Rotor Stability Criteria for Multi-Stage Centrifugal Compressors

2003 ◽  
Author(s):  
John W. Fulton
Keyword(s):  
Tangential Force ◽  
Centrifugal Compressors ◽  
Labyrinth Seals ◽  
Gas Density ◽  
7Th Edition ◽  
Multi Stage ◽  
Bending Mode ◽  
Tooth Type ◽  
The Stability ◽  
Threshold Line

The American Petroleum Standard 617, 7th edition [1], screens new designs of centrifugal compressors using its Figure 1.2-5, which plots mean gas density versus rotor flexibility ratio. The purpose is to avoid rotor instability from causing unacceptable vibrations, typically whirling of the first-forward bending mode. The API figure is based on a plot by Fulton [2,3] of the same variables showing a number of compressors tested near the threshold of instability, thus forming an empirical basis for a Stability Map. This paper develops a method to derive a threshold line, using a set of typical industrial rotors varying in flexibility and running on tilt pad bearings. Instability requires a tangential force (normal to the bending displacement) to act on the rotor in the direction of whirl. The source of this force is taken to be the (tooth type) labyrinth seals inside the compressor. This tangential force is represented as linear function of whirl/spin scaled by gas density. This function is applied to the set of rotors to produce a threshold line. The derivation thus forms a basis for understanding the Stability Map.

Numerical Characterization of Swirl Brakes for High Pressure Centrifugal Compressors

2013 ◽  
Author(s):  
Riccardo Da Soghe ◽  
Mirko Micio ◽  
Antonio Andreini ◽  
Bruno Facchini ◽  
Luca Innocenti ◽  
...  
Keyword(s):  
High Pressure ◽  
Tangential Velocity ◽  
Operating Conditions ◽  
Design Parameters ◽  
Centrifugal Compressors ◽  
Labyrinth Seals ◽  
Numerical Characterization ◽  
Lean Angle ◽  
The Stability ◽  
The Many

High pressure centrifugal compressors continue to experience vibrations due to rotordynamic stability. The main cause for aero-induced exciting forces that affects the stability, is the tangential velocity component of the gas entering the many labyrinth seals throughout the machine. In order to control or limit these swirling flows, swirl brakes are generally implemented both at the impeller eye seals and at the balance piston or division wall seal of a centrifugal compressor. This paper deals with the aerodynamic characterization, by means of CFD, of such kind of devices. Several design parameters, such as teeth lean, angle of attack and pitch-to-chord ratio have been considered and also the operating conditions (pressure level and swirl at the swirl brake inlet) are accounted for. This paper aims to improve the physical understanding of the fluid flow of centrifugal compressors swirl brakes allowing an optimization of such systems.

Rotordynamic Comparison of Built-Up Versus Solid Rotor Construction

2009 ◽  
Author(s):  
J. Jeffrey Moore ◽  
Andrew H. Lerche
Keyword(s):  
Stability Analysis ◽  
Critical Speed ◽  
Oil And Gas ◽  
Oil And Gas Industry ◽  
Centrifugal Compressors ◽  
Gas Industry ◽  
7Th Edition ◽  
Multi Stage ◽  
Shrink Fit ◽  
Level 2

Most manufacturers of multi-stage centrifugal compressors for the oil and gas industry utilize a solid shaft rotor construction. The impellers use a shrink fit onto the shaft with spacers in between the impellers. With the introduction of the guidelines in the 7th edition of API 617, built-up rotors for centrifugal compressors using a tie-bolt are recognized by API. This study compares the rotordynamic performance of the identical compressor using both a tie-bolt design and a more conventional solid rotor for a two-stage pipeline application. A full API 617 lateral analysis is performed on the two designs, assuming identical impeller flow path, stage spacing, and hub diameter. The critical speed and unbalance response are computed, and a full Level 2 stability analysis is performed for each case. The results show the tie-bolt construction to be slightly lighter and stiffer, resulting in a higher critical speed and improved rotordynamic stability.

Roles of vanes in diffuser on stability of centrifugal compressor

2019 ◽  
Vol 233 (14) ◽  
pp. 5380-5392
Author(s):  
Wangzhi Zou ◽  
Xiao He ◽  
Wenchao Zhang ◽  
Zitian Niu ◽  
Xinqian Zheng
Keyword(s):  
High Pressure ◽  
Centrifugal Compressor ◽  
Dynamic Pressure ◽  
Pressure Ratio ◽  
Pressure Rise ◽  
Rotating Stall ◽  
Centrifugal Compressors ◽  
Compression System ◽  
The Stability ◽  
Rotating Instability

The stability considerations of centrifugal compressors become increasingly severe with the high pressure ratios, especially in aero-engines. Diffuser is the major subcomponent of centrifugal compressor, and its performance greatly influences the stability of compressor. This paper experimentally investigates the roles of vanes in diffuser on component instability and compression system instability. High pressure ratio centrifugal compressors with and without vanes in diffuser are tested and analyzed. Rig tests are carried out to obtain the compressor performance map. Dynamic pressure measurements and relevant Fourier analysis are performed to identify complex instability phenomena in the time domain and frequency domain, including rotating instability, stall, and surge. For component instability, vanes in diffuser are capable of suppressing the emergence of rotating stall in the diffuser at full speeds, but barely affect the characteristics of rotating instability in the impeller at low and middle speeds. For compression system instability, it is shown that the use of vanes in diffuser can effectively postpone the occurrence of compression system surge at full speeds. According to the experimental results and the one-dimensional flow theory, vanes in diffuser turn the diffuser pressure rise slope more negative and thus improve the stability of compressor stage, which means lower surge mass flow rate.

Design and Optimization of Multi-Stage Centrifugal Compressors With Uncertainty Quantification of Off Design Performance

2017 ◽  
Author(s):  
A. Romei ◽  
R. Maffulli ◽  
C. Garcia Sanchez ◽  
S. Lavagnoli
Keyword(s):  
Uncertainty Quantification ◽  
Oil And Gas ◽  
Low Cost ◽  
Design Procedure ◽  
Design Tool ◽  
Test Case ◽  
Centrifugal Compressors ◽  
Design Performance ◽  
Leading Role ◽  
Multi Stage

The use of multi-stage centrifugal compressors carries out a leading role in oil and gas process applications. Green operation and market competitiveness require the use of low-cost reliable compression units with high efficiencies and wide operating range. A methodology is presented for the design optimization of multi-stage centrifugal compressors with prediction of the compressor map and estimation of the uncertainty limits. A one-dimensional (1D) design tool has been developed that automatically generates a multi-stage radial compressor satisfying the target machine requirements based on a few input parameters. The compressor performance map is then assessed using the method proposed by Casey-Robinson [1], and the approach developed by Al-Busaidi-Pilidis [2]. The off-design performance method relies on empirical correlations calibrated on the performance maps of many single-stage centrifugal compressors. An uncertainty quantification study on the predicted performance maps was conducted using Monte Carlo method (MCM) and generalized Polynomial Chaos Expansion (gPCE). Finally, the design procedure has been coupled to an in-house optimizer based on evolutionary algorithms. The complete design procedure has been applied to a multi-stage industrial compressor test case. A multi-objective optimization of a multi-stage industrial compressor has been performed targeting maximum compressor efficiency and flow range. The results of the optimization show the existence of optimum compressor architectures and how the Pareto fronts evolve depending on the number of stages and shafts.

Optimization of Bearing Locations for Rotor Systems With Magnetic Bearings

1995 ◽  
Author(s):  
Sriram Srinivasan ◽  
Eric H. Maslen ◽  
Lloyd E. Barrett
Keyword(s):  
Design Process ◽  
Magnetic Bearing ◽  
Rotating Machinery ◽  
Rotor Systems ◽  
Infinity Norm ◽  
Multi Stage ◽  
Scalar Measure ◽  
Bearing Design ◽  
The Stability ◽  
Practical Measure

This paper presents a method for quickly evaluating the effect of changes in bearing location on bearing design for stability of rotating machinery. This method is intended for use by rotating machinery designers to select the “best” bearing locations prior to the bearing design process. The purpose of the method is to improve the design process by separating the problem of determining the “best” bearing locations from that of determining the actual bearing design. The method is independent of the type of bearing employed. For each candidate bearing configuration, the method provides a scalar measure of the relative ability of bearings to meet stability specifications. Within certain limits, the stability specifications are defined by the designer. The scalar measure is used to rank the candidate bearing locations and thereby select the best one. The scalar measure is compared to a practical measure of magnetic bearing design such as the infinity norm of the controller for an example design of a multi-stage centrifugal compressor.

Criteria for the Stability Limit Prediction of High Speed Centrifugal Compressors With Vaneless Diffuser: Part I — Flow Structure Analysis

2020 ◽  
Author(s):  
Carlo Cravero ◽  
Davide Marsano
Keyword(s):  
Rotational Speed ◽  
High Speed ◽  
Stability Limit ◽  
Vaneless Diffuser ◽  
Centrifugal Compressors ◽  
Vaned Diffuser ◽  
High Rotational Speed ◽  
Lower Accuracy ◽  
The Stability ◽  
Computational Resources

Abstract High-speed centrifugal compressor requirements include a wide operating range between choking and stall especially for turbocharging applications. The prediction of the stability limit at different speeds is still challenging. In literature, several studies have been published on the phenomena that trigger the compressor instability. However, a comprehensive analysis of criteria that can be used in the first steps of centrifugal compressors design to predict the stability limit is still missing. In previous work the authors have already presented a criterion, so called “Stability Parameter”, to predict the surge line of centrifugal compressors based on a simplified CFD approach that does not require excessive computational resources and that can be efficiently used in the preliminary design phases. The above methodology has demonstrated its accuracy for centrifugal compressors with vaned diffuser, but a lower accuracy has been detected for vaneless diffusers. Before proceeding to identify additional criteria focused on compressors with vaneless diffuser, an in-depth fluid dynamics analysis has been necessary. This analysis has been also carried out through fully 3D unsteady simulations to allow identifying the real phenomena linked to the trigger of the instability of centrifugal compressors. It has been found how these phenomena are strongly related to the rotational speed, in particular have been shown the key role of the volute at high rotational speed.

Conceptual Flutter Analysis of Stepped Labyrinth Seals

2019 ◽  
Author(s):  
Roque Corral ◽  
Almudena Vega ◽  
Michele Greco
Keyword(s):  
Natural Frequency ◽  
Fundamental Mode ◽  
Second Step ◽  
Pressure Side ◽  
Dimensional Model ◽  
Labyrinth Seals ◽  
Acoustic Frequency ◽  
Flutter Analysis ◽  
Dimensional Parameters ◽  
The Stability

Abstract A simple non-dimensional model to describe the flutter onset of two-fin straight labyrinth seals [1] is extended to stepped seals. The effect of the axial displacement of the seal is analyzed first in isolation. It is shown that this fundamental mode is always stable. In a second step, the combination of axial and torsion displacements is used to determine the damping of modes with arbitrary torsion centers. It is concluded that the classical Abbot’s criterion stating that seals supported in the low-pressure side of the seal are stable provided that natural frequency of the mode is greater than the acoustic frequency breaks down under certain conditions. An analytical expression for the non-dimensional work-per-cycle is derived and new non-dimensional parameters controlling the seal stability identified. It is finally concluded the stability of stepped seals can be assimilated to that of a straight through seal if the appropriate distance of the torsion center to the seal is chosen.

Deficiencies in Turbulence Modelling for the Prediction of the Stability Boundary in Highly Loaded Compressors

2019 ◽  
Author(s):  
Jose Moreno ◽  
John Dodds ◽  
Mehdi Vahdati ◽  
Sina Stapelfeldt
Keyword(s):  
High Speed ◽  
Stability Boundary ◽  
Turbulence Models ◽  
Stability Limit ◽  
Major Effect ◽  
Navier Stokes ◽  
Tip Leakage Flow ◽  
Stall Margin ◽  
Multi Stage ◽  
The Stability

Abstract Reynolds-averaged Navier-Stokes (RANS) equations are employed for aerodynamic and aeroelastic modelling in axial compressors. Their solutions are highly dependent on the turbulence models for closure. The main objective of this work is to assess the widely used Spalart-Allmaras model’s suitability for compressor flows. For this purpose, an extensive investigation of the sources of uncertainties in a high-speed multi-stage compressor rig was carried out. The grid resolution near the casing end wall, which affects the tip leakage flow and casing boundary layer, was found to have a major effect on the stability limit prediction. Refinements in this region led to a stall margin loss prediction. It was found that this loss was exclusively due to the destruction term in the SA model.

Tip-Shroud Labyrinth Seal Effect on the Flutter Stability of Turbine Rotor Blades

2019 ◽  
Author(s):  
Roque Corral ◽  
Michele Greco ◽  
Almudena Vega
Keyword(s):  
Rotor Blade ◽  
Labyrinth Seal ◽  
Turbine Rotor ◽  
Rotor Blades ◽  
Stability Prediction ◽  
Labyrinth Seals ◽  
Turbine Rotor Blade ◽  
The Stability ◽  
Shrouded Rotor ◽  
Tip Shroud

Abstract The effect of the tip-shroud seal on the flutter onset of a shrouded turbine rotor blade, representative of a modern gas turbine, is numerically tested and the contribution to the work-per-cycle of the aerofoil and the tip-shroud are clearly identified. The numerical simulations are conducted using a linearised frequency domain solver. The flutter stability of the shrouded rotor blade is evaluated for an edgewise mode and compared with the standard industrial approach of not including the tip-shroud cavity. It turns out that including the tip shroud significantly changes the stability prediction of the rotor blade. This is due to the fact that the amplitude of the unsteady pressure created in the inter-fin cavity, due to the motion of the airfoil, is much greater than that of the airfoil. It is concluded that the combined effect of the seal and its platform tends to stabilise the rotor blade for all the examined nodal diameters and reduced frequencies. Finally, the numerical results are shown to be consistent with those obtained using an analytical simplified model to account for the effect of the labyrinth seals.

Stability of Multi-Stage Axial Flow Compressors

1964 ◽  
Vol 15 (4) ◽  
pp. 328-356 ◽  
Author(s):  
W. T. Howell
Keyword(s):  
Axial Flow ◽  
Rotational Frequency ◽  
Oscillatory Instability ◽  
Operating Point ◽  
Axial Flow Compressor ◽  
Multi Stage ◽  
Wide Range ◽  
Surge Line ◽  
Flow Compressor ◽  
The Stability

SummaryThe following theoretical investigation is concerned with the stability of the flow through a system composed of a multi-stage axial flow compressor followed by a throttle.Such an investigation was carried out by Pearson and Bowmer in 1949. In 1962 Pearson’s work on the analysis of axial flow compressor characteristics, and the accumulation of empirical data regarding factors affecting the surge line, re-awakened interest in the possibility of predicting the surge line of a multi-stage axial flow compressor-throttle system.In this paper the equations governing the stability of flow at any operating point in such a system are obtained by applying Kirchhoff’s laws to the associated electric circuit at that operating point, and the analysis is applied to a wide range of flows of the calculated characteristics of a seven-stage axial flow compressor.A study of the simplest compressor-throttle system is given, in which the equations of motion of the system are derived mechanically and electrically, and the range of validity of the equations and their stability are discussed in order to bring out the relation between the mathematics and physics of the simple system before applying these methods to multi-stage axial flow compressors.For the relatively simple electrical representation used in this paper for an axial compressor of n stages, there are shown to be 2n possible values of p, the transient rotational frequency, and these are determined over a sufficiently wide range of flows on the seven-stage compressor studied.As a result, a region of the compressor characteristic map can be marked out in which all the values of the transient rotational frequency have their real parts less than zero, corresponding to stability of operation, a region where at least one of the values of p is real and positive corresponding to non-oscillatory instability of operation, and an intermediate region where some of the values of the rotational frequency p are complex with positive real part, corresponding to oscillatory instability of operation.It is suggested that the non-oscillatory instability found here is associated with the surge and the line of inception of non-oscillatory instability with the surge line.

Sign in / Sign up

Export Citation Format

Share Document