F646 CompleteSample

The Mar k et f or Gas Tur bi ne
El ec t r i c al Pow er Gener at i on

Pr oduc t Code #F646

A Spec i al Foc used Mar k et Segment Anal ysi s by:

Industrial & Marine Turbine Forecast - Gas & Steam Turbines
2009 September 2009
Anal ysi s 1
The Mar ket f or Gas Tur bi ne
El ec t r i c al Power Gener at i on
2009-2018
Tabl e of Cont ent s
Executive Summary .................................................................................................................................................2
Introduction................................................................................................................................................................3
Format and Methodology........................................................................................................................................4
Trends and Competitive Environment ................................................................................................................6
Manufacturers Review.............................................................................................................................................7
Market Statistics .....................................................................................................................................................15
Figure 1 - Gas Turbine Electrical Power Generation
Power Class Unit Comparison 2009 - 2018 (Bar Graph).........................................................16
Power Class Unit Comparison 2009 - 2018 (Pie Chart) ..........................................................16
Power Class Value Comparison 2009 - 2018 (Bar Graph)......................................................17
Power Class Value Comparison 2009 - 2018 (Pie Chart)........................................................17
Table 1 - The Market for Gas Turbine Electrical Power Generation
Unit Production by Headquarters/Company/Program 2009 - 2018................................................20
Value Statistics by Headquarters/Company/Program 2009 - 2018.................................................27
Unit Production 2009 - 2018 (Bar Graph) ...............................................................................34
Value of Production 2009 - 2018 (Bar Graph).........................................................................34
Unit Production % Market Share by Headquarters/Company 2009 - 2018....................................35
Value Statistics % Market Share by Headquarters/Company 2009 - 2018.....................................37
Unit Production % Market Share by Headquarters 2009 - 2018 (Pie Chart) ...........................39
Value Statistics % Market Share by Headquarters 2009 - 2018 (Pie Chart)............................39
Conclusion ...............................................................................................................................................................40
* * *

Product Code F646 The Market for Gas Turbine Electrical Power Generation
2009 September 2009
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 (I&M) Gas Turbines: 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
Rolls-Royce 501-K
Siemens SGT-100
2009 September 2009
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 (I&M) Gas Turbines: Design and Development
2009
I nt r oduc t i on
One of the beauties of gas turbine machines is their
extreme flexibility. Schools, civic centers and shopping
malls are good applications for 200-kilowatt units;
entire cities can be powered by 200-megawatt units.
Heat recovery units add the ability to cooperate with
industry and provide steam for power or processes, or
even supply a municipality with district heating/cooling.
Many lobbies and special interests proclaim dubious
facts, incomplete pictures and questionable statistics in
an attempt to shape public policy. It is time to develop a
comprehensive energy policy that strikes a balance,
moving toward renewable and sustainable goals without
hobbling the horsepower of economic and technological
development.
No solitary source will meet all of the world's power
requirements, but gas turbines are increasingly being
adapted to many schemes to improve the efficiency and
reliability of power projects. Renewable fuels show
promise, as well as synthetic fuels from coal and
biomass; careful consideration of the energy demand for
energy investment is required. It makes no sense to
process materials through so many steps that it costs
more to make them than any value you will ever get out
of them. With the energy demand projected in the next
decade, there will be room for unprecedented
development in all sectors and regions.
When the need becomes critical, new electrical power
generation capacity can come from several sources:
fossil-fuel-burning machines such as gas turbines
(including microturbine machines of under 250 kW) and
the new wave of gas engines and diesels; hydroelectric,
nuclear, solar, and wind power; waste-to-energy plants
(which burn paper/wood, scrap, food waste, and
bagasse); and exotic means such as geothermal energy,
ocean currents, and fuel cells.
One source of electrical power, which many dismiss for
initially appearing to be fiscally unproductive, is
conservation. Though it may slow the demand for new
machine installations, there is a positive side to
concerted conservation efforts in established markets.
First, showing concern for overall efficiency, and not
simply immediate profit, helps build credibility with the
customer. While many original equipment
manufacturers (OEMs) are entering into long-term
operations and maintenance contracts, they must be
realizing that steady, baseloaded machines and
unencumbered transmission and distribution lines are
favorable in terms of maintenance costs and overall
financial performance.
Fuel cells are still considered to be in the demonstration
stage despite their immense appeal stemming from their
"relocation" of harmful emissions, but we believe they
will be abundant from about 2014. Wind power, while
commercially available, is not available everywhere; its
overall efficiency is about 50 percent, and it is
expensive in the near term on a dollar-per-kilowatt-hour
basis. Nuclear power and hydroelectric plants are very
expensive and require a long period of hearings,
followed by attempts to obtain financing and approvals,
and finally, construction. Solar power is very appealing,
but shares the drawbacks of wind power it is not
available everywhere, electrical power storage
technology is immature and cannot handle the capacity,
and it, too, is expensive on a dollar-per-kilowatt-hour
basis.
The viable alternatives are few. Above the level of
microturbines, whose efficiencies range from
20-28 percent, are what we consider to be true gas
turbine machines that range in power output from
200-250 kW at the low end to the super-high-power
machines of 350+MW. Today, gas turbine machines
have simple-cycle efficiencies of at least 35 percent,
with some approaching 45 percent, while some are
advertised as already having a 60 percent efficiency in
combined-cycle mode.
What does past performance predict? While gas turbine
machines continued to be ordered and fabricated for
electrical generation for their usual end uses (continuous
duty, standby duty, and peaking duty), the lower-
powered gas turbine machines, those up to 3.5-4 MW,
have traditionally been employed in standby duty. As
we move up the power spectrum, the normal-use shift
toward continuous duty becomes more noticeable at the
power level of 20-30 MW. At 120-125 MW and larger,
virtually all gas turbine machines have been/should be
ordered for use in continuous generation duty.
Given the current need for new baseload capacity, as
well as for power plant capacity additions, Forecast
International believes that the worldwide demand for
the latest technology gas turbine-based power plants
will result in modest production of the super-large gas
turbine machines, those of 180 MW and larger.
Production of those machines could grow from 48
machines in 2003 to 150-160 machines per year in the
period 2011-2014. Those machines can be expected to
be procured by China, North Korea, Vietnam,
Indonesia, Thailand, Brazil, and the Middle East.
With combined-cycle installations touching the
60 percent mark for net plant efficiency ratings, we do
not believe that gas turbine machines will continue to
Continued

Industrial & Marine Turbine Forecast
GE Model 7000

Or i ent at i on
Description. Single-shaft, axial-flow, heavy-duty,
industrial-design 60-Hz gas turbine machine with a
power output (in simple-cycle operation) in the range of
85 to 172 MW, depending on model.
Sponsor. The Model 7000 was privately developed
by the prime manufacturer.
Power Class. The approximate power outputs of the
current models in the Frame 7 series (for electrical
generation) are as follows:
Simple- Cycle Combined-Cycle
Model Output Output
Model 7001EA 85.4 MW 130.2 MW
Model 7001FA 171.7 MW 262.6 MW
Model 7001FB 184.4 MW 280.3 MW
Model 7001H 400.0 MW

For the Frame 7EA, GE Energy performance parameters
list a mechanical drive model (see Technical Data
section, Performance subsection, for unit outputs for
electrical generation and mechanical drive).
Status. In production.
Total Produced. At the start of 2008, about 1,450
GE Energy Frame 7 machines of all current production
models had been built by GE and its allied firms.
Application. Utility and industrial power generation
installations, including cogeneration and combined-
cycle plants and mechanical load drive duty.
Price Range. The prices (in 2008 U.S. dollars) of
Frame 7 machines are as follows:
Simple-Cycle Combined-Cycle
Model Plant Price Plant Price
Model 7001EA $18 -$20 million $76-$78 million
Model 7001FA $30 -$32 million $131-$133 million
Model 7001FB $34 -$36 million $138-$140 million
Model 7001H $176-$178 million

For electrical generation (simple-cycle), the genset price
covers a single-fuel skid-mounted gas turbine, electric
generator, air intake with basic filter and silencer,
exhaust stack, basic starter and controls, and
conventional combustion system.
For mechanical drive, the prices cover a gas-fired gas
turbine (without driven equipment) with gearbox, skid,
enclosure, inlet and exhaust ducts and exhaust silencer;
basic turbine controls; fire protection; starting systems;
and conventional combustion system.
For combined-cycle plants, the prices cover a basic gas-
fired combined-cycle plant having a gas turbine (usually
a DLN-equipped machine), unfired multi-pressure heat
recovery steam generator (HRSG) without bypass stack,
multi-pressure condensing steam turbine, electric
generator, step-up transformer, water-cooled heat
rejection equipment, standard controls, starting system,
and plant auxiliaries.
The Frame 7EAs 2008 package price for mechanical
drive duty is estimated at $15.5-$16.5 million.

Out l ook
Production activity currently increasing, as power
installers are maintaining a cautious order pattern
0
10
20
30
40
50
60
70
80
90
100
U
n
its
Unit Production Forecast
2008-2017
Units 43 61 75 87 89 92 88 90 85 83
2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
STAG-cogen packages are particularly attractive for U.S.
customers
Model 7FB and 7H production to rise noticeably in the
decade
7FA projected to remain the most popular model in the
Frame 7 family, especially in the U.S.
2008
December 2008
Page 2 Industrial & Marine Turbine Forecast
GE Model 7000

Competition. The 60-Hz GE Energy Frame 7
machine faces competition from gas turbine machines
built by Alstom, Mitsubishi, and Siemens Westing-
house. At the high end of the power spectrum, the
60-Hz Frame 7H in combined-cycle duty competes
against packages from Alstom, Mitsubishi and Siemens
Westinghouse W501F.
Cont r ac t or s
Pr i me
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
Hitachi Ltd http://www.hitachi.com, 6-6 Marunouchi 1-chome, Chiyoda-ku, Tokyo, 101-8280 J apan,
Tel: +81 3 3258 1111, Fax: +81 3 3258 2507, Licensee
Toshiba Corp http://www.toshiba.co.jp, 1-1, Shibaura, 1-chome, Minato-ku, Tokyo, 105-8001 J apan,
Tel: +81 3 3457 4511, Fax: +81 3 34556 1631, Licensee

Subc ont r ac t or
Howmet Castings, Corporate
Machining
http://www.alcoa.com, 145 Price Rd, Winsted Industrial Park, Winsted, CT 06098 United
States, Tel: +1 (860) 379-3314, Fax: +1 (860) 379-4239 (Blade, Stage 1)
Mee Industries Inc http://www.meefog.com, 204 West Pomona Ave, Monrovia, CA 91016 United States,
Tel: +1 (626) 359-4550, Fax: +1 (626) 359-4660 (Gas Turbine Cooling Fog System)
Power Systems Manufacturing
LLC
http://www.powermfg.com, 1440 W Indiantown Rd, Suite 200, J upiter, FL 33458-7925
United States, Tel: +1 (561) 354-1100, Fax: +1 (561) 354-1199 (Low Emission
Combustion Liner)
Powmat Ltd http://www.powmat.com, Northway 10 Technical Bldg, Ballston Lake, NY 12019 United
States, Tel: +1 (518) 877-8518, Fax: +1 (518) 877-8523 (Soft Clutch)
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 (TBC
Combustor Coating)
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
- Virginia Power/Chesterfield 7 & 8)

Comprehensive information on Contractors can be found in Forecast Internationals International Contractorsseries. 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

Tec hni c al Dat a
Design Features
Intake. Air enters radially through an intake plenum
and is turned 90 degrees to enter the compressor.
Compressor. A 17-stage, axial-flow compressor
provides a pressure ratio of 12.5:1 (7EA) at an exhaust
flow of 298 kg/sec. Inlet guide vanes are provided
forward of stage one, with no variable stages thereafter.
Stators are integral with the compressor casing, which is
horizontally split. Rotors are built up from forged discs,
which are fastened with through-bolts. Blades are of
wide chord design. Rotor speed is 3,600 rpm.
Compressor casing is A46 cast iron or A395 ductile cast
iron. Blades and stator vanes are of 12 percent Cr steel
and discs are of Ni-Cr-Mo-V steel. MS7001FA is an
18-stage axial unit, with a 15.5:1 compression ratio and
exhaust flow of 432 kg/sec. Stages 2-17 are scaled up
from the MS7001E. Stage 1 and a zero stage (borrowed
from GE aero engine designs) have been redesigned for
operation in transonic flow. The MS7001F has
extraction provisions at Stage 13.
The MS7001EC compressor has 18 stages and a
pressure ratio of 14.2:1. Airflow is 769 lb/sec (349 kg/
sec). High-strength, corrosion-resistant C450 stainless
steel blading is used for inlet guide vanes (IGVs) and

December 2008
Industrial & Marine Turbine Forecast Page 3
GE Model 7000

2008
December 2008
the first four stages. Stages 4-8 use AISI 403+Cb
stainless steel with GECC-1 coating; the remaining
blading is of uncoated AISI 403+Cb alloy. Stator 17
and EGV 1-2 are of cast IN718.
Combustor. Cannular, reverse-flow with
10 combustors, fuel nozzles and two igniters. Fuel
nozzles are air atomizing for multi-fuel capability. All
chambers are interconnected by flame tubes. Liner and
transition ducts are of Hastelloy X, with 7F also using
HS-188 in the lower portion. T
f
is approximately
2,012F (1,100C). MS7001F has 14 cannular
reverse-flow combustors, each 25 inches (63.5mm)
shorter than on the MS7001E. Each of the 14
combustors is fitted with six fuel nozzles. The
combustion liners and new transition piece impingement
sleeves are coated with a ceramic thermal barrier for
elevated temperatures. MS7001F T
f
is approximately
2,300F (1,260C).
MS7001EC has five circumferentially arranged fuel
nozzles.
Turbine. A three-stage, axial-flow turbine with cooled
Stage 1-2 blades and vanes drives the machine at its
design speed. Turbine casing is made of A395 ductile
cast iron; Stage 1-2 blades are of GTD-111. Stage 1
blades of F are DS-cast and use the GE Evendale-
developed cooling technique. Stage 3 blades are of
Udimet 500. Stage 1 vanes are FSX414 and discs and
shafts are of Cr-Mo-V steel. All three vane stages of the
MS7001F are air-cooled. Stages 2-3 have Z tip shrouds.
Nozzles on Stages 2-3 are of GTD-222. All three
F blade stages are coated. Stage 1 blades have a
plasma-spray coating of CoCrAlY; Stage 2 components
are coated with CoCrY; Stage 3 airfoils have a high-Cr
coating applied using the pack cementation process.
Stage 3 of the MS7001EC is uncooled. All turbine
buckets are investment cast GTD 111; Stage 1 is DS,
while Stages 2-3 are equiaxed.
Control System. Control and protection functions for
automatic start, loading, shutdown, and other phases of
operation are handled by the GE triple-redundant
SpeedTronic Mark V control system. The
microcomputer and microprocessor are contained in a
separate control console.
Accessories. Accessory equipment is located forward
of the intake plenum and driven by an extension of the
forward compressor shaft. Starting: diesel engine with a
torque converter electric motor; steam or expansion
turbine. The 7E/F and 7F are modular in design.
Bearings. The machine is mounted on five bearings:
one tilting and two elliptical pad journal bearings, and
two tilting pad thrust bearings (active and inactive).

Dimensions. The approximate dimensions and weights of the Frame 7EA (PG7121(EA)) and Frame 7FA
(PG7121(FA)) in a packaged power plant configuration (including inlet and exhaust losses and shaft-driven
equipment) are as follows:
Metric Units English Units
Frame 7EA (PG7121(EA))
Length 40.23 m 132 ft
Width 21.64 m 71 ft
Height, with exhaust 9.45 m 31 ft
Weight, dry, with accessories 485 tonnes 535 tons

Frame 7FA (PG7121(FA))
Length 54.86 m 180 ft
Width 22.86 m 75 ft
Height, with exhaust 9.45 m 31 ft
Weight, dry, with accessories 745 tonnes 821 tons

Performance. The performance parameters of the MS7001 models for electrical generation (generator drive) are
as follows (ISO, dry, natural gas fuel, standard inlet/exhaust pressure drops):
APPLICATION = SIMPLE-CYCLE GENERATION
MS7001EA MS7001FA
Output 85.4 MW 171.7 MW
Heat Rate (LHV) 10,991 kJ /kWh 9,873 kJ /kWh
Pressure Ratio 12.6:1 16.0:1
Mass Flow 292 kg/sec 432 kg/sec
Exhaust Temperature 537C 601C
Model Designation PG7121EA PG7241FA

GE Model 7000

APPLICATION = COMBINED-CYCLE GENERATION
MS7001EA MS7001FA MS7001FB MS7001H
Output 130.2 MW 262.6 MW 280.3 MW 400.0 MW
Heat Rate (LHV) 7,175 kJ /kWh 6,424 kJ /kWh 6,276 kJ /kWh 6,000 kJ /kWh
Net Plant Efficiency 50.2% 56.0% 57.3% 60.0%
GT Number & Type 1x MS7001EA 1x MS7001FA 1x MS7001FB 1x MS7001H

The performance parameters of the MS7001EA model for mechanical load drive applications are as follows (ISO
conditions, natural gas fuel):
APPLICATION = MECHANICAL LOAD DRIVE
English Units Metric Units
Output 115,630 shp 86.2 MW
Heat Rate (LHV) 9,795 Btu/shp-hr 10,920 kJ /kWh
Pressure Ratio 11.9:1 11.9:1
Exhaust Flow 659 lb/sec 299 kg/sec
Exhaust Temperature 998F 537C
Model Designation M7121EA M7121EA

GE offers a range of gas turbines that can efficiently be integrated with IGCC plants. The power outputs of the
Frame 7 models for IGCC plant applications are as follows:
APPLICATION = IGCC PLANTS
GT Model Syngas Power Rating IGCC Model Net Plant Output Power
7EA 90 MW (60 Hz) 107EA 130 MW (60 Hz)
7FA 197 MW (60 Hz) 107FA 280 MW (60 Hz)

Var i ant s/Upgr ades
Since the inception of the program, GE and its
associates/licensees have installed numerous MS7001
models, starting with the MS7001A rated at
approximately 48 MW. Major in-production or soon-to-
be-available machine models include the following:
MS7001EA. The MS7001EA is the lowest-power-
output production model in the Frame 7 series. It
currently has a generator drive output of 85.4 MW, and
is listed at 115,630 shp (equivalent to 86.2 MW) for
mechanical drive duty.
The 7EA for mechanical load drive duty is available as
the MS7111EA at 109,370 shp at an efficiency rating of
32.7 percent, and as the MS7121EA at 115,630 shp at
an efficiency rating of 33.0 percent. The MS7111EA is
priced at approximately $14.6 million, while the
MS7121EA is priced at approximately $15.9 million
(both in 2007 U.S. dollars).
MS7001FA. The MS7001FA is a more powerful
machine in the Model 7000 line; it has a simple-cycle
output rate of 171.7 MW and a simple-cycle-duty
efficiency rating of 36 percent.
MS7001FB. The MS7001FB is one of the newer
machines in the Model 7000 line. While this model is
now available only for combined-cycle duty, we
estimate that its simple-cycle output rate is 184.4 MW;
its output in combined-cycle operation is listed at
280.3 MW, with a net plant efficiency of 57.3 percent.
This model has a T
f
of 2,500F (1,371C) and a mass
flow of 441.3 kg/sec.
MS7001H. The 60-Hz MS7001H, introduced in 1995
along with the 50-Hz MS9001H, produces 400 MW in
combined-cycle operation. Its net plant efficiency in
that mode is 60 percent. This model has a maximum T
f

of 2,600F (1,430C).
Pr ogr am Revi ew
Background. The GE MS7001 first emerged on the
drawing boards at GEs Schenectady (New York)
facility in 1970. In designing the new MS7000, GE
drew heavily on its experience with the earlier MS5001
and MS5002 single- and twin-shaft models. It designed
the MS7001 to provide packaged power in the 60-Hz
arena. The MS7001 compressor is directly scaled from
the MS5001 and features the same construction, with
individual discs joined by through bolts and wide-chord
stainless steel blades; the design makes use of a
precision-cast, long-shank air-cooled nozzle and Stage 1
blades.

December 2008
GE Model 7000

2008
December 2008
The current Model 7000 machine design incorporates
improvements to the compressor, adds cooling to the
Stage 2 turbine components, and utilizes new Stage 3
turbine blades. GE has continued to refine the system
(at its division located in Evendale, Ohio), emphasizing
new high-temperature materials and using a modified
combustion system that will increase life under
water-injection conditions for NOx control.
As is the case with all GE-designed power generating
systems, the Model 7000 is offered in single- or
multi-unit packaged power plants in both simple and
combined cycle. The MS7001 forms the base of GEs
combined-cycle plant designs, the S-107E (one gas
turbine) and the S-207E (two machines). Also on offer
is the S-107F, featuring one MS7001F machine. The
combined-cycle plants are also referred to as STAG
plants.
Frame 7 Update Program. GE is offering a Frame 7
update program to customers of the MS7001 machine.
Under the program, pre-MS7001E models can be
updated to the MS7001E standard by re-engineering the
machines hot path and incorporating new-technology
parts from the 7E. The key component, as used in
Chugach Electrics Beluga #3 turbine-generator set, is
the 7E Stage 1 turbine nozzle, which results in a
6 percent increase in the units compressor pressure
ratio and a 3 percent thermal efficiency improvement.
Three options are available in GEs Frame 7 update
program. Option I utilizes new reduced camber high-
flow inlet guide vanes and 7E Stage 1 buckets and
nozzles. Owing to increased efficiency, the actual
exhaust gas temperature (EGT) decreases under this
option. Chugach Electric decided on this option.
Option II involves an increase in firing temperature to
keep EGTs at pre-update levels. This option is
attractive for units installed in heat-recovery
applications where EGT changes could affect
combined-cycle efficiency. Option III is intended to
achieve maximum firing temperature (1,074C) with the
replacement of all hot gas path components with
Frame 7E parts. This option increases Frame 7 ratings
to approximately 70-MW ISO conditions.
In addition to uprating the Beluga #3 turbine, GE also
increased the rating of the generator while upgrading the
generator field with Class F insulation and with
18 percent Mn and 18 percent Cr retaining rings.
Similar generator uprates are available for all Frame 7
generators.
Early Sales of MS7001. In 1970, the first MS7001A
machine, rated at 48 MW, was installed at the Wading
River plant of the Long Island Lighting Co. The
following year, 30 units were installed. Those first units
remained in production through 1977, when the current
design entered production.
During the 1970s, the U.S. utility market was the target
of the Model 7000 marketing effort. However, in 1973,
the first overseas sale by a manufacturing associate was
completed. Hitachi was the builder and, since that time,
the J apanese affiliate of GE has sold at least 19 of the
heavy gas turbines. In addition, one of the newest
additions to the GE associate list, Marubeni Trading
Corp, has sold six Frame 7 machines that were produced
by other members of the consortium.
Most of the Model 7000 sales have been for the PPP
(Packaged Power Plant) series of prime movers. PPPs
include the gas turbine-driven equipment, accessories,
controls, enclosures, etc. They can be coupled into
power blocks for increased flexibility and efficiency.
While the U.S. market has dominated the order book for
this machine, recent projects in the Middle East, Asia,
and South America have nudged the Model 7000 into
the export market.
In 1982, GE and Toshiba began an association in the
gas turbine field. In 1983, Toshiba USA bought five
MS7001Es for a combined-cycle plant, while Saudi
Consolidated Electric ordered two Packaged Power
Plants for 1984 commercial startup. Finally, Trinidad
and Tobago put two gensets into operation in 1985.
MS7001 in Cogeneration. The big news recently
has been in the cogeneration market. In 1983, the
U.S. Supreme Court upheld the 1978 PURPA
regulations and, almost immediately, GE announced the
formation of the Cogeneration Department and the huge
partnership agreement with Big Three Industries. Big
Three and GE own and operate the new cogeneration
plant outside Houston, Texas. The multi-unit facility
generates power and steam for industry in the Houston
area and sells excess power to Houston Power and
Light. Other major industrial plants in the area could
also use the GE power plants as industry seeks to
protect itself from the historical monopoly of the utility
industry.
Among the more notable installations of the
GE MS7001 is the Taiwan Electric Power station,
which has six GE gas turbines in two STAG 307E
systems. Together, they provide a thermal efficiency of
45.3 percent on distillate and 44.8 percent on residual
fuel oil.
Uprated GE MS7001F Series. GE had long been
working on a higher rated Model 7000. The new,
completely redesigned model, the MS7001F
(Frame 7F), is ISO baseload rated at 150 MW, nearly
80 percent more powerful than the MS7001EA. The
GE Model 7000

new machine has a thermal efficiency of 34.5 percent
and a firing temperature of over 1,260C. In August
1988, GE announced that it had increased the ratings of
the Frame 7F machine, basing the new ratings on the
units prototype test series results. The output was
raised from 141 to 150 MW, and the heat rate was
decreased from 10,545 kJ /kWh to 10,425 kJ /kWh.
Pressure ratio, turbine speed, and firing temperature
remained the same. The improvements were made
without a size or weight change.
Perhaps the most striking difference is that the 7F is a
cold-end drive machine. The switch to the front-end
drive, where the generator is connected to the turbine
shaft aft of the compressor, is in line with accepted
practice with machines whose power output is 100 MW
or greater. This design permits the use of an axial
exhaust, making an in-line plant arrangement possible.
For combined-cycle applications, this eliminates loss-
inducing elbow sections upstream of the boiler. The
7Fs combustor is designed to be compatible with a
variety of fuels, including natural gas, fuel oil, and
gasified coal. Accessories are designed for separate
mounting in any conventional power plant location.
In combined-cycle installations, the steam and gas
(STAG) systems featuring MS7001F machines are
available in increments of 225 MW (gas turbine power
output plus steam turbine power output).
Around the late 1980s, the Virginia Electric and Power
Co (VEPCO), Richmond, Virginia, placed a Letter of
Intent with GE for the first 7F unit. The power
company installed one new machine to replace two
retired coal-fired steam sets. The first unit went
commercial in J une 1990, and during the summer peak
it provided 600,000 kWh of power to VEPCOs grid,
with 200 starts; it accumulated 4,000 hours of operation
at a reliability rate of 99 percent. The first field
inspection of the unit, performed shortly before the
4,000-hour mark, showed some unexpected hardware
distress. This was minor in nature, however, and the
causes were quickly determined and design changes
implemented.
Emissions testing began with an O
2
traverse of the
exhaust, which showed a uniform distribution. NOx
emissions were below the detectable limit, set at 0.5 to
0.25 ppm. Visible emissions were negligible, and
particulates were less than the guaranteed value for the
site. Proper measurement of unburned hydrocarbon
during gas firing was not attainable due to a leaking gas
purge valve. (Laboratory data for natural gas, however,
show UHCs to be negligible until the firing temperature
goes below 1,700F [926C], after which point they rise
markedly.) Dynamic pressure readings during dry firing
and with water injection fell within a broad band with
no significant variations. Combustor liner temperatures
were also within acceptable limits.
In J une 1988, GE announced that Potomac Electric
Power Co had ordered four MS7001F gas turbine
generators for its power-generating plant in Dickerson,
Maryland. The four machines were installed at the plant
as simple-cycle units, providing 560 MW of power to
meet the utilitys near-term summer peaking needs. In
the late 1990s, heat recovery equipment and steam
turbine-generators were added to the gas turbines to
meet the utilitys intermediate load requirements. In
addition, provisions were made for the future utilization
of coal as a baseload fuel through the addition of coal
gasification equipment.
In 1990, five 7EAs and four 7Fs were ordered by
customers in the state of Florida. Florida Power Corp
ordered four 7EAs for its Debary site, the city of
Lakeland ordered one 7EA for its Larsen site, and
Florida Power & Light ordered four 7Fs for its Martin
3-4 site.
For the most current power outputs and performance
parameters, see the Performance section, above.
Frame 7 and PROGEN. The basic power design of
the Frame 7F is compatible with a concept GE calls
Progressive Generation, or PROGEN, the staged
construction of a power plant over a period of years
with operation in three modes: simple cycle, combined
cycle, and integrated coal gasification.
Low NOx Work. GE, an early developer of dry low
NOx (DLN) combustion systems, announced in
November 1991 the commercial availability of
single-digit DLN combustors for its heavy-duty gas
turbine machines. While the DLN combustors are
available for new-production machines, they will
become available for retrofit packages for older units at
a later date.
DLN systems meeting current emissions standards are
being shipped on Frame 6 and Frame 7EA machines;
advanced systems achieving emission of 9 ppm are
being shipped on E and F technology machines.
GE Offers MS7001EA Uprate Packages
GE Energy offers an uprate package for its MS7001EA
gas turbine that uses state-of-the-art components to
enable firing temperatures to be increased. According
to General Electric Power Systems, the improvements
can increase power output by up to 6 percent. GE offers
four uprate packages to accommodate the wide range of
Frame 7 unit configurations: IGV Upgrade to
GTD-450-IGV, Turbine Section Upgrade, Compressor
Upgrade to EA Compressor, and Exhaust Isotherm

December 2008
GE Model 7000

2008
December 2008
Temperature Upgrade to 1,100F (593C). Since the
uprate options will increase the T
f
and output of the
unit, emissions will increase. As such, an evaluation of
whether to include an emissions abatement system
upgrade or retrofit may be required.
Also being uprated are two 7EA gas turbines at Cogen
Technologies plant in Linden, New J ersey, and an
additional eight 7E machines located at the Kern River
and Sycamore Cogen facilities in California.
MS7001EA for Mechanical Load Drive. GE Energy
Frame 7/7E/7EA gas turbine machines had been ordered
for mechanical load drive duty; those machines are
produced by GE in the U.S. and GE Oil & Gas in Italy.
While most 7EAs date from 1998, five earlier machines
were designated MS7001 or MS7001E. In 1993, three
Frame 7 machines were engineered by (then) Nuovo
Pignone into mechanical drive machines for duty at an
LNG facility in Malaysia.
The 7EA for mechanical load drive duty is available in
two models: as the MS7111EA at 109,370 shp, with an
efficiency of 32.7 percent and a heat rate of
7,790 Btu/shp-hr; and as the MS7121EA at
115,630 shp, with an efficiency of 33.0 percent and a
heat rate of 7,720 Btu/shp-hr.
The 7/7E/7EA has been installed for mechanical load
drive duty in Australia, Canada, Egypt, Indonesia,
Malaysia, Nigeria, Oman, and Qatar.
MS7001G/H. At the Power-Gen Europe 1995
Conference and Exhibition in Amsterdam, GE Power
Systems introduced the G and H series gas turbines.
While the G machines were said to be able to reach
58 percent net thermal efficiency in combined-cycle
operation, the advanced H technology platform would
have at least 60 percent net thermal efficiency. The rise
from 55 percent to 60 percent is considered dramatic,
since an increase of a single percentage point of
efficiency can reduce operating costs by $15 million to
$20 million over the life of a typical gas-fired,
combined-cycle plant in the 400-500 MW range.
G technology gas turbines were said at the time to be
planned for use in both simple-cycle and combined-
cycle operation, while H technology machines would be
offered solely for use in combined-cycle operation.
According to the manufacturer, the H technology is a
platform of combined-cycle technology that integrates
the gas turbine, steam turbine, and generator into a
seamless system in which each component is optimized
for the highest level of performance. The centerpiece of
this new technology is an advanced closed-loop steam
cooling system in the gas turbine, which permits higher
firing temperatures while retaining combustion
temperatures at levels consistent with low emissions.
Unlike aircraft engines, which only have air for cooling,
a combined-cycle system has a ready steam supply.
That steam is captured and used for cooling in a
closed-loop system.
General Electric estimates that for a typical 480-MW
7H-equipped combined-cycle plant, the period for
recovering an initial investment could be shortened by
20 percent compared to more conventional installations.
The G models no longer appear in the most current GE
Energy documentation.
7H Orders. Orders for the 7H have come from Sithe
Energies Inc for two units for an 800-MW power plant
to be located in the upstate region of New York, near
the town of Scriba. The Sithe plant project was put on
hold in May 2002.
A second order was placed by Hydro Quebec for the
800-MW Suroit facility in Beauharnois, Quebec,
Canada. That facility was placed on hold in February
2004.
In November 2004, Calpine Corp signed a Letter of
Intent with GE Energy for the joint construction of a
power plant based on the H System. The new facility
will be based on two GE 107H combined-cycle systems
that will provide a total plant output of more than
775 MW.
In February 2005, Calpine and GE Energy selected
Calpines Inland Empire Energy Center in Southern
California for the North American launch of GEs
H System. The Inland Empire Energy Center is located
in the unincorporated community of Romoland in
Riverside County, California. It is scheduled to be
on-line by the summer of 2008, at which point energy
officials have predicted energy supplies might not be
sufficient to meet demand. The plant is currently in the
construction phase.
The GE Energy Model MS7001FB, rated at 280+MW
for combined-cycle and about 185 MW for simple-cycle
operation, offers customers increased efficiency and
output, especially for use in combined-cycle operation.
The STAG 107FB has a combined thermal efficiency of
57.3 percent, which is about 1.3 percent greater than
that of the STAG 107FA. A STAG 107FB combined-
cycle system generates a total of 280.3 MW, at just over
57.3 percent efficiency.
7FB Orders. As of late October 2008, the Frame 7FB
had been ordered by the following firms:
GE Model 7000

December 2008
Firm # Ordered States
Calpine Corp 5 CA, NY, WI
Customer not
identified
4 CA
LG&E Energy Corp 6 TX
Reliant Energy 6 MS, PA
Sithe Energies 18 NJ , NY, PA

Frame 7 Production Locations. In the U.S., the
Frame 7 machines are produced in Greenville, South
Carolina. In France, the machine is produced by GE in
Belfort.

Rel at ed New s
First Two F Technology Gas Turbines Begin Operation in Saudi Arabia In April 2006, GE announced
that two GE Frame 7FA gas turbines had started operating at the Uthmaniyah Cogeneration Plant in Saudi Arabia,
becoming the first F technology machines to enter service in the Kingdom.
The two gas turbines are among six F technology units GE has supplied for three cogeneration plants being built by
the Tihama Power Generation Co of Saudi Arabia. The largest independent power producer in Saudi Arabia,
Tihama Power is a joint venture between International Power of the U.K. and Saudi Oger of Saudi Arabia, an
affiliate of the Saudi Arabia Oil Co (Saudi Aramco).
All of the plants are located in Saudi Arabias eastern region. Saudi Aramco is supplying the natural gas for the
projects and is using the power and steam generated for its processing plants.
The 7FA gas turbines were manufactured at GEs facility in Greenville, South Carolina. Installation at the
Uthmaniyah site began in April 2005. The major contractor for the project was Hyundai Heavy Industries of Ulsan,
Korea. (GE, 4/06)
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.
Fundi ng
No U.S. government funding for the GE Frame 7 series of gas turbine machines has been identified.
Cont r ac t s/Or der s & Opt i ons
Award
Contractor ($ millions) Date/Description
Black & Veatch N/A Sep 2006 Black & Veatch was awarded a contract to install two
150-MW Frame 7 turbines at Tampa Electric Cos Polk Power Station to
provide power during times of peak customer electric demand.

The simple-cycle natural gas turbines will be Units 4 and 5 at the Polk
Power Station, about 40 miles east of Tampa, FL. The Polk power
station currently includes a 250-MW integrated coal gasification
combined-cycle (IGCC) plant, as well as two 150-MW gas peaking units.

Black & Veatch was to complete the installation of the two 150-MW gas
turbines in Feb 2007. The company previously was awarded contracts
for the disassembly and transport of the Polk Power Stations gas
turbines, generators and associated equipment.

GE Oil & Gas N/A J ul 2006 GE Oil & Gas won a contract to supply two Frame 7 gas
turbine-driven turbocompressor trains to Peru LNG SRL for a new gas
liquefaction plant in Pampa Melchorita, south of Lima, Peru. Each train
will have two centrifugal compressors.

GE Model 7000

2008
December 2008
Award
GE Energy N/A J an 2005 Nevada Power Co selected a GE gas turbine for the
expansion of the Harry Allen Generating Station, located 30 miles north
of Las Vegas. The GE Frame 7EA gas turbine, rated at 77 MW, entered
commercial service in May 2006.

The new GE gas turbine is used in peaking service, with natural gas as
the primary fuel. The machine utilizes GEs latest DLN combustion
system, so NOx emissions are limited to 5 ppm. The air-cooled
generator for the project was manufactured in Austria.

GE Oil & Gas <$95 Oct 2004 GE Oil & Gas was selected to supply major rotating
equipment for Train 5, the latest expansion of the RasGas (II) facility
owned by Ras Laffan Liquefied Natural Gas (LNG) Co Ltd in Qatar. The
new LNG Train 5 was to be built adjacent to the existing LNG Train 3
that was completed in December 2003, and Train 4. GE Energy also
has supplied equipment for these two projects. The Train 5 project was
scheduled for completion by the end of 2006.

Under the contract, GE Energys oil and gas business was to provide
two Frame 7EA mechanical drive gas turbines, two Frame 6B gas
turbine generator packages, one Frame 5D residue gas compressor
package, and one Rotoflow Frame 60 turbo expander-compressor. All
the gas turbines were to be equipped with dry low NOx combustion
systems to meet the stringent NOx emissions levels now required in
Qatar.

The equipment was to be supplied through a joint venture including
Chiyoda Corp of J apan and Snamprogetti SpA of Italy, the latter of
which received the engineering, procurement and construction contract
for the plant.

Ti met abl e
Month Year Major Development
1967 Model 7000 granted design go-ahead
Aug 1969 First MS7001 prototype becomes operational
1970 First unit installed
1971 30 units installed
1973 First overseas sale of Frame 7 machine
Oct 1986 GE announces 7F model
1987 First 7EA installed
Aug 1988 GE announces the uprating of 7EA and 7F machines
Late 1988 First 7F shipped
Feb 1989 Duke Power agrees to take up to 16 7EAs
J un 1991 GE announces 125-MW MS7001E/F machine
1993 MS7001E/F become available
Feb 1993 Hartwell Energy LP orders 7FA for simple-cycle peaking duty
2Q 1994 Hartwell Energy 7FA machines begin commercial operation
Late 1994 GEPS reports on MS7001EC machine
1994 MS7001EA uprate packages become available
1995 G and H models announced
Summer 1999 First 60-Hz version of H model combined-cycle machine sold
Nov 1999 MS7001FB introduced at Power-Gen
1Q 2000 First 7H pre-shipment test conducted
1Q-2Q 2000 First 7FB full load test conducted
2001 First shipment of 7FB
May 2002 Sithe Energies Scriba project canceled
GE Model 7000

December 2008
By end of 2003 Start of commercial operation of 7FB-equipped power plants
J an 2004 Hydro Quebec orders two 7H GTs for 800-MW Suroit facility in Canada
Nov 2004 Suroit P/P program officially scrapped
Nov 2004 Calpine, GE announce plans to build 7H plant in U.S.
By end of 2004 Originally intended start of operation of 7H-equipped Sithe Energies power plant
Feb 2005 Calpine and GE Energy select Calpines Inland Empire Energy Center for North
American launch of GEs H System.
Thru 2017 Continued production of MS7001 gas turbine machine series

Wor l dw i de Di st r i but i on/I nvent or i es
At the start of 2008, about 1,975 60-Hz Frame 7 (new series) gas turbine machines had been built and installed in 23
countries worldwide, with the largest number of installations being in the U.S. (1,518 machines). Other nations
having a large number of installations include Brazil (24), Japan (54), Korea (ROK) (30), Mexico (36), Saudi
Arabia (180) and Taiwan (35).
The total above includes 28 Frame 7E and 7EA machines (5 and 23, respectively) installed for mechanical load
drive duty in eight countries worldwide. Variants no longer in active production are not reflected in the table below.
For ec ast Rat i onal e
The 60-Hz GE Energy Frame 7 gas turbine machine
continues to be widely used to meet the capacity needs
of utilities and IPPs in the current decade and beyond.
Many of these machines are being used in a staged
power plant construction concept whereby a facility can
evolve from simple cycle to combined cycle and
perhaps on to combined-cycle cogeneration, or even to
combined-cycle with integrated coal or waste-gas
gasification.
It should be borne in mind that because the MS7001 is a
60-Hz machine, its sales opportunities outside the U.S.
are limited to J apan, Saudi Arabia, and a small number
of other nations worldwide, including selected countries
in Central/South America. In J apan, GEs partner
Toshiba is capable of building the 170-MW machine.
There is ongoing interest in the MS7001EA and 7FA for
use in simple-cycle operation, and in the 7FA (again),
7FB, and 7H for use in combined-cycle operation,
especially given the large number of utilities and
non-utility generators that have expressed interest in the
Frame 7 in all its variants, for every role from simple-
cycle generation to repowering.
Production of the Frame 7 series for the Southeast Asian
and J apanese markets is expected to eventually increase
when that part of the world regains momentum and
begins to order gas turbine machines for its electrical
power needs. Hitachi and Toshiba are well-positioned
to benefit in the upcoming decade, along with
GE Energy itself.
An even more important marketplace emerging for the
Frame 7 (for all models, but especially the 7FB and 7H)
is Central/South America. The orders from customers
in Brazil, Mexico, and Venezuela are just the tip of the
iceberg, with more orders expected to come. It would
not be inconceivable for GE Energy to seek a fully
capable manufacturing site or manufacturing partner in
that region.
Despite the previous gloom in the electrical generation
marketplace, the Frame 7 family remains popular,
especially with a simple-cycle power offering of 85 to
172 MW in the increasingly popular medium- (peaking
duty) to high-power (baseload power) bands.
Production supporting the next major wave of utility
re-equipping should rise noticeably in 2008 or 2009.
In our newly revised production forecast for the decade
2008-2017, GE Energy and its allied firms are projected
to build 793 Frame 7 machines of all variants and power
outputs. Production by such firms as Bharat, Hitachi,
and Toshiba is included in the GE Licensees/Affiliated
Firms segment; their individual totals are a small part of
total production in the early part of the decade, but are
expected to increase during the second half.
Of the 793-unit total, 245 units are projected to be 7FBs
and 7Hs, representing nominally 30 percent of the GE
production total. Production by GE Energys GE Oil &
Gas in Italy is included in the GE Energy total.
GE Model 7000

2008
December 2008
The popular 7FA will continue to be the leading model
of the Frame 7 series, although from about the
mid-point of the decade, the 7FB and 7H should see
greater increases than the 7FA.
At least 34 Frame 7EA gas turbine machines were
installed through 2008 for various mechanical load
drive duties (mainly for compressor drive roles), and we
are now issuing a combined production forecast for the
MS7111EA and MS7121EA for mechanical load drive
duty. Production models of those two variants are
production-line Frame 7EA units that have been slightly
modified. We project that 54 7EAs will be built for that
marketplace over the course of the decade.
With the announcement that GE and Calpine would
build North Americas most advanced combined-cycle
power plant in Riverside County, California, it looks as
if the Frame 7H is finally moving to a production status
after a few near-hits.
Ten-Year Out l ook
ESTI MATED CALENDAR YEAR UNI T PRODUCTI ON
Designation or Program High Confidence Good Confidence Speculati ve
Thru 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Total
GE Energy
Model 7000 (Frame 7) (MS7001) E A <> MW 50.0 to <125.0 <> Industrial Power Generation
466 7 8 9 10 10 12 10 10 9 9 94
Model 7000 (Frame 7) (MS7001) E A <> SHP =>20,000 <> Mechanical Dri ve (Pumps & Compressors)
34 3 4 4 4 4 4 3 3 2 2 33
Model 7000 (Frame 7) (MS7001) F B <> MW =>180.0 <> Industrial Power Generation
7 5 8 12 15 15 15 14 14 14 14 126
Model 7000 (Frame 7) (MS7001) F/F A <> MW 125.0 to <180.0 <> Industrial Power Generation
930 18 24 30 36 36 36 36 36 35 35 322
Model 7000 (Frame 7) (MS7001) F/F A <> SHP =>20,000 <> Mechanical Dri ve (Pumps & Compressors)
5 4 5 5 5 4 4 5 5 4 4 45
Model 7000 (Frame 7) (MS7001) H <> MW =>180.0 <> Industrial Power Generation
3 3 6 10 12 14 14 14 16 16 14 119
Subtotal 1,445 40 55 70 82 83 85 82 84 80 78 739
MFR Varies
Model 7000 (Frame 7) (MS7001) E A <> MW 50.0 to <125.0 <> Industrial Power Generation
2 2 3 2 1 2 3 3 3 2 2 23
Model 7000 (Frame 7) (MS7001) E A <> SHP =>20,000 <> Mechanical Dri ve (Pumps & Compressors)
3 1 3 3 4 4 4 3 3 3 3 31
Subtotal 5 3 6 5 5 6 7 6 6 5 5 54

Total 1,450 43 61 75 87 89 92 88 90 85 83 793

Industrial & Marine Turbine Forecast - Gas & Steam Turbines
2009 August 2009
Rol l s-Royc e 501-K

Or i ent at i on
Description. Single-shaft/cold-end drive and
two-shaft/hot-end drive, axial-flow, aero-derivative
industrial gas generators and industrial and marine gas
turbine machines in the 4-6-MW class.
Sponsor. The 501-K I&M series was privately
developed by (then) Allison Gas Turbine, a division of
General Motors Corporation.
Power Class. The power output of the Rolls-Royce
501-K series is 3.95-6.4 kWe and 5,500-7,400 bhp.
Status. In production.
Total Produced. At the start of 2009, more than
2,137 501-K machines were supplied to 500 customers
in over 40 countries and territories worldwide.
Application. Electrical generation (including
combined-cycle and cogeneration); mechanical load
drives (compression and pumping); marine power.
Price Range. Approximate costs of the 501-K I&M
series are $360-$445 per kilowatt for generation and
$295-$345 per kilowatt for mechanical drive machines.
Marine engines/sets are about 0.775-0.825 times that of
generation.
For electrical generation (simple-cycle), the generator
set (genset) price covers a single-fuel skid-mounted gas
turbine, electric generator, air intake with basic filter
and silencer, exhaust stack, basic starter and controls,
and a conventional combustion system.
For mechanical drive, the price covers a gas-fired gas
turbine (without driven equipment) with gearbox, skid,
enclosure, inlet and exhaust ducts and exhaust silencer,
basic turbine controls, fire protection, starting systems,
and conventional combustion system.
Competition. The 501-K series' main competition
comes from GE Oil & Gas, Kawasaki, Siemens AG, and
Solar.
Cont r ac t or s
Pr i me
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) 230-4020, Prime
Samsung Techwin Co Ltd http://www.samsungtechwin.com, KIPS Center, 647-9 Yoksam-Dong, Seoul, 135-080
Korea, South, Tel: +82 2 3467 7114, Fax: +82 2 3467 7080, Licensee

Out l ook
501-K series main competition is from GE Oil & Gas,
Solar, Siemens AG, and Kawasaki
501-K line remains competitive for electrical generation
and mechanical load drive; it continues to be well
established due to companys modernization efforts
Centrax very active in generating orders for 501-K series
Production funding still expected from the U.S. Navy;
RDT&E is waning
38
40
42
44
46
48
50
U
n
its
Unit Production Forecast
2009-2018
Units 43 42 46 49 48 49 49 49 48 48
2009 2010 2011 2012 2013 2014 2015 2016 2017 2018
Page 2 Industrial & Marine Turbine Forecast - Gas & Steam Turbines

Subc ont r ac t or
Associated Spring, Group
Headquarters
http://www.associatedspring.com, 80 Scott Swamp Rd, Farmington, CT 06032 United
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 Lane, 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 Internationals International Contractorsseries. 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

Tec hni c al Dat a
Design Features
Compressor. Fourteen-stage (15 in 501-KB7)
axial-flow, with fixed stators and inlet guide vanes.
Pressure ratio of 9.4 to 13.5. Mass flow is 15.4 to
21.1 kg/sec. Blades are 17-4PH; vanes are 410SS.
Stage 1 disc in AMS6260; Stage 2-13 discs of 410SS;
Stage 14 of 17 4PH. Cases are of steel, inlet case of
aluminum.
Combustor. Six can annular chambers of the
through-flow type are enclosed within an outer
combustor liner. Models can be equipped for
liquid-fuel, natural gas, or dual-fuel operation. Two DC
igniters supply ignition. Liners and duct are made of
Hastelloy X; casing is made of titanium. Extensive
combustor optimization efforts have been undertaken
recently by Rolls-Royce (see Program Review).
Gas Generator Turbine. Model 501-K engines are
manufactured in single- or two-shaft versions. In
single-shaft models, the four axial-flow stages are
tie-bolted together: Two-shaft variants use the first two
stages to drive the gas producer and the second two
stages to drive the power shaft. IN738 blades are held
in place by fir-tree roots. All subsequent models now
utilize hollow, air-cooled Stage 1 blades and vanes.
Discs are made of Waspaloy, vanes of X40. Turbine
casing is of Hastelloy X. Blades and vanes are
aluminum diffusion-coated for sulfidation protection.
Model 501-KC5 Stage 1 turbine blades are MAR-M246,
while vanes are MAR-M509.
Power Turbine. The last two stages of the 501-K
turbine section are separated to form a free power
turbine. Design speed range is 6,000 to 14,600 rpm.

August 2009
Industrial & Marine Turbine Forecast - Gas & Steam Turbines Page 3

2009 August 2009
Stage 1 blades are made of IN738; Stage 2 blades of
Waspaloy. Discs are also made of Waspaloy, while
vanes are of X40. The power turbine casing is of
Hastelloy X, while the vane casing is of Hastelloy C.
Two roller bearings and a single ball bearing support the
turbine shaft, and carry thrust and axial loads.
Bearings. Five pressure-lubricated, aircraft-type
bearings: three roller journal bearings and two thrust
ball bearings.
Accessories. Single-shaft versions use a
front-mounted gearbox to reduce output speeds from
between 13,600 and 14,600 rpm down to synchronous
generator speeds. Starting is normally by means of an
air turbine, but electric or hydraulic starting is available.
Control System. Manual, semiautomatic, or fully
automatic operation is accomplished using a Woodward
Electronic Control/Governor System. The system
provides multiple monitoring features and protective
shutdown in the event of excessive vibration or other
abnormal operation.

Dimensions. The approximate dimensions and weights of the Rolls-Royce 501-K series-equipped gensets
(complete packaged units) are as follows:
APPLICATION = ELECTRICAL GENSETS APPLICATION = MECHANICAL DRIVE SETS
Metric Units English Units Metric Units English Units
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 GENSETS
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 560C 15.4 kg/sec
501-KB7 5,300 kW 11,380 kJ /kWh 13.5 1 +14 501C 21.1 kg/sec
501-KH5

(a) 6,420 kW 9,037 kJ /kWh 9.4 14 530C 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):

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 571C 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 520C 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 100F, 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
Maximum Power Output (b) 4,500 kW 4,500 kW
Fuel Rate (a) 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 2,142F 2,142F
Exhaust Gas Flow 29.0 lb/sec 31.1 lb/sec
Exhaust Gas Temperature 1,117F 1,097F
Engine Bleed Capacity 2.37 lb/sec 0.0

(a) Includes generator and gearbox losses.
(b) For emergency, use up to five minutes.
Var i ant s/Upgr ades
AG9130/AG9140. Rolls-Royce has evolved a
complete ship service gas turbine generator set under
the designation AG9130. A derivative of the
Model 501-K34/KB5, the AG9130 is rated at 2,500 kW
continuous with air bleed, 3,000 kW continuous without
air bleed, and 4,500 kW emergency service. The unit,
entirely a Rolls-Royce/Allison product, was designed
for marine applications on board the U.S. Navy
DDG-51 Arleigh Burke class vessels. The AG9130
meets U.S. Navy requirements for shipboard generation.
It features an automatic dual-voltage regulation system,
low-pressure air starting with silencing, and a generator
with the lowest airborne noise signature in the service. It
is completely self-contained to include all controls, sea
water systems, expansion joints, and a fire damper.
Allison began working under a contract awarded in
March/April 1986, and shipped the first unit to Bath
Iron Works, located in Bath, Maine, in 1987. The
AG9130 is the replacement for the 501-KF package;
three such packages are used in each vessel.
The AG9140 incorporates significant maintainability
and reliability upgrades and technology enhancements,
based on lessons learned from the deployment of the
early ships in the class. These upgrades have provided
the U.S. Navy with the latest generator set technology.
Allison began shipment to Bath Iron Works in 1994.
Features of the AG9140 include the generation of
3,000 kW of 440 V, three-phase power, local or remote
control, removable panels and doors, a built-in
maintenance beam and hoist, and high corrosion-
resistance. It has been MIL-G22077 qualified and shock
tested per MIL-S-901C. Additional features of the
AG9140RF include a built-in mechanical starter
(250-KS4), dark ship start from batteries only,
redundant start capability, and Full Authority Digital
Control (FADC).
The AG9140 is on board the ROK's three KDX-3
destroyers (see Korea KDX-3 Class Destroyers below).
ATS (Advanced Turbine System). The U.S.
Department of Energy, the Chicago-based Gas Research
Institute, and Rolls-Royce Engine Company are in the
process of developing what is described as a new
generation of gas turbines that utilize a natural
gas-fueled catalytic combustion system. The intent is to
lower the emission levels to ultra-low ratings
reportedly a first in gas turbine technology. Component
tests began in 1999, followed by a full-scale
demonstration and an 8,000-hour durability test in 2000.

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2009 August 2009
Work at Rolls-Royce on this effort is ongoing, although
at a somewhat reduced level of activity.
Early tests showed that the ATS reduced NOx emissions
by 0.9 tons per year and CO
2
emissions by 5.8 tons
annually. Rolls-Royce estimated that the ATS could
reduce the fuel costs of turbine operators by about
$380,000 a year.
The ATS is targeted for modular and distributed power
generation markets, both significant growth areas in the
power generation arena thanks to ongoing deregulation
in the U.S. and elsewhere. Funding for the program is
provided by the U.S. DoE.
Meanwhile, San Diego-based Solar Turbines is
developing a recuperated-cycle industrial turbine under
the same ATS program. Larger systems (400+ MW) for
utility-scale applications are being developed by GE and
Siemens Westinghouse.
501-KB. The Model 501-KB is a single-shaft generator
drive with a power output of 4,450 kW at base load, and
5,420 kW at intermediate power on distillate or natural
gas fuels. The 501-KB3 and 501-KB4 were both
introduced in 1994. The 501-KB3 offers a low mass
flow (28 lb/13 kg per second) with a relatively high
exhaust temperature (1,051F/566C). The 501-KB3 has
a thermal efficiency of 26.5 percent. The 501-KB4 is a
4-MW machine rated for standby duty, and features
liquid fuel with natural gas and dual-fuel options. The
501-KB4's thermal efficiency rating is 29.7 percent.
The 501-KB5 is available with high temperature
capability (1,895F TIT) Stage 1 turbine blades and
vanes, either as the 3.94 MW 501-KB5 or as a retrofit
enhancement kit; that capability increases blade life by
30 percent to 40,000 hours. The 501-KB17 is the
onboard generating set for the U.S. Navy CG-47 class
ships.
501-KB7. In June 1991, (then) Allison announced that
it was developing an increased power version of the
501-K single-shaft engine. The 501-KB7 is the most
powerful offering, providing 5,300 kWe continuous.
The design added a boost module to the front of the
current 501-K. This module incorporates the functions
of the current air inlet housing assembly, but adds a
compressor stage consisting of 29 compressor blades
and 35 stator vanes. The KB7 utilizes the PTO shaft
arrangement as produced for the 501-KB5/KH models.
For the 501-KB7, the rear turbine bearing support,
which is also the turbine exhaust section, was
redesigned to provide for increased airflow with the
addition of the boost module. The Stage 4 turbine blades
were also redesigned to reduce losses in the exhaust
system. Other changes or modifications from earlier
models include the use of thermal barrier-coated vanes
in the turbine section and effusion-cooled combustion.
501-KF. The Model 501-KF is a two-shaft marine
propulsion engine that powers the Boeing Jetfoil in
commercial and military service (designated 501-K20A
by Boeing). Production Model 501-KFs are rated at
4,330 horsepower (3,229 kW) at a gas generator speed
of 13,885 rpm and power turbine speed of 13,820 rpm.
Maximum rated power (intermittent) is 5,420
horsepower at 14,560 gas generator rpm and at
13,820-rpm power turbine output speed. Many 501-KF
units have been supplied to the U.S. Navy by Stewart &
Stevenson (for more details, see Program Review
below).
Pr ogr am Revi ew
Background. The current manufacturer is
Rolls-Royce plc, Rolls-Royce Corp, located in
Indianapolis, Indiana, USA. This series of gas turbine
machines is produced in Indianapolis.
OEMs/EPSs Compressors & Pumps:
Dresser-Rand Co, Turbo Products Division, based in
Olean, New York, USA, is the current Original
Equipment Manufacturer (OEM)/Engineered Product
Supplier (EPS) for compressors and pumps.
OEMs Marine Drive:
Cincinnati Gear Company, Cincinnati, Ohio
Kawasaki Heavy Industries Ltd, Kobe, Japan
Licensees/Distributors Generator Sets:
CEC-STR Distribuicao de Turbinas, Rio de Janeiro,
RJ, Brazil
Centrax Ltd, Newton Abbot, Devon, U.K
Detroit Engine & Turbine Co, Adelaide, SA,
Australia
Samsung Techwin, Seoul, Korea (ROK)
Tominaga & Co Ltd, Tokyo, Japan
U.S. Turbine Corp, Maineville, Ohio (now a part of
Rolls-Royce Energy Systems Inc, Power
Generation)
The Rolls-Royce I&M Model 501-K series of gas
generators and gas turbine machines are derivatives of

the well-known and prolific military T56 turboprop
engine, which has provided power to such aircraft as the
Lockheed P-3C, Lockheed C-130, and Grumman E-2C.
Over 16,000 aero T56 engines were built through 2000
(including the civil aero Model 501-D) by Allison and
licensee IHI.
The I&M Model 501-K draws heavily upon the design
features of the T56, and has inherited the aviation
engine's high level of performance, durability, and
reliability. The I&M Model 501-K series machines are
currently rated at 3.9 MW and 5.2 MW for generation
duty.
The first industrial installation occurred in 1962, when
DeLaval of Houston, Texas, fabricated a compression
set using a 501-K as the prime mover. Since that time,
the gas turbine has found wide use in the industrial and
marine markets, and is handled by many OEMs,
distributors, and EPSs.
Major Licensees, Distributors, Packagers,
OEMs, and EPSs. Rolls-Royce's Engineered Product
Suppliers combine responsibilities of the Rolls-Royce
traditional distributors and Original Equipment
Manufacturer; EPSs supply the same product and
service as the 501-K distributors, along with providing a
mechanical driver for compressors and pump
applications.
The following are the major firms currently working
with Rolls-Royce on the Model 501-K:
IHI. Ishikawajima-Harima Heavy Industries is a
licensee of Rolls-Royce in Japan. The company builds
the aero T56 turboprop for the P-3C, also built under
license in Japan. It has been a producer of the industrial
variant of the I&M Model 501-K, under the designation
IM400. IHI offered both stationary and mobile
configurations of the IM400. IHI is no longer an active
licensee of the I&M Model 501-K.
Stewart & Stevenson. Stewart & Stevenson has long
been an innovative packager of gas turbines and
driven-equipment products; it can act as a single-source
for the prime mover, driven equipment, and, when
desired, for heat recovery and combined-cycle
apparatus. S&S has packaged more Model 501-K gas
turbines and accumulated more time on the 501-K for
industrial applications than any other supplier; more
than 150 units have been shipped to the U.S. Navy
alone.
Configured as a single-shaft machine for generator set
applications, the 501-K is a prime mover for hundreds
of installations worldwide. For compressor and marine
drive, the 501-K is available in a two-shaft
configuration (501-KSS) to provide the flexibility of
variable-speed operation.
The S&S 501-KSS5 two-shaft gas turbine engine is an
advanced version of the already proven 501-KF gas
turbine. S&S has enhanced the KF power turbine design
to provide increased torque capability, lower fuel
consumption, and a wider range of operation. The
501-KSS5 is considered an excellent prime mover for
marine propulsion and mechanical drive.
Stewart & Stevenson Gas Turbine Products was
purchased by General Electric in 1998, ending that
entity's work with Allison on the 501-K.
Centrax. This U.K.-based firm previously offered the
CX350, and currently offers the CX501 generator set
powered by the Model 501-KB3, -KB5, -KN, -KB7, and
-KH gas turbine machines. Its gensets supply electrical
power in a variety of applications, and have been
included in cogeneration installations.
In 1990, Centrax received an order for the first
steam-injected 501-KH machine in Europe. The project
was a combined heat and power (CHP) district heating
scheme at Osimo, Italy. The equipment incorporated
the Cheng Cycle method of reinjecting steam produced
by the exhaust back into the machine's combustion
casing. The main contractor for the scheme was the
Austrian engineering firm SGP-VA Energie und
Umwelttechnik GmbH, which is the licensee for
Cheng Cycle in Europe; it supplied all support
equipment other than the Centrax equipment.
Centrax has also provided a pair of CX501-KB5s for a
CHP plant at Par Harbor, Cornwall, England, owned by
ECC International in partnership with BP Energy Ltd.
The plant successfully completed commissioning tests
in the first half of 1992. The generator sets run on
natural gas at 12 bar pressure to provide 3.7 MW each.
US Turbine Corporation. US Turbine Corp (now a
part of Rolls-Royce Energy Systems Inc, Power
Generation) has offered a full range of gas turbine and
engine generating sets in the 660-51,580 kWe range. It
has offered the 501-K in its generator sets under the
designations UST3400 (501-KB), UST3800 (501-KB5),
UST4000 (501-KB5S), UST5000 (501-KB7),
UST5600CC (501-KH), and UST6600CC (501-KH5),
the latter two being fully steam-injected systems
(Cheng Cycle system optimization).
U.S. Turbine and Standard Aero Ltd announced in 1995
that they had initiated a cooperative service organization
to provide comprehensive site maintenance, parts
support, and overhaul and repair services to users of the
Model 501-K. Standard Aero and U.S. Turbine opened

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2009 August 2009
a jointly operated aftermarket support facility at San
Jose (California) Airport in support of the venture.
Tominaga. Tominaga & Company Ltd of Japan has
supplied 501-K series engines to Hitachi Zosen for
packaging, as well as performing total service on its
own. Tominaga Model 501-K generator sets are
designated TM501KB-301 (501-KB) and
TM501KB5-351 (501-KB5). Base load ratings for
these two gensets are 3,100 and 3,620 kW, respectively,
at ISO conditions. Mechanical drive machines are
designated TM501KC-301 and TM501KC5-351;
continuous ratings are 5,250 horsepower and 5,750
horsepower.
Turbomeca. In 1998, France's Turbomeca (a unit of
the Snecma Group's Propulsion Branch) indicated that it
would take up the Allison 501-K gas turbines for
distribution in Europe, under the designations TM4000
and TM5000. The machines give Turbomeca a high-end
power band.
Samsung Techwin. Among the newest suppliers and
distributors is Samsung Techwin in the Republic of
Korea. It is building the Rolls-Royce AG9140 gas
turbines under license for the three KDX-3 destroyers.
The first vessel launched in May 2007, and the
remaining vessels should be launched in 2010 and 2012.
Industrial Applications
Dual-Fuel Cycle. The dual-fuel cycle was invented by
Dr. Dah Yu Cheng. Rolls-Royce Model 501-KHs have
been tested and installed for commercial operation with
Cheng Cycle equipment. Heat recovery steam
generators (HRSGs) produce high-pressure and
high-temperature steam for reinjection into the gas
turbine combustion chamber. The Model 501-K, for
example, can produce up to 7 MW of electric power
with the maximum use of injected steam, and provide
thermal efficiencies of up to 50 percent.
The first installation of a Cheng Cycle gas turbine was
by Dr. Cheng's International Power Technology (IPT) at
California State University. The second Rolls-Royce
Model 501-K Cheng Cycle installation is at Sunkist
Growers in California, where two Model 501s are now
in service producing up to 14 MW of power and
variable amounts of process steam for Sunkist food
processing.
The Kalina Cycle is the second dual-fuel cycle that has
been explored. Kalina involves the use of ammonia/
water injection, which greatly increases effective power.
Both new cycles, while producing much higher outputs
and thermal efficiencies, also greatly reduce the air
pollutant levels versus simple-cycle machines. Indeed,
IPT states that the Sunkist installation meets the NOx
standard of 25 ppm for the San Francisco area and
9 ppm for all of southern California, all without the use
of expensive selective catalytic reduction (SCR)
equipment normally specified by the state.
In 1987, it was announced that Turbonetics Energy Inc
of Latham, New York, was developing a steam injection
system for the 501-K. The firm, working with the
support of the Gas Research Institute, ran a test program
of its system at the General Motors Corp Hydra-matic
Division facility in Warren, Michigan, in the U.S.
Turbonetics' system is primarily targeted at the
replacement industrial boiler market. The system can
boost the power output of the turbine from 3 MW to
4 MW, and can increase the electric power generating
efficiency from 27 percent to 35 percent. In addition,
supplementary gas firing can increase the boiler's steam
delivery from a nominal 8,840 kg/hr to 15,875 kg/hr,
and raise overall system thermal efficiency from
60 percent to 85 percent.
NOx Reduction Efforts. Rolls-Royce focused on
technologies that would reduce emissions and allow the
burning of alternative fuels. For its gas turbine engines,
work has been centered on the combustion system. The
work bore fruit in the LE4 Dry Low Emission
Combustion Configuration for the 501. The LE4 utilizes
lean premix and fuel staging to reduce NOx formation
and enhance the operational range of the turbine, while
maintaining low levels of CO and providing combustion
stability.
Rolls-Royce also worked on a direct coal-fueled turbine
and conducted component development tests under a
U.S. DoE contract. A full-scale combustor
(70 MMBtu/hr) has successfully been run on 100
percent coal water slurry (CWS) fuel. Separately, an
engine with an external combustor configuration has
successfully been run on distillate fuel; engine tests
using the CWS external combustor were completed at
the end of 1990.
To further explore combustor capabilities and minimize
the fuel costs for future commercial applications, a
production-standard 501-KB5 machine was successfully
tested in August 1991 during a four-hour test using the
ground coal and water mixture. Data from the test
showed complete and stable fuel combustion and
turbine output performance to base load design
conditions.
In addition to work on emission technology,
Rolls-Royce has improved the durability of the
combustion system. On the 501-K, Rolls-Royce has
developed an effusion-cooled combustion liner that uses
laser-drilled holes in the walls of the liners to lower

temperatures by 300F to 400F. The new liners were
initially field-tested in 1991 and are now available on
the 501-KB7.
In May 1993, Catalytica Inc (Mountain View,
California) and Allison announced that they had signed
a Letter of Intent for a joint program to develop an
ultra-low emissions catalytic combustion system for the
501-K industrial engine. The intent of the program is to
provide an engine with NOx emissions that meet the
most stringent emission requirements worldwide.
Marine Applications. Model 501-K gas turbines are
in use as propulsion drive systems and shipboard
generation sets for both military and civil applications.
Spruance Class Destroyers. In the early 1970s, the
U.S. Navy ordered 31 8,040-ton DD-963 Spruance class
destroyers. Powered by four GE LM2500 gas turbines
in a COGAG (combined gas and gas) mode and using
three 501-K17-based shipboard generation systems,
these were the first all-gas turbine units in operation
with the Navy. The 501-K17s were the first gas turbines
to pass the U.S. Navy's 3,000-hour salt injection
endurance test in May 1971.
The Rolls-Royce/Allison units provide 2 MW of net
generator output power on a 100F (38C) day with
2.37 lb/sec (1.07 kg/sec) of compressor bleed loss. In
addition to the 31 units built, four similar designs were
ordered by Iran, featuring different weapons systems
and onboard facilities. However, those were canceled
following the Iranian revolution. All used the 501-K17
generation systems packaged by Stewart & Stevenson.
The Spruance class vessels were laid down in the period
from November 1972-April 1978. As of mid-2006, only
three vessels remained in the Navy's inventory.
Ticonderoga Class Guided Missile Cruiser.
Building on the proven hull and machinery of the
DD-963s, the Navy developed the 9,407-9,590-ton
Ticonderoga class Guided Missile Cruiser (AEGIS
cruiser), intended for the highly sophisticated AEGIS
weapons system. The lead ship, the USS Ticonderoga
(CG-47), was launched in 1981. By July 1994, all 27
vessels had been commissioned.
Three 501-K17 generation sets have been installed,
although each has increased capacity to accommodate
the power demands of the AEGIS system. The ships
operate in high-density, high-threat areas with carrier
battle groups, as well as separately with associated
escorts. Aboard the AEGIS cruisers, the 501-K17s have
a rating of 2.5 MW.
The Ticonderoga class vessels were laid down in the
period from January 1980-October 1991. As of
mid-2006, 25 vessels of this type were in service with
the U.S. Navy.
Arleigh Burke Class Guided Missile Destroyer. The
Navy developed a new 8,422-9,035-ton class of
destroyer, incorporating a somewhat less capable
AEGIS system; ostensibly, the vessels are to work in
conjunction with the CG-47 units. The Navy selected
the LM2500 package and the 501-K34 genset
arrangement. The use of the genset enhances logistic
and maintenance capabilities and facilitates exchanges
of spare parts between ships. The initial ship of the
Arleigh Burke class, the DDG-51, was commissioned
on July 4, 1991.
As of mid-2006, 28 Arleigh Burke (Flight I and II) class
guided missile vessels were in U.S. Navy service. In
addition, 28 Arleigh Burke (Flight IIA) class vessels
had been laid down, out of a total of 34 vessels planned;
all Flight IIA vessels are in U.S. Navy service.
Note: The Japanese MSDF has four Kongou class
destroyers/frigates in its inventory. The vessels are an
enlarged and improved version of the Arleigh Burke
class vessels, with a lightweight version of the AEGIS
system. While the vessels are powered by four
GE LM2500 gas turbines as in the Arleigh Burke class,
it is considered unlikely that the MSDF vessels also
employ 501-K gas turbines, utilizing Japanese-design
machines instead. The Kongou class vessels were laid
down in the period from 1990-May 1995.
Pegasus Hydrofoil. Saudi Arabia has one Pegasus
class 115-ton hydrofoil vessel, the Al Aziziah. The
vessel was ordered in 1984 from Lockheed and
subcontractor Boeing; it was delivered in 1985. The
vessel has two 501-KF20A gas turbines and two Detroit
Diesel 8V92 diesel engines.
Korea KDX-3 Class Destroyers. The Republic of
Korea's KDX-3 vessels are a further development of the
KDX-2 destroyers, but optimized for anti-air warfare.
Each vessel has a displacement of 7,000 tons, and each
is 166 meters (544.6 ft) in length. The first vessel
launched in May 2007, and the remaining vessels
should be launched in 2010 and 2012.
Rolls-Royce AG9140 gas turbines are currently being
built under license by Samsung Techwin for the three
KDX-3 destroyers.
In early 2006, information had been issued regarding
the choice of GE LM2500 gas turbine propulsion
machinery of the KDX-3. Korea's KDX-2 and KDX-1
destroyers are also GE LM2500-powered.
Boeing J etfoil. The Jetfoil was begun as a private
venture by Boeing Marine Systems Division, Seattle,

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2009 August 2009
for the commercial passenger ferry sector. The initial
service date was April 1975. Two 501-Ks power the
craft at speeds up to 45 knots when foil-borne, and
current production variants include hydrodynamic and
foil improvements. The ships are designated Model
929-100T and 929-115, with the latter launched in 1978.
An estimated 25 Allison-powered Jetfoils and similar
surface craft operate worldwide.
Westermoen Ferry. Two 501-K engines provide
power for Westermoen's W-100T catamaran ferry in
service in Norway. The 100-ton vessel has capacity for
up to 250 passengers and provides high-density
transportation at speeds up to 45 knots (83.3 km/h),
depending upon the sea conditions. With reserve fuel,
the W-100T has a range of 418 nautical miles (774 km).
Configuration as an offshore platform workboat has
been explored.
Halter Marine Company. A single 501-K powers the
American Enterprise, a 32-meter, 80-ton workboat in
service in the Gulf of Mexico. Designed by Halter
Marine of Louisiana, the boat has capacity for up to 82
passengers with reduced cargo, or 20 metric tons of
cargo without passengers. Cruise speed is provided by
two Detroit Diesel reciprocating compression-ignition
engines; both the GT and diesels drive Rocketdyne
waterjet pumps.
Magnum Marine. U.S. boat designer/builder Magnum
Marine unveiled a 63-foot (19.2-m) 18-ton Super Yacht
Magnum 63 at the 1985 Miami International Boat
Show. The craft is powered by an Allison/Stewart &
Stevenson Model 501-KF gas turbine providing
4,500 shp and speeds in excess of 60 knots (111 km/h).
Antifouling Compressor Coatings Evaluation. The
Naval Surface Warfare Center, Carderock Division
(NSWCCD) Gas Turbine Emerging Technologies
Code 9334 was tasked by NSWCCD Shipboard Energy
Office Code 859 to research and evaluate fouling
resistant compressor coatings for Rolls Royce Allison
501-K Series gas turbines. The objective of these tests
was to investigate the feasibility of reducing the rate of
compressor fouling degradation and associated rate of
specific fuel consumption (SFC) increase through the
application of anti-fouling coatings Tests, which were
conducted at the Philadelphia Land Based Engineering
Site (LBES).
Testing was first performed on the existing
LBES 501-K17 gas turbine, which had an uncoated
compressor. The compressor was then replaced by a
coated compressor, and the test was repeated. The test
plan consisted of injecting a known amount of salt
solution into the gas turbine inlet while gathering
compressor performance degradation and fuel economy
data for 0-, 500-, 1,000-, and 1,250-KW generator load
levels. This method facilitated a direct comparison of
compressor degradation trends for the coated and
uncoated compressors operating with the same turbine
section, thereby reducing the number of variables
involved. The collected data for turbine inlet,
temperature, compressor efficiency, and fuel
consumption were plotted as a percentage of the
baseline conditions for each compressor. The results of
each plot show a decrease in the rates of compressor
degradation and SFC increase for the coated compressor
compared with the uncoated compressor. Overall test
results show that it is feasible to utilize antifouling
compressor coatings to reduce the rate of specific fuel
consumption increase associated with compressor
performance degradation.
Fundi ng
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 FY09 Department of Defense Budget submission (May 2009),
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 accurately,
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. All 22 units have been procured through FY 2007. 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. Ten units have been procured through
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 FY 2007 and out will
be used to resolve additional issues identified by the TMA/TMI, Metrics, the PESC, and the DDG-51 Top Tech Issues
Programs. The specific additional issues addressed are intake systems, with a new type air filtration system that will reduce
maintenance and increase engine life.

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. Procurements will complete in FY08.

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.

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 FY08.
Funding for Cost Codes GF001, GF007, GF009, GF010, GF830, GF016, and GF017 is identified below, as
contained in the U.S. Navy's FY10 budget submission of May 2009.
U.S. NAVY PROCUREMENT FUNDING
FY08 FY08 FY09 FY09 FY10 FY10
QTY AMT QTY AMT QTY AMT
GF001 501-K34 1 1.35 - - - -
GF007 Modific. Prog. - 6.34 - 3.48 - 6.41
GF009 Spec. Support Equip. - 0.26 - 0.26 - 0.26
GF015 FADC 15 5.85 10 4.00 10 4.00
GF830 Production Engrg. - 0.16 - 0.15 - 0.15

August 2009

2009 August 2009
FY08 FY09 FY09 FY10 FY10

FY08
GF016 Electric Starter 2 0.56 2 0.58 2 0.58
GT017 Optical Flash Det. Sys. - - - - - -
GF018 Hot Section Replacement - - 10 2.0 10 2.0

All dollar amounts are in millions of FY09 U.S. dollars.
Beyond FY08, the total planned funding request is as follows (as of March 2009): FY09, $9.44 million; FY10, $9.4 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).
The following top-line funding is for all activities within Project R1050; Industrial Preparedness: Metal Processing
line is funding solely for the sub-effort Metals Processing and Fabrication.
U.S. NAVY RDT&E FUNDING
FY08 FY08 FY09 FY09 FY10 FY10
PE#0708011N
R1050 Manuf. Technology - 59.45 - 57.32 - 56.68
(Metals Processing) - 19.72 - 12.9 - -

All dollar amounts are in millions of FY08 U.S. dollars.
Beyond FY09, the total planned RDT&E request for PE#0708011N, Project R1050, is as follows (as of May 2009): FY10, $58.92
million and FY11, $59.83 million.

Cont r ac t s/Or der s & Opt i ons
Award
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 J oint 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 J un 2006 Centrax has been awarded a contract to supply a CX501-KB7 gas
turbine-powered generator set to the Tunisian paper mill, 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 paper
mill 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 J an 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. 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 Spanish ceramics giant Taulell SA's plant near
Castellon, Spain.

Ti met abl e
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
J un 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 begins
1998 Turbomeca becomes supplier of 501-K gensets
1999 ATS component tests begun

August 2009

2009 August 2009
Nov 2005 Centrax gets first order from Tunisia
2006 Launch of first ROK AG9140-equipped KDX-3 destroyer
Thru 2018 Continued production/availability of 501-K I&M series

Wor l dw i de Di st r i but i on/I nvent or i es
At the start of 2009, more than 2,137 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).
For ec ast Rat i onal e
The Rolls-Royce 501-K machine series continues to
garner orders despite brisk competition from machines
from Solar, Kawasaki, GE Oil & Gas, and Siemens AG
(the latter referring to the former Alstom line of
machines whose power output is less than 50 MW).
Rolls-Royce has been working actively in emissions
reduction, focusing on lean premix and catalytic
combustion systems (Rolls and Solar have even worked
together on assessing the durability of various catalysts).
The ongoing effort has made the 501 K very viable and
competitive from an emissions perspective. In addition,
Rolls-Royce continues to update the gas turbine with the
most current technology, including adopting aeroengine
technology.
The 501-K continues to be sold for electrical generation
duty, in particular by Centrax, the U.K.-based firm that
remains in the forefront for booking the greatest number
of orders for the engine model. Even with Centrax
active, a few machines have been installed recently in
Japan by IHI. We have not yet heard of any orders
booked by Turbomeca.
In the mechanical drive arena, the 501-K should
continue to sell well, taking advantage of the large base
of installed Allison/Rolls-Royce machines worldwide.
With the use of Rolls-Royce's long-term service
agreements, the customer of 501-Ks (and of all of
Rolls-Royce's product line) secures Rolls-Royce as the
service and maintenance provider in multiyear
contracts, ensuring continuity and reducing costs over
the long term.
Overall, Rolls Royce is projected to produce 471 of the
501-K series gas turbines in the 10-year period
2009-2018, largely for generation/cogeneration duty. A
total of 114 501-K units are forecast for duty as
mechanical drivers, including the 501-KC7.
Our forecast contains many 501-KH5 steam-injected
models. We feel that the time is ripe for those models.
Our forecast does not break out the mechanical drive
501-KC7 from that of the 501-KC5. We have not seen
sufficient orders for that 5,500-bhp machine (as of the
date of this report) to warrant a separate line item in the
Ten-Year Outlook chart, below.
Our forecast does not include regular series production
of the 501-K for marine propulsion. Orders for the gas
turbine for that application will most likely be twos and
threes at infrequent intervals in the decade.
The AG9140s for the ROK's 7,000-ton KDX-3 class
destroyers are contained in the chart, below, under
"Industrial Power Generation."
Page 14 Industrial & Marine Turbine Forecast Gas & Steam Turbines

Ten-Year Out l ook
ESTI MATED CALENDAR YEAR UNI T PRODUCTI ON
Designation or Program High Confidence Good Confidence Speculati ve
Thru 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 Total
Rolls-Royce Energy
501 (RR) -K B5 <> MW 3.0 to <10.0 <> Industrial Power Generation
1,316 10 10 10 10 10 11 11 11 10 10 103
501 (RR) -K B7 <> MW 3.0 to <10.0 <> Industrial Power Generation
236 20 20 20 22 22 22 20 20 20 20 206
501 (RR) -K C5 <> MW 3.0 to <10.0 <> Industrial Power Generation
31 3 0 4 5 6 6 6 6 6 6 48
501 (RR) -K C5 <> SHP 3,000 to <10,000 <> Mechanical Dri ve (Pumps & Compressors)
554 10 12 12 12 10 10 12 12 12 12 114
Subtotal 2,137 43 42 46 49 48 49 49 49 48 48 471

Total 2,137 43 42 46 49 48 49 49 49 48 48 471

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