Frame 6:
Frame 6C: The New Kid on the Block. GE • Bharat Heavy Electricals Ltd; New Delhi, India
Energy’s 40-MW MS6001C gas turbine was designed • CMEC International Engineering Company Ltd;
for low electricity costs, and offers an ideal product fit Beijing, China (PRC)
for heat recovery applications. • Hitachi Ltd; Tokyo, Japan
The Frame 6C gas turbine represents the application of • Kanis Energie GmbH; Essen, Germany
GE “F” technology to the 40-MW segment and allows • Kvaerner Energie a.s.; Oslo, Norway (now a part of
GE to offer the best heavy-duty gas turbine technology GE Oil & Gas)
in this output range. GE introduced the new gas turbine • Marubeni Corporation; Tokyo, Japan
in June 2002 at Power-Gen Europe.
• Mitsui Engineering and Shipbuilding Company
GE also announced that the first two Frame 6C gas Limited; Tokyo, Japan
turbines would be purchased by Akenerji, a leading • Thomassen International bv; Rheden, the
electricity producer in Turkey, to be installed at the Netherlands (now a part of Calpine Corporation)
company’s Kemalpasa-Izmir site in Turkey. GE was to
supply an equipment-engineered power island package • Toshiba Corporation; Tokyo, Japan
©
2007 June 2007
GE Model 6000
Significant News
GE in Belfort World’s First Gas Turbine Manufacturer to be ATEX-Certified – In April 2006, GE
Energy’s gas turbine manufacturing facility in Belfort was awarded ATEX certification, issued by Lloyds, for its
Frame 6B, 6FA and 9E machines. ATEX is European directive 94/9/EC that applies to protection products and
systems for use in explosive atmospheres.
Compliance with the directive, which derives its name from the French expression “ATmosphère EXplosible,” has
been compulsory since July 1, 2003, for all products and systems sold within the European Union for use in this type
of environment. The certification follows a voluntary action by GE Energy, the sole producer of high-power gas
turbines in France, freeing it from the obligation to have each unit individually certified, and thus reducing the
delivery times for its products.
“The certification enables our customers to meet the legal requirements while minimizing their costs and times to
entry into service,” stated Yves Menat, general manager of GE Energy at Belfort. “It greatly simplifies the approval
process for entry into industrial service.” (GE Energy, 4/06)
GE Introduces Compressor and Combustor Upgrades – As was announced in early 2006, for its 6B gas
turbines with Tf of 2,020ºF (1,104ºC) and above, GE was offering a new DLN combustion system with NOx
guarantee levels of up to 5 ppm (10 mg/Nm3) and CO levels up to 25 ppm. The upgraded combustion system can be
installed during a combustion, hot gas path, or major inspection, and is designed to increase the combustion
inspection interval to 24,000 hours (based on operation with natural gas) (Turbomachinery International, January
and February 2006)
Market Intelligence Service Subscribers: For additional news, go to the online E-Market Alert page located in the Intelligence Center at
www.forecastinternational.com and click on the links to the products you subscribe to.
Funding
No U.S. government funding for the GE Frame 6 series of machines has been identified, although funding
(non-military) was granted by the U.S. Department of Energy for an IGCC plant in Nevada (USA) that has a single
Frame 6.
Contracts/Orders & Options

Note that no major military contracts pertaining to the GE Energy Frame 6 gas turbine machine series have been
identified recently.
Award
Contractor (in millions) Date/Description
GE Energy, GE Oil N/A Oct 2006 – Three Frame 6B turbines for power generation at a LNG
& Gas; Florence, production facility in Ras Laffan for Qatar Liquified Gas Company. Commercial
Italy operation expected 3Q 2007.
GE Energy; N/A Jul 2006 – Two modified Frame 6B machines in Xiaoyi City, Shanxi Province,
Belfort, France burning coke oven gas for energy production. The client is Eurofo International
Group.
GE Energy; N/A Apr 2006 – a Frame 6FA machine in Zagreb, Croatia, for CHP, burning natural
Belfort, France gas for 100-MW energy production and 80 MW of thermal power for district
heating. The client is Hrvatska Elektroprivreda, the Croatian utility.
GE Energy; N/A Dec 2005 – Two Frame 6B gas turbine machines to be manufactured for
Belfort, France shipment to Doosan Heavy Industries & Construction Company Ltd for a new
cogeneration power plant in Yeochun City, Korea (ROK). The new facility will
be owned and operated by Yeochun NCC Company Ltd: the gas turbines will
be used in a naphtha-cracking facility. The gas turbines’ primary fuel will be
methane gas.
June 2007
GE Model 6000
Award
Contractor (in millions) Date/Description
GE Energy; N/A Nov 2005 – Two Frame 6B gas turbine machines to be manufactured for
Belfort, France shipment to a new 100-MW combined-cycle power plant being built at the Kota
Kinabalu Industrial Estate in Sabah, Malaysia. The plant is owned by the
Sepangar Bay Power Corporation Sdn Bhd, headquartered in Kuala Lumpur.
GE will also provide two 6A6 generators.
GE Energy; N/A Sep 2005 – Two Frame 6B gas turbine machines to be manufactured for
Belfort, France shipment to the 110-MW Bukit Panggal combined-cycle power plant being built
in the Tutong region of Brunei Darussalam. The plant will be owned and
operated by Brunei’s Ministry of Development, through the Department of
Electrical Services. For the project, GE is part of a consortium led by
Marubeni Corporation, with Toshiba Plant Systems and Services Corporation
an associate member. GE will also supply an SC4 single-flow steam turbine
and three generators.
GE Energy; N/A Apr 2005 – One Frame 6B gas turbine machine to be manufactured for
Belfort, France shipment to an expanded PT Fajar Surya Wisesa Tbk paper plant on the
outskirts of Jakarta, Indonesia. GE will also supply a 6A6 generator.
GE Energy, GE Oil >$80 Apr 2005 – Eight Frame 6 (PG6581) gas turbine machines to be manufactured
& Gas; Florence, for shipment to PTT Utility Company Ltd of Thailand. The first gas turbine
Italy package awarded under the agreement with GE was purchased by National
Petrochemical, an affiliate of PTT.
Timetable
Month Year Major Development
Jan 1976 Model 6000 development
Sep 1978 First unit shipped
4Q 1978 First unit becomes operational
Apr 1979 Installation begins on second unit
Sep 1979 Installation of second unit completed; CFE order placed
Dec 1979 First two CFE machines shipped
Feb 1980 Last two CFE units delivered
Early 1985 Sale to China announced; GE/China production agreement announced
1988 Four units ordered by the German Democratic Republic
Jun 1991 GE announces sale of Frame 6 machines for mechanical drive application
1Q 1992 ARCO machines shipped to fabrication facility
1993 First set of ARCO machines arrives in Alaska
4Q 1993 First ARCO machines enter service
May 1994 MS6001FA introduced
4Q 1994 Second set of ARCO machines enter service
Dec 1995 First shipment of MS6001FA
1996 Nine machines ordered for installation in China
1999 Static Frequency Converters made available for starting 6FA, 9FA machines
Jun 2002 6FA uprated; 6C introduced
2Q 2003 First shipment of uprated 6FA
2004 First shipment of 6C
Dec 2005 First 6C begins commercial operation in Turkey
Jul 2006 First 206C combined-cycle plant in Izimir, Turkey logs over 10,000 combined
operating hours. Output set at 136 MW with 54.9 percent net efficiency; NOx
emissions 15 ppm dry on natural gas.
Dec 2006 First 6FA+e surpasses 8,000 fired hours in Duisburg-Weinheim, Germany
Thru 2016 Continued production of Frame 6 series of gas turbines projected
©
2007 June 2007
GE Model 6000
Worldwide Distribution/Inventories
At the start of 2007, at least 1,000 GE-design Frame 6 machines had been installed in 75 countries and territories
worldwide. Major customer nations include Australia (24 machines), China (53), Germany (48), India (69),
Indonesia (28), Malaysia (44), Oman (44), Saudi Arabia (32), Spain (36, including Canary Islands), Thailand
(21), UAE (49), and the U.S. (133).
Of the 35 machines that had been installed for mechanical load drive duty worldwide, 11 were installed in Saudi
Arabia and five in Qatar.
Historical production is as follows:
Engine/Machine Application Thru 06

ALSTOM
MS6001B/C GENERATION 221
MS6001B/C MECHANICAL DRIVE 6
MS6001FA GENERATION 11
ANSALDO
BHARAT
CMEC
ELIN
HITACHI
JOHN BROWN
KANIS
KVAERNER
MHI
MITSUI
THOMASSEN
GE OIL & GAS
COOPER-ROLLS
Forecast Rationale
The Frame 6, which previously had fallen on the hard While the “good old days” of very high Frame 6
times that affected many machine models from other production totals will not be seen again in the near term,
original equipment manufacturers (OEMs), has now Forecast International believes that modest production
passed into the realm of reasonableness and soundness. will take place for the foreseeable future.
June 2007
GE Model 6000
In the near future, the U.S. must add a huge amount of Outside the electric generation arena, we expect the
electrical generation capacity. Orders to fill that MS6001 to garner additional orders for use as
growing requirement for energy produced by mechanical load drivers, particularly in pipeline and
independent power producers (IPPs) must be placed, process industries. We project that about 33 machines
and the Frame 6 series is well positioned to take will be built, with production shared by GE Energy and
advantage of the order pattern. With virtually no new by its affiliates/licensees.
nuclear power plants – and only a few coal-burning
Overall, we forecast that 220 GE Frame 6 series
plants – expected to come on-line in the next several
machines will be built in the decade 2006-2015, with
years, there will be a capacity crunch during the next
119 projected to be the Frame 6FA variant.
decade, notwithstanding activity in the overall
cogeneration arena. Of GE’s licensees and affiliated firms, projected to be
among the most active in the decade is Bharat Heavy
Given the financial considerations weighing against the
Electricals, with most of its production likely to be of
procurement of 1,000-MW and larger thermal and
the Frame 6B variant. The Indian firm continues to
nuclear systems, and the questions about environmental
garner orders for that machine at a moderate pace, and
damage and safety, natural-gas-burning gas turbines are
we feel that it is the current star in the GE Energy
viewed as one of the most economical and fastest ways
associates/licensees pool.
to generate energy. Their flexibility as prime movers for
driving generators in utility service, short lead times For GE Energy itself, much of the Frame 6 production
from order to installation, and moderately low will take place at its facility in Belfort, France, with
installation cost per kW combine to make them a good lesser volume production in Florence, Italy.
choice.
For GE’s associates/licensees, our forecast chart
With a revised outlook in the electrical generation includes production for the group as a whole. We cannot
arena, we are confident that the Frame 6 machines will forecast production for each entity individually since
continue to be ordered at a level higher than anyone orders placed directly with GE Energy may be handled
would have guessed two or three years ago. It should by one of the associates/licensees. As detailed historical
be kept in mind here that the 6B, 6C, and 6FA information becomes available regarding each firm’s
incorporate modular-packaged design characteristics, installation activity, that activity will be reflected in the
allowing powertrain components to be shipped and in the chart.
assembled for both 50-Hz and 60-Hz applications in a
very short time – and that those models can be ordered
by virtually any enterprise worldwide.
Ten-Year Outlook
ESTIMATED CALENDAR YEAR UNIT PRODUCTION

Designation or Program High Confidence Good Confidence Speculative
Thru 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 Total
GE Energy
Model 6000 (Frame 6) (MS6001) B/C <> mechanical drive (pumps & compressors)
3 1 3 4 4 4 3 4 4 3 3 33
Model 6000 (Frame 6) (MS6001) B/C <> power generation

354 6 6 6 6 7 7 7 7 8 8 68
Model 6000 (Frame 6) (MS6001) F A <> power generation

59 4 6 10 14 15 14 14 15 14 13 119
Subtotal 416 11 15 20 24 26 24 25 26 25 24 220
Total 416 11 15 20 24 26 24 25 26 25 24 220
©
2007 June 2007
Rolls-Royce 501-K
Outlook Unit Production Forecast

• 501-K series’ main competition is from GE Oil & Gas, 50
2007-2016
Solar, Siemens AG, and Kawasaki 45
40
• 501-K line remains competitive for electrical generation 35
30
and mechanical load drive; it continues to be well 25
established due to company’s modernization efforts 20
15
• Centrax very active in generating orders for 501-K series 10
5
• Production funding still expected from the U.S. Navy; 0

2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Units
RDT&E is waning Units 40 43 46 43 47 49 48 48 48 48
Orientation
Description. Single-shaft/cold-end drive and two- $295-$345 per kW for mechanical drive machines.
shaft/hot-end drive, axial-flow, aero-derivative indus- Marine engines/sets are about 0.775-0.825 times that of
trial gas generators and industrial and marine gas generation.
turbine machines in the 4-6 MW class. For electrical generation (simple-cycle), the genset price
Sponsor. The 501-K I&M series was privately covers a single-fuel skid-mounted gas turbine, electric
developed by the (then) Allison Gas Turbine Division of generator, air intake with basic filter and silencer,
General Motors Corporation. exhaust stack, basic starter and controls, and a
conventional combustion system.
Power Class. The power output of the Rolls-Royce
501-K series is 3.95-6.4 kWe and 5,500-7,400 bhp. For mechanical drive, the price covers a gas-fired gas
turbine (without driven equipment) with gearbox, skid,
Status. In production.
enclosure, inlet and exhaust ducts and exhaust silencer,
Total Produced. At the start of 2007, more than basic turbine controls, fire protection, starting systems,
2,150 501-K machines were supplied to 500 customers and conventional combustion system.
in over 40 countries and territories worldwide.
Competition. The 501-K series’ main competition
Application. Electrical generation (including comes from GE Oil & Gas, Kawasaki, Siemens AG, and
combined-cycle and cogeneration); mechanical load Solar.
drives (compression and pumping); marine power.
Price Range. Approximate costs of the 501-K I&M
series are $360-$445 per kW for generation and
Contractors
Prime
Rolls-Royce Corp http://www.rolls-royce.com/northamerica, PO Box 420, 2001 S Tibbs Ave, Indianapolis,
IN 46206-0420 United States, Tel: + 1 (317) 230-2000, Fax: + 1 (317) 230-6763, Prime
Samsung Techwin Co Ltd http://www.samsungtechwin.com, KIPS Center, 647-9 Yoksam-Dong, Seoul, 135-080
Korea, Republic of (South), Tel: + 82 2 3467 7114, Fax: + 82 2 3467 7080, Licensee
©
2007 August 2007
Rolls-Royce 501-K
Subcontractor
Associated Spring, Group http://www.associatedspring.com, 80 Scott Swamp Rd, Farmington, CT 06032 United
Headquarters States, Tel: + 1 (860) 678-0700, Fax: + 1 (860) 409-4611, Email: springs@asbg.com
(Gear Spring)
Cabot Corp http://www.cabot-corp.com, Two Seaport Ln, Boston, MA 46904-9013 United States,
Tel: + 1 (617) 345-0100, Fax: + 1 (617) 342-6103 (High Temperature Superalloy Mill
Product; Investment Casting)
Cincinnati Gear Co http://www.cintigear.com, 5657 Wooster Pike, Cincinnati, OH 45227-4120 United States,
Tel: + 1 (513) 271-7700, Fax: + 1 (513) 271-0049 (High Power Density Reduction Gearing)
Danville Metal Stamping Co Inc http://www.danvillemetal.com, 20 Oakwood Ave, Danville, IL 61832 United States,
Tel: + 1 (217) 446-0647, Fax: + 1 (217) 446-3751 (Anti-Icing Cowl Assembly; Baffle Collect
Assembly)
Dyna-Empire Inc http://www.dyna-empire.com, 1075 Stewart Ave, Garden City, NY 11530-4812 United
States, Tel: + 1 (516) 222-2700, Fax: + 1 (516) 222-1896 (Control Assembly)
Honeywell Aerospace http://www.honeywellaerospace.com, 1300 W Warner Rd, Tempe, AZ 85284 United
States, Tel: + 1 (480) 592-5000, Fax: + 1 (480) 496-7811 (Air Turbine Starter)
Honeywell Aerospace http://www.honeywell.com/sites/aero/, 717 N Bendix Dr, South Bend, IN 46620 United
States, Tel: + 1 (574) 231-2000, Fax: + 1 (574) 231-3335 (Cable Assembly; Lever
Assembly; Body Assembly; Valve Assembly)
Precision Castparts Corp http://www.precast.com, 4650 SW Macadam Ave, Suite 440, Portland, OR 97239-4262
United States, Tel: + 1 (503) 417-4800, Fax: + 1 (503) 417-4817,
Email: info@precastcorp.com (Structural Casting)
TurboCombustor Technology Inc http://www.tct-inc.com, 3651 SE Commerce Ave, Stuart, FL 34997-4967 United States,
Tel: + 1 (561) 287-7770, Fax: + 1 (561) 287-0476 (Combustor; Transition Liner)
Woodward Governor Co http://www.woodward.com, 5001 N Second St, PO Box 7001, Rockford, IL 61125-7001
United States, Tel: + 1 (815) 877-7441, Fax: + 1 (815) 639-6033 (Model 503 Digital
Control System)
Comprehensive information on Contractors can be found in Forecast International’s “International Contractors” series. For a detailed description,
go to www.forecastinternational.com (see Products & Samples/Governments & Industries) or call + 1 (203) 426-0800.
Contractors are invited to submit updated information to Editor, International Contractors, Forecast International, 22 Commerce Road, Newtown,
CT 06470, USA; rich.pettibone@forecast1.com
Technical Data
Design Features Gas Generator Turbine. Model 501-K engines are
Compressor. Fourteen-stage (15 in 501-KB7) axial- manufactured in single- or two-shaft versions. In
flow, with fixed stators and inlet guide vanes. Pressure single-shaft models, the four axial-flow stages are
ratio of 9.4 to 13.5. Mass flow is 15.4 to 21.1 kg/sec. tie-bolted together: two-shaft variants use the first two
Blades are 17-4PH; vanes are 410SS. Stage 1 disc in stages to drive the gas producer, and the second two
AMS6260; Stage 2-13 discs of 410SS; Stage 14 of stages to drive the power shaft. IN738 blades are held
17 4PH. Cases are of steel, inlet case of aluminum. in place by fir-tree roots. All subsequent models now
utilize hollow, air-cooled Stage 1 blades and vanes.
Combustor. Six can annular chambers of the
through-flow type are enclosed within an outer Discs are made of Waspaloy, vanes of X40. Turbine
combustor liner. Models can be equipped for casing is of Hastelloy X. Blades and vanes are
liquid-fuel, natural gas, or dual-fuel operation. Two DC aluminum diffusion-coated for sulfidation protection.
igniters supply ignition. Liners and duct are made of Model 501-KC5 Stage 1 turbine blades are MAR-M246,
Hastelloy X; casing is made of titanium. Extensive while vanes are MAR-M509.
combustor optimization efforts have been undertaken
Power Turbine. The last two stages of the 501-K
recently by Rolls-Royce (see Program Review
turbine section are separated to form a free power
section).
turbine. Design speed range is 6,000 to 14,600 rpm.
August 2007
Rolls-Royce 501-K
Stage 1 blades are made of IN738; Stage 2 blades of 13,600 and 14,600 rpm down to synchronous generator
Waspaloy. Discs are also made of Waspaloy, while speeds. Starting is normally by means of an air turbine,
vanes are of X40. The power turbine casing is of but electric or hydraulic starting is available.
Hastelloy X, while the vane casing is of Hastelloy C.
Control System. Manual, semiautomatic, or fully
Two roller bearings and a single ball bearing support the
automatic operation is accomplished using a Woodward
turbine shaft, and carry thrust and axial loads.
Electronic Control/Governor System. The system pro-
Bearings. Five pressure-lubricated, aircraft-type vides multiple monitoring features and protective
bearings: three roller journal bearings and two thrust shutdown in the event of excessive vibration or other
ball bearings. abnormal operation.
Accessories. Single-shaft versions use a front-
mounted gearbox to reduce output speeds from between
Dimensions. The approximate dimensions and weights of the Rolls-Royce 501-K series-equipped generator sets
(complete packaged units) are as follows:
APPLICATION = ELECTRICAL GENSETS APPLICATION = MECHANICAL DRIVE SETS
Model L x W x H (meters) L x W x H (feet) L x W x H (meters) L x W x H (feet)
501-KB5 9.0 x 2.7 x 3.0 30.0 x 8.7 x 10.0 – –
Weight 15,875 kg 35,000 lb – –
501-KB7 9.0 x 2.7 x 3.0 30.0 x 8.7 x 10.0 – –
Weight 16,328 kg 36,000 lb – –
501-KH5 (a) 9.0 x 2.7 x 3.0 30.0 x 8.7 x 10.0 – –
Weight 16,328 kg 36,000 lb – –
501-KC5 – – 6.4 x 2.4 x 3.0 21.0 x 8.0 x 10.0

Weight – – 11,400 kg 25,000 lb
501-KC7 – – 6.4 x 2.4 x 3.0 21.0 x 8.0 x 10.0
Weight – – 11,800 kg 26,000 lb
(a)
Water injected.
The approximate dimensions and weights of the Rolls-Royce AG9140 and AG9140RF ship service generators for
marine duty are as follows:
APPLICATION = MARINE SERVICE GENERATOR
Metric Units English Units Machine Machine
Model L x W x H (meters) L x W x H (feet) Dry Weight Dry Weight
AG9140/40RF 8.65 x 2.37 x 3.38 28.395 x 7.8 x 11.1 29,257 kg 64,500 lb
Performance. The approximate performance parameters of the Rolls-Royce 501-K series-equipped generator sets
(complete packaged units) are as follows (ISO, no losses; PT speed of 14,600 rpm):
APPLICATION = ELECTRICAL GENERATOR SETS
GG GG
Rating Heat Rate Compression Compression Exhaust Exhaust
Model ISO Base LHV Ratio Stages Temp Mass Flow
501-KB5 3,938 kW 12,266 kJ/kWh 9.4 14 560°C 15.4 kg/sec
501-KB7 5,300 kW 11,380 kJ/kWh 13.5 1 + 14 501°C 21.1 kg/sec
501-KH5 (a) 6,420 kW 9,037 kJ/kWh 9.4 14 530°C 18.3 kg/sec
(a)
Water injected.
The approximate performance parameters of the Rolls-Royce 501-K series-equipped mechanical load drive sets
(complete packaged units) are as follows (ISO, gaseous fuel, no losses; PT speed of 13,600 rpm):
©
2007 August 2007
Rolls-Royce 501-K
APPLICATION = MECHANICAL DRIVE SETS

GG GG
Rating Heat Rate Compression Compression Stack Exhaust
Model ISO Base LHV Ratio Stages Temp Mass Flow
501-KC5 5,500 bhp 8,495 Btu/hph 9.4 14 571°C 31.2 lb/sec
4,100 kW 12,170 kJ/kWh 15.5 kg/sec
501-KC7 7,400 bhp 7,902 Btu/hph 13.5 1 + 14 520°C 46.2 lb/sec
5,500 kW 11,340 kJ/kWh 20.9 kg/sec
The approximate performance parameters of the Rolls-Royce AG9140 and AG9140RF gas turbine for marine duty
in a ship service generator are as follows (at 100°F, S/L, with 6” inlet/10” exhaust losses and using DF2 fuel):
APPLICATION = SHIP SERVICE GENERATOR
With Bleed Without Bleed
Continuous Power Output (a) 2,500 kW 3,000 kW
(b)
Maximum Power Output 4,500 kW 4,500 kW
(a)
Fuel Rate 15,375 Btu/kW-hr 13,250 Btu/kW-hr
Turbine Speed 14,340 rpm 14,340 rpm
Generator Speed 1,800 rpm 1,800 rpm
Firing Temperature 2,142°F 2,142°F
Exhaust Gas Flow 29.0 lb/sec 31.1 lb/sec
Exhaust Gas Temperature 1,117°F 1,097°F
Engine Bleed Capacity 2.37 lb/sec 0.0
(a)
Includes generator and gearbox losses.
(b)
For emergency use up to five minutes.
Variants/Upgrades
AG9130/AG9140. Rolls-Royce has evolved a Features of the AG9140 include the generation of
complete ship service gas turbine generator set under 3,000 kW of 440 V, three-phase power, local or remote
the designation AG9130. A derivative of the control, removable panels and doors, a built-in
Model 501-K34/KB5, the AG9130 is rated at 2,500 kW maintenance beam and hoist, and high corrosion-
continuous with air bleed, 3,000 kW continuous without resistance. It has been MIL-G22077 qualified and shock
air bleed, and 4,500 kW emergency. The unit, entirely a tested per MIL-S-901C. Additional features of the
Rolls-Royce/Allison product, was designed for marine AG9140RF include a built-in mechanical starter
applications on board the U.S. Navy DDG-51 Arleigh (250-KS4), dark ship start from batteries only,
Burke class vessels. The AG9130 meets U.S. Navy redundant start capability, and Full Authority Digital
requirements for shipboard generation. It features an Control (FADC).
automatic dual-voltage regulation system, low-pressure
The AG9140 is on board the ROK’s three KDX-3
air starting with silencing, and a generator with the
destroyers (see below).
lowest airborne noise signature in the service. It is
completely self-contained to include all controls, sea ATS (Advanced Turbine System). The U.S.
water systems, expansion joints, and a fire damper. Department of Energy, the Chicago-based Gas Research
Institute, and Rolls-Royce Engine Company are in the
Allison began working under a contract awarded in
process of developing what is described as a new
March/April 1986, and shipped the first unit to Bath
generation of gas turbines that utilize a natural
Iron Works, located in Bath, Maine, in 1987. The
gas-fueled catalytic combustion system. The intent is to
AG9130 is the replacement for the 501-KF package;
lower the emission levels to ultra-low ratings –
three such packages are used in each vessel.
reportedly a first in gas turbine technology. Component
The AG9140 incorporates significant maintainability tests began in 1999, followed by a full-scale
and reliability upgrades and technology enhancements, demonstration and an 8,000-hour durability test in 2000.
based on lessons learned from the deployment of the Work at Rolls-Royce on this effort is ongoing, although
early ships in the class. These upgrades have provided at a somewhat reduced level of activity.
the U.S. Navy with the latest generator set technology.
Early tests showed that the ATS reduced NOx emissions
Allison began shipment to Bath Iron Works in 1994.
by 0.9 tons per year and CO2 emissions by 5.8 tons
August 2007
Rolls-Royce 501-K
annually. Rolls-Royce estimated that the ATS could 501-KB7. In June 1991, (then) Allison announced that
reduce the fuel costs of turbine operators by about it was developing an increased power version of the
$380,000 a year. 501-K single-shaft engine. The 501-KB7 is the most
powerful offering, providing 5,300 kWe continuous.
The ATS is targeted for modular and distributed power
The design added a boost module to the front of the
generation markets, both significant growth areas in the
current 501-K. This module incorporates the functions
power generation arena thanks to ongoing deregulation
of the current air inlet housing assembly, but adds a
in the U.S. and elsewhere. Funding for the program is
compressor stage consisting of 29 compressor blades
provided by the U.S. DoE.
and 35 stator vanes. The KB7 utilizes the PTO shaft
Meanwhile, San Diego-based Solar Turbines is arrangement as produced for the 501-KB5/KH models.
developing a recuperated-cycle industrial turbine under
For the 501-KB7, the rear turbine bearing support,
the same ATS program. Larger systems (400+ MW) for
which is also the turbine exhaust section, was
utility-scale applications are being developed by GE and
redesigned to provide for increased airflow with the
Siemens Westinghouse.
addition of the boost module. The Stage 4 turbine blades
501-KB. The Model 501-KB is a single-shaft generator were also redesigned to reduce losses in the exhaust
drive with a power output of 4,450 kW at base load, and system. Other changes or modifications from earlier
5,420 kW at intermediate power on distillate or natural models include the use of thermal barrier-coated vanes
gas fuels. The 501-KB3 and 501-KB4 were both in the turbine section and effusion-cooled combustion.
introduced in 1994. The 501-KB3 offers a low mass
501-KF. The Model 501-KF is a two-shaft marine
flow (28 lb/13 kg per second) with a relatively high
propulsion engine that powers the Boeing Jetfoil in
exhaust temperature (1,051°F/566°C). The 501-KB3 has
commercial and military service (designated 501-K20A
a thermal efficiency of 26.5 percent. The 501-KB4 is a
by Boeing). Production Model 501-KFs are rated at
4-MW machine rated for standby duty, and features
4,330 horsepower (3,229 kW) at a gas generator speed
liquid fuel with natural gas and dual-fuel options. The
of 13,885 rpm and power turbine speed of 13,820 rpm.
501-KB4’s thermal efficiency rating is 29.7 percent.
Maximum rated power (intermittent) is 5,420 horse-
The 501-KB5 is available with high temperature power at 14,560 gas generator rpm and at 13,820-rpm
capability (1,895°F TIT) Stage 1 turbine blades and power turbine output speed. Many 501-KF units have
vanes, either as the 3.94 MW 501-KB5 or as a retrofit been supplied to the U.S. Navy by Stewart & Stevenson
enhancement kit; that capability increases blade life by (for more details, see Program Review below).
30 percent to 40,000 hours. The 501-KB17 is the
onboard generating set for the U.S. Navy CG-47 class
ships (see below).
Program Review
Background. The current manufacturer is Rolls- Licensees/Distributors – Generator Sets:
Royce plc, Rolls-Royce Corp, located in Indianapolis,
Indiana, USA. This series of gas turbine machines is • CEC-STR Distribuicao de Turbinas, Rio de Janeiro,
produced in Indianapolis. RJ, Brazil
• Centrax Ltd, Newton Abbot, Devon, U.K
OEMs/EPSs – Compressors & Pumps: Dresser-
• Detroit Engine & Turbine Co, Adelaide, SA,
Rand Co, Turbo Products Division, based in Olean,
Australia
New York, USA, is the current Original Equipment
Manufacturer (OEM)/Engineered Product Supplier • Samsung Techwin, Seoul, Korea (ROK)
(EPS) for compressors and pumps. • Tominaga & Co Ltd, Tokyo, Japan
OEMs – Marine Drive: • U.S. Turbine Corp, Maineville, Ohio (now a part of
Rolls-Royce Energy Systems Inc, Power
• Cincinnati Gear Company, Cincinnati, Ohio Generation)
• Kawasaki Heavy Industries Ltd, Kobe, Japan
©
2007 August 2007
Rolls-Royce 501-K
The Rolls-Royce I&M Model 501-K series of gas drive, the 501-K is available in a two-shaft
generators and gas turbine machines are derivatives of configuration (501-KSS) to provide the flexibility of
the well-known and prolific military T56 turboprop variable-speed operation.
engine, which has provided power to such aircraft as the
The S&S 501-KSS5 two-shaft gas turbine engine is an
Lockheed P-3C, Lockheed C-130, and Grumman E-2C.
advanced version of the already proven 501-KF gas
Over 16,000 aero T56 engines were built through 2000
turbine. S&S has enhanced the KF power turbine design
(including the civil aero Model 501-D) by Allison and
to provide increased torque capability, lower fuel
licensee IHI.
consumption, and a wider range of operation. The
The I&M Model 501-K draws heavily upon the design 501-KSS5 is considered an excellent prime mover for
features of the T56, and has inherited the aviation marine propulsion and mechanical drive.
engine’s high level of performance, durability, and
Stewart & Stevenson Gas Turbine Products was
reliability. The I&M Model 501-K series machines are
purchased by General Electric in 1998, ending that
currently rated at 3.9 MW and 5.2 MW for generation
entity’s work with Allison on the 501-K.
duty.
Centrax. This U.K.-based firm previously offered the
The first industrial installation occurred in 1962, when
CX350, and currently offers the CX501 generator set
DeLaval of Houston, Texas, fabricated a compression
powered by the Model 501-KB3, -KB5, -KN, -KB7, and
set using a 501-K as the prime mover. Since that time,
-KH gas turbine machines. Its gensets supply electrical
the gas turbine has found wide use in the industrial and
power in a variety of applications, and have been
marine markets, and is handled by many OEMs,
included in cogeneration installations.
distributors, and EPSs.
In 1990, Centrax received an order for the first
Major Licensees, Distributors, Packagers,
steam-injected 501-KH machine in Europe. The project
OEMs, and EPSs. Rolls-Royce’s Engineered Product
was a combined heat and power (CHP) district heating
Suppliers combine responsibilities of the Rolls-Royce
scheme at Osimo, Italy. The equipment incorporated
traditional distributors and Original Equipment
the Cheng Cycle method of reinjecting steam produced
Manufacturer; EPSs supply the same product and
by the exhaust back into the machine’s combustion
service as the 501-K distributors, along with providing a
casing. The main contractor for the scheme was the
mechanical driver for compressors and pump
Austrian engineering firm SGP-VA Energie und
applications.
Umwelttechnik GmbH, which is the licensee for Cheng
Major firms currently working with Rolls-Royce on the Cycle in Europe; it supplied all support equipment other
Model 501-K are the following: than the Centrax equipment.
IHI. Ishikawajima-Harima Heavy Industries is a Centrax has also provided a pair of CX501-KB5s for a
licensee of Rolls-Royce in Japan. The company builds CHP plant at Par Harbor, Cornwall, England, U.K.,
the aero T56 turboprop for the P-3C, also built under owned by ECC International in partnership with BP
license in Japan. It has been a producer of the industrial Energy Ltd. The plant successfully completed
variant of the I&M Model 501-K, under the designation commissioning tests in the first half of 1992. The
IM400. IHI offered both stationary and mobile generator sets run on natural gas at 12 bar pressure to
configurations of the IM400. IHI is no longer an active provide 3.7 MW each.
licensee of the I&M Model 501-K.
U.S. Turbine Corporation. U.S. Turbine Corp (now a
Stewart & Stevenson. Stewart & Stevenson has long part of Rolls-Royce Energy Systems Inc, Power
been an innovative packager of gas turbines and Generation) has offered a full range of gas turbine and
driven-equipment products; it can act as a single-source engine generating sets in the 660-51,580 kWe range. It
for the prime mover, driven equipment, and, when has offered the 501-K in its generator sets under the
desired, for heat recovery and combined-cycle designations UST3400 (501-KB), UST3800 (501-KB5),
apparatus. S&S has packaged more Model 501-K gas UST4000 (501-KB5S), UST5000 (501-KB7),
turbines and accumulated more time on the 501-K for UST5600CC (501-KH), and UST6600CC (501-KH5),
industrial applications than any other supplier; more the latter two being fully steam-injected systems (Cheng
than 150 units have been shipped to the U.S. Navy Cycle system optimization).
alone.
U.S. Turbine and Standard Aero Ltd announced in 1995
Configured as a single-shaft machine for generator set that they had initiated a cooperative service organization
applications, the 501-K is a prime mover for hundreds to provide comprehensive site maintenance, parts
of installations worldwide. For compressor and marine support, and overhaul and repair services to users of the
August 2007
Rolls-Royce 501-K
Model 501-K. Standard Aero and U.S. Turbine opened IPT states that the Sunkist installation meets the NOx
a jointly operated aftermarket support facility at San standard of 25 ppm for the San Francisco area and
Jose (California) Airport in support of the venture. 9 ppm for all of southern California, all without the use
of expensive selective catalytic reduction (SCR) equip-
Tominaga. Tominaga & Company Ltd of Japan has
ment normally specified by the state.
supplied 501-K series engines to Hitachi Zosen for
packaging, as well as performing total service on its In 1987, it was announced that Turbonetics Energy Inc
own. Tominaga Model 501-K generator sets are desig- of Latham, New York, was developing a steam injection
nated TM501KB-301 (501-KB) and TM501KB5-351 system for the 501-K. The firm, working with the
(501-KB5). Base load ratings for these two gensets are support of the Gas Research Institute, ran a test program
3,100 and 3,620 kW, respectively, at ISO conditions. of its system at the General Motors Corp Hydra-matic
Mechanical drive machines are designated Division facility in Warren, Michigan, in the U.S.
TM501KC-301 and TM501KC5-351; continuous
Turbonetics’ system is primarily targeted at the
ratings are 5,250 horsepower and 5,750 horsepower.
replacement industrial boiler market. The system can
Turbomeca. In 1998, France’s Turbomeca (a unit of boost the power output of the turbine from 3 MW to
the Snecma Group’s Propulsion Branch) indicated that 4 MW, and can increase the electric power generating
it would take up the Allison 501-K gas turbines for efficiency from 27 percent to 35 percent. In addition,
distribution in Europe, under the designations TM4000 supplementary gas firing can increase the boiler’s steam
and TM5000. The machines give Turbomeca a high-end delivery from a nominal 8,840 kg/hr to 15,875 kg/hr,
power band. and raise overall system thermal efficiency from 60
percent to 85 percent.
Samsung Techwin. Among the newest suppliers and
distributors is Samsung Techwin in the Republic of NOx Reduction Efforts. Rolls-Royce focused on
Korea. It is building the Rolls-Royce AG9140 gas technologies that would reduce emissions and allow the
turbines under license for the three KDX-3 destroyers. burning of alternative fuels. For its gas turbine engines,
The vessels should be launched in 2006, 2008, and work has been centered on the combustion system. The
2010. work bore fruit in the LE4 Dry Low Emission
Combustion Configuration for the 501. The LE4 utilizes
Industrial Applications
lean premix and fuel staging to reduce NOx formation
Dual-Fuel Cycle. The dual-fuel cycle was invented by
and enhance the operational range of the turbine, while
Dr. Dah Yu Cheng. Rolls-Royce Model 501-KHs have
maintaining low levels of CO and providing combustion
been tested and installed for commercial operation with
stability.
Cheng Cycle equipment. Heat recovery steam
generators (HRSGs) produce high-pressure and Rolls-Royce also worked on a direct coal-fueled turbine
high-temperature steam for reinjection into the gas and conducted component development tests under a
turbine combustion chamber. The Model 501-K, for U.S. DoE contract. A full-scale combustor (70 MMBtu/
example, can produce up to 7 MW of electric power hr) has successfully been run on 100 percent coal water
with the maximum use of injected steam, and provide slurry (CWS) fuel. Separately, an engine with an
thermal efficiencies of up to 50 percent. external combustor configuration has successfully been
run on distillate fuel; engine tests using the CWS
The first installation of a Cheng Cycle gas turbine was
external combustor were completed at the end of 1990.
by Dr. Cheng’s International Power Technology (IPT)
at California State University. The second Rolls-Royce To further explore combustor capabilities and minimize
Model 501-K Cheng Cycle installation is at Sunkist the fuel costs for future commercial applications, a
Growers in California, where two Model 501s are now production-standard 501-KB5 machine was successfully
in service producing up to 14 MW of power and tested in August 1991 during a four-hour test using the
variable amounts of process steam for Sunkist food ground coal and water mixture. Data from the test
processing. showed complete and stable fuel combustion and
turbine output performance to base load design
The Kalina Cycle is the second dual-fuel cycle that has
conditions.
been explored. Kalina involves the use of
ammonia/water injection, which greatly increases In addition to work on emission technology,
effective power. Rolls-Royce has improved the durability of the
combustion system. On the 501-K, Rolls-Royce has
Both new cycles, while producing much higher outputs
developed an effusion-cooled combustion liner that uses
and thermal efficiencies, also greatly reduce the air
laser-drilled holes in the walls of the liners to lower
pollutant levels versus simple-cycle machines. Indeed,
©
2007 August 2007
Rolls-Royce 501-K
temperatures by 300°F to 400°F. The new liners were mid-2006, 25 vessels of this type were in service with
initially field-tested in 1991 and are now available on the U.S. Navy.
the 501-KB7.
Arleigh Burke Class Guided Missile Destroyer. The
In May 1993, Catalytica Inc (Mountain View, Navy developed a new 8,422-9,035-ton class of
California) and Allison announced that they had signed destroyer, incorporating a somewhat less capable
a Letter of Intent for a joint program to develop an AEGIS system; ostensibly, the vessels are to work in
ultra-low emissions catalytic combustion system for the conjunction with the CG-47 units. The Navy selected
501-K industrial engine. The intent of the program is to the LM2500 package and the 501-K34 genset
provide an engine with NOx emissions that meet the arrangement. The use of the genset enhances logistic
most stringent emission requirements worldwide. and maintenance capabilities and facilitates exchanges
of spare parts between ships. The initial ship of the
Marine Applications. Model 501-K gas turbines are
Arleigh Burke class, the DDG-51, was commissioned
in use as propulsion drive systems and shipboard
on July 4, 1991.
generation sets for both military and civil applications.
As of mid-2006, 28 Arleigh Burke (Flight I and II) class
Spruance Class Destroyers. In the early 1970s, the
guided missile vessels were in U.S. Navy service. In
U.S. Navy ordered 31 8,040-ton DD-963 Spruance class
addition, 28 Arleigh Burke (Flight IIA) class had been
destroyers. Powered by four GE LM2500 gas turbines
laid down, out of a total of 34 vessels planned; all
in a COGAG (combined gas and gas) mode and using
Flight IIA vessels are in U.S. Navy service.
three 501-K17-based shipboard generation systems,
these were the first all-gas turbine units in operation Note: The Japanese MSDF has four Kongou class
with the Navy. The 501-K17s were the first gas turbines destroyers/frigates in its inventory. The vessels are an
to pass the U.S. Navy’s 3,000-hour salt injection enlarged and improved version of the Arleigh Burke
endurance test in May 1971. class vessels, with a lightweight version of the AEGIS
system. While the vessels are powered by four GE
The Rolls-Royce/Allison units provide 2 MW of net
LM2500 gas turbines as in the Arleigh Burke class, it is
generator output power on a 100°F (38°C) day with
considered unlikely that the MSDF vessels also employ
2.37 lb/sec (1.07 kg/sec) of compressor bleed loss. In
501-K gas turbines, utilizing Japanese-design machines
addition to the 31 units built, four similar designs were
instead. The Kongou class vessels were laid down in the
ordered by Iran, featuring different weapons systems
period from 1990-May 1995.
and onboard facilities. However, those were cancelled
following the Iranian revolution. All used the 501-K17 Pegasus Hydrofoil. Saudi Arabia has one Pegasus
generation systems packaged by Stewart & Stevenson. class 115-ton hydrofoil vessel, the Al Aziziah. The
vessel was ordered in 1984 from Lockheed and
The Spruance class vessels were laid down in the period
subcontractor Boeing; it was delivered in 1985. The
from November 1972-April 1978. As of mid-2006, only
vessel has two 501-KF20A gas turbines and two Detroit
three vessels remained in the Navy’s inventory.
Diesel 8V92 diesel engines.
Ticonderoga Class Guided Missile Cruiser.
Korea KDX-3 Class Destroyers. The Republic of
Building on the proven hull and machinery of the
Korea’s KDX-3 vessels are a further development of the
DD-963s, the Navy developed the 9,407-9,590-ton
KDX-2 destroyers, but optimized for anti-air warfare.
Ticonderoga class Guided Missile Cruiser (AEGIS
cruiser), intended for the highly sophisticated AEGIS Each vessel has a displacement of 7,000 tons: they are
weapons system. The lead ship, the USS Ticonderoga 166 meters (544.6 ft) in length. The vessels should be
(CG-47), was launched in 1981. By July 1994, all 27 launched in 2006, 2008, and 2010.
vessels had been commissioned.
Rolls-Royce AG9140 gas turbines are currently being
Three 501-K17 generation sets have been installed, built under license by Samsung Techwin for the three
although each has increased capacity to accommodate KDX-3 destroyers.
the power demands of the AEGIS system. The ships
In early 2006, information had been issued regarding
operate in high-density, high-threat areas with carrier
the choice of GE LM2500 gas turbine propulsion
battle groups, as well as separately with associated
machinery of the KDX-3. Korea’s KDX-2 and KDX-1
escorts. Aboard the AEGIS cruisers, the 501-K17s have
destroyers are also GE LM2500-powered.
a rating of 2.5 MW.
Boeing Jetfoil. The Jetfoil was begun as a private
The Ticonderoga class vessels were laid down in the
venture by Boeing Marine Systems Division, Seattle,
period from January 1980-October 1991. As of
for the commercial passenger ferry sector. The initial
August 2007
Rolls-Royce 501-K
service date was April 1975. Two 501-Ks power the (NSWCCD) Gas Turbine Emerging Technologies Code
craft at speeds up to 45 knots when foil-borne, and 9334 was tasked by NSWCCD Shipboard Energy
current production variants include hydrodynamic and Office Code 859 to research and evaluate fouling
foil improvements. The ships are designated Model resistant compressor coatings for Rolls Royce Allison
929-100T and 929-115, with the latter launched in 1978. 501-K Series gas turbines. The objective of these tests
was to investigate the feasibility of reducing the rate of
An estimated 25 Allison-powered Jetfoils and similar
compressor fouling degradation and associated rate of
surface craft operate worldwide.
specific fuel consumption (SFC) increase through the
Westermoen Ferry. Two 501-K engines provide application of anti-fouling coatings Tests, which were
power for Westermoen’s W-100T catamaran ferry in conducted at the Philadelphia Land Based Engineering
service in Norway. The 100-ton vessel has capacity for Site (LBES). Testing was first performed on the existing
up to 250 passengers and provides high-density LBES 501-K17 gas turbine, which had an uncoated
transportation at speeds up to 45 knots (83.3 km/h), compressor. The compressor was then replaced by a
depending upon the sea conditions. With reserve fuel, coated compressor and the test was repeated. The test
the W-100T has a range of 418 nautical miles (774 km). plan consisted of injecting a known amount of salt
Configuration as an offshore platform workboat has solution into the gas turbine inlet while gathering
been explored. compressor performance degradation and fuel economy
data for 0, 500, 1000, and 1250 KW generator load
Halter Marine Company. A single 501-K powers the levels. This method facilitated a direct comparison of
American Enterprise, a 32-meter, 80-ton workboat in compressor degradation trends for the coated and
service in the Gulf of Mexico. Designed by Halter uncoated compressors operating with the same turbine
Marine of Louisiana, the boat has capacity for up to 82 section, thereby reducing the number of variables
passengers with reduced cargo, or 20 metric tons of involved. The collected data for turbine inlet,
cargo without passengers. Cruise speed is provided by temperature, compressor efficiency, and fuel consump-
two Detroit Diesel reciprocating compression-ignition tion were plotted as a percentage of the baseline
engines; both the GT and diesels drive Rocketdyne conditions for each compressor. The results of each plot
waterjet pumps. show a decrease in the rates of compressor degradation
Magnum Marine. U.S. boat designer/builder Magnum and SFC increase for the coated compressor compared
Marine unveiled a 63-foot (19.2-m) 18-ton Super Yacht to the uncoated compressor. Overall test results show
Magnum 63 at the 1985 Miami International Boat that it is feasible to utilize antifouling compressor
Show. The craft is powered by an Allison/Stewart & coatings to reduce the rate of specific fuel consumption
Stevenson Model 501-KF gas turbine providing increase associated with compressor performance
4,500 shp and speeds in excess of 60 knots (111 km/h). degradation.
Antifouling Compressor Coatings Evaluation. The
Naval Surface Warfare Center, Carderock Division
Significant News
Centrax Order Book Grows – Spanish ceramic company Arcilla Blanca SA has placed an order for a second
combined heat and power package from Centrax. The new 5.2 MWe natural gas-fueled CX501-KB7 package will sit
alongside the existing Centrax unit at the Arcilla Blanca site in Alcora near Castellón. The site produces the white
clay needed for high-quality porcelanico tiles.
The original Centrax package has been operating successfully in a direct drying role at the site since 2003. The new
unit will boost the total output of the CHP plant to approximately 10.4MW of electricity. As with the first unit, the
heat recovered from the turbine exhaust will be ducted to a new additional atomiser for drying the raw material used
in the tile making process. (Centrax, 10/06)
R-R AG9140 Being Built by Samsung Techwin – In October 2005, Rolls-Royce announced that AG9140 gas
turbines were being built under license by Samsung Techwin for the ROK’s KDX-3 Aegis destroyers.
©
2007 August 2007
Rolls-Royce 501-K
R-R purchases engine components for both commercial and military purposes, which are manufactured by Samsung
Techwin, such as the Trent 900 combustor and Adour combustion liners. The Korean firm, as part of a long-term
agreement signed in 2001, is the sole supplier of combustor modules for the Trent 900 for the Airbus A380. (Seoul
Air Show 2005, 10/05).
Market Intelligence Service Subscribers: For additional news, go to the online E-Market Alert page located in the Intelligence Center at
www.forecastinternational.com and click on the links to the products you subscribe to.
Funding
U.S. Navy Ship Propulsion/Power Procurement. The U.S. Navy continues to request funding for the
procurement of the marine 501-K gas turbine. In the FY08 Department of Defense Budget submission (February
2007), the Navy sought funds under the category “Other Procurement, Navy, BA 1: Ship Support Equipment, P-1
Item Nomenclature = Allison 501-K Gas Turbine (81GF) (0120).”
Note: The U.S. Navy continues to refer to the manufacturer of the 501-K engine/machine as Allison.
U.S. Navy documentation contains the following information pertaining to the Allison (more appropriately,
Rolls-Royce) 501-K gas turbine:
The 501-K Series Gas Turbines are used to drive electrical generators in Ship Service Gas Turbine Generators (SSGTG).
The 501-K17 is used on the CG-47 Class ships. The501-K34 is an upgraded version used on the DDG-51 Class ships and is
not interchangeable with the 501-K17.
501-K34 Stock Rotating Spares (GF001)
The Stock Rotating Spares Program provides an engine as a single assembly for the replacement of an engine requiring
depot repair. The current 501-K17 engine is being replaced by the upgraded (more powerful) 501-K34 engine commencing
with the DDG-51 Class. The 501-K34 upgraded engine can only be replaced with another 501-K34 upgraded engine. The
501-K34 inventory objective is 22 units. Twenty-one units have been procured through FY06, and one unit is included in the
budget for FY07. In addition, the RRC-250-KS4 gas turbine engine has been introduced into the DDG-51 Class Destroyers,
as part of the starting system for the 501-K34, commencing with DDG-78. A spare pool of 10 KS4 engines is required to
ensure adequate sparing. Eight units have been procured through FY06. The remaining two engines will be procured in
FY07.
Modification Program (GF007)
Allison 501-K Gas Turbines are identified as the number one fleet issue by the Top Management Attention/Top
Management Issues (TMA/TMI) Program, the Combatant Technical Issues Conference (CTIC), and the DDG-51 Top Tech
Issue Program. Procurement of improved hardware for installation in the 501-K gas turbine is essential to increase engine
reliability, Mean Time Between Removal (MTBR), and maintainability. Analysis of 501-K engineering performance data,
TMA/TMI, Metrics, the DDG-51 Top Tech Issues, CTIC, and the component improvement program has identified
necessary improvements to correct 501-K deficiencies. The modifications will reduce failure rates of system
components,improving 501-K and SSGTG readiness, and address the Fleet’s top maintenance and reliability issues. The
additional requirement in FY06 and out will be used to resolve additional issues identified by the TMA/TMI, Metrics, and
the DDG-51 Top Tech Issues Programs. The specific additional issues addressed are Fuel Nozzles and Engine Controls.
Special Support Equipment (SSE) (GF009)
Procurement of Gas Turbine SSE is required to provide increased SIMA and depot repair capability to support the CG-47
and DDG-51 class ships. SIMA capability is enhanced by providing them the SSE necessary to reduce engine change-outs
and is required to incorporate new modifications that will eliminate deficiencies identified through the TMA/TMI, Metrics,
and the DDG-51 Top Tech Issues Programs, and enhance MTBR reliability and maintainability. Procured SSE supports the
depot by increasing repair capability and allowing installation of new modifications that will eliminate deficiencies
identified through the TMA/TMI, Metrics, and the DDG-51 top Tech Issues Programs, and enhance MTBR reliability and
maintainability.
Full Authority Digital Control (FADC) (GF015)
Funding will be used to procure and install the replacement for the Local Operating Panel with the FADC that will upgrade
reliability and maintainability of the control system. Those units will be installed on both the DDG-51 and CG-47 class
ships. Three FADCs are required on each ship.
Production Engineering (GF830)
The review and approval of any production contract technical documentation or the separate development of this
documentation to include: technical manuals, signal flow diagrams, PMS, production drawings, Provisioning Technical
Documentation (PTD), and Allowance Parts Lists (APLs) and engineering in support of final design reviews.
August 2007
Rolls-Royce 501-K
Electric Starter (GF016)

Gas turbines are started with pneumatic (air) starters: these are maintenance-intensive and complex. In FY06, we will start to
backfit the fleet with electric starters.
Optical Flash Detector (GF017)
This sensor will detect and record an irregular start in the engine, then notify the operator that maintenance is required. This
new technology will increase the life of the engine.
Hot Section Replacement (GF018)
The current hot section (blades and blade track) will benefit greatly by utilizing different coatings and a metal, versus a
ceramic blade track. We have evaluated several types, and will begin to procure the best replacement in FY07.
Funding for Cost Codes GF001, GF007, GF009, GF010, GF830, GF016, and GF017 is identified below, as
contained in the U.S. Navy’s FY07 Budget Submission of February 2006.
U.S. NAVY PROCUREMENT FUNDING
FY06 FY06 FY07 FY07 FY08 FY08
QTY AMT QTY AMT QTY AMT
GF001 501-K34 1 1.36 1 1.35 - -
GF007 Modific. Prog. - 8.96 - 6.41 - 3.48
GF009 Spec. Support Equip. - 0.26 - 0.26 - 0.26
GF015 FADC 27 9.93 15 5.85 10 4.00
GF830 Production Engrg. - 0.14 - 0.16 - 0.15
GF016 Electric Starter 2 0.55 2 0.56 2 0.58
GT017 Optical Flash Det. Sys. - 2.4 - - - -
GF018 Hot Section Replacement - - - - 10 2.0
All dollar amounts are in millions of FY08 U.S. dollars.

Beyond FY08, the total planned funding request is as follows (as of February 2007): FY08, $9.46 million; FY09,
$9.44 million; FY10, $9.0 million; and FY11, $9.2 million.
U.S. Navy RDT&E. Funding for the Rolls-Royce Marine 501-K machine has been provided/sought under several
U.S. Navy program elements, as follows:
In 1970, PE#63508N, Ship Propulsion System (Advanced) was initiated to develop advanced gas turbine propulsion
and auxiliary power systems for U.S. naval combatants. It was the progenitor of the GE LM2500, Rolls-Royce
501-KF, AlliedSignal Garrett IE 831 (now Vericor ASE 8), Pratt & Whitney FT9, and Solar Turbines Rankine
Cycle Energy Recovery System. Recent emphasis has been on improvements to the LM2500 propulsion systems
and 501-KF generating systems, the since-canceled RACER project, and the LM3000 Intercooled, Recuperated (or
Regenerative) Cycle (ICR) gas turbine.
Allison 501-K funding has been awarded under PE#0603508N and PE#0603573N. No 501-K funding has been
awarded in PE#0603508N since FY99. Non-501-K-related funding can be found in PE#0603573N.
In the FY07 Department of Defense Budget submission (February 2006), the Navy sought funds under RDT&E
Budget Activity 7, PE#0708011N, Industrial Preparedness, Project R1050, Manufacturing Technology. Work on
the 501-K machine is contained in the first of five subefforts, “Metals Processing and Fabrication” (excluding the
FY05-FY06 congressional plus-ups).
Work identified in that PE’s “Accomplishments” and “Plans,” in the subeffort “Metals Processing and Fabrication,”
includes the following:
A. FY06 Accomplishments
Completed Hot Section Corrosion Protection for 501-K34 Gas Turbine effort.
B. FY07 Plans
Complete Turbine Inspection Techniques effort.
C. FY08 Plans
(No tasks specifically identifying the 501-K engine/machine).
D. FY09 Plans
(No tasks specifically identifying the 501-K engine/machine).
©
2007 August 2007
Rolls-Royce 501-K
The following top-line funding is for all activities within Project R1050; the second line in parentheses and italics is
funding solely for the sub-effort “Metals Processing and Fabrication.”
U.S. NAVY RDT&E FUNDING
FY06 FY06 FY07 FY07 FY08 FY08
QTY AMT QTY AMT QTY AMT
PE#0708011N
R1050 Manuf. Technology - 55.44 - 54.96 - 56.44
(Metals Processing) - 18.98 - 19.72 - 21.57
All dollar amounts are in millions of FY08 U.S. dollars.
Beyond FY08, the total planned RDT&E request for PE#0708011N, Project R1050, is as follows (as of February
2007: FY09, $58.76 million; FY10, $58.92 million; and FY11, $59.83 million.
Contracts/Orders & Options

Award
Contractor ($ millions) Date/Description
Centrax Ltd N/A Aug 2006 – Centrax has won an order from Portugal to supply a generator set to the
Continental Tyres plant in Lousado, near Porto. The CX 501-KB7 DLE package has
been sold to Enerlousado, a special-purpose Joint Venture CEM company between
Finerge and TP (Sociedade Termica Portuguese SA). The 5.2-MWe Centrax
package, powered by the Rolls-Royce 501-KB7 gas turbine, is coupled to an
oversized 15-kV generator. The size of the generator will help to counter any
instability of supply from the Portuguese electricity grid.
Centrax Ltd N/A Jun 2006 – Centrax has been awarded a contract to supply a CX501-KB7 gas
turbine-powered generator set to Tunisian papermill, Sotipapier. The new 5.2-MWe
package is the first generator set sold by Centrax into Tunisia. The Centrax unit is
natural gas-fueled and will be used for cogeneration at the Sotipapier papermill in the
town of Belli, which is approximately 35 kilometers southeast of Tunis.
Centrax Ltd N/A May 2006 – Centrax was awarded an order from Elyo, part of Suez Energie Services,
to supply two CX501-KB5 generator sets. The sets will be used to provide power for
Goodyear’s two Goodyear Dunlop tire plants in Amiens. The Centrax packages will
be operated in a cogeneration capacity.
Centrax Ltd N/A Jan 2006 – Centrax was awarded an order for a 3.5-MWe CX501-KB5 generator set
for the INA Molve gas processing facility in Croatia. The package will be supplied
through KONCAR – Power Plant and Electric Traction Engineering Inc, which is the
project’s main contractor on behalf of INA-Naftaplin, the Croatia national oil and gas
company.
Nov 2005 – Centrax was awarded an order for a 5.2-MWe CX501-KB7 generator set
for installation at the Tunisian paper mill, Sotipapier, in the town of Belli, 30
kilometers from Tunis. The gas turbine package will supply electricity and heat, the
latter to be used to generate steam for use in the production of paper.
Centrax Ltd N/A Sep 2005 – Centrax was awarded a follow-on order for a 5.2-MWe CX501-KB7
generator set for installation at the Spanish ceramics giant Taulell SA’s plant near
Castellon, Spain.
August 2007
Rolls-Royce 501-K
Timetable
Month Year Major Development
1952 Start of development of Model 501/T56 aviation turboprop engine
1956 First aero-engine application acquired
1962 First industrial 501-K installed
1971 First marine application garnered on DD-963 class
Mid- 1987 Initial AG9130s sent to Bath Iron Works
Aug 1990 First sea trial of AG9130-equipped Arleigh Burke class destroyer
Late 1990 Testing of CWS external combustor completed
Jun 1991 Allison announces work on Model 501-KB7
Late 1991 Effusion-cooled combustion liners made available
Late 1991 Pilotless dual-fuel nozzles become available
1992 Model 501-KB7 becomes available
May 1993 Catalytica and Allison announce LoI for joint program on ultra-low emission catalytic
combustion system
1994 Model 501-KB3 and Model 501-KB4 become available
1998 Model 601-K machines shipped
1998 ATS low-emissions project with DoE, Gas Research Institute begun
1998 Turbomeca becomes supplier of 501-K gensets
1999 ATS component tests begin
Nov 2005 Centrax gets first order from Tunisia
2006 Launch of first ROK AG9140-equipped KDX-3 destroyer
Thru 2016 Continued production/availability of 501-K I&M series
Worldwide Distribution/Inventories
At the start of 2007, more than 2,050 Rolls-Royce 501-K series gas turbine engines had been built and installed in
43 nations and territories worldwide. Major customer nations are China (32 machines, including Hong Kong),
Canada (35), Egypt (56), France (72) India (91), Iran (65), Japan (51), Mexico (56), U.K. (59), U.S. (944), and
Venezuela (60).
Forecast Rationale
The Rolls-Royce 501-K machine series continues to active, a few machines have been installed recently in
garner orders despite brisk competition from machines Japan by IHI. We have not yet heard of any orders
from Solar, Kawasaki, GE Oil & Gas, and Siemens AG booked by Turbomeca.
(the latter referring to the former Alstom line of
In the mechanical drive arena, the 501-K should
machines whose power output is less than 50 MW).
continue to sell well, taking advantage of the large base
Rolls-Royce has been working actively in emissions of installed Allison/Rolls-Royce machines worldwide.
reduction, focusing on lean premix and catalytic
With the use of Rolls-Royce’s Long Term Service
combustion systems (Rolls and Solar have even worked
Agreements (LTSAs), the customer of 501-Ks (and of
together on assessing the durability of various catalysts).
all of R-R’s product line) secures Rolls-Royce as the
The ongoing effort has made the 501-K very viable and
service and maintenance provider in multiyear
competitive from an emissions perspective. In addition,
contracts, ensuring continuity and reducing costs over
Rolls-Royce continues to update the gas turbine with the
the long term.
most current technology, including adopting aeroengine
technology. Overall, Rolls-Royce is projected to produce 460 of the
501-K series gas turbines in the 2007-2016 decade,
The 501-K continues to be sold for electrical generation
largely for generation/cogeneration duty. A total of 109
duty, in particular by Centrax, the U.K.-based firm that
501-K units are forecast for duty as mechanical drivers,
remains in the forefront for booking the greatest number
including the 501-KC7.
of orders for the engine model. Even with Centrax
©
2007 August 2007
Rolls-Royce 501-K
Our forecast contains many 501-KH5 steam-injected Our forecast does not include regular series production
models: we feel that the “time is ripe” for those models. of the 501-K for marine propulsion. Orders for the gas
turbine for that application will most likely be twos and
Our forecast does not break out the mechanical drive
threes at infrequent intervals in the decade.
501-KC7 from that of the 501-KC5. We have not seen
sufficient orders for that 5,500-bhp machine (as of the The AG9140s for the ROK’s 7,000-ton KDX-3 class
date of this report) to warrant a separate line item in the destroyers are contained in the chart below under
chart below. “Generation.”
Ten-Year Outlook
ESTIMATED CALENDAR YEAR UNIT PRODUCTION

Designation or Program High Confidence Good Confidence Speculative
Thru 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 Total
Rolls-Royce Energy
501 (RR) -K B5 <> MW 3.0 to <10.0 <> power generation
Note: Historical production has included some 501-KB5S models.
1,296 9 11 11 11 11 10 10 10 10 10 103
501 (RR) -K B7 <> MW 3.0 to <10.0 <> power generation

195 20 21 22 20 20 22 22 22 20 20 209
501 (RR) -K C5 <> MW 3.0 to <10.0 <> power generation

Note: Machine model is steam injected.
28 2 1 3 0 4 5 6 6 6 6 39
501 (RR) -K C5 <> SHP 3,000 to <10,000 <> mechanical drive (pumps & compressors)
Note: Historical production includes one 501-KC7.
535 9 10 10 12 12 12 10 10 12 12 109
Subtotal 2,054 40 43 46 43 47 49 48 48 48 48 460
Total 2,054 40 43 46 43 47 49 48 48 48 48 460
August 2007
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The Gas Turbine Electrical

Power Generation Market

Product Code #F646

A Special Focused Market Segment Analysis by:

Heavy Gas Turbines (11,185 kW and Larger)

Light Gas Turbines (Up to 11,185 kW)

Outlook Unit Production Forecast

expected to garner sales in the decade, especially for

The MS6001B in combined-cycle duty has the following performance parameters:

The MS6001FA in combined-cycle duty has the following performance parameters:

GE MS6001FA (Frame 6FA)

Contracts/Orders & Options

Engine/Machine Application Thru 06

ESTIMATED CALENDAR YEAR UNIT PRODUCTION

Model 6000 (Frame 6) (MS6001) B/C <> power generation

Model 6000 (Frame 6) (MS6001) F A <> power generation

Total 416 11 15 20 24 26 24 25 26 25 24 220

Outlook Unit Production Forecast

• Production funding still expected from the U.S. Navy; 0

501-KC5 – – 6.4 x 2.4 x 3.0 21.0 x 8.0 x 10.0

APPLICATION = MECHANICAL DRIVE SETS

Electric Starter (GF016)

All dollar amounts are in millions of FY08 U.S. dollars.

All dollar amounts are in millions of FY08 U.S. dollars.

Contracts/Orders & Options

ESTIMATED CALENDAR YEAR UNIT PRODUCTION

501 (RR) -K B7 <> MW 3.0 to <10.0 <> power generation

501 (RR) -K C5 <> MW 3.0 to <10.0 <> power generation

Total 2,054 40 43 46 43 47 49 48 48 48 48 460

Name of Product/Service Code E-Mail Address Qty. Price

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