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General Electric GE90
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General Electric GE90

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GE90
The worlds most powerful engine (World record holder!) (2678713012).jpg
GE90-115B
TypeTurbofan
ManufacturerGE Aviation
First runMarch 1993[1]
Major applicationsBoeing 777
Number built2000 as of 2014[2]
Unit costGE90: US$ 27.5 million list price (2011)[3]
Developed intoGeneral Electric GEnx
Engine Alliance GP7000
General Electric GE9X

The General Electric GE90 is a family of high-bypass turbofan aircraft engines built by GE Aviation for the Boeing 777, with thrust ratings from 81,000 to 115,000 lbf (360 to 510 kN). It entered service with British Airways in November 1995. It is one of three options for the 777-200, -200ER, and -300 versions, and the exclusive engine of the -200LR, -300ER, and 777F. It is the world's largest and the most powerful jet engine.[3]


Contents

  [hide


Development[edit]

The GE90 was developed from the NASA 1970s Energy Efficient Engine. GE's GE36 UDF (propfan) was meant to replace the CFM International CFM56 high-bypass turbofan which was initially noncompetitive against the rival IAE V2500, however when the V2500 ran into technical problems sales of the CFM56 took off. GE was not interested in having the GE36 cannibalize the CFM56, and while "the UDF could be made reliable by earlier standards, turbofans were getting much, much better than that". However, GE used the UDF¡¯s blade technology directly into the GE90.[4]

A 1998 CFD simulation of airflow through the engine

The GE90 engine was launched in 1990.[5] GE Aviation teamed with Snecma (France, 24%), IHI (Japan) and Avio (Italy) for the program.[6]

Design[edit]

The GE90's 10-stage high-pressure compressor develops an industry record pressure ratio of 23:1 and is driven by a 2-stage, air-cooled, HP turbine. A 3-stage low-pressure compressor, situated directly behind the fan, supercharges the core. The fan/LPC is driven by a 6-stage low-pressure turbine.

The higher-thrust variants, GE90-110B1 and -115B, have a different architecture from the earlier GE90 versions, with one stage removed from the HP compressor and an extra stage added to the LP compressor. A net increase in core flow was achieved. General Electric performed a similar re-staging exercise when they upgraded the CF6 from the -6 to the higher-thrust -50. However, this thrust growth route is expensive, since all the downstream components (e.g. turbines) must be larger for flow capacity. The fan is an advanced, larger diameter unit made from composite materials and is the first production engine to feature swept rotor blades.[7][8]

Operational history[edit]

As one of the three available engines for the new Boeing 777, the GE90 was an all-new $2 billion design meant to handle transoceanic routes, in contrast to the offerings from Pratt & Whitney and Rolls-Roycewhich were modifications of existing engines.[7]

The first General Electric-powered Boeing 777 was delivered to British Airways on November 12, 1995;[9] the aircraft, with two GE90-77Bs, entered service five days later.[10] Initial service was affected by gearbox bearing wear concerns, which caused the airline to temporarily withdraw its 777 fleet from transatlantic service in 1997.[10] British Airways' aircraft returned to full service later that year.[11]

Problems with GE90 development and testing caused delays in Federal Aviation Administration certification. In addition the GE90's increased output was not yet put to use by airlines and it was also the heaviest engine of the three available choices, making it the least popular option while Rolls-Royce held the top spot. British Airways soon replaced the GE90 with Rolls-Royce engines on their 777s.[7][8]

A person standing in front of a GE90-115B engine

For Boeing's second-generation 777 long-range versions (later named 777-200LR, 777-300ER, and 777F), greater thrust was needed to meet the specifications. General Electric and Pratt & Whitney insisted on a winner-take-all contract due to the $500 million investment in engine modifications needed to meet the requirements. GE received sole engine supplier status for the higher-thrust engine variants for the 777-200LR, -300ER, and 777F.[7][8]

The higher-output GE90-110B1 and -115B engines, in combination with the second-generation 777 variants -200LR and -300ER, has been a primary driver of the twinjet's sales past the rival A330/340 series.[12][13] Using two engines produces a typical operating cost advantage of around 8¨C9% for the -300ER over the A340-600.[14] The 777-300ER has also been seen as a 747-400 replacement amid rising fuel prices given its 20% fuel burn advantage.[15][16]

The GE90 series are physically the largest engines in aviation history, the fan diameter of the original series being 123 in (310 cm), and the largest variant GE90-115B has a fan diameter of 128 in (330 cm). As a result GE90 engines can only be air freighted in assembled form by outsize cargo aircraft such as the Antonov An-124, presenting unique problems if, due to emergency diversions, a 777 were stranded in a place without the proper spare parts. If the fan is removed from the core, then the engines may be shipped on a 747 Freighter.[17]

The -94B for the -200ER is being retrofitted with some of the first FAA-approved 3D-printed components.[18]

It has an in-flight shutdown rate (IFSD) of one per million engine flight-hours.[3] It accumulated more than 8 million cycles and 50 million flight hours in 20 years.[19]

Records[edit]

GE90 without cowlingThe higher-thrust GE90-115B mounted on GE's Boeing 747 test aircraft.

The GE90-115B is powerful enough to fully operate GE's Boeing 747 testbed on its own power, an attribute demonstrated during a flight test.[20][21]

According to the Guinness Book of Records, at 127,900 lbf (569 kN), the engine holds the record for the highest thrust (although rated at 115,300 lbf (513 kN)). This thrust record was accomplished inadvertently as part of a one-hour, triple-red-line engine stress test. To accommodate the increase in torsional stresses, a new steel alloy, GE1014 was created and then machined to extreme tolerances.[22] The new record was set during testing of a GE90-115B development engine at GE Aviations' Peebles Test Operation, which is an outdoor test complex outside Peebles, Ohio. It eclipsed the engine's previous Guinness world record of 122,965 lbf (546.98 kN).[23]

In October 2003, a Boeing 777-300ER broke the ETOPS record by being able to fly five and a half hours (330 minutes) with one engine shut down.[24] The aircraft, with GE90-115B engines, flew from Seattle to Taiwan as part of the ETOPS certification program.

On November 10, 2005, the GE90 entered the Guinness World Records for a second time. The GE90-110B1 powered a 777-200LR during the world's longest flight by a commercial airliner, though there were no fare-paying passengers on the flight, only journalists and invited guests. The 777-200LR flew 13,422 mi (21,601 km) in 22 hours, 42 minutes, flying from Hong Kong to London "the long way": over the Pacific, over the continental U.S., then over the Atlantic to London.[25]

Incidents[edit]

On May 28, 2012, an Air Canada 777 taking off from Toronto en route to Japan suffered failure of a GE90-115B at 1,500 feet (460 m) and returned safely. Engine debris was found on the ground.[26][27]

On September 8, 2015, a GE90-85B powering a Boeing 777-236ER on British Airways Flight 2276 suffered an uncontained failure during take-off roll leading to a fire. NTSB and FAA investigations were begun to determine the cause; initial findings were reported in September 2015.[28][29]

On June 27, 2016, a GE90-115B powering a Boeing 777-300ER, on Singapore Airlines Flight 368, received an engine oil warning during flight and returned to Singapore Changi Airport. On landing the malfunctioning right engine caught fire, leading to fire damage to the engine and the wing.[30]

Transfer gearbox failures[edit]

The FAA issued an Airworthiness Directive (AD) on May 16, 2013, and sent it to owners and operators of General Electric GE90-110B1 and GE90-115B turbofan engines. This emergency AD was prompted by reports of two failures of transfer gearbox assemblies (TGBs) which resulted in in-flight shutdowns (IFSDs). Investigation revealed that the failures were caused by TGB radial gear cracking and separation. Further inspections found two additional radial gears with cracks. This condition, if not corrected, could result in additional IFSDs of one or more engines, loss of thrust control, and damage to the airplane. The Airworthiness Directive requires compliance by taking remedial measures within five days of receipt of the AD.[31]

Specifications[edit]

A GE90-94B (B777-200ER), straight fan bladesA GE90-110B1 (B777-200LR), curved fan blades

GE90 Type Certificate Data Sheet[32]
Variant-76B/-77B/-85B/-90B/-94B-110B1/-113B/-115B
TypeDual rotor, axial flow, high bypass ratio turbofan
Compressor1 fan, 3-stage LP, 10-stage HP1 fan, 4-stage LP, 9-stage HP[33]
Turbine2-stage HP, 6-stage LP
Length[a]286.9 in (729 cm)286.67 in (728.1 cm)
Max. width152.4 in (387 cm)148.38 in (376.9 cm)
Max. height155.6 in (395 cm)154.56 in (392.6 cm)
Fan diameter[34]123 in (310 cm)128 in (330 cm)
Weight17,400 lb (7,893 kg)19,316 lb (8,762 kg)
Takeoff thrust-76B: 81,070 lbf (360.6 kN)
-77B: 81,700 lbf (363 kN)
-85B: 88,870 lbf (395.3 kN)
-90B: 94,000 lbf (420 kN)
-94B: 97,300 lbf (433 kN)
-110B1: 110,760 lbf (492.7 kN)
-113B: 113,530 lbf (505.0 kN)
-115B: 115,540 lbf (513.9 kN)©
LP rotor speed2,261.5 RPM2,355 RPM
HP rotor speed9,332 RPM
Bypass ratio[6]8.4 - 99
Pressure ratio[33]40:142:1
Thrust-to-weight ratio5.595.98

Derivatives[edit]

GEnx[edit]

Main article: General Electric GEnx

The GEnx engine, that has been developed for the Boeing 787 Dreamliner and 747-8, is derived from a smaller core variant of the GE90, but features a fan with swept rotor blades.

GP7000[edit]

Main article: Engine Alliance GP7000

GE Aviation has also set up a cooperative venture with Pratt & Whitney, named Engine Alliance, under which the companies have developed an engine for the Airbus A380, named GP7000, based on an 0.72 flow scale of the GE90-110B/115B core.

GE9X[edit]

Main article: General Electric GE9X

In February 2012, GE announced studies on a 10% more efficient derivative, dubbed the GE9X, to power the new Boeing 777-8X/9X aircraft.

LM9000[edit]

The LM9000 is an aeroderivative gas turbine, outputting 65 MW (87,000 hp) at a 43% efficiency before cogeneration : its 33:1 pressure ratio comes from a 4 stage low pressure compressor followed by a 9 stage high pressure compressor, driven by a 2 stage high pressure turbine and a 1 stage low pressure turbine, powering a 4 stage Free Turbine.[35]

See also[edit]

  • Related development

  • Comparable engines

  • Related lists

References[edit]

  1. Jump up^ Fan spinner to nozzle centerbody

  2. Jump up^ Dry, Includes basic engine, basic engine accessories, and optional equipment

  3. Jump up^ world record set at 127,900 lbf (568.9 kN) in testing 827 feet above sea level[23]

Notes[edit]

  1. Jump up^ Brian J. Cantwell (2 Feb 2010). "The GE90 - An Introduction" (PDF). Stanford University.

  2. Jump up^ "Delivering the 2,000th GE90 Engine... And Counting" (Press release). GE Aviation. December 15, 2014.

  3. Jump up to:a b c "Record Year For The World's Largest, Most Powerful Jet Engine" (Press release). GE Aviation. January 19, 2012.

  4. Jump up^ The Short, Happy Life of the Prop-fan | History | Air & Space Magazine

  5. Jump up^ "First Year in Service for GE90 a Huge Success" (Press release). GE Aviation. November 18, 1996.

  6. Jump up to:a b "commercial aircraft engines -GE90" (PDF)Snecma. Safran.

  7. Jump up to:a b c d "GE90 secures exclusive position on 777X"Flight Global. July 14, 1999.

  8. Jump up to:a b c "How Ge Locked Up That Boeing Order". Bloomberg. August 9, 1999.

  9. Jump up^ Eden 2004, p. 115

  10. Jump up to:a b Norris & Wagner 1999, p. 143

  11. Jump up^ Norris & Wagner 1999, p. 144

  12. Jump up^ Cite error: The named reference centreforaviation.com was invoked but never defined (see the help page).

  13. Jump up^ "Airbus A350 XWB puts pressure on Boeing 777". flightglobal. 26 November 2007.

  14. Jump up^ Ben Kingsley-Jones; Guy Norris (November 29, 2005). "Enhanced A340 to take on 777"Flight International.

  15. Jump up^ Cite error: The named reference fuelsaver was invoked but never defined (see the help page).

  16. Jump up^ Jens Flottau (14 November 2011). "Airbus Bids Adieu to A340, Postpones A350 Delivery"Aviation Week & Space Technology.

  17. Jump up^ "GE strives to identify Air France engine fault"Flight International. January 3, 2006.

  18. Jump up^ "The FAA Cleared The First 3D Printed Part To Fly In A Commercial Jet Engine From GE"GE reports. GE Aviation. April 14, 2015.

  19. Jump up^ "Etihad Airways signs engine agreements with GE for Boeing 777 Freighters" (Press release). GE Aviation. November 10, 2015.

  20. Jump up^ General Electric Biggest Jet Engine for B-777. History Channel. 2008. Event occurs at 3:00¨C3:10 min. Retrieved July 11, 2013.

  21. Jump up^ "GE90-115B certification: a look at the flight tests"Le Webmag. Safran. August 8, 2003. Archived from the original on November 1, 2006.

  22. Jump up^ "Impressive Progress of GE90-115B Engine Continues" (Press release). GE Aviation. July 24, 2000.

  23. Jump up to:a b "GE90 Sets New World Record For Thrust; Engine Completes FAR 33 Certification Tests" (Press release). GE Aviation. February 5, 2003.

  24. Jump up^ "Boeing 777-300ER Performs 330-Minute ETOPS Flight" (Press release). Boeing. October 15, 2003.

  25. Jump up^ "Flight-distance record awaits as big 777 heads to London"Seattle Post-Intelligencer. November 8, 2005.

  26. Jump up^ "Maintenance inspection a factor in 2012 Air Canada engine failure during take-off from Lester B. Pearson International Airport". Transportation Safety Board of Canada. December 13, 2013. Retrieved September 11, 2015.

  27. Jump up^ Edmiston, Jake (May 29, 2012). "Air Canada plane debris struck cars after engine failure, safety board confirms"National Post.

  28. Jump up^ Charles Alcock (September 8, 2015). "Engine Failure Causes Fire on British Airways Boeing 777"Aviation International News.

  29. Jump up^ "NTSB Issues Update on the British Airways Engine Fire at Las Vegas". NTSB. September 8, 2015. Retrieved August 8, 2015.

  30. Jump up^ "Fire damage apparent on SIA 777 wing"Flight Global. 27 June 2016.

  31. Jump up^ "Emergency airworthiness directive (AD) 2013-10-52" (PDF). FAA. May 16, 2013. sent to owners and operators of General Electric Company (GE) GE90-110B1 and GE90-115B turbofan engines.

  32. Jump up^ "Type Certificate Data Sheet E00049EN" (PDF). FAA. June 23, 2016.

  33. Jump up to:a b "GE90 Commercial Aircraft Engine". GE Aviation.

  34. Jump up^ "GE90-115B Fan Completing Blade Testing; On Schedule For First Engine To Test" (Press release). GE Aviation. June 17, 2001.

  35. Jump up^ "LM9000 - The new prime mover for oil and gas" (PDF). General Electric. 2017.

Bibliography[edit]

  • Eden, Paul, ed. (2008). Civil Aircraft Today: The World's Most Successful Commercial Aircraft. London: Amber Books Ltd. ISBN 1-84509-324-0.

  • Norris, Guy; Mark Wagner (1999). Modern Boeing Jetliners. Minneapolis, Minnesota: Zenith Imprint. ISBN 0-7603-0717-2.


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