The Evolution of Gas Turbine Generator Set Reliability in the U.S. Navy

2006 ◽  
Author(s):  
Dennis M. Russom ◽  
Ivan Pin˜eiro
Keyword(s):  
Gas Turbine ◽  
Lessons Learned ◽  
Turbine Generator ◽  
Mean Time Between Failure ◽  
The Future ◽  
Generator Sets ◽  
Mean Time ◽  
The U.S

This paper looks back at the evolution of the Gas Turbine Generator sets (GTGs) in the U.S. Navy’s DDG 51 Class, reviewing lessons learned, successes and areas where work is still required. Topics are discussed in the context of Mean Time Between Failure (MTBF) Total Ownership Cost (TOC) and maintainability. It reviews changes that resulted in MTBF increasing by a factor of five and TOC dropping by a factor of four. It also looks to the future, identifying potential areas of further improvement.

U.S. Navy Experience With SSS (Synchro-Self-Shifting) Clutches

2008 ◽  
Author(s):  
Morgan L. Hendry ◽  
B. Michael Zekas
Keyword(s):  
Steam Turbine ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Failure Modes ◽  
Lessons Learned ◽  
Design Features ◽  
Propulsion Systems ◽  
Turbine Generator ◽  
Mean Time ◽  
The U.S

The U.S. Navy has nearly forty years of experience using SSS (Synchro-Self-Shifting) Clutches in main reduction gears of gas-turbine-driven ships and propulsion systems with combinations of gas turbines and diesel engines or electric motors, and in steam-turbine propulsion plants for use with electric motor drives. Over 900 SSS Clutches have been installed in fourteen different classes of U.S. Navy ships, some in service for over thirty years. This paper presents a brief overview of the principle SSS Clutch design features and the operating experience in naval propulsion systems worldwide, including operation in various propulsion plants such as controllable reversible pitch (CRP) propellers, fixed-pitch propellers (FPP), etc. The paper will also focus on SSS Clutch designs for specific U.S. Navy applications and installations, U.S. Navy experience, and design changes and improvements that have been implemented since the initial U.S. Navy use of SSS Clutches. Detailed metric (statistical) data, used by the U.S. Navy to evaluate equipment performance and life cycle costs, such as mean time between failure (MTBF), mean time to repair (MTTR), mean logistics delay time (MLDT), and operational availability (Ao) will be used to support experience. In-service experience and failure modes will also be explained as well as findings from the evaluation of clutches that have been subjected to extreme operation/incidents such as overspeed, overtorque, high shock blast, and flood damage. The final part of the paper will discuss current/future applications on U.S. Navy vessels such as the LHD-8, LCS and others; and how the design/features of those SSS Clutch designs will satisfy the operational, reliability, and maintainability requirements established for each ship platform. The metrics and lessons learned will be shown to be equally applicable to clutches for critical auxiliary drive applications such as naval gas turbine generator starting and naval steam turbine generator turning gear systems and how these metrics and lessons learned are being applied for current and future U.S. Navy ship systems.

Improving Operational Availability of Gas Turbine Generators Aboard U.S. Navy DDG-51 Class Ships by Combining the Capabilities of the Integrated Condition Assessment System (ICAS) and the Generator Set’s Full Authority Digital Controller (FADC)

2005 ◽  
Author(s):  
Dennis M. Russom ◽  
Russell A. Leinbach ◽  
Helen J. Kozuhowski ◽  
Dana D. Golden
Keyword(s):  
Life Cycle ◽  
Gas Turbine ◽  
Condition Assessment ◽  
Assessment System ◽  
Digital Controller ◽  
Life Cycle Costs ◽  
Turbine Generator ◽  
Turbine Generators ◽  
Generator Sets ◽  
The U.S

Operational availability of Gas Turbine Generator Sets (GTGs) aboard the U.S. Navy’s DDG 51 Class ships is being enhanced through the combined capabilities of the ship’s Integrated Condition Assessment System (ICAS) and the GTG’s Full Authority Digital Control (FADC). This paper describes the ICAS and FADC systems; their current capabilities and the vision of how those capabilities will evolve in order to improve equipment readiness and reduce life cycle costs.

scholarly journals Phase 1 Testing of the Redundant Internal Mechanical Start System for the Ship Service Gas Turbine Generator Sets on the U.S. Navy’s DDG-51 Class Ships

1997 ◽  
Author(s):  
Dennis M. Russom ◽  
William E. Masincup ◽  
John Eghtessad
Keyword(s):  
Gas Turbine ◽  
Systems Engineering ◽  
Phase 1 ◽  
Extended Period ◽  
Turbine Generator ◽  
Turbine Engine ◽  
Generator Sets ◽  
Life Predictions ◽  
Successful Phase ◽  
The U.S

The Redundant Independent Mechanical Start System (RIMSS) is a gas turbine powered, mechanically coupled start system for the Allison AG9140 Ship Service Gas Turbine Generator Sets (SSGTGs) of the U.S. Navy’s DDG-51 Class ships. The system will be original equipment on DDG-86 and follow. It will also be a candidate for backfit onto earlier DDG-51 Class ships. This paper describes RIMSS and details a very successful phase of the RIMSS program. All U.S. Navy testing was conducted on an Allison AG9140 located at the Carderock Division, Naval Surface Warfare Center-Ship Systems Engineering Station, DDG-51 Gas Turbine Ship Land Based Engineering Site (NSWCCD-SSES LBES), Figure 1. The test agenda included 516 SSGTG starts and 75 SSGTG motoring cycles. The primary goal was to validate engine life predictions for the Allison 250-C20B gas turbine engine in the RIMSS application. A secondary goal was to evaluate the overall RIMSS system during an extended period of operation.

scholarly journals Improved Reliability of the TF40B Marine Gas Turbine Engine in the LCAC Fleet

1991 ◽  
Author(s):  
Eleanor M. Allison ◽  
Edward M. House
Keyword(s):  
Gas Turbine ◽  
Gas Turbine Engine ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Turbine Engine ◽  
Mean Time Between Failure ◽  
Air Cushion ◽  
Corrective Actions ◽  
Mean Time ◽  
The U.S

Four Textron Lycoming TF40B marine gas turbine engines are used to power the U.S. Navy’s Landing Craft Air Cushion (LCAC) vehicle. This is the first hovercraft of this configuration to be put in service for the Navy. Operation and test of the first production craft revealed deficiencies and less than desirable reliability, but confirmed the validity of its design and ability to perform the mission. After intensive efforts to resolve these problems, reliability trends began to improve as a result of corrective actions incorporated. Today, the LCAC fleet has accrued over 50,000 engine operating hours. Presented here are the changes which have been incorporated into the configuration of the TF40B engine to eliminate both engine unique and vehicle related discrepancies revealed through fleet experience. These changes have contributed significantly toward the improvement of the engine’s mean time between removal (MTBR) and mean time between failure (MTBF) rates.

U.S. Navy Rolls-Royce Allison 501-K34 Operating Experience

2000 ◽  
Author(s):  
Dennis M. Russom ◽  
Robert L. Jernoske
Keyword(s):  
Life Cycle ◽  
Gas Turbine ◽  
Operating Experience ◽  
Life Cycle Costs ◽  
Prime Mover ◽  
Turbine Generator ◽  
Prototype Experience ◽  
Generator Sets ◽  
The U.S ◽  
Future Plans

The Rolls-Royce Allison (RRA) 501-K34 serves as the prime mover for the Ship Service Gas Turbine Generator sets (SSGTGs) of the U.S. Navy’s DDG-51 Class ships. Navy experience with the 501-K34 began in 1988 with the testing of the first prototype. Experience to date includes over 700,000 fired hours on a growing fleet of engines. This paper explores that operating experience and discusses future plans to improve the engine’s operational availability while lowering life cycle costs.

Gas Turbine Online Waterwash for DDG-51 Class U.S. Navy Ships

2010 ◽  
Author(s):  
Daniel E. Caguiat
Keyword(s):  
Data Analysis ◽  
System Design ◽  
Gas Turbine ◽  
Engine Performance ◽  
Lessons Learned ◽  
Turbine Generator ◽  
Fuel Savings ◽  
Performance Issues ◽  
System Designs ◽  
The U.S

Currently, the U.S. Navy DDG-51 class ships employ a system of piping, tanks, and nozzles for washing the four Gas Turbine Main (GTM) engines and three Ship Service Gas Turbine Generator (SSGTG) engines. The wash system employed, referred to as the crankwash system, allows the user to wash the compressor section of a gas turbine only when the turbine in question is not operating. On a DDG-51 class ship, it is possible to utilize the existing crankwash piping, tank, and overall architecture to supply water to an online water wash system. An online water wash system allows the compressor section to be cleaned while the gas turbine is in operation. This is intended to reduce the periodicity of crankwashing and associated starter cycling costs. Online water wash is also intended to maintain compressor cleanliness in the interval between crankwashes. NAVSEA Philadelphia researched appropriate online water wash system designs, methods for collecting data to address fuel savings and engine performance issues, and installation methods. GTM and SSGTG Online Water Wash Systems were then installed on USS PREBLE (DDG-88) in late 2008. USS PREBLE subsequently deployed for a period of six months beginning January 2009. During the deployment, data was collected as the systems were operated. This paper will discuss the system design, provide data analysis results, and discuss lessons learned.

Seawater Contamination of a Gas Turbine Lube Oil System in the U.S. Navy

1999 ◽  
Author(s):  
Dennis M. Russom
Keyword(s):  
System Design ◽  
Gas Turbine ◽  
Failure Mechanism ◽  
Gas Turbine Engine ◽  
Turbine Generator ◽  
Turbine Engine ◽  
Oil Cooler ◽  
Seawater Contamination ◽  
Generator Sets ◽  
The U.S

The Ship Service Gas Turbine Generator sets (SSGTGs) on the U.S. Navy’s DDG-51 Class ships have experienced several gas turbine engine failures resulting from seawater contamination of the lube oil. The seawater enters the turbine lube oil system after a corrosion related failure of the lube oil cooler. This paper examines the system design, failure mechanism, and consequence of the failure. It also discusses maintenance actions intended to minimize the possibility of cooler failures, methods that have been used to clean up contaminated systems and alternate cooler designs that are being considered for backfit.

Development, Testing, and Implementation of a Gas Turbine Starting Clutch With Manual Turning Feature for U.S. Navy Ships

2006 ◽  
Vol 129 (3) ◽  
pp. 785-791 ◽  
Author(s):  
Morgan L. Hendry ◽  
Matthew G. Hoffman
Keyword(s):  
Gas Turbine ◽  
Operating Experience ◽  
Turbine Rotor ◽  
Turbine Generator ◽  
Rotor Rotation ◽  
Turbine Generators ◽  
Generator Sets ◽  
The U.S

Most gas turbine generators rely on an automatic-engaging, free-wheel clutch to connect a starting motor to accelerate the gas turbine generator from zero to some intermediate speed to enable ignition and then provide torque assistance to a higher speed until the gas turbine is self-sustaining. The U.S. Navy has used various designs of starter motors and clutches for its gas turbine fleet. In addition, there has been a requirement to periodically borescope each gas turbine, which has necessitated removal of the starting system and clutch assembly in each instance. This paper examines the U.S. Navy experience with starting clutches and provides details of the development and testing of a synchronous-self-shifting clutch with an additional, stationary, manual turning feature to provide very slow and precise gas turbine rotor rotation for borescope purposes. This paper also gives details of the installation of the first two prototype clutches on the USS Ramage, DDG 61, operating experience for approximately four years, and possible future installations of this type of clutch in U.S. Navy gas turbine generator sets.

The U.S. Navy’s Design, Development and Implementation Program for Gas Turbine Generator Sets

1992 ◽  
Author(s):  
John J. McGroarty
Keyword(s):  
Gas Turbine ◽  
Design Development ◽  
Timely Manner ◽  
Turbine Generator ◽  
Implementation Program ◽  
Engineering Problems ◽  
Problems And Solutions ◽  
Drawing Board ◽  
Generator Sets ◽  
The U.S

The Design Development and Implementation Program (DDIP) evolved as a result of an organized progression of In-Service Engineering (ISE) responsibilities required to implement improvements to Gas Turbine Generator Sets (GTGS) in the U.S. Navy. The DDIP was established to bring a design concept, whether it be to correct a problem or to make a design improvement, from the drawing board through testing and development to the implementation of a Technical Directive as quickly as possible. Presently all engineering improvements on U.S. Navy Gas Turbine Generator Sets are implemented through the DDIP. Providing this central point of engineering has helped the Naval Sea Systems Command implement improvements in a well tested and timely manner. This paper describes the sequential processes in the DDIP methodology and further discusses specific engineering problems and solutions using the DDIP process.

Development, Testing and Implementation of a Gas Turbine Starting Clutch With Manual Turning Feature for U.S. Navy Ships

2006 ◽  
Author(s):  
Morgan L. Hendry ◽  
Matthew G. Hoffman
Keyword(s):  
Gas Turbine ◽  
Operating Experience ◽  
Turbine Rotor ◽  
Turbine Generator ◽  
Rotor Rotation ◽  
Turbine Generators ◽  
Generator Sets ◽  
The U.S

Most gas turbine generators rely on an automatic-engaging, free-wheel clutch to connect a starting motor to accelerate the gas turbine generator from zero to some intermediate speed to enable ignition and then provide torque assistance to a higher speed until the gas turbine is self-sustaining. The U.S. Navy has used various designs of starter motors and clutches for its gas turbine fleet. In addition, there has been a requirement to periodically borescope each gas turbine and this has necessitated removal of the starting system and clutch assembly in each instance. This paper examines the U.S. Navy experience with starting clutches and provides details of the development and testing of a synchronous-self-shifting clutch with an additional, stationary, manual turning feature to provide very slow and precise gas turbine rotor rotation for borescope purposes. This paper also gives details of the installation of the first two prototype clutches on the USS Ramage, DDG 61, operating experience for approximately four years, and possible future installations of this type of clutch in U.S Navy gas turbine generator sets.

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