Development of a Criterion for a Robust Identification of Diffuser Rotating Stall Onset in Industrial Centrifugal Compressors

2018 ◽  
Author(s):  
Alessandro Bianchini ◽  
Giulia Andreini ◽  
Giovanni Ferrara ◽  
Lorenzo Ferrari ◽  
Dante Tommaso Rubino
Keyword(s):  
Aerodynamic Force ◽  
Dynamic Pressure ◽  
Safety Margin ◽  
Specific Model ◽  
Rotating Stall ◽  
Centrifugal Compressors ◽  
Stall Inception ◽  
Spectrum Area ◽  
Definition Of ◽  
New Criterion

Recent studies showed that a prompt detection of the stall inception, connected with a specific model to predict its associated aerodynamic force, could provide room for an extension of the left margin of the operating curve of high-pressure centrifugal compressors. In industrial machines working in the field, however, robust procedures to detect and identify the phenomenon are still missing, i.e. the operating curve is almost ever cut preliminary by the manufacturer by a proper safety margin; moreover, no agreement is found in the literature about a well-defined threshold to define the onset of the stall. In particular, in some cases the intensity of the arising subsynchronous frequency is compared to the revolution frequency, while in many other ones it is compared to the blade passage frequency. A large experience in experimental stall analyses collected by the authors revealed that in some cases unexpected spikes could make this direct comparison not reliable for a robust automatic detection. To this end, a new criterion was developed based on an integral analysis of the area subtended to the entire subsynchronous spectrum of the dynamic pressure signal of probes positioned just outside the impeller exit. A dimensionless parameter was then defined to account for the spectrum area increase in proximity to stall inception. This new parameter enabled the definition of a reference threshold to highlight the arising of stall conditions, whose validity and increased robustness was here verified based on a set of experimental analyses of different types of full-stage test cases of industrial centrifugal compressors at the test rig.

Development of a Criterion for a Robust Identification of Diffuser Rotating Stall Onset in Industrial Centrifugal Compressors

2018 ◽  
Vol 141 (2) ◽  
Author(s):  
Alessandro Bianchini ◽  
Giulia Andreini ◽  
Lorenzo Ferrari ◽  
Dante Tommaso Rubino ◽  
Giovanni Ferrara
Keyword(s):  
Aerodynamic Force ◽  
Dynamic Pressure ◽  
Safety Margin ◽  
Specific Model ◽  
Rotating Stall ◽  
Centrifugal Compressors ◽  
Stall Inception ◽  
Spectrum Area ◽  
Definition Of ◽  
New Criterion

Recent studies showed that a prompt detection of the stall inception, connected with a specific model to predict its associated aerodynamic force, could provide room for an extension of the left margin of the operating curve of high-pressure centrifugal compressors. In industrial machines working in the field, however, robust procedures to detect and identify the phenomenon are still missing, i.e., the operating curve is almost ever cut preliminarily by the manufacturer by a proper safety margin; moreover, no agreement is found in the literature about a well-defined threshold to define the onset of the stall. In particular, in some cases, the intensity of the arising subsynchronous frequency is compared to the revolution frequency, while in many other ones it is compared to the blade passage frequency. A large experience in experimental stall analyses collected by the authors revealed that in some cases unexpected spikes could make this direct comparison not reliable for a robust automatic detection. To this end, a new criterion was developed based on an integral analysis of the area subtended to the entire subsynchronous spectrum of the dynamic pressure signal of probes positioned just outside the impeller exit. A dimensionless parameter was then defined to account for the spectrum area increase in proximity to stall inception. This new parameter enabled the definition of a reference threshold to highlight the arising of stall conditions, whose validity and increased robustness was here verified based on a set of experimental analyses of different types of full-stage test cases of industrial centrifugal compressors at the test rig.

A Systematic Approach to Estimate the Impact of the Aerodynamic Force Induced by Rotating Stall in a Vaneless Diffuser on the Rotordynamic Behavior of Centrifugal Compressors

2013 ◽  
Author(s):  
Alessandro Bianchini ◽  
Davide Biliotti ◽  
Giovanni Ferrara ◽  
Lorenzo Ferrari ◽  
Elisabetta Belardini ◽  
...  
Keyword(s):  
Aerodynamic Force ◽  
Dynamic Pressure ◽  
Journal Bearings ◽  
Rotating Stall ◽  
Squeeze Film ◽  
Accurate Estimation ◽  
Vaneless Diffuser ◽  
Test Rig ◽  
Centrifugal Compressors ◽  
The Impact

One of the main challenges of the present industrial research on centrifugal compressors is the need of extending the left margin of the operating range of the machines. As a result, interest is being paid in accurately evaluating the amplitude of the pressure fluctuations caused by rotating stall, which usually occurs prior to surge. The related aerodynamic force acting on the rotor can produce subsynchronous vibrations, which can prevent the machine to further operate, in case their amplitude is too high. These vibrations are often contained thanks to the stiffness of the oil journals. Centrifugal compressors design is, however, going towards alternative journal solutions having lower stiffness levels (e.g. Active Magnetic Bearings or Squeeze Film Dampers), which hence will be more sensitive to this kind of excitation: consequently, a more accurate estimation of the expected forces in presence of dynamic external forces like those connected to an aerodynamically unstable condition is needed to predict the vibration level and the compressor operability in similar conditions. Within this scenario, experimental tests were carried out on an industrial impeller operating at high peripheral Mach number. The dedicated test rig was equipped with several dynamic pressure probes that were inserted in the gas flow path; moreover, the rotor vibrations were constantly monitored with typical vibration probes located near the journal bearings. The pressure field induced by the rotating stall in the vaneless diffuser was reconstructed by means of an ensemble average approach, defining the amplitude and frequency of the external force acting on the impeller. The calculated force value was then included in the rotordynamic model of the test rig: the predicted vibrations on the bearings were compared with the measurements, showing satisfactory agreement. Finally, the prospects of the proposed approach are discussed by investigating the response of a real machine in high-pressure functioning when different choices of journal bearings are made.

A Systematic Approach to Estimate the Impact of the Aerodynamic Force Induced by Rotating Stall in a Vaneless Diffuser on the Rotordynamic Behavior of Centrifugal Compressors

2013 ◽  
Vol 135 (11) ◽  
Author(s):  
Alessandro Bianchini ◽  
Davide Biliotti ◽  
Giovanni Ferrara ◽  
Lorenzo Ferrari ◽  
Elisabetta Belardini ◽  
...  
Keyword(s):  
Aerodynamic Force ◽  
Dynamic Pressure ◽  
Journal Bearings ◽  
Rotating Stall ◽  
Squeeze Film ◽  
Accurate Estimation ◽  
Vaneless Diffuser ◽  
Test Rig ◽  
Centrifugal Compressors ◽  
The Impact

One of the main challenges of the present industrial research on centrifugal compressors is the need for extending the left margin of the operating range of the machines. As a result, interest is being paid to accurately evaluating the amplitude of the pressure fluctuations caused by rotating stall, which usually occurs prior to surge. The related aerodynamic force acting on the rotor can produce subsynchronous vibrations, which can prevent the machine's further operation, in case their amplitude is too high. These vibrations are often contained due to the stiffness of the oil journals. Centrifugal compressor design is, however, going towards alternative journal solutions having lower stiffness levels (e.g., active magnetic bearings or squeeze film dampers), which will be more sensitive to this kind of excitation: consequently, a more accurate estimation of the expected forces in the presence of dynamic external forces such as those connected to an aerodynamically unstable condition is needed to predict the vibration level and the compressor operability in similar conditions. Within this scenario, experimental tests were carried out on industrial impellers operating at high peripheral Mach numbers. The dedicated test rig was equipped with several dynamic pressure probes that were inserted in the gas flow path; moreover, the rotor vibrations were constantly monitored with typical vibration probes located near the journal bearings. The pressure field induced by the rotating stall in the vaneless diffuser was reconstructed by means of an ensemble average approach, thus defining the amplitude and frequency of the external force acting on the impeller. The calculated force value was then included in the rotordynamic model of the test rig: the predicted vibrations on the bearings were compared with the measurements, showing satisfactory agreement. Moreover, the procedure was applied to two real multistage compressors, showing notable prediction capabilities in the description of rotating stall effects on the machine rotordynamics. Finally, the prospects of the proposed approach are discussed by investigating the response of a real machine in high-pressure functioning when different choices of journal bearings are made.

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.

Some Guidelines for the Experimental Characterization of Vaneless Diffuser Rotating Stall in Stages of Industrial Centrifugal Compressors

2014 ◽  
Author(s):  
Alessandro Bianchini ◽  
Davide Biliotti ◽  
Marco Giachi ◽  
Elisabetta Belardini ◽  
Libero Tapinassi ◽  
...  
Keyword(s):  
Dynamic Pressure ◽  
Industrial Test ◽  
Rotating Stall ◽  
Operating Conditions ◽  
Design Parameters ◽  
Accurate Estimation ◽  
Pressure Measurements ◽  
Vaneless Diffuser ◽  
Centrifugal Compressors ◽  
Test Models

An accurate estimation of rotating stall is one of the key technologies for high-pressure centrifugal compressors, as it is often connected with the onset of detrimental subsynchronous vibrations which can prevent the machine from operating beyond this limit. With particular reference to the vaneless diffuser stall, much research has been directed at investigating the physics of the phenomenon, the influence of the main design parameters and the prediction of the stall inception. Few of them, however, focused attention on the evaluation of the aerodynamic unbalance due to the induced pressure field in the diffuser, which, however, could provide a valuable contribution to both the identification of the actual operating conditions and the enhancement of the compressor operating range by a suitable choice of the control strategy. Although advanced experimental techniques have been successfully applied to the recognition of the stall pattern in a vaneless diffuser, the most suitable solution for a wider application in industrial test-models is based on dynamic pressure measurements by means of a reduced number of probes. Within this context, a procedure to transpose pressure measurements into the spatial pressure distribution was developed and validated on a wide set of industrial test-models. In this work, the main guidelines of the procedure are presented and discussed, with particular reference to signals analysis and manipulation as well as sensors positioning. Moreover, the prospects of using a higher number of sensors is analyzed and compared to standard solutions using a limited probes number.

Experimental Determination of Mechanical Stress Induced by Rotating Stall in Unshrouded Impellers of Centrifugal Compressors

2016 ◽  
Author(s):  
Philipp Jenny ◽  
Yves Bidaut
Keyword(s):  
High Cycle Fatigue ◽  
Dynamic Pressure ◽  
Pressure Fluctuations ◽  
Rotating Stall ◽  
Operating Conditions ◽  
Design Phase ◽  
Cycle Fatigue ◽  
Centrifugal Compressors ◽  
Impeller Blade ◽  
Pressure Transducers

Unshrouded centrifugal compressor impellers typically operate at high rotational speeds and volume flow rates. The resulting high mean stress levels leave little margin for dynamic excitations that can cause high cycle fatigue. In addition to the well-established high frequency impeller blade excitations of centrifugal compressors caused by the stationary parts, such as vaned diffusers or inlet guide vanes, the presented study addresses an unsteady rotating flow feature (rotating stall) which should be taken into account when addressing high cycle fatigue during the design phase. The unsteady fluid-structure interaction between rotating stall and unshrouded impellers was experimentally described and quantified during two different measurement campaigns with two full-size compression units operating under real conditions. In both campaigns dynamic strain gauges and pressure transducers were mounted at various locations on the impeller of the first compression stage. The casing was also equipped with a set of dynamic pressure transducers to complement the study. Rotating pressure fluctuations were found to form an additional impeller excitation at a frequency that is not a multiple of the shaft speed. The measurements show that the excitation amplitude and frequency caused by the rotating pressure fluctuations depend on the operating conditions and are therefore challenging to predict and consider during the design phase. Furthermore, the excitation mechanism presented was found to cause resonant impeller blade response under specific operating conditions. For the experimentally investigated impeller geometries a rotating pressure fluctuation caused approximately 1.5 MPa of additional dynamic stress in the structure per 1 mbar of dynamic pressure amplitude when exciting the first bending mode of the impeller. The induced dynamic mechanical stresses due to rotating stall are in the order of 10% of the endurance limit of the material for the tested impeller geometries, therefore they are not critical and confirm a robust and reliable design.

Simulation of air jets for controlling stall in a centrifugal fan

2014 ◽  
Vol 229 (11) ◽  
pp. 2045-2055 ◽  
Author(s):  
Zhang Lei ◽  
Wang Rui ◽  
Yuan Wei ◽  
Wang Songling
Keyword(s):  
Active Control ◽  
Stokes Equations ◽  
Control Method ◽  
Safety Margin ◽  
Stability Margin ◽  
Rotating Stall ◽  
Enhancement Effect ◽  
Centrifugal Fan ◽  
Stall Inception ◽  
Active Control Method

The main goal of the present work is to analyze the three-dimensional unsteady flow field of a centrifugal fan by solving Navier–Stokes equations, coupled with the throttle condition. The results show that rotating stall occurs in the original fan when the flow rate is 4.30 m3/s, and the stall inception first appears at three impeller passages near the volute tongue and front disc. An active control method is proposed to inhibit the stall inception, which involves blowing air at the inlets of the three impeller passages. This blowing control method cannot inhibit the stall inception when the blowing speed is lower than 50 m/s. The stability margin of the centrifugal fan is extended when the blowing speed is increased from 50 to 110 m/s, while no further effect is obvious with a further increase in the blowing speed. At a blowing speed of 110 m/s, rotating stall occurs again when the fan flow reaches 3.46 m3/s. After the application of the nozzle blowing, the safety margin of the centrifugal fan is extended by 13%, and an obvious stability enhancement effect is achieved. From an engineering standpoint, this new active control method for rotating stall offers a valuable means to ensure the safe operation of a centrifugal fan.

Experimental Analysis of the Pressure Field Inside a Vaneless Diffuser From Rotating Stall Inception to Surge

2015 ◽  
Author(s):  
Alessandro Bianchini ◽  
Davide Biliotti ◽  
Dante Tommaso Rubino ◽  
Lorenzo Ferrari ◽  
Giovanni Ferrara
Keyword(s):  
Transient Analysis ◽  
Pressure Field ◽  
Dynamic Pressure ◽  
Rotating Stall ◽  
Accurate Estimation ◽  
Vaneless Diffuser ◽  
Ensemble Averaging ◽  
Stall Inception ◽  
Key Points ◽  
Real Time Visualization

An accurate estimation of rotating stall is one of the key points for high-pressure centrifugal compressors, as it is often connected with the onset of detrimental subsynchronous vibrations which can prevent the machine from operating beyond this limit. With particular reference to vaneless diffuser rotating stall, the most common practice in industrial machines is to make use of a limited number of dynamic pressure probes to reconstruct the stall characteristics after an ensemble averaging approach. In this study, a 1:1 model of an industrial compressor stage was tested in a dedicated test rig and equipped with 24 pressure probes properly distributed along the diffuser circumference with the scope of providing a real-time visualization of the spatial pressure distribution within the diffuser. The results allowed the assessment of some important characteristics of the stall cells that were historically supposed based on averaged data, e.g. the cells rigidity. Moreover, the present study confirmed the existence of a stall pattern with two almost axisymmetric lobes. Finally, the transient analysis of both the stall inception and the surge onset was carried out, highlighting the flow field evolution in the diffuser under these conditions.

Experimental Determination of Mechanical Stress Induced by Rotating Stall in Unshrouded Impellers of Centrifugal Compressors

2016 ◽  
Vol 139 (3) ◽  
Author(s):  
Philipp Jenny ◽  
Yves Bidaut
Keyword(s):  
High Cycle Fatigue ◽  
Dynamic Pressure ◽  
Pressure Fluctuations ◽  
Rotating Stall ◽  
Operating Conditions ◽  
Design Phase ◽  
Cycle Fatigue ◽  
Centrifugal Compressors ◽  
Impeller Blade ◽  
Pressure Transducers

Unshrouded centrifugal compressor impellers typically operate at high rotational speeds and volume flow rates. The resulting high mean stress levels leave little margin for dynamic excitations that can cause high-cycle fatigue. In addition to the well-established high-frequency impeller blade excitations of centrifugal compressors caused by the stationary parts, such as vaned diffusers or inlet guide vanes (IGVs), the presented study addresses an unsteady rotating flow feature (rotating stall) which should be taken into account when addressing the high-cycle fatigue during the design phase. The unsteady fluid–structure interaction between rotating stall and unshrouded impellers was experimentally described and quantified during two different measurement campaigns with two full-size compression units operating under real conditions. In both campaigns, dynamic strain gauges and pressure transducers were mounted at various locations on the impeller of the first compression stage. The casing was also equipped with a set of dynamic pressure transducers to complement the study. Rotating pressure fluctuations were found to form an additional impeller excitation at a frequency that is not a multiple of the shaft speed. The measurements show that the excitation amplitude and frequency caused by the rotating pressure fluctuations depend on the operating conditions and are therefore challenging to predict and consider during the design phase. Furthermore, the excitation mechanism presented was found to cause resonant impeller blade response under specific operating conditions. For the experimentally investigated impeller geometries, a rotating pressure fluctuation caused approximately 1.5 MPa of additional dynamic stress in the structure per 1 mbar of dynamic pressure amplitude when exciting the first bending mode of the impeller. The induced dynamic mechanical stresses due to rotating stall are in the order of 10% of the endurance limit of the material for the tested impeller geometries; therefore, they are not critical and confirm a robust and reliable design.

Experimental Analysis of the Pressure Field Inside a Vaneless Diffuser From Rotating Stall Inception to Surge

2015 ◽  
Vol 137 (11) ◽  
Author(s):  
Alessandro Bianchini ◽  
Davide Biliotti ◽  
Dante Tommaso Rubino ◽  
Lorenzo Ferrari ◽  
Giovanni Ferrara
Keyword(s):  
Transient Analysis ◽  
Pressure Field ◽  
Dynamic Pressure ◽  
Rotating Stall ◽  
Accurate Estimation ◽  
Vaneless Diffuser ◽  
Ensemble Averaging ◽  
Stall Inception ◽  
Key Points ◽  
Real Time Visualization

An accurate estimation of rotating stall is one of the key points for high-pressure centrifugal compressors, as it is often connected with the onset of detrimental subsynchronous vibrations which can prevent the machine from operating beyond this limit. With particular reference to vaneless diffuser rotating stall, the most common practice in industrial machines is to make use of a limited number of dynamic pressure probes to reconstruct the stall characteristics after an ensemble averaging approach. In this study, a 1:1 model of an industrial compressor stage was tested in a dedicated test rig and equipped with 24 pressure probes properly distributed along the diffuser circumference with the scope of providing a real-time visualization of the spatial pressure distribution within the diffuser. The results allowed the assessment of some important characteristics of the stall cells that were historically supposed based on averaged data, e.g., the cells rigidity. Moreover, the present study confirmed the existence of a stall pattern with two almost axisymmetric lobes. Finally, the transient analysis of both the stall inception (SI) and the surge onset (SO) was carried out, highlighting the flow field evolution in the diffuser under these conditions.

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