scholarly journals Surge Margin Optimization of Centrifugal Compressors Using a New Objective Function Based on Local Flow Parameters

2019 ◽  
Vol 4 (4) ◽  
pp. 42
Author(s):  
Johannes Ratz ◽  
Sebastian Leichtfuß ◽  
Maximilian Beck ◽  
Heinz-Peter Schiffer ◽  
Friedrich Fröhlig
Keyword(s):  
Objective Function ◽  
Centrifugal Compressor ◽  
Computational Effort ◽  
Angle Distribution ◽  
Centrifugal Compressors ◽  
Local Flow ◽  
Vaned Diffuser ◽  
Flow Parameters ◽  
Surge Margin ◽  
Beta Angle

Currently, 3D-CFD design optimization of centrifugal compressors in terms of the surge margin is one major unresolved issue. On that account, this paper introduces a new kind of objective function. The objective function is based on local flow parameters present at the design point of the centrifugal compressor. A centrifugal compressor with a vaned diffuser is considered to demonstrate the performance of this approach. By means of a variation of the beta angle distribution of the impeller and diffuser blade, 73 design variations are generated, and several local flow parameters are evaluated. Finally, the most promising flow parameter is transferred into an objective function, and an optimization is carried out. It is shown that the new approach delivers similar results as a comparable optimization with a classic objective function using two operating points for surge margin estimation, but with less computational effort since no second operating point near the surge needs to be considered.

Backward Traveling Rotating Stall Waves in Centrifugal Compressors

2002 ◽  
Author(s):  
Z. S. Spakovsky
Keyword(s):  
Mass Flow ◽  
Centrifugal Compressor ◽  
First Principles ◽  
Rotating Stall ◽  
Air Injection ◽  
System Stability ◽  
Centrifugal Compressors ◽  
Injection Scheme ◽  
Surge Margin ◽  
Low Order

Rotating stall waves that travel against the direction of rotor rotation are reported for the first time and a new, low-order analytical approach to model centrifugal compressor stability is introduced. The model is capable of dealing with unsteady radially swirling flows and the dynamic effects of impeller-diffuser component interaction as it occurs in centrifugal compression systems. A simple coupling criterion is developed from first principles to explain the interaction mechanism important for system stability. The model findings together with experimental data explain the mechanism for first-ever observed backward traveling rotating stall in centrifugal compressors with vaned diffusers. Based on the low-order model predictions, an air injection scheme between the impeller and the vaned diffuser is designed for the NASA Glenn CC3 high-speed centrifugal compressor. The steady air injection experiments show an increase of 25% in surge-margin with an injection mass flow of 0.5% of the compressor mass flow. In addition, it is experimentally demonstrated that this injection scheme is robust to impeller tip-clearance effects and that a reduced number of injectors can be applied for similar gains in surge-margin. The results presented in this paper firmly establish the connection between the experimentally observed dynamic phenomena in the NASA CC3 centrifugal compressor and a first principles based coupling criterion. In addition, guidelines are given for the design of centrifugal compressors with enhanced stability.

Enhancing the Centrifugal Compressor Performance Map Measurements Through a Developed One–Dimensional Calculation Tool to Analyse Local Flow Phenomena

2014 ◽  
Author(s):  
Matthias Hamann ◽  
Elias Chebli ◽  
Markus Müller ◽  
Alexander Krampitz
Keyword(s):  
Centrifugal Compressor ◽  
Static Pressure ◽  
Flow Characteristics ◽  
Local Flow ◽  
One Dimensional ◽  
Casing Treatment ◽  
Surge Margin ◽  
Performance Map ◽  
Flow Phenomena ◽  
Compressor Performance

Centrifugal compressors for automotive turbochargers have large influence on the operation characteristic of combustion engines. Especially the improvement of the surge margin is one of the most important development targets. Thereby, a reliable detection of local flow phenomena within the compressor stage is necessary and a procedure to gain this information from standard measurement data is discussed in this paper. A one–dimensional calculation methodology for a single-stage centrifugal compressor with a vaneless diffuser and casing treatment is presented. The tool calculates the flow properties at the impeller inlet and exit as well as at diffuser exit, based on the measured inlet and outlet data and the geometry information of the compressor. The calculated flow characteristics are plotted within the measured compressor performance map to show local flow parameters. The unsteady recirculation flow within the casing treatment, the inflow angle and the total pressure losses are considered. The tool is validated on different compressor sizes. Thereby the compressor is equipped with static pressure measuring points at the impeller inlet and exit as well as at the diffuser exit. The calculated static pressure correlated well with the measured data with an accuracy of 2 % to 5 % on 95 % of the operating range. In this paper an experimental parameter study is executed in order to improve the surge margin. Thereby the geometry of the diffuser and the casing treatment is varied and the compressor performance is measured on a turbocharger test rig. The calculation of the flow angles and other flow characteristics within the diffuser enables one to find out whether surge is triggered through the diffuser or the impeller.

The Use of Cascade Technology in Centrifugal Compressor Vaned Diffuser Design

1972 ◽  
Vol 94 (3) ◽  
pp. 187-192 ◽  
Author(s):  
R. C. Pampreen
Keyword(s):  
Centrifugal Compressor ◽  
Centrifugal Compressors ◽  
Vaned Diffuser ◽  
Circular Arc ◽  
Performance Results

This paper highlights some results from experience with use of cascade technology in the design of diffusers for centrifugal compressors. The designs consisted of conformally transformed tandem blade-rows using 65-Series and double-circular-arc vane sections. Performance results are presented and comparisons to conventional diffuser data are made.

Surge Characteristics and Range Extension With Steam Injection in a Centrifugal Compressor With Vaned Diffuser

2013 ◽  
Author(s):  
Chuang Gao ◽  
Weiguang Huang ◽  
Weijia Yao ◽  
Jicheng Duan
Keyword(s):  
Stability Analysis ◽  
Flow Rate ◽  
Centrifugal Compressor ◽  
Flow Behavior ◽  
Steam Injection ◽  
Experimental Results ◽  
Saturated Steam ◽  
Vaned Diffuser ◽  
Surge Margin ◽  
Static Performance

This paper describes the experimental results of both steady and unsteady flow behavior and surge extension with steam injection in a centrifugal compressor with vaned diffuser and downstream collector. Specifically, the stage stability analysis and effects of steam injection on surge margin are reported based on experimental results in detail. As the first step, a meanline analysis based on empirical correlations is utilized to find the possible stability dominated component. Then surge extension methods are put forward on the investigated compressor to enhance field operability. To validate the meanline analysis, the static performance of both stage and components from the experiments were analyzed and the root cause of system surge was again given based on the classic stability theory. The experimental results not only prove the validity of the former stability analysis but also extend the surge margin at least 9.0% with only 0.3% saturated steam of designed mass flow rate. During the experiments, it was also found that the surge margin improvement was not in proportion to the flow injected. In certain cases, the injected steam at large flow rate can even trigger system surge earlier. To the authors’ known, this is the first report on surge extension with steam injection in open literature.

Centrifugal Compressor Inlet Guide Vanes for Increased Surge Margin

1991 ◽  
Vol 113 (4) ◽  
pp. 696-702 ◽  
Author(s):  
C. Rodgers
Keyword(s):  
Centrifugal Compressor ◽  
High Speed ◽  
System Stability ◽  
Negative Slope ◽  
Vaned Diffuser ◽  
Guide Vanes ◽  
Inlet Guide Vanes ◽  
Surge Margin ◽  
Compressor Inlet ◽  
Surge Line

This paper describes the results of compressor rig testing with a moderately high specific speed, high inducer Mack number, single-stage centrifugal compressor, with a vaned diffuser, and adjustable inlet guide vanes (IGVs). The results showed that the high-speed surge margin was considerably extended by the regulation of the IGVs, even though the vaned diffuser was apparently operating stalled. Simplified one-dimensional analysis of the impeller and diffuser performances indicated that at inducer tip Mach numbers approaching and exceeding unity, the high-speed surge line was triggered by inducer stall. Also, IGV regulation increased impeller stability. This permitted the diffuser to operate stalled, providing the net compression system stability remained on a negative slope.

The Impact of Reciprocating Compressor Pulsations on the Surge Margin of Centrifugal Compressors

2016 ◽  
Author(s):  
Klaus Brun ◽  
Rainer Kurz ◽  
Sarah Simons
Keyword(s):  
Centrifugal Compressor ◽  
Pressure Pulsation ◽  
Numerical Approach ◽  
Piping System ◽  
Analysis Tool ◽  
Reciprocating Compressor ◽  
Centrifugal Compressors ◽  
Surge Margin ◽  
Periodic Pressure ◽  
The Impact

Pressure pulsations into a centrifugal compressor can move its operating point into surge. This is concerning in pipeline stations where centrifugal compressors operate in series/parallel with reciprocating compressors. Sparks (1983), Kurz et al., (2006), and Brun et al., (2014) provided predictions on the impact of periodic pressure pulsation on the behavior of a centrifugal compressor. This interaction is known as the “Compressor Dynamic Response” (CDR) theory. Although the CDR describes the impact of the nearby piping system on the compressor surge and pulsation amplification, it has limited usefulness as a quantitative analysis tool, due to the lack of prediction tools and test data for comparison. Testing of compressor mixed operation was performed in an air loop to quantify the impact of periodic pressure pulsation from a reciprocating compressor on the surge margin of a centrifugal compressor. This data was utilized to validate predictions from Sparks' CDR theory and Brun's numerical approach. A 50 hp single-stage, double-acting reciprocating compressor provided inlet pulsations into a two-stage 700 hp centrifugal compressor. Tests were performed over a range of pulsation excitation amplitudes, frequencies, and pipe geometry variations to determine the impact of piping impedance and resonance responses. Results provided clear evidence that pulsations can reduce the surge margin of centrifugal compressors and that geometry of the piping system immediately upstream and downstream of a centrifugal compressor will have an impact on the surge margin reduction. Surge margin reductions of <30% were observed for high centrifugal compressor inlet suction pulsation.

Backward Traveling Rotating Stall Waves in Centrifugal Compressors

2004 ◽  
Vol 126 (1) ◽  
pp. 1-12 ◽  
Author(s):  
Z. S. Spakovszky
Keyword(s):  
Mass Flow ◽  
Centrifugal Compressor ◽  
First Principles ◽  
Rotating Stall ◽  
Air Injection ◽  
System Stability ◽  
Centrifugal Compressors ◽  
Injection Scheme ◽  
Surge Margin ◽  
Low Order

Rotating stall waves that travel against the direction of rotor rotation are reported for the first time and a new, low-order analytical approach to model centrifugal compressor stability is introduced. The model is capable of dealing with unsteady radially swirling flows and the dynamic effects of impeller-diffuser component interaction as it occurs in centrifugal compression systems. A simple coupling criterion is developed from first principles to explain the interaction mechanism important for system stability. The model findings together with experimental data explain the mechanism for first-ever observed backward traveling rotating stall in centrifugal compressors with vaned diffusers. Based on the low-order model predictions, an air injection scheme between the impeller and the vaned diffuser is designed for the NASA Glenn CC3 high-speed centrifugal compressor. The steady air injection experiments show an increase of 25% in surge-margin with an injection mass flow of 0.5% of the compressor mass flow. In addition, it is experimentally demonstrated that this injection scheme is robust to impeller tip-clearance effects and that a reduced number of injectors can be applied for similar gains in surge-margin. The results presented in this paper firmly establish the connection between the experimentally observed dynamic phenomena in the NASA CC3 centrifugal compressor and a first principles based coupling criterion. In addition, guidelines are given for the design of centrifugal compressors with enhanced stability.       Winner of the “Best Paper Award,” Turbomachinery Committee

scholarly journals A Study of Testing Procedures of Vaned Diffusers of a Centrifugal Compressor Stage in a Virtual Wind Tunnel

2019 ◽  
pp. 51-64
Author(s):  
E.P. Petukhov ◽  
Y.B. Galerkin ◽  
A.F. Rekstin
Keyword(s):  
Wind Tunnel ◽  
Centrifugal Compressor ◽  
Stationary Flow ◽  
Compressor Stage ◽  
Vaned Diffuser ◽  
Testing Procedures ◽  
Centrifugal Compressor Stage ◽  
Flow Parameters ◽  
Blade Cascade ◽  
Physical Experiments

A mathematical model of a vaned diffuser of a centrifugal compressor stage can be constructed based on the results of mass CFD-calculations, similar to that of vaneless diffusors. The methods for calculating the annular cascade and the straight cascade differ due to the existence of vaneless diffusor sections in front of the cascade and behind it. The rational dimensions of these sections are determined. The calculations of two-dimensional cascades without restricting walls appear to be irrational. The calculation is effective for a sector with one vane channel, a moderate number of cells, and the turbulence model k–ε. Averaging the flow parameters at the blade cascade exit leads to ambiguous results. To calculate the characteristics of the blade cascade, the parameters in a section with a diameter equal to 1.85 of the diameter of the blade cascade exit should be used. In domestic and foreign literature, it is customary to emphasize the effectiveness of the CFD methods that replace physical experiments. Calculations of the compressor stages are called virtual rig testing, while those of the blade cascade are known as virtual wind tunnel testing. To study stationary flow, as a virtual wind tunnel, it suffices to consider the blade cascade itself, the preceding and the subsequent vaneless spaces.

Improvement of the Flow Range of Transonic Centrifugal Compressors With a Low-Solidity Cascade Diffuser

2000 ◽  
Author(s):  
Hiroshi Hayami
Keyword(s):  
Centrifugal Compressor ◽  
High Speed ◽  
Pressure Ratio ◽  
Input Power ◽  
Velocity Of Sound ◽  
Centrifugal Compressors ◽  
Vaned Diffuser ◽  
Transonic Centrifugal Compressor ◽  
Series Of Experiments ◽  
Low Solidity Cascade Diffuser

If the pressure ratio of a typical single-stage centrifugal compressor is larger than four, the velocity relative to the impeller and to the diffuser exceeds the velocity of sound. The flow range of transonic centrifugal compressors with a vaned diffuser is usually very narrow. Low-solidity cascade diffusers with solidity 0.69 have been successfully applied as a part of the diffuser system of a transonic centrifugal compressor. On the basis of this type of diffuser, a series of experiments to broaden the operating range are discussed focusing on the control of the geometry of impeller and/or diffuser; one was to reduce the inducer blade turning upstream of the throat, and the other was to reduce the inlet passage width of diffuser. The milder inducer blade camber realized the improvement in flow range by 1.5 times to the original one. Regarding the diffuser inlet passage width contraction, the flow range was not broadened so much owing to the change in impeller characteristics, but the input power was reduced and then the high speed efficiency was much improved.

The Impact of Reciprocating Compressor Pulsations on the Surge Margin of Centrifugal Compressors

2017 ◽  
Vol 139 (8) ◽  
Author(s):  
Klaus Brun ◽  
Sarah Simons ◽  
Rainer Kurz
Keyword(s):  
Centrifugal Compressor ◽  
Pressure Pulsation ◽  
Piping System ◽  
Reciprocating Compressor ◽  
Centrifugal Compressors ◽  
Surge Margin ◽  
Periodic Pressure ◽  
Compressor Surge ◽  
The Impact ◽  
Asme Paper

Pressure pulsations into a centrifugal compressor can move its operating point into surge. This is concerning in pipeline stations where centrifugal compressors operate in series/parallel with reciprocating compressors. Sparks (1983, “On the Transient Interaction of Centrifugal Compressors and Their Piping Systems,” ASME Paper No. 83-GT-236); Kurz et al. (2006, “Pulsations in Centrifugal Compressor Installations,” ASME Paper No. GT2006-90700); and Brun et al. (2014, “Impact of the Piping Impedance and Acoustic Characteristics on Centrifugal Compressor Surge and Operating Range,” ASME J. Eng. Turbines Power, 137(3), p. 032603) provided predictions on the impact of periodic pressure pulsation on the behavior of a centrifugal compressor. This interaction is known as the “compressor dynamic response” (CDR) theory. Although the CDR describes the impact of the nearby piping system on the compressor surge and pulsation amplification, it has limited usefulness as a quantitative analysis tool, due to the lack of prediction tools and test data for comparison. Testing of compressor mixed operation was performed in an air loop to quantify the impact of periodic pressure pulsation from a reciprocating compressor on the surge margin (SM) of a centrifugal compressor. This data was utilized to validate predictions from Sparks’ CDR theory and Brun’s numerical approach. A 50 hp single-stage, double-acting reciprocating compressor provided inlet pulsations into a two-stage 700 hp centrifugal compressor. Tests were performed over a range of pulsation excitation amplitudes, frequencies, and pipe geometry variations to determine the impact of piping impedance and resonance responses. Results provided clear evidence that pulsations can reduce the surge margin of centrifugal compressors and that geometry of the piping system immediately upstream and downstream of a centrifugal compressor will have an impact on the surge margin reduction. Surge margin reductions of over 30% were observed for high centrifugal compressor inlet suction pulsation.

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