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To verify the aerodynamic per-formance and mechanical integrity of the W501ATS compressor, a full-scale unit was manufactured and tested in 1997. SWPC confirmed performance expectations through extensive, highly instrumented tests in a specially designed facility at the Philadelphia Naval Base.
The ATS compressor technol-ogy has been retrofitted into the W501F product line using analyti-cal techniques developed and proven under the ATS program. This significantly expands the ben-efit of the ATS program,

 

ATS Row 4 Turbine Blade

To accommodate the 25 percent increase in mass flow associated with the ATS compressor, the W501G uses the ATS Row 4 turbine blade assembly. The new design uses a large annulus area to reduce the exit velocity and capture the maximum amount of the gas flow kinetic energy before leaving the turbine. The uncooled ATS Row 4 turbine blade assembly met pre-dicted performance levels through-out the W501G test program and established a new level in gas tur-bine output capability.
Brush Seals and Abradable Coatings

The W501ATS design applies brush seals to minimize air leakage and hot gas ingestion into turbine disc cavities. Seal locations include the compressor diaphragms, turbine disc front, turbine rims, and turbine interstages. SWPC used test rigs to develop effective, rugged, and reli-able brush seals for the various ap-plications. ATS compressor tests at the Philadelphia Naval Base veri-fied brush seal low leakage and wear characteristics, which resulted in application of the seals to W501F and W501G product lines. Retrofit-ted units have demonstrated signifi-cantly improved performance.
Abradable coatings on turbine and compressor blade ring seals are also a part of the W501ATS design. This approach permits reduced tip clearances without risk of hardware damage, and provides more uniform tip clearance around the perimeter. Stage 1 turbine ring segment condi-tions present a particular challenge, requiring state-of-the-art thermal barrier properties while providing abradability.  Engine testing verified the targeted abradability, tip-to-seal wear, and erosion characteristics. The coatings have been incorpo-rated into the compressor and the first two turbine stages of both the W501F and W501G machines.
Siemens Westinghouse W501G at Lakeland Electric’s McIntosh Power Station, Lakeland, Florida

 

Completing ATS Development
Development activities are fo-cused on extending the W501G per-formance to ATS efficiencies by introducing additional technology advancements and increasing the firing temperature to 2,750 oF.
Closed-Loop Steam Cooling
The next major step will be in-corporation of closed-loop steam cooling into the W501G stage 1 tur-bine vane. This addition will extend the benefits of the existing steam cooled transition by eliminating cooling air at the turbine inlet, rais-ing the firing temperature, and free-ing more compressor air to reduce NO emissions.
　
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