A Review of W501G Engine Design, Development and Field Operating Experience

Abstract

At the end of 2002 there were nine W501G engines in commercial operation, with the lead engine having accumulated 13,000 operating hours and the total fleet about 50,000 operating hours. By the end of 2003 we expect to double the number of operating engines. This paper describes the advanced design features incorporated into the W501G engine, technology/component verification programs carried out in its development, extensive field verification tests, and engine operational experience since its introduction in 1999. The W501G is the latest in a series of successful heavy duty frames developed by Siemens Westinghouse. It is the most powerful and most efficient operating 60 Hz gas turbine, with combined cycle net LHV based efficiency of 58%. Its design is based on viscous 3-D aerodynamics, advanced cooling and sealing, ultra lean premixed combustion, and proven aero engine materials and coatings. It is the first operating engine with closed-loop steam cooling in the transition. Its compressor aerodynamics and mechanical integrity were verified in a full scale test. Numerous rig tests were carried out on its cooling designs, sealings, combustion system, and coatings. An extensive field test program, including telemetry, pyrometry and thermal paint tests, was carried out to verify its performance, emissions and mechanical integrity.