Experimental Investigation for Enhanced Control of Rotating Unsteady Flow Instabilities in an Unshrouded Centrifugal Compressor Impeller

2019 ◽  
Vol 142 (1) ◽  
Author(s):  
B. Mischo ◽  
P. Jenny ◽  
Y. Bidaut ◽  
N. Fonzi ◽  
D. Hermann ◽  
...  
Keyword(s):  
Centrifugal Compressor ◽  
Leading Edge ◽  
Fem Analysis ◽  
Rotating Stall ◽  
Test Rig ◽  
Blade Vibration ◽  
Impeller Blade ◽  
Compressor Impeller ◽  
Frequency Interaction ◽  
Computational Fluid Dynamics Cfd

Abstract Unshrouded industrial centrifugal compressor impellers operate at high rotational speeds and volume flow rates. Under such conditions, impeller blade excitation is dominated by high frequency interaction with stationary parts, i.e., vaned diffusers or inlet guide vanes. In a previous study conducted on two full compression units of the original equipment manufacturer (OEM), the authors identified, characterized, and quantified resonant blade vibration caused by the interaction of the impeller blades with rotating stall cells during severe off-design conditions. This caused significant dynamic stress in the blades. In a follow-up study, this phenomenon was reproduced successfully experimentally under representative off-design conditions in a downscaled test rig and numerically with unsteady computational fluid dynamics (CFD) and structural mechanical finite element method (FEM) analysis. The gained knowledge was translated into a new diffuser design philosophy, based on sectorwise circumferential variation of the leading edge angle. This paper presents the patented philosophy, which is experimentally verified on the same test rig configuration in terms of flow path geometry and measurement equipment that was used in the mentioned prior study to assess resonant blade interaction. The results confirm the design aims: rotating stall onset was delayed without affecting the aerodynamic performance of the stage. Resonant blade interaction with rotating stall observed in the baseline diffuser could not be avoided with the two new diffuser designs. However, with the two new diffusers, the induced mechanical stresses in the impeller and the excitability were reduced by up to 12%.

Experimental Investigation for Enhanced Control of Rotating Unsteady Flow Instabilities in an Unshrouded Centrifugal Compressor Impeller

2019 ◽  
Author(s):  
B. Mischo ◽  
P. Jenny ◽  
Y. Bidaut ◽  
N. Fonzi ◽  
D. Hermann ◽  
...  
Keyword(s):  
Centrifugal Compressor ◽  
Leading Edge ◽  
Fem Analysis ◽  
Rotating Stall ◽  
Test Rig ◽  
Blade Vibration ◽  
Impeller Blade ◽  
Compressor Impeller ◽  
Frequency Interaction ◽  
Computational Fluid Dynamics Cfd

Abstract Unshrouded industrial centrifugal compressor impellers operate at high rotational speeds and volume flow rates. Under such conditions impeller blade excitation is dominated by high frequency interaction with stationary parts, i.e. vaned diffusers or inlet guide vanes. In a previous study conducted on two full compression units of the original equipment manufacturer (OEM), the authors also identified, characterized and quantified resonant blade vibration caused by the interaction of the impeller blades with sub-synchronous rotating stall cells during severe off-design conditions. The resonant impeller excitation lead to significant dynamic stress in the blades. In a follow-up study the authors have reproduced this phenomenon under representative off-design conditions in a downscaled test rig and successfully reproduced the phenomenon with unsteady Computational Fluid Dynamics (CFD) and structural mechanical Finite Element Method (FEM) analysis. The gained knowledge of these studies was translated into a new diffuser design philosophy, based on a sectorwise circumferential variation of the leading edge angle. In this paper, the patented philosophy by the OEM is presented and verified experimentally on the same test rig configuration in terms of flow path geometry and measurement equipment that was used in the mentioned prior study to assess resonant blade interaction. The results confirm the design aims: rotating stall onset was delayed without affecting the aerodynamic performance of the stage. Resonant blade interaction with rotating stall observed in the baseline diffuser could not be avoided with the two new diffuser designs. However, with the two new diffusers, the induced mechanical stresses in the impeller and the excitability were reduced by up to 12%.

Numerical Study on the Influence of Tip Clearance on Rotating Stall in an Unshrouded Centrifugal Compressor

2017 ◽  
Author(s):  
Wenying Ju ◽  
Shengli Xu ◽  
Xiaofang Wang ◽  
Xudong Chen ◽  
Shuhua Yang ◽  
...  
Keyword(s):  
Centrifugal Compressor ◽  
Numerical Study ◽  
Leading Edge ◽  
Rotating Stall ◽  
Tip Clearance ◽  
Forming Process ◽  
Impeller Blade ◽  
Tip Clearance Flow ◽  
Rotating Speed ◽  
Operation Conditions

Whole annulus unsteady simulations are performed by CFD with the whole flow passage model from inlet guide vanes to volute of an unshrouded centrifugal compressor. Characteristics and development mechanism of rotating stall are analyzed including the flow field and the impeller blade load in time and frequency domain. Rotating stall with three cells is observed in both two actual operation conditions but the cell rotating speed and the forming process is different. Leading edge tip clearance leakage is a criterion to predict the formation of a spike stall in centrifugal compressors. Tip clearance flow also plays an important role in the moving of rotating instabilities and the propagation of stall cells. It can effectively slow down the stall forming and decrease the pressure load on blade by reduced the tip clearance size at the leading edge.

Unsteady and Three-Dimensional Flow Phenomena in a Transonic Centrifugal Compressor Impeller at Rotating Stall

2009 ◽  
Author(s):  
Kenichiro Iwakiri ◽  
Masato Furukawa ◽  
Seiichi Ibaraki ◽  
Isao Tomita
Keyword(s):  
Centrifugal Compressor ◽  
Wavelet Transforms ◽  
Three Dimensional ◽  
Axial Compressor ◽  
Internal Flow ◽  
Leading Edge ◽  
Rotating Stall ◽  
Detached Eddy Simulation ◽  
Transonic Centrifugal Compressor ◽  
Compressor Impeller

This paper presents a combined experimental and numerical analysis of rotating stall in a transonic centrifugal compressor impeller for automotive turbochargers. Stall characteristics of the compressor were examined by two high-response pressure transducers mounted on the casing wall near the impeller inlet. The pressure traces were analyzed by wavelet transforms to estimate the disturbance waves quantitatively. Three-dimensional unsteady internal flow fields were simulated numerically by Detached Eddy Simulation (DES) coupled LES-RANS approach. The analysis results show good agreements on both compressor performance characteristics and the unsteady flow features at the rotating stall. At stall inception, spiral-type breakdown of the full-blade tip leakage vortex was found out at some passages and the brokendown regions propagated against the impeller rotation. This phenomenon changed with throttling, and tornado-type separation vortex caused by the full-blade leading edge separation dominated the flow field at developed stall condition. It is similar to the flow model of short-length scale rotating stall established in an axial compressor rotor.

Evolution Process of Diffuser Stall in a Centrifugal Compressor With Vaned Diffuser

2018 ◽  
Author(s):  
Nobumichi Fujisawa ◽  
Tetsuya Inui ◽  
Yutaka Ohta
Keyword(s):  
Centrifugal Compressor ◽  
Leading Edge ◽  
Boundary Layer Separation ◽  
Rotating Stall ◽  
Evolution Process ◽  
Cfd Analysis ◽  
Pressure Measurements ◽  
Velocity Measurements ◽  
Vaned Diffuser ◽  
Computational Fluid Dynamics Cfd

The evolution process of a diffuser rotating stall in a centrifugal compressor with a vaned diffuser was investigated by experimental and numerical analyses. From velocity measurements, it was found that the diffuser stall propagated near the shroud side in the vaneless space. As the mass flow decreased, a stage stall rotated within both the impeller and diffuser passages, instead of a diffuser stall. The evolution process of the diffuser stall had three stall forms. First, the diffuser stall, which was rotating on the shroud side, shifted to the hub side. Then, the diffuser stall moved into the impeller passages and evolved to a stage stall. From computational fluid dynamics (CFD) analysis, a tornado-type vortex was generated first, near the hub side of the diffuser leading edge, when the diffuser stall was shifted to the hub side. Next, a throat area blockage was formed near the hub side because of the boundary layer separation in the vaneless space. Finally, the blockage within the diffuser passages expanded to the impeller passages and developed into a stage stall. From the pressure measurements along the impeller and diffuser passages, the magnitude of pressure fluctuation on the casing wall of the diffuser throat area also suddenly increased when the diffuser stall shifted to the hub side. Therefore, the evolution area of the diffuser stall was caused by the evolution of the blockage near the throat area of the diffuser passage.

scholarly journals Rotating Stall Induced Non-Synchronous Blade Vibration Analysis for an Unshrouded Industrial Centrifugal Compressor

Sensors ◽  
2019 ◽  
Vol 19 (22) ◽  
pp. 4995 ◽  
Author(s):  
Xinwei Zhao ◽  
Qiang Zhou ◽  
Shuhua Yang ◽  
Hongkun Li
Keyword(s):  
Centrifugal Compressor ◽  
Pressure Wave ◽  
Pressure Sensors ◽  
Load Condition ◽  
Rotating Stall ◽  
Aerodynamic Load ◽  
Blade Vibration ◽  
Impeller Blade ◽  
Time Space ◽  
Stall Cells

Rotating stall limits the operating range and stability of the centrifugal compressor and has a significant impact on the lifetime of the impeller blade. This paper investigates the relationship between stall pressure wave and its induced non-synchronous blade vibration, which will be meaningful for stall resonance avoidance at the early design phase. A rotating disc under a time-space varying load condition is first modeled to understand the physics behind stall-induced vibration. Then, experimental work is conducted to verify the model and reveal the mechanism of stall cells evolution process within flow passage and how blade vibrates when suffering such aerodynamic load. The casing mounted pressure sensors are used to capture the low-frequency pressure wave. Strain gauges and tip timing sensors are utilized to monitor the blade vibration. Based on circumferentially distributed pressure sensors and stall parameters identification method, a five stall cells mode is found in this compressor test rig and successfully correlates with the blade non-synchronous vibration. Furthermore, with the help of tip timing measurement, all blades vibration is also evaluated under different operating mass flow rate. Analysis results verify that the proposed model can show the blade forced vibration under stall flow condition. The overall approach presented in this paper is also important for stall vibration and resonance free design with effective experimental verification.

scholarly journals Rotating Stall Flow and Dangerous Blade Excitation of Centrifugal Compressor Impeller: Part 1 — Phenomenon of Large-Number Stall Cells

1991 ◽  
Author(s):  
U. Seidel ◽  
J. Chen ◽  
U. Haupt ◽  
H. Hasemann ◽  
D. Jin ◽  
...  
Keyword(s):  
Phase Analysis ◽  
Centrifugal Compressor ◽  
High Performance ◽  
Fast Response ◽  
Rotating Stall ◽  
Blade Vibration ◽  
Response Dynamic ◽  
Compressor Impeller ◽  
Stall Cells ◽  
High Level

A new structure of rotating stall with unusual large-number stall cells (up to 7) has been detected experimentally in a high performance single stage centrifugal compressor system with backswept impeller and vaned diffusers. The number of stall cells is firstly identified by a phase analysis of pressure signals obtained from fast response dynamic transducers located at different circumferential positions on the shroud wall, and then verified by comparing the resulting frequencies of blade vibration with that measured from blade mounted strain gages. Up to 6 transducers in one radial position have been used for more certainty of the phase analysis. For the case of intermittent stall patterns, the frequency analysis of pressure and blade vibration signals is performed separately for sections with different characters of oscillation to avoid the smearing effect if signals of the whole pattern are averaged. As a result, the large-number stall cells, numbered 4–7, were determined in the speed range of 12000–14000 rpm, and in the higher speeds of 15000–16000 rpm right after the occurrence of normal stall cells of 2, when the flow rate is slightly reduced along the constant speed line. For the large-number stall cell case, the measured blade vibration strain has reached such a high level that is already beyond the tolerance of blade material. Moreover, frequencies of blade excitation are always in the vincinity of resonance. These two features, which are not observed for the normal stall cell case and for the excitation of broadband character, show a particular danger of this phenomenon to the compressor operation.

Stall Inception in a High Speed Centrifugal Compressor During Speed Transients

2017 ◽  
Author(s):  
Fangyuan Lou ◽  
John C. Fabian ◽  
Nicole L. Key
Keyword(s):  
Heat Transfer ◽  
Centrifugal Compressor ◽  
High Speed ◽  
Flow Instability ◽  
Leading Edge ◽  
Fast Response ◽  
Rotating Stall ◽  
Transient Performance ◽  
Stall Inception ◽  
Pressure Transducers

The inception and evolution of rotating stall in a high-speed centrifugal compressor are characterized during speed transients. Experiments were performed in the Single Stage Centrifugal Compressor (SSCC) facility at Purdue University and include speed transients from sub-idle to full speed at different throttle settings while collecting transient performance data. Results show a substantial difference in the compressor transient performance for accelerations versus decelerations. This difference is associated with the heat transfer between the flow and the hardware. The heat transfer from the hardware to the flow during the decelerations locates the compressor operating condition closer to the surge line and results in a significant reduction in surge margin during decelerations. Additionally, data were acquired from fast-response pressure transducers along the impeller shroud, in the vaneless space, and along the diffuser passages. Two different patterns of flow instabilities, including mild surge and short-length-scale rotating stall, are observed during the decelerations. The instability starts with a small pressure perturbation at the impeller leading edge and quickly develops into a single-lobe rotating stall burst. The stall cell propagates in the direction opposite of impeller rotation at approximately one third of the rotor speed. The rotating stall bursts are observed in both the impeller and diffuser, with the largest magnitudes near the diffuser throat. Furthermore, the flow instability develops into a continuous high frequency stall and remains in the fully developed stall condition.

Flow Behavior of a Centrifugal Compressor With Vaneless Diffuser at Design and Off Design Conditions

2012 ◽  
Author(s):  
Chuang Gao ◽  
Weiguang Huang ◽  
Haiqing Liu ◽  
Hongwu Zhang ◽  
Jundang Shi
Keyword(s):  
Centrifugal Compressor ◽  
Flow Behavior ◽  
Travelling Waves ◽  
Leading Edge ◽  
Pressure Oscillation ◽  
Rotating Stall ◽  
Vaneless Diffuser ◽  
Unstable Flow ◽  
Flow Recirculation ◽  
Static Performance

This paper concerns with the numerical and experimental aspects of both steady and unsteady flow behavior in a centrifugal compressor with vaneless diffuser and downstream collector. Specifically, the appearance of flow instabilities i.e., rotating stall and surge is investigated in great detail. As the first step, the static performance of both stage and component was analyzed and possible root cause of system surge was put forward based on the classic stability theory. Then the unsteady pressure data was utilized to find rotating stall and surge in frequency domain which could be classified as mild surge and deep surge. With the circumferentially installed transducers at impeller inlet, backward travelling waves during stall ramp could be observed. The modes of stall waves could be clearly identified which is caused by impeller leading edge flow recirculation at Mu = 0.96. However, for the unstable flow at Mu = 1.08, the system instability seems to be caused by reversal flow in vaneless diffuser where the pressure oscillation was strongest. Thus steady numerical simulation were performed and validated with the experimental performance data. With the help of numerical analysis, the conjectures are proved.

Influence of Labyrinth Seal Leakage on Centrifugal Compressor Performance

2009 ◽  
Author(s):  
Bob Mischo ◽  
Beat Ribi ◽  
Christof Seebass-Linggi ◽  
Sebastiano Mauri
Keyword(s):  
Centrifugal Compressor ◽  
Leading Edge ◽  
Suction Side ◽  
Labyrinth Seal ◽  
Main Flow ◽  
Low Flow ◽  
Leakage Flow ◽  
Multi Stage ◽  
Compressor Impeller ◽  
Rotating Impeller

The focus of this paper lies on the leakage flow across the shroud of a centrifugal compressor impeller. It is common practice to use shrouded impellers in multi stage compressors featuring a single shaft. The rotating impeller then has to be sealed against the higher pressure in the downstream diffuser by means of labyrinths. The relative amount of leakage is higher for stages designed for low flow, meaning that the associated losses gain in relevance. In addition to this loss source, the injection of the leakage flow has a serious influence on the main flow in a region where it is prone to separation, i.e. at the suction side of the impeller blades close to the shroud, where the highest relative velocities are found. The present paper discusses the numerical results of several geometrical arrangements where the leakage flow was mixed with the main flow in different ways. The distance between the location of injection and the leading edge of the impeller as well as the orientation of the injected flow showed a distinct influence on the performance of the entire stage, mainly on stability.

On the Influence of a Hubside Exducer Cavity and Bleed Air in a Close-Coupled Centrifugal Compressor Stage

2017 ◽  
Vol 139 (7) ◽  
Author(s):  
Peter Kaluza ◽  
Christian Landgraf ◽  
Philipp Schwarz ◽  
Peter Jeschke ◽  
Caitlin Smythe
Keyword(s):  
Centrifugal Compressor ◽  
Pressure Field ◽  
State Of The Art ◽  
Test Rig ◽  
Cfd Simulations ◽  
Trailing Edge ◽  
Loss Mechanism ◽  
Aero Engine ◽  
Computational Fluid Dynamics Cfd ◽  
Stage Efficiency

In aero-engine applications, centrifugal compressors are often close-coupled with their respective diffusers to increase efficiency at the expense of a reduced operating range. The aim of this paper is to show that state-of-the art steady-state computational fluid dynamics (CFD) simulations can model a hubside cavity between an impeller and a close-coupled diffuser and to enhance the understanding of how the cavity affects performance. The investigated cavity is located at the impeller trailing edge, and bleed air is extracted through it. Due to geometrical limitations, the mixing plane is located in the cavity region. Therefore, the previous analyses used only a cut (“simple”) model of the cavity. With the new, “full” cavity model, the region inside the cavity right after the impeller trailing edge is not neglected anymore. The numerical setup is validated using the experimental data gathered on a state-of-the art centrifugal compressor test-rig. For the total pressure field in front of the diffuser throat, a clear improvement is achieved. The results presented reveal a drop in stage efficiency by 0.5%-points caused by a new loss mechanism at the impeller trailing edge. On the hubside, the fundamentally different interaction of the cavity with the coreflow increases the losses in the downstream components resulting in the mentioned stage efficiency drop. Finally, varying bleed air extraction is investigated with both cavity models. Only the full cavity (FC) model captures the changes measured in the experiment.

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