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algary-based TransCanada PipeLines (TCPL) blazed a trail in 1964 in the oil and gas sector when it put the first industrial Avon into action – a gas turbine originally developed to power

military and commercial jets. Five decades later, that engine is still providing the

power to drive natural gas through underground pipes, having run 203,887 hours since new while 83 more have been added to TransCanada’s roster because of their reliability and efficiency.

Today, TransCanada boasts the biggest fleet of Rolls-Royce industrial gas turbines in the world and together the two companies remain energy innovation pioneers, constantly proving up new technologies in an industry with ever changing demands.

“TransCanada and Rolls-Royce have a long relationship

that’s grown over the years — not only in terms of the amount of equipment they have but also in the power range within their fleet,” says Steve Robinson, Customer Business Manager for oil and gas, Rolls-Royce. “It has been a very fruitful relationship.”

The seeds of the industrial Avon were first planted in the 1940s, when jet propulsion was still an engineering marvel. Jet aircraft were the stars of black and white movies touting fiery power and sonic-barrier-breaking abilities.

The Avon first entered service on the wing of the English Electric Canberra B.2 light bomber — a tactical aircraft whose stealth and performance surpassed all others through the 1950s. It proved popular for its advanced performance over other bombers and was bought by many nations. In later years, it powered supersonic fighter jets like the Lightning.

It achieved fame when a single engine with 17,100lbs of

When the first Rolls-Royce industrial Avon gas turbine fired up in Canada it marked the lift-off of a 50-year marriage, one that continues to spawn technological advancement.

C

Above Industrial RB211 (DLE) gas turbines are a mainstay of the network.

Right TransCanada PipeLines power North America with natural gas.

Canada’s NATURALPOWERHOUSE

thrust in the Saab Draken, a Swedish fighter aircraft, achieved Mach 2 – travelling twice

the speed of sound. But perhaps the ultimate tribute to the Avon came in 1983, when the Thrust II, a British-designed and built jet-

propelled car, broke land-speed records. The car driven by Richard Noble clocked in at

1019.47km/h averaged over two runs.As the Avon was making its mark in the aviation industry,

Rolls-Royce engineers were already looking at how to take this then-advanced technology and produce

a package that could be used on land —

providing the drive to compress gas, pump oil,

or produce electricity. That was achieved when the

first industrial Avon roared to life at Station 70 on the northern shore of Lake Superior, Ontario, five decades ago this June. It

was one of ten installed that year in Ontario and Saskatchewan. Those stations formed the backbone of TransCanada’s 14,114-kilometre gas Mainline, which stretches from the Alberta/Saskatchewan border east to the Quebec/Vermont border, connecting with other natural gas pipelines across Canada and the United States.

In the ensuing years, TransCanada’s network has more than quadrupled to include 68,500 kilometres of wholly and partially owned natural gas pipelines tapping into virtually every supply basin in North America. An incredible amount of customers across the continent rely on the company every day to deliver natural gas, from individual homeowners to large industrial customers using it to power electrical plants. The industrial Avon is key to that mission, proving its reliability through its longevity. TransCanada’s fleet of 84 Avons has collectively logged 11.1 million hours of operation during the past five decades.

“You turn them on and let them run and they are happy to do so,” says Chris Murphy, TransCanada’s fleet manager, noting that an engine used in the oil and gas industry in the Middle East boasts the longest known continuous run at 476 days (11,424) hours.

“That’s pretty incredible. They just keep on running.” Over the course of its production, the industrial Avon has

seen its power increase 44 per cent while its efficiency has

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improved by about 14 per cent.The Avon 200, introduced in 2007, was a significant

upgrade providing a life extension for the original engine. A demonstrator version was installed and operated at TransCanada’s Clarkson Valley gas compressor station for testing.

However, industry demands for bigger blocks of power drove the development of a new design, leading to the second-generation gas turbine RB211. It was first trialled by TransCanada, which now has 88 in its fleet. The first industrial RB211, number 1700-003 with a rating of 26,400hp was installed at the company’s station 2F in Burstall, Saskatchewan, 40 years ago in 1974, replacing an older Avon unit. Later, in the 1990s, TransCanada installed dry low emissions (DLE) RB211s at various locations.

Aside from the environmental benefits through lowering emissions, the new DLE gas turbines are also boosting the bottom line. On one of the more important strands of the web-like natural gas transportation infrastructure spread through North America, is that the exhaust is being recovered and converted into electrical power. A relatively new system enhancement in natural gas pipeline operations was added to four of the RB211-powered compressor stations on the Northern Border Pipeline (in which TransCanada is a co-owner), to produce up to 22MW of low-cost power without the consumption of additional fuel or increased pollutants.

“We are constantly testing promising new technologies to minimise natural gas consumption of pipeline compressors and associated emissions of greenhouse gases (GHGs) linked to climate change,” says Murphy.

To advance the new technologies, TransCanada tested an even lower emission RB211 in Alberta. That unique pilot project co-managed by Rolls-Royce and TransCanada from

2003 to 2006 in the eastern slopes of the Rocky Mountains produced impressive results and proved the commercial viability of a new engine design.

The RB211 6761, the first to be utilised in mechanical drive installed at TransCanada’s Nordegg Compressor Station – a remote, unmanned station with harsh weather conditions in the winter – delivered a nine per cent reduction in fuel consumption and GHG emissions. The unit achieved 39 per cent efficiency and slightly better than 95 per cent operational availability, setting a new standard for future projects.

Now, Rolls-Royce and TransCanada are poised to lead the world in yet another first. They have entered into an agreement to test and trial another new version of the RB211 combustor, which takes existing technology on the engine and combines it with new technology.

“It may well lead to millions of dollars in fuel savings annually,” says Steve Robinson. In looking forward, however, it remains important to look back because the technology of the past – the Avon – still proves critical in meeting the needs of tomorrow. “We have every intention of using these engines for another 25 years,” says Chris Murphy. “These units are not going away. I’m pretty sure they will outlast me.”

Author: Suzanne Wilton is an award-winning journalist who spent more than 20 years in newspapers, television and radio. She is now principal of Calgary-based Corporate Content. 

Above A TransCanada station housing a Rolls-Royce gas turbine.

UPDATE: SIEMENS AGREEMENTLast month, Rolls-Royce confirmed it had agreed the sale of its Energy gas turbine and compressor business to Siemens. This comprises the aero-derivative gas turbines, compressor systems and related services to customers in the oil and gas, and power generation sectors. The transition is expected to be completed by the end of the year.

We have every intention of using these engines for another 25 years.