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Prior to retrofitting into the W501G, the ATS steam cooled vane underwent evaluation in a test rig incorporating a single full-scale combustor and transition capable of achieving ATS temperatures and pressures. The tests were con-ducted at the Arnold Air Force Base-Arnold Engineering De-velopment Center in Tennes-see. Instrumentation verified analytical predictions of metal temperatures, heat transfer co-efficients, and stress. SWPC released the stage 1 turbine vane for manufacture and sub-sequent installation in the W501G, with testing sched-uled for 2001.

Plans for the W501ATS are to incorporate closed-loop steam cool-ing into both stage 1 and stage 2 vanes and ring segments.
Catalytic Combustion
To achieve NO emission tar-
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gets across a wide range of ATS operating conditions, SWPC is de-veloping a catalytic combustor in conjunction with Precision Com-bustion, Inc. (PCI) under DOE’s Small Business Innovation Re-search Program. Catalytic com-bustion serves to stabilize flame formation by enhancing oxidation under lean firing conditions. The SWPC/PCI piloted-ring combustor will replace the standard diffusion flame pilot burner with a catalytic pilot burner. Initial atmospheric pressure combustion testing deter-mined turndown and emission characteristics. Follow-on tests successfully demonstrated catalytic combustion at full-scale under ATS combustion temperatures and pres-sures. Engine testing is planned for early 2001.

Materials
An active materials develop-ment program has been ongoing to support incorporation of single crystal and directionally solidified turbine blade alloys and steam cool-ing into the ATS design. The pro-gram has addressed the effect of steam cooling on materials, blade life prediction, advanced vane al-loys, single crystal and directionally solidified blade alloy properties, and single crystal airfoil casting. Single crystal casting trials, using a CMSX-4 alloy on first stage vanes and blades, demonstrated the viabil-ity of casting these large compo-nents with their thin-wall cooling designs. But alternative manufac-turing methods and alloys are be-ing explored to reduce cost.
SWPC plans to use a new ce-ramic TBC emerging from the Oak Ridge National Laboratory Thermal 11 Barrier Coatings Program—a part of the ATS Technology Base Pro-gram. The ceramic TBC, compat-ible with ATS temperatures, will be integrated with the new bond coat evaluated by SWPC earlier in the W501G tests.
S
iemens Westinghouse is fur-
ther expanding the benefits
of the ATS program by intro-
ducing ATS-developed tech-
nologies into its mature product
lines. For example, the latest
W501F incorporates ATS brush
seals, coatings, and compressor
technology.  Because the F frame
accounts for a majority of cur-
rent new unit sales, this infusion
of technology yields significant
savings in fuel and emissions.

 

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