Rolls-Royce RB211
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Search Wikipedia Rolls-Royce RB211 The Rolls-Royce RB211 is a family of high-bypass turbofan engines made RB211 by Rolls-Royce plc and capable of generating 37,400 to 60,600 pounds- force (166 to 270 kilonewtons) thrust. Originally developed for the Lockheed L-1011 TriStar, it entered service in 1972 and was the only engine to power this type of aircraft. Its RB211 engine was the first three-spool engine, and it was to turn Rolls-Royce from a significant player in the aero-engine industry into a global leader. Already in the early 1970s the engine was reckoned by the company to be capable of at least 50 years of continuous development.[1][2] Rolls Royce RB211-524C2 engine on a Bahrain The RB211 was officially superseded in the 1990s by the Rolls-Royce Trent Royal Flight Boeing 747SP family of engines, the conceptual offspring of the RB211.[1] Type Turbofan National origin United Kingdom Contents Manufacturer Rolls-Royce First run 1969 History Major applications Lockheed L-1011 TriStar Background Boeing 747 Boeing 757 Finalisation of design Boeing 767 Tupolev Tu-204 RB211-22 series Developed into Rolls-Royce Trent Development and testing Insolvency and aftermath RB211-524 series RB211-535 series Industrial RB211 Marine WR-21 Specifications RB211-22 series RB211-524 series RB211-535 series Leading particulars See also References External links History Background In 1966 American Airlines announced a requirement for a new short-medium range airliner with a focus on low-cost per-seat operations. While they were looking for a twin-engined plane, the aircraft manufacturers needed more than one customer to justify developing a new airliner. Eastern Airlines were also interested, but needed greater range and needed to operate long routes over water; at the time this demanded three engines in order to provide redundancy. Other airlines were also in favour of three engines. Lockheed and Douglas responded with designs, the L-1011 TriStar and DC-10 respectively. Both had three engines, transcontinental range and seated around 300 passengers in a widebody layout with two aisles. Both planes also required new engines. Engines were undergoing a period of rapid advance due to the introduction of the high bypass concept, which provided for greater thrust, improved fuel economy and less noise than the earlier low-bypass designs. Rolls-Royce had been working on an engine of the required 45,000 lbf (200 kN) thrust class for an abortive attempt to introduce an updated Hawker Siddeley Trident as the RB178. This work was later developed for the 47,500 lbf (211 kN) thrust RB207 to be used on the Airbus A300, before it was cancelled in favour of the RB211 programme. Meanwhile Rolls-Royce was also working on a series of triple-spool[3] designs as replacements for the Conway, which promised to deliver higher efficiencies. In this configuration, three groups of turbines spin three separate concentric shafts to power three sections of the compressor area running at different speeds. In addition to allowing each stage of the compressor to run at its optimal speed, the triple-spool design is also more compact and rigid, although more complex to build and maintain. Several designs were being worked on at the time, including a 10,000 lbf (44 kN) thrust design known as the RB203 intended to replace the Rolls-Royce Spey. Work started on the Conway replacement engine in July 1961 and a twin-spool demonstrator engine to prove the HP compressor, combustor, and turbine system designs, had been run by 1966. Rolls- Royce chose the triple-spool system in 1965 as the simplest, lowest cost solution to the problem of obtaining lower fuel consumption and reduced noise levels at a constant power setting. Work on the RB211 as essentially a scaled-down RB207 began in 1966-7 with the first certificated engines being scheduled to be available by December 1970 at 33,260lb take-off thrust and at a price of $511,000 each.[4] Finalisation of design On 23 June 1967, Rolls-Royce offered Lockheed the RB211-06 for the L-1011. The new engine was to be rated at 33,260 lbf (147,900 N) thrust and combined features of several engines then under development: the large high-power, high-bypass design from the RB207 and the triple-spool design of the RB203.[5] To this they added one totally new piece of technology, a fan stage built of a new carbon fibre material called Hyfil developed at RAE Farnborough. The weight savings were considerable over a similar fan made of steel, and would have given the RB211 an advantage over its competitors in terms of power-to-weight ratio. Despite knowing that the timescale would be challenging for an engine incorporating these new features, Rolls-Royce committed to putting the RB211 into service in 1971.[6] Lockheed felt the new engine would offer a distinct advantage over the otherwise similar DC-10 product. However, Douglas had also requested proposals from Rolls for an engine to power its DC-10, and in October 1967 Rolls responded with a 35,400 lbf (157,000 N) thrust version of the RB211 designated the RB211-10. There followed a period of intense negotiations between airframe manufacturers Lockheed and Douglas, potential engine suppliers Rolls-Royce and General Electric and Pratt & Whitney, as well as the major U.S. airlines. During this time prices were negotiated downwards, while the required thrust ratings were raised ever higher. By early 1968, Rolls was offering a 40,600 lbf (181,000 N) thrust engine designated RB211-18. Finally, on 29 March 1968 Lockheed announced that it had received orders for 94 TriStars, and placed an order with Rolls-Royce for 150 sets of engines designated RB211-22.[6][7] RB211-22 series Development and testing The RB211's complexity required a lengthy development and testing period. By Autumn 1969 Rolls-Royce was struggling to meet the performance guarantees to which it had committed: the engine had insufficient thrust, was over-weight and its fuel consumption was too high. The situation deteriorated further when in May 1970 the new Hyfil (a Carbon (fiber) composite) fan stage, after passing every other test, shattered into pieces when a chicken was fired into it at high speed.[8] Rolls had been developing a titanium blade as an insurance against difficulties with Hyfil, but this meant extra cost and more weight. It also brought its own technical problems when it was discovered that only one side of the titanium billet was of the right metallurgical quality for blade fabrication.[9] In addition, the project had suffered a serious setback with the sudden death of Chief Engineer Adrian "Lom" Lombard in July 1967, a loss that was described as Rolls-Royce having been "deprived of one of the finest trouble-shooting engineers in the industry".[10] In September 1970, Rolls-Royce reported to the government that development costs for the RB211 had risen to £170.3 million - nearly double the original estimate; furthermore the estimated production costs now exceeded the £230,375 selling price of each engine.[6] The project was in crisis.[11] Insolvency and aftermath By January 1971 Rolls-Royce had become insolvent, and on 4 February 1971 was placed into receivership,[note 1] seriously jeopardising the L-1011 TriStar programme. Because of its strategic importance, the company was nationalised by the then- Conservative government of Edward Heath, allowing development of the RB211 to be completed.[12] As Lockheed was itself in a vulnerable position, the government required that the US government guarantee the bank loans that Lockheed needed to complete the L-1011 project. If Lockheed (which was itself weakened by the difficulties) had failed, the market for the RB211 would have evaporated. Despite some opposition, the US government provided these guarantees.[13] In May 1971, a new company called "Rolls-Royce (1971) Ltd." acquired the assets of Rolls-Royce from the Receiver, and shortly afterwards signed a new contract with Lockheed. This revised agreement cancelled penalties for late delivery, and increased the price of each engine by £110,000.[14] Hugh Conway (managing director RR Gas Turbines), persuaded Stanley Hooker to come out of retirement and return to Rolls Royce.[15][16] As technical director he led a team of other retirees to fix the remaining problems on the RB211-22. The engine was finally certified on 14 April 1972,[17] about a year later than originally planned, and the first TriStar entered service with Eastern Air Lines on 26 April 1972. Hooker was knighted for his role in 1974.[18] The RB211's initial reliability in service was not as good as had been expected because of the focus of the development programme on meeting the engine's performance guarantees. Early deliveries were of the RB211-22C model, derated slightly from the later -22B. However, a programme of modifications during the first few years in service improved matters considerably, and the series has since matured into a highly reliable engine. RB211-524 series Although originally designed for the L-1011-1, Rolls-Royce knew that the RB211 could be developed to provide greater thrust. By redesigning the fan and the IP compressor, Hooker's team managed to increase the engine's thrust to 50,000 lbf (220 kN). The new version, which first ran on 1 October 1973,[19] was designated RB211-524, and would be able to power new variants of the L- 1011, as well as the Boeing 747. Rolls-Royce had tried without success to sell the RB211 to Boeing in the 1960s, but the new -524 offered significant performance and efficiency improvements over the Pratt & Whitney JT9D which Boeing had originally selected to power the 747.