Unsteady Flow in a Turbocharger Centrifugal Compressor: 3D-CFD Simulation, Impeller Blade Vibration and Vaned Diffuser-Volute Interaction

2009 ◽  
Author(s):  
Hans-Peter Dickmann ◽  
Thomas Secall Wimmel ◽  
Jaroslaw Szwedowicz ◽  
Janpeter Ku¨hnel ◽  
Uwe Essig
Keyword(s):  
Unsteady Flow ◽  
Centrifugal Compressor ◽  
Axisymmetric Flow ◽  
Forced Response ◽  
Operating Conditions ◽  
Mode Shapes ◽  
Impeller Blade ◽  
Vaned Diffuser ◽  
Flow Angle ◽  
Rotating Blades

Experimental investigations on a single stage centrifugal compressor with radial inlet duct showed that measured alternating strains of the rotating blades depend considerably on the circumferential position of the diffuser ring to the volute tongue. By modeling of the entire turbocharger compressor stage with volute and inducer casing bleed system included, 3D unsteady flow simulations provided comprehensive insight into the excitation mechanism. A part load operating point was investigated experimentally and numerically. For operating conditions due to resonance transient CFD was employed, since only then a meaningful prediction of the blade excitation, induced by the unsteady air flow, is expected. The CFD results show primarily the interaction between the volute tongue and the two different vaned diffuser ring positions. It is shown that pressure and flow angle vary significantly due to the circumferential position of the flow entering the volute and the turning impeller blades. The geometrical arrangement of the volute and suction elbow imposes a non-axisymmetric flow field, which excites rotating blades periodically. These vibrations depend on the circumferential assembly position of the vaned diffuser. Outflow and reverse flow at the tongue region also differ with respect to the vaned diffuser ring position. The time dependent pressure distribution on the impeller blades resulting from the CFD calculation was transformed into the frequency domain by Fourier decomposition. The complex modal pressure data were imposed as exciting load on the structure which was simulated by the FEM. By applying a fine FE mesh the measured resonant frequencies for the lower modes were reproduced very well by FEM. After determining the 3D mode shapes of the impeller by means of a free vibration calculation, forced response simulations without considering transient vibration effects were carried out for predicting the resonance strain amplitudes which were computed for both minimum and maximum experimental modal damping ratios. Comparisons with the experimental results at the strain gauges demonstrate that this employed methodology is capable of predicting the 3D impeller’s vibration behavior under real engine conditions up to 8 kHz. Considering strong influence of mistuning on real impeller vibrations, a new method for the comparison of experimental and numerical data has been successfully introduced. In general, this approach is based on the resonance sensitivity assessment, which takes into account the excitation, damping and mistuning parameters. Then, the measured resonance strain amplitudes of all experimental tests match very well the predicted scatter range of numerical results.

Experimental and Numerical Analysis of Unsteady Flow Structure in a Centrifugal Compressor With Variable Vaned Diffuser

2018 ◽  
Author(s):  
Xiang Xue ◽  
Tong Wang ◽  
Yuchang Shao ◽  
Bo Yang ◽  
Chuangang Gu
Keyword(s):  
Numerical Simulation ◽  
Unsteady Flow ◽  
Flow Structure ◽  
Centrifugal Compressor ◽  
Dynamic Pressure ◽  
Operating Conditions ◽  
Experimental Result ◽  
Vaned Diffuser ◽  
Tip Leakage ◽  
Stall Precursor

The unsteady flow at small flow rates is always the most important of typical unsteady phenomena in centrifugal compressors, since it is closely related to the operating safety and efficiency. To study the mechanism of stall and surge generation, an experimental research on an industrial centrifugal compressor with variable vaned diffuser is carried out to study the unsteady flow structure from design point to surge. A multi-phase dynamic pressure measurement is conducted, based on 23 dynamic pressure sensors mounted on the shroud side casing surface of the compressor. The sensors are circumferentially distributed in a non-uniform manner at seven different radial positions, including the impeller region, the vaneless region and the diffuser throat region. Real-time data is recorded during the whole valve-adjusting process. The characteristics of pressure fields at some specific operating conditions are focused on, especially the pre-stall, stall precursor, stall and surge conditions. According to the multiphase data association, the originating position of the stall precursor can be determined. The features of the unsteady flow structure are also obtained, such as the surge pattern and the propagation direction of stall cells. In addition, when the diffuser vane setting angle (OGV) is turned up, the core factors to trigger total instability will change. In order to visually show how the tip leakage and separation vortex in the impeller gradually affect the flow structure in the vaned diffuser region and even the whole machine, numerical simulation and dynamic mode decomposition (DMD) method are used to study the flow mechanisms. The numerical simulation result is well matched with the experimental result. With the help of the DMD method, a few low-frequency tip leakage vortex structures are extracted from the unsteady numerical result over a period of time, which correlate with the experimental result. Meanwhile, on this issue, the feasibility of dynamic experimental analysis combined with multi-channel numerical simulation analysis is verified and discussed. Through the two analytic methods, a detailed understanding of the unsteady flow structure in the centrifugal compressor with variable vaned diffuser is obtained.

scholarly journals Experimental Flow Field Investigation in a Centrifugal Compressor Vaned Diffuser

1995 ◽  
Author(s):  
Ali Pinarbasi ◽  
Mark W. Johnson
Keyword(s):  
Kinetic Energy ◽  
Flow Field ◽  
Centrifugal Compressor ◽  
Field Investigation ◽  
Vaneless Diffuser ◽  
Mean Velocity ◽  
Cross Sectional ◽  
Impeller Blade ◽  
Vaned Diffuser ◽  
Flow Angle

The purpose of this study was to improve the understanding of the flow physics in a centrifugal compressor vaned diffuser. A low speed compressor with a 19 bladed backswept impeller and diffuser with 16 wedge vanes was used. The measurements were made at three inter-vane positions and are presented as mean velocity, turbulent kinetic energy and flow angle distributions on eight diffuser cross sectional planes. The impeller blade wakes mix out rapidly within the vaneless space and more rapidly than in an equivalent vaneless diffuser. Although the flow is highly non uniform in velocity at the impeller exit, there is no evidence in the results of any separation from the diffuser vanes. The results do however suggest that the use of twisted vanes within the diffuser would be beneficial in reducing losses.

Unsteady Flow in a Turbocharger Centrifugal Compressor: 3D-CFD-Simulation and Numerical and Experimental Analysis of Impeller Blade Vibration

2005 ◽  
Author(s):  
Hans-Peter Dickmann ◽  
Thomas Secall Wimmel ◽  
Jaroslaw Szwedowicz ◽  
Dietmar Filsinger ◽  
Christian H. Roduner
Keyword(s):  
Unsteady Flow ◽  
Pressure Distribution ◽  
Centrifugal Compressor ◽  
Cfd Simulation ◽  
Forced Response ◽  
Experimental Investigations ◽  
Excitation Mechanism ◽  
Blade Vibration ◽  
Impeller Blade ◽  
Vibration Behavior

Experimental investigations on a single stage centrifugal compressor showed that measured blade vibration amplitudes vary considerably along a constant speed line from choke to surge. The unsteady flow has been analysed to obtain detailed insight into the excitation mechanism. Therefore, a turbocharger compressor stage impeller has been modeled and simulated by means of Computational Fluid Dynamics (CFD). Two operating points at off-design conditions were analysed. One was close to choke and the second one close to the surge line. Transient CFD was employed, since only then a meaningful prediction of the blade excitation, caused by the unsteady flow situation, can be expected. Actually, it was observed that close to surge a steady state solution could not be obtained; only transient CFD could deliver a converged solution. The CFD results show the effect of the interaction between the inducer casing bleed system and the main flow. Additionally, the effect of the non-axisymmetric components, such as the suction elbow and the discharge volute, was analysed. The volute geometry itself had not been modeled. It turned out to be sufficient to impose a circumferentially asymmetric pressure distribution at the exit of the vaned diffuser to simulate the volute. Volute and suction elbow impose a circumferentially asymmetric flow field, which induces blade excitation. To understand the excitation mechanism, which causes the measured vibration behavior of the impeller, the time dependent pressure distribution on the impeller blades was transformed into the frequency domain by Fourier decomposition. The complex modal pressure data were imposed on the structure that was modeled by Finite Element Methods (FEM). Following state-of-the-art calculations to analyze the free vibration behavior of the impeller, forced response calculations were carried out. Comparisons with the experimental results demonstrate that this employed methodology is capable of predicting the impeller’s vibration behavior under real engine conditions. Integrating the procedure into the design of centrifugal compressors will enhance the quality of the design process.

High Dimensional Matching Optimization of Impeller–Vaned Diffuser Interaction for a Centrifugal Compressor Stage

2020 ◽  
Vol 142 (12) ◽  
Author(s):  
Ruihong Qin ◽  
Yaping Ju ◽  
Lee Galloway ◽  
Stephen Spence ◽  
Chuhua Zhang
Keyword(s):  
Centrifugal Compressor ◽  
High Speed ◽  
Pressure Ratio ◽  
Sequential Optimization ◽  
High Dimensional ◽  
Compressor Stage ◽  
Optimization Strategy ◽  
Impeller Blade ◽  
Vaned Diffuser ◽  
Flow Angle

Abstract The matching and interaction between the impeller and vaned diffuser is the most important aerodynamic-coupling between the components of a high-speed centrifugal compressor. Many research studies have been carried out during the last decade, both experimentally and numerically, on the flow mechanisms underlying impeller–vaned diffuser matching and interaction, with the aim of achieving a high-performance stage. However, the published work lacks any study that optimizes the matching of the impeller–vaned diffuser components in the environment of a full compressor stage due to two unresolved issues, i.e., identifying an effective matching optimization strategy and the high dimensional nature of the problem. To tackle these difficulties, four different optimization strategies (i.e., (1) integrated, (2) single component, (3) parallel, and (4) sequential optimization strategies) have been proposed and validated through a high dimensional matching optimization of the Radiver compressor test case published by the Institute of Jet Propulsion and Turbomachinery at Rheinisch-Westfälische Technische Hochschule (RWTH) Aachen University. Particular attention has been paid to the slope of the diffuser total pressure ratio characteristic near the surge point to further extend the stage surge margin. The results showed that the integrated optimization strategy was the most effective one for achieving good matching of the impeller–vaned diffuser interaction due to its inherently strong coupling optimization. Compared with the baseline compressor, the optimized stage achieved a gain of 1.2% in total-to-total isentropic efficiency at the peak efficiency point as well as a predicted 26.17% increase in stable operating range. For the stage examined in this study, a fore-loaded design of impeller blade as well as an increased vane angle for the diffuser vane was beneficial to the impeller–vaned diffuser matching. The more uniform spanwise distributions of the impeller discharge flow angle and the diffuser vane incidence presented the opportunity for a more optimized matching of the flow field between the 3D impeller and the 2D vaned diffuser. The outcomes of this work are particularly relevant for the advanced design of high-speed centrifugal compressors.

scholarly journals Flow Studies in a Centrifugal Compressor Stage

2014 ◽  
Author(s):  
R. Rajendran
Keyword(s):  
Centrifugal Compressor ◽  
Flow Behavior ◽  
Compressor Stage ◽  
Impeller Blade ◽  
Vaned Diffuser ◽  
Flow Angle ◽  
Centrifugal Compressor Stage ◽  
Operating Range ◽  
Impeller Outlet ◽  
Outlet Flow

The overall efficiency of a compressor is dependent on the design of both the impeller and the diffuser. The vaned diffuser reduces the operating range compared to the vaneless diffuser. However, by proper setting of the diffuser with reference to the impeller, it is possible to achieve a good stage performance. This paper describes the experimental investigation of the detailed flow behavior inside a centrifugal compressor stage for three different setting angles of the vaned diffuser with reference to the fixed impeller blade outlet angle. It is seen that diffuser setting angles lower than the impeller outlet flow angle gives wide operating range.

scholarly journals Computational Analysis of the Performance Characteristics of a Supercritical CO2 Centrifugal Compressor

Computation ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 54 ◽  
Author(s):  
Senthil Raman ◽  
Heuy Kim
Keyword(s):  
Centrifugal Compressor ◽  
Stokes Equations ◽  
National Laboratory ◽  
Sandia National Laboratory ◽  
Ideal Gas ◽  
Operating Conditions ◽  
Tip Clearance ◽  
Performance Characteristics ◽  
Supercritical Regime ◽  
Vaned Diffuser

A centrifugal compressor working with supercritical CO 2 (S-CO 2 ) has several advantages over other supercritical and conventional compressors. S-CO 2 is as dense as the liquid CO 2 and becomes difficult to compress. Thus, during the operation, the S-CO 2 centrifugal compressor requires lesser compression work than the gaseous CO 2 . The performance of S-CO 2 compressors is highly varying with tip clearance and vanes in the diffuser. To improve the performance of the S-CO 2 centrifugal compressor, knowledge about the influence of individual components on the performance characteristics is necessary. This present study considers an S-CO 2 compressor designed with traditional engineering design tools based on ideal gas behaviour and tested by SANDIA national laboratory. Three-dimensional, steady, viscous flow through the S-CO 2 compressor was analysed with computational fluid dynamics solver based on the finite volume method. Navier-Stokes equations are solved with K- ω (SST) turbulence model at operating conditions in the supercritical regime. Performance of the impeller, the main component of the centrifugal compressor is compared with the impeller with vaneless diffuser and vaned diffuser configurations. The flow characteristics of the shrouded impeller are also studied to analyse the tip-leakage effect.

Some Studies on Low Solidity Vaned Diffusers of a Centrifugal Compressor Stage

2005 ◽  
Author(s):  
T. Ch. Siva Reddy ◽  
G. V. Ramana Murty ◽  
Prasad Mukkavilli ◽  
D. N. Reddy
Keyword(s):  
Centrifugal Compressor ◽  
Static Pressure ◽  
Pressure Ratio ◽  
Pressure Recovery ◽  
Compressor Stage ◽  
Recovery Coefficient ◽  
Vaned Diffuser ◽  
Flow Angle ◽  
Centrifugal Compressor Stage ◽  
Pressure Recovery Coefficient

Numerical simulation of impeller and low solidity vaned diffuser (LSD) of a centrifugal compressor stage is performed individually using CFX- BladeGen and BladeGenPlus codes. The tip mach number for the chosen study was 0.35. The same configuration was used for experimental investigation for a comparative study. The LSD vane is formed using standard NACA profile with marginal modification at trailing edge. The performance parameters obtained form numerical studies at the exit of impeller and the diffuser have been compared with the corresponding experimental data. These parameters are pressure ratio, polytropic efficiency and flow angle at the impeller exit where as the parameters those have been compared at the exit of diffuser are the static pressure recovery coefficient and the exit flow angle. In addition, the numerical prediction of the blade loading in terms of blade surface pressure distribution on LSD vane has been compared with the corresponding experimental results. Static pressure recovery coefficient and flow angle at diffuser exit is seen to match closely at higher flows. The difference at lower flows could be due to the effect of interaction between impeller and diffuser combinations, as the numerical analysis was done separately for impeller and diffuser and the effect of impeller diffuser interaction was not considered.

Non-Axisymmetric Flows and Rotordynamic Forces in an Eccentric Shrouded Centrifugal Compressor—Part 2: Analysis

2019 ◽  
Vol 141 (11) ◽  
Author(s):  
Jieun Song ◽  
Seung Jin Song
Keyword(s):  
Pressure Distribution ◽  
Centrifugal Compressor ◽  
Axisymmetric Flow ◽  
Mass Conservation ◽  
Labyrinth Seal ◽  
Operating Conditions ◽  
New Model ◽  
Flow Coupling ◽  
Order Of Magnitude ◽  
Rotordynamic Forces

AbstractAn integrated analytical model to predict non-axisymmetric flow fields and rotordynamic forces in a shrouded centrifugal compressor has been newly developed and validated. The model is composed of coupled, conservation law-based, bulk-flow submodels, and the model takes into account the flow coupling among the blades, labyrinth seals, and shroud cavity. Thus, the model predicts the entire flow field in the shrouded compressor when given compressor geometry, operating conditions, and eccentricity. When compared against the experimental data from part 1, the new model accurately predicts the evolution of the pressure perturbations along the shroud and labyrinth seal cavities as well as the corresponding rotordynamic stiffness coefficients. For the test compressor, the cross-coupled stiffness rotordynamic excitation is positive; the contribution of the shroud is the highest; the contribution of the seals is less than but on the same order of magnitude as that of the shroud; and contribution of impeller blades is insignificant. The new model also enables insight into the physical mechanism for pressure perturbation development. The labyrinth seal pressure distribution becomes non-axisymmetric to satisfy mass conservation in the seal cavity, and this non-axisymmetry, in turn, serves as the influential boundary condition for the pressure distribution in the shroud cavity. Therefore, for accurate flow and rotordynamic force predictions, it is important to model the flow coupling among the components (e.g., impeller, shroud, labyrinth seal, etc.), which determines the non-axisymmetric boundary conditions for the components.

Hydro Francis Runner Stability and Forced Response Calculations

2019 ◽  
Author(s):  
Charles Seeley ◽  
Sunil Patil ◽  
Andy Madden ◽  
Stuart Connell ◽  
Gwenael Hauet ◽  
...  
Keyword(s):  
Large Scale ◽  
Forced Response ◽  
Operating Conditions ◽  
Mode Shapes ◽  
Symmetric Model ◽  
Validation Data ◽  
Fea Model ◽  
Forcing Function ◽  
Cyclic Symmetric ◽  
Work Done

Abstract Hydroelectric power generation accounts for 7% of the total world electric energy production. Francis turbines are often employed in large-scale hydro projects and represent 60% of the total installed base. Outputs up to 800 MW are available and efficiencies of 95% are common. Cost, performance, and design cycle time are factors that continue to drive new designs as well as retrofits. This motivates the development of more sophisticated analysis tools to better assess runner performance earlier in the design phase. The focus of this paper is to demonstrate high fidelity and time-efficient runner damping and forced response calculations based on one-way fluid-structure interaction (FSI) using loosely coupled commercial finite element analysis (FEA) and computational fluid dynamics (CFD) codes. The runner damping is evaluated based on the work done by the fluid on the runner. The calculation of the work first involves determining the runner mode shapes and natural frequencies using a cyclic symmetric FEA model with structural elements to represent the runner hardware, and acoustic fluid elements to represent the mass loading effect of the fluid. The mode shapes are then used in a transient CFD calculation to determine the damping which represents the work done by the fluid on the runner. Positive damping represents stability from flutter perspective while negative damping represents unstable operating conditions. A transient CFD calculation was performed on a runner to obtain engine order forcing function from upstream stationary vanes. This unsteady forcing function was mapped to the FEA model. Care is taken to account for the proper inter-blade phase angle on the cyclic symmetric model. The hydraulic damping from flutter calculations was also provided as input to the forced response. The forced response is then determined using this equivalent proportional damping and modal superposition of the FEA model that includes both the structural and acoustic elements. Results of the developed analysis procedure are presented based on the Tokke runner, that has been the basis of several studies through the Norwegian HydroPower Center. Unique features of the workflow and modeling approaches are discussed in detail. Benefits and challenges for both the FEA model and the CFD model are discussed. The importance of the hydraulic damping, that is traditionally ignored in previous analysis is discussed as well. No validation data is available for the forced response, so this paper is focused on the methodology for the calculations.

scholarly journals Aerodynamic and Structural Characteristics of a Centrifugal Compressor Impeller

2019 ◽  
Vol 9 (16) ◽  
pp. 3416 ◽  
Author(s):  
T R Jebieshia ◽  
Senthil Kumar Raman ◽  
Heuy Dong Kim
Keyword(s):  
Centrifugal Compressor ◽  
Structural Characteristics ◽  
Pressure Ratio ◽  
Operating Conditions ◽  
Von Mises Stress ◽  
Impeller Blade ◽  
Compressor Impeller ◽  
The One ◽  
Von Mises ◽  
Von Mises Stresses

The present study focuses on the aerodynamic performance and structural analysis of the centrifugal compressor impeller. The performance characteristics of the impeller are analyzed with and without splitter blades by varying the total number of main and splitter blades. The operating conditions of the compressor under centrifugal force and pressure load from the aerodynamic analysis are applied to the impeller blade and hub to perform the one-way Fluid–Structure Interaction (FSI). For the stress assessment, maximum equivalent von Mises stresses in the impeller blades are compared with the maximum allowable stress of the impeller material. The effects of varying the pressure field on the deformation and stress of the impeller are also calculated. The aerodynamic and structural performance of the centrifugal compressor at 73,000 rpm are investigated in terms of the efficiency, pressure ratio, equivalent von Mises stress, and total deformation of the impeller.

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