The Pratt & Whitney Purepower® Geared Turbofan™ Engine Overview
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9/27/2015 The Pratt & Whitney PurePower® Geared Turbofan™ Engine Alan Epstein VP, Technology and Environment Pratt & Whitney Academie de l’Air et de l’Espace Paris, September 2015 © 2015 United Technologies Corporation This document has been publicly released 1 Overview The Development of the Geared TurbofanTM Engine • Some historical perspective • A recurrent theme - conventional wisdom vs. reality • The roles of architecture, design, and technology • Speculation on the future © 2015 United Technologies Corporation This document has been publicly released 2 1 9/27/2015 PurePower® Geared Turbofan™ Engine © 2015 United Technologies Corporation This document has been publicly released 3 Why History? “There is nothing new in the world except the history you do not know.” Harry S. Truman © 2015 United Technologies Corporation This document has been publicly released 4 2 9/27/2015 Pratt & Whitney – Dependable Engines Wasp Pic Wasp Engine Turbofan Engine 1925 2015 © 2015 United Technologies Corporation This document has been publicly released 5 Eras of Engine Architecture Single Spool Dual Spool Turbojet High Bypass Turbofan Ultra-High Bypass (1937) (1951) (1969) Geared Turbofan (2015) >10% STEPS IN EFFICIENCY OVERALL EFFICIENCY EFFICIENCY OVERALL 1940 1960 1980 2000 2020 © 2015 United Technologies Corporation This document has been publicly released 6 3 9/27/2015 Geared Turbofan Technology Demonstrators Over 50 years of interest Hamilton Standard General Electric Lycoming ALF502 4 5 Pratt & Whitney PW304, 1957 Q-Fan, 19722 QCSEE, 1977 1980 1960 1970 1980 1990 Turbomeca Astafan Variable Garrett TFE731 Rolls Royce Dowty Pratt & Whitney 1 Pitch Fan, 1969 19705 M45SD-02, 19753 ADP X-Engine, 1992 Image Credits 1 Johan Visschedijk Collection 2 Schaefer, et al, NASA, 1977 3 Simon JP O’Riordan 4 NASA 5 Wikimedia Commons © 2015 United Technologies Corporation This document has been publicly released 7 P&W Hydrogen Fueled Aircraft Engine Project Suntan – Liquid H2 engine circa 1957-58 © 2015 United Technologies Corporation This document has been publicly released 8 4 9/27/2015 Geared Turbofan Technology Demonstrators Variable pitch fans Hamilton Standard General Electric Q-Fan, 19722 QCSEE, 19774 1960 1970 1980 1990 Turbomeca Astafan Variable Rolls Royce Dowty Pratt & Whitney 1 Pitch Fan, 1969 M45SD-02, 19753 ADP X-Engine, 1992 Image Credits 1 Johan Visschedijk Collection 2 Schaefer, et al, NASA, 1977 3 Simon JP O’Riordan 4 NASA © 2015 United Technologies Corporation This document has been publicly released 9 Turbofan Conversion Geared Engines Turboprops/shaft transformed into high FPR turbofans Garrett TFE731 1970 1960 1970 1980 1990 Lycoming ALF502 1980 Image Credits Wikipedia commons FPR = fan pressure ratio © 2015 United Technologies Corporation This document has been publicly released 10 5 9/27/2015 $1B Technology Investment 25 years of research prior to product launch © 2015 United Technologies Corporation This document has been publicly released 11 Challenging Conventional Wisdom Conventional wisdom - areas of general consensus • Gears – too heavy, too much heat to reject, short-lived © 2015 United Technologies Corporation This document has been publicly released 12 6 9/27/2015 GTF™ Engine Architecture for the 21st Century Conventional Engine Higher Efficiency, Lower Noise © 2015 United Technologies Corporation This document has been publicly released 13 GTF™ Engine Architecture for the 21st Century Turning Vision Conventional Engine Higher Efficiency, Lower Noise © 2015 United Technologies Corporation This document has been publicly released 14 7 9/27/2015 GTF™ Engine Architecture for the 21st Century Into Reality Conventional Engine Higher Efficiency, Lower Noise © 2015 United Technologies Corporation This document has been publicly released 15 Fan Drive Gear System 25 years of technology development Efficient: >99.5% Simple: 13 major parts Reliable: 20 years before maintenance © 2015 United Technologies Corporation This document has been publicly released 16 8 9/27/2015 Three Interlocking Enabling Technologies Enable step change in propulsor performance Very Light Weight Light Weight Advanced Reliable Gear Extra Efficient Fan Nacelle 2 + 2 + 2 = 16% Improvement in Fuel Burn © 2015 United Technologies Corporation This document has been publicly released 17 Challenging Conventional Wisdom Conventional wisdom - areas of general consensus • Gears – too heavy, too much heat to reject, short lived • Low FPR Fans – need variable pitch or variable nozzle © 2015 United Technologies Corporation This document has been publicly released 18 9 9/27/2015 Low Fan Pressure Ratio Needs a Variable Area Nozzle A widely accepted view “Fan pressure ratios at cruise significantly lower than, say, 1.45 will probably have to wait until variable nozzles for the bypass stream become available or acceptable, a point that has been recognized in the industry for some time. In other words, the variable area nozzle is an enabling technology for lower fan pressure ratio.” * *Cumpsty, N.A., Journal of Turbomachinery, Oct 2010 © 2015 United Technologies Corporation This document has been publicly released 19 Low Fan Pressure Ratio Needs a Variable Area Nozzle © 2015 United Technologies Corporation This document has been publicly released 20 10 9/27/2015 PW1100G-JM / A320neo Nacelle © 2015 United Technologies Corporation This document has been publicly released 21 Challenging Conventional Wisdom Conventional wisdom - areas of general consensus • Gears – too heavy, too much heat to reject, short lived • Low FPR Fans – need variable pitch or variable nozzle • Nacelles – too large in diameter, too much drag © 2015 United Technologies Corporation This document has been publicly released 22 11 9/27/2015 Low Noise Fans Enable Short Inlets Less noise produced less acoustic treatment needed Legacy GTF Inlet L/D~1 Inlet L/D ~0.5-0.6 © 2015 United Technologies Corporation This document has been publicly released 23 Engine Diameter Grows as Length Shrinks 35,000 lbs thrust (today) versus 47,000 lbs (1976) © 2015 United Technologies Corporation This document has been publicly released 24 12 9/27/2015 A Challenge to Retrofit a Much Larger Engine Image courtesy of JetBlue © 2015 United Technologies Corporation This document has been publicly released 25 Challenging Conventional Wisdom Conventional wisdom - areas of general consensus • Gears – too heavy, too much heat to reject, short lived • Low FPR Fans – need variable pitch or variable nozzle • Nacelles – too large in diameter, too much drag • Composite blades are a superior, lighter solution © 2015 United Technologies Corporation This document has been publicly released 26 13 9/27/2015 Hybrid Metallic Fan Blade Disciplined approach surprised conventional wisdom Solid TiSolid Ti Hollow Ti Hybrid Metallic 1980 1990 2000 2010 2020 Fiber reinforced 2D Composite 3D Woven Fiber reinforced Composite © 2015 United Technologies Corporation This document has been publicly released 27 Advanced Fan Blade Very high efficiency, very low noise Bird Strike Resistant Superior Aerodynamics Hybrid-Metallic 1% Better Fuel Burn Construction © 2015 United Technologies Corporation This document has been publicly released 28 14 9/27/2015 Challenging Conventional Wisdom Conventional wisdom - areas of general consensus • Gears – too heavy, too much heat to reject, short lived • Low FPR Fans – need variable pitch or variable nozzle • Nacelles – too large in diameter, too much drag • Composite blades are a superior solution • Low emissions requires lean burn combustors © 2015 United Technologies Corporation This document has been publicly released 29 TALON™ X Rich Burn Quick Quench Combustor Best in class emissions and performance Blow out free 3rd Generation RQL aero World-class emissions and smoke levels Highly durable float wall construction 3rd Gen combustor alloys for oxidation Compact, lightweight configuration No complicated fuel nozzles or staging Optimized exit profile temperatures emissions X >40% Margin to CAEP/8 NO -35% to -40% © 2015 United Technologies Corporation This document has been publicly released 30 15 9/27/2015 Challenging Conventional Wisdom Conventional wisdom - areas of general consensus • Gears – too heavy, too much heat to reject, short lived • Low FPR Fans – need variable pitch or variable nozzle • Nacelles – too large in diameter, too much drag • Modern fans must use composite blades • Low emissions requires lean burn combustors • Higher pressure ratio core compressors are superior © 2015 United Technologies Corporation This document has been publicly released 31 Architecture and Spool Pressure Ratio Engine architecture sets optimum low-high split 10 9 3-Spool 8 8 50/50 7 2-Spool Geared 6 6 50 5 40 30 4 4 2-Spool Pressure Ratio Pressure 3 2 2 Fan+Low Pressure Compressor Fan+Low Compressor Pressure 1 412462 68 810 10 12 14 1614 1618 1820 20 222 High Pressure Compressor Pressure Ratio © 2015 United Technologies Corporation This document has been publicly released 32 16 9/27/2015 Same Overall Pressure Ratio (OPR) Geared vs. direct drive different split among spools 450 1300 140 400 PW1000G geared turbofan engine Two Spool engine 600 1350 220 2100 45% fewer airfoils – 6 fewer stages © 2015 United Technologies Corporation This document has been publicly released 33 High Speed Low Pressure Turbine Higher speed improves efficiency and drops weights Gear Enables High Speed LPT Higher Efficiency Lower Stage Count >1700 fewer Airfoils Lower Weight Smaller Diameter and Length Better installation, lower airframe weight Lower Maintenance