Numerical and Experimental Study on Rotating Stall in Industrial Centrifugal Compressor

2021 ◽  
Vol 143 (8) ◽  
Author(s):  
Toshimasa Miura ◽  
Hideaki Yamashita ◽  
Ryota Takeuchi ◽  
Naoto Sakai
Keyword(s):  
Oil And Gas ◽  
Cfd Simulation ◽  
Aerodynamic Force ◽  
Oil And Gas Industry ◽  
Rotating Stall ◽  
Gas Pressure ◽  
Experimental Result ◽  
Vibration Prediction ◽  
Shaft Vibration ◽  
Good Agreement

Abstract Centrifugal compressors employed in the oil and gas industry are operated at high gas pressure conditions and are used in a wide operation range. Accurate prediction of the rotating stall and the destabilizing aerodynamic force is one of the key technologies for these compressors. The aim of this study is to establish a method of accurately predicting the inception of rotating stall and its effect on shaft vibration. To achieve this, numerical investigations are carried out by unsteady flow and rotordynamic simulations. To validate the accuracy, an experiment is carried out at relatively high gas pressure conditions. In the first part of the study, the accuracy of compressor performance prediction is studied by steady computational fluid dynamics (CFD) simulation. It is found that by taking the wall roughness effect into account, the predicted performance shows good agreement with the experimental result. In the second part of the study, the accuracy of predicting the rotating stall is studied. In the experiment, two types of rotating stalls are measured. One is a multiple-cell stall induced in the vaneless diffuser and the other is a one-cell stall induced in the impeller. It is found that the simulation can predict the inception of the rotating stall with relatively high accuracy as the predicted results show good agreement with the experimental results in terms of cell count, rotation speed, pressure fluctuation level, and the effect on shaft vibration. Through this study, the effectiveness of simulation is validated for the stall and vibration prediction.

Numerical and Experimental Study on Rotating Stall in Industrial Centrifugal Compressor

2020 ◽  
Author(s):  
Toshimasa Miura ◽  
Hideaki Yamashita ◽  
Ryota Takeuchi ◽  
Naoto Sakai
Keyword(s):  
Cfd Simulation ◽  
Aerodynamic Force ◽  
Rotating Stall ◽  
Gas Pressure ◽  
Experimental Result ◽  
Vaneless Diffuser ◽  
Vibration Prediction ◽  
Multiple Cell ◽  
Shaft Vibration ◽  
Good Agreement

Abstract Centrifugal compressors employed in the oil and gas industry are operated at high gas pressure conditions and are used in a wide operation range. Accurate prediction of the rotating stall and the destabilizing aerodynamic force is one of the key technologies for these compressors, because rotating stall can sometimes cause severe problems with subsynchronous shaft vibration and limit its operation range. Thus, the aim of this study is to establish a method of accurately predicting the inception of rotating stall and its effect on shaft vibration. To achieve this, numerical investigations are carried out by unsteady Reynolds-averaged Navier-Stokes (RANS) simulation with a full annulus model of the compressor stage. Also, to assess the accuracy of the simulation qualitatively and quantitatively, a high-pressure compressor test rig that contains a shrouded impeller and a vaneless diffuser is built. To investigate the effect of the rotating stall on the shaft vibration, an experiment is carried out at relatively high gas pressure with the inlet pressure level exceeding 30 barA. In the first part of the study, the accuracy of compressor performance prediction is studied by steady computational fluid dynamics (CFD) simulation. It is found that by taking the wall roughness effect into account, the predicted performance shows good agreement with the experimental result. Thus, a subsequent study of the rotating stall is also carried out by considering its effect. In the second part of the study, the accuracy of predicting the rotating stall is studied. In the experiment, two types of rotating stall are measured. One is a multiple-cell stall induced in the vaneless diffuser, for which the speed of rotation is relatively low and the other is a one-cell stall induced in the impeller region. The properties of the multiple-cell stall agree with the previous experimental and numerical studies, and the rotating stall has the limited effect on shaft vibration. Conversely, the one-cell stall shows severe subsynchronous vibration. In this study, both types of stall prediction are examined by CFD simulation. It is found that the simulation can predict the inception of the rotating stall with relatively high accuracy as the predicted results show good agreement with the experimental results in terms of cell count, rotation speed, pressure fluctuation level and the effect on shaft vibration. Through this study, the effectiveness of unsteady CFD simulation is confirmed for these types of stall and vibration prediction.

scholarly journals Comparative Study of CFD and LedaFlow Models for Riser-Induced Slug Flow

Energies ◽  
2020 ◽  
Vol 13 (14) ◽  
pp. 3733
Author(s):  
Rasmus Thy Jørgensen ◽  
Gunvor Rossen Tonnesen ◽  
Matthias Mandø ◽  
Simon Pedersen
Keyword(s):  
Slug Flow ◽  
Oil And Gas ◽  
Cfd Simulation ◽  
Numerical Models ◽  
Oil And Gas Industry ◽  
Test Facility ◽  
Cfd Model ◽  
Two Phase ◽  
Transient Model ◽  
Vof Model

The goal of this study is to compare mainstream Computational Fluid Dynamics (CFD) with the widely used 1D transient model LedaFlow in their ability to predict riser induced slug flow and to determine if it is relevant for the offshore oil and gas industry to consider making the switch from LedaFlow to CFD. Presently, the industry use relatively simple 1D-models, such as LedaFlow, to predict flow patterns in pipelines. The reduction in cost of computational power in recent years have made it relevant to compare the performance of these codes with high fidelity CFD simulations. A laboratory test facility was used to obtain data for pressure and mass flow rates for the two-phase flow of air and water. A benchmark case of slug flow served for evaluation of the numerical models. A 3D unsteady CFD simulation was performed based on Reynolds-Averaged Navier-Stokes (RANS) formulation and the Volume of Fluid (VOF) model using the open-source CFD code OpenFOAM. Unsteady simulations using the commercial 1D LedaFlow solver were performed using the same boundary conditions and fluid properties as the CFD simulation. Both the CFD and LedaFlow model underpredicted the experimentally determined slug frequency by 22% and 16% respectively. Both models predicted a classical blowout, in which the riser is completely evacuated of water, while only a partial evacuation of the riser was observed experimentally. The CFD model had a runtime of 57 h while the LedaFlow model had a runtime of 13 min. It can be concluded that the prediction capabilities of the CFD and LedaFlow models are similar for riser-induced slug flow while the CFD model is much more computational intensive.

Centrifugal Compressor Stability Prediction Using a New Physics Based Approach

2009 ◽  
Author(s):  
J. Jeffrey Moore ◽  
David L. Ransom
Keyword(s):  
Centrifugal Compressor ◽  
Oil And Gas ◽  
Cfd Simulation ◽  
Cost Effective ◽  
Oil And Gas Industry ◽  
New Physics ◽  
System Stability ◽  
Stability Prediction ◽  
Stability Margins ◽  
Area Of Interest

The accurate prediction of centrifugal compressor stability continues to be an important area of interest in the oil and gas industry. Ensuring stability is critical to the cost-effective installation and operation of these machines in remote environments, where field stability problems are much more expensive to diagnose and correct. Current industry standards and tools for the prediction of impeller destabilizing forces are based on empirical methods that, to date, have served fairly well for systems with reasonable stability margins. However, as stability margins are decreased, use of a modeling method that is more physics based and can better represent the observed trends in machine behavior at low stability margins is required. Furthermore, the development of mega-class Liquefied Natural Gas (LNG) compressors and ultra-high pressure reinjection compressors provides further motivation to improve accuracy. In this paper, a new physics based expression for the prediction of impeller cross-coupling, previously described by Moore, et al. [1] is further investigated by analyzing several classes and scale factors of impellers ranging from 2-D designs used in reinjection to full 3-D impellers typically used in LNG. The new expression is based on both Computational Fluid Dynamics (CFD) simulation and experimental test data from a known instability. These results are then applied to two case studies of marginally stable and unstable compressors in the field that were studied by the authors’ company. For each case study, the system stability is evaluated using both the new physics based expression as well as the more traditional empirical approaches. Comparisons are made for overall stability prediction as well as sensitivity to system changes. Conclusions are made regarding the applicability and limits of this new approach.

CFD Simulation of Multiphase Flow in Concentric Annuli

2018 ◽  
Author(s):  
Amina Shynybayeva ◽  
Luis R. Rojas-Solórzano ◽  
Kristian Sveen
Keyword(s):  
Multiphase Flow ◽  
Oil And Gas ◽  
Cfd Simulation ◽  
Flow Behavior ◽  
Droplet Diameter ◽  
Turbulence Models ◽  
Oil And Gas Industry ◽  
Continuous Phase ◽  
Two Phase ◽  
Well Design

Multiphase flow is commonly found in almost every process related to oil and gas industry. The precise prediction of the flow behavior is essential to provide safe and efficient hydrocarbon recovery. An accurate characterization of multiphase flow plays a major role in well design optimization and development of successful production and transportation facilitiess. Even though the hydrodynamic behavior of multiphase flow in various pipe geometries typically found in the industry has been widely studied, there is still very little known about the flow pattern and hydrodynamic conditions presented in horizontal annular geometry. Current work presents Computational Fluid Dynamics (CFD) simulation of two-phase oil-water flow in horizontal concentric annuli using different turbulence models and Eulerian-Eulerian continuous-disperse interphase drag model. Water was modelled as disperse phase, while oil was considered as continuous phase. Effect of water droplet diameter in the interphase model is extensively discussed in this paper. Results of the simulations are compared to the experimental data for a variety of liquid velocities and water cuts.

Behavior Evaluation of Subsea Jumpers Exposed to Current by Experiment and FEM

2018 ◽  
Author(s):  
Mohammad Mobasheramini ◽  
Luciene Alves ◽  
Antonio Carlos Fernandes ◽  
Gilberto Bruno Ellwanger
Keyword(s):  
Deep Water ◽  
Oil And Gas ◽  
New Technologies ◽  
Flow Direction ◽  
Experimental Tests ◽  
Oil And Gas Industry ◽  
Experimental Result ◽  
Gas Industry ◽  
Oil Companies ◽  
Offshore Production

The oil and gas industry is headed toward deep water in recent years. Oil companies are seeking new technologies to meet the challenges of deep-water oil exploration and in the near future, this will bring new discoveries. The most difficulty of exploring oil in this region is the depth where the equipment is installed and the production lines must be safe for such activities. Full understanding of the dynamics of the behavior of this equipment is vital to the success of offshore production and operation due to environmental problems that can occur in an accident and a large amount of economic and human resources involved. The phenomenon of the vortex induced vibration (VIV) is complex and involves an interaction between hydrodynamic forces and the response of the structure. The force and displacement can be determined through experimental tests or the complete numerical simulation of the interaction between the structure and fluid. DNV-GL has recently published a guideline about the design of a subsea jumper [1], but it is still needed many studies and experiments to improve the evaluation of VIV in rigid subsea jumpers in the oil industry. The main objective of the present work is to investigate VIV phenomenon in a jumper exposed to uniform flow and verify its oscillation in the flow direction, which called inline VIV (VIVx). Throughout this study, the finite element method was used to perform the structural and modal analysis of the structure, in order to obtain the modes, frequencies and then validate the experimental result. Experimental analysis of jumpers was also performed in a current tank to evaluate the behavior of the jumper with the current flow.

A 3D Time-Accurate CFD Simulation of the Flow Field Inside a Vaneless Diffuser During Rotating Stall Conditions

2016 ◽  
Author(s):  
Michele Marconcini ◽  
Alessandro Bianchini ◽  
Matteo Checcucci ◽  
Giovanni Ferrara ◽  
Andrea Arnone ◽  
...  
Keyword(s):  
Cfd Simulation ◽  
Pressure Field ◽  
Mechanical Stability ◽  
Aerodynamic Force ◽  
Rotating Stall ◽  
Regulation System ◽  
Vaneless Diffuser ◽  
Return Channel ◽  
University Of Florence ◽  
The University

An accurate characterization of rotating stall in terms of inception modality, flow structures, and stabilizing force is one of the key goals for high-pressure centrifugal compressors. The unbalanced pressure field that is generated within the diffuser can be in fact connected to a non-negligible aerodynamic force and then to the onset of detrimental sub-synchronous vibrations which can prevent the machine from operating beyond this limit. An inner comprehension on how the induced flow pattern in these conditions affects the performance of the impeller and its mechanical stability can therefore lead to the development of a more effective regulation system able to mitigate the effects of the phenomenon and extend the left-side margin of the operating curve. In the present study, a 3D-unsteady CFD approach was applied to the simulation of a radial stage model including the impeller, the vaneless diffuser and the return channel. Simulations were carried out with the TRAF code of the University of Florence. The tested rotor was an industrial impeller operating at high peripheral Mach number, for which unique experimental pressure measurements, including the spatial reconstruction of the pressure field at the diffuser inlet, were available. The comparison between experiments and simulations showed a good matching and corroborated the CFD capabilities in correctly describing also some of the complex unsteady phenomena taking place in proximity of the left margin of the operating curve.

Experiments and CFD Predictions of Particles Velocity and Trajectory in Flow with Non-Newtonian Fluid through a Partially Obstructed Duct

2017 ◽  
Vol 899 ◽  
pp. 83-88 ◽  
Author(s):  
Isabele Cristina Bicalho ◽  
Dyovani Bruno Lima dos Santos ◽  
Carlos Henrique Ataíde ◽  
Claudio Roberto Duarte
Keyword(s):  
Newtonian Fluid ◽  
Xanthan Gum ◽  
Oil And Gas ◽  
Drilling Fluid ◽  
Oil And Gas Industry ◽  
Industrial Applications ◽  
Mean Velocity ◽  
Gas Industry ◽  
Computational Fluid Dynamics Cfd ◽  
Good Agreement

Dynamic of particles in annular fluid flow is a very relevant subject for many industrial applications, especially for the oil and gas industry. Successful drilling is, to a large extent, dependent upon the ability of the drilling fluid to clean the hole by conveying the cuttings to the surface. The aim of this work was to evaluate experimentally and through numerical simulations, the helical path and the axial mean velocity developed by glass beads with diameter of 2.7 mm flowing with a non-Newtonian fluid through a partially obstructed annulus. Experimental data are reported for flow of 1 m3/h of an aqueous solution with 0.5% Xanthan gum through concentric annulus with partial obstruction of 6 mm and a 183 rpm rotation of the inner cylinder. Techniques of computational fluid dynamics (CFD) were applied to obtain detailed information about the flow field, allowing to estimate the radial position of launching of particles in the range of 35.5 mm to 39.1 mm. Comparisons between numerical calculations and the flow data indicated, in general, a very good agreement.

Numerical Vortex-Induced Vibration Prediction of Marine Risers in Time-Domain Based on a Forcing Algorithm

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Peter Ma ◽  
Wei Qiu ◽  
Don Spencer
Keyword(s):  
Experimental Data ◽  
Time Domain ◽  
Oil And Gas ◽  
Oil And Gas Industry ◽  
Analysis Tool ◽  
Time Step ◽  
Vortex Induced Vibration ◽  
Marine Risers ◽  
Hydrodynamic Damping ◽  
Vibration Prediction

Vortex-induced vibration (VIV) of marine risers poses a significant challenge as the offshore oil and gas industry moves into deep water. A time-domain analysis tool has been developed to predict the VIV of marine risers based on a forcing algorithm and by making full use of the available high Reynolds number experimental data. In the formulation, the hydrodynamic damping is not treated as a special case but simply an extension of the experimentally derived lift curves. The forcing algorithm was integrated into a mooring analysis program based on the global coordinate-based finite element method. At each time step, the added mass, lifting force, and drag force coefficients and their corresponding loads are computed for each element. Validation studies have been carried out for a full-scale rigid riser segment and a model-scale flexible riser. The numerical results were compared with experimental data and solutions by other programs.

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