IN-STALL COMPRESSOR PERFORMANCE AND THE EFFECTS OF REYNOLDS NUMBER

Previous research into axial compressor stall has mainly focused on stall inception and methods to extend the stable operating range. This paper considers the performance of an axial compressor beyond stall and investigates how the characteristics of stall cells depend on Reynolds number. An experimental study has been conducted using a single-stage axial compressor capable of operating across the Reynolds number range of 10,000 – 100,000. Detailed unsteady measurements have been used to measure the behaviour across a range of in-stall flow coefficients. These measurements have been used to extract the stall hysteresis and to determine the size, speed, number, and spanwise extent of the stall cells. The results show that for the stalled compressor, as Reynolds number increases, the size of the minimum stable stall cell decreases. This means that a larger change in throttle area is needed to reduce the stall cell down to a size where the compressor can recover from stall. At the design Reynolds number, the number of stall cells that form transitions from one, to two, and then to four stall cells as the flow coefficient is reduced. At lower Reynolds numbers, the two-stall-cell state becomes unstable; instead, a single stall cell transitions directly into five stall cells. As the number of stall cells increases, so do the speed of the stall cells and the total size. Further reductions in the flow coefficient cause an increase in the total size and a decrease in the stall cell speed.

A Parametric Study on the Effect of Casing Treatment Slots on Performance Enhancement of a Single Stage Axial Flow Compressor

This paper numerically investigates the effect of slots on the performance of a highly subsonic axial flow compressor. The axial flow compressor consisting of 21 rotor blades with NACA 65 series blade profile was used for the simulations. The present results were obtained using different turbulence models and shear stress transport model was found to be the best one. Studies were conducted to determine the influence of length, depth and skew angle of the slot on the compressor performance. The slot width and centre-to-centre distance between the successive slots were maintained at 6.3% Ca and 11% Ca, respectively. The present study was carried out at different slot lengths (0 to 100% of axial chord, 20 to 100% of axial chord and 40 to 100% of axial chord), slot depths (7.9, 11 and 15.7% Ca) and skew angles (0°, 30°, 45° and 60°). The slot length of 20 to 100% of Ca, depth of 15.7% Ca and skew angle of 60° resulted in the best compressor performance leading to 22.1% stall margin improvement. Subsequently, flow characteristics were studied without and with slots.

Sensitivity analysis of centrifugal compressors aerodynamic losses using 1D-mean streamline prediction technique

One-dimensional modeling and prediction of the centrifugal compressor performance are challenging as they require conservation equations and empirical and semi-empirical correlations. Therefore, there is a need to perform a consolidated study of the compressor aerodynamic loss models to conclude the importance of each loss to the compressor performance modeling. Accordingly, the purpose of this paper is to examine the effect of each aerodynamic loss on the compressor performance and explore more about which loss could have a negligible effect on the compressor performance. A MATLAB code was developed to predict the performance of five different small turbocharger centrifugal compressors at different geometric and operating conditions. The developed code was validated using the available experimental data of the investigated compressors. A sensitivity analysis methodology was performed using the validated code to check the effect of ten aerodynamic losses for the impeller and volute sections on the compressor performance. This paper concludes that impeller disk friction, blade loading, and clearance losses have a negligible effect on the small turbocharger vanless diffuser compressor performance.

CFD investigation of flow through a centrifugal compressor diffuser with splitter blades

The aerodynamic losses in centrifugal compressors are mainly associated with the separated flow on the suction sides of impeller and diffuser vanes. The overall performance of such compressors can be improved by adding splitter vanes. The present work examines the effect of varying the geometrical location of the splitter vanes in the diffuser on the overall performance of a high-speed centrifugal compressor stage of a small gas turbine. To increase the pressure recovery through the diffuser, two radial sets of vanes are used. The first set of vanes (diffuser-1) is equipped with splitter vanes, placed mid-distance between the main vanes, while the vanes of the second set (diffuser-2) are conventional vanes. Flow through the compressor was simulated using the ANSYS 19 workbench program. Flow characteristics and compressor performance were obtained and analyzed for different circumferential positions of the splitting vanes relative to the main vanes of diffuser-1. The study covered seven positions of the splitter vanes including the original design of the diffuser where the splitter vanes were located at mid-distance between the main vanes. The analysis shows that, at design conditions, selecting the position of the splitter vanes to be nearer to the pressure side of the main vanes improves the stage performance. In the present study, locating the splitters at 33% of the angular distance between the main vanes leads to the best performance, and a significant improvement in the overall stage performance is recorded. The pressure recovery coefficient is raised by about 17%, the pressure ratio is increased by about 1.13%, and the stage efficiency is increased by about 2.01%, compared to the original splitter position. Performance improvement is related to the suppression of the flow separation and the more uniformity of flow. On the contrary, further moving the splitter closer to the main blade, the pressure recovery coefficient is decreased by about 2% than the position of 33% of the angular distance, but still higher than the original position by about 15% and a limited improvement in the compressor performance is noticed. Moving the splitter far out the main blade annihilates the static pressure recovery of the diffuser by about 2:7% compared with the original position. So, for the investigated compressor, the best position of the splitter blade in the circumferential direction, which provides the best stage performance in our parametric analysis, is not necessary to be at the mid-angular distance between the diffuser’s main blades, but it is achieved by moving the splitter to about 33% of the angular distance where the diminished loss from the suppressed flow separation is more prevailing and the instigated friction losses from splitter surfaces are less critical.

Effect of three non-axisymmetric stator schemes on compressor performance with distorted inlet

In the boundary layer ingesting propulsion system, the compressor suffers from a non-uniform flow field. The compressor operating with distorted inflow continuously results in the loss of aerodynamic performance and stability margin. In this paper, three non-axisymmetric configurations are described for the stator of a transonic compressor to match the non-uniform flow field. The flow fields with distorted inflow at near stall condition are obtained and analyzed, the effects of the prototype stator and the three non-axisymmetric stators on aerodynamic performance are compared in detail. Results show that the non-axisymmetric stator schemes can effectively improve the stability margin of the transonic compressor and the maximum stability margin is relatively increased by 22.3% in all the three non-axisymmetric stators. The non-axisymmetric stator design is effective on decreasing the aerodynamic losses and improving the performance of the compressor operating with distorted inflow. Overall, the results show that in the design of the non-axisymmetric stator, the adoption of a curved-twisted blade and the increase of cascade solidity have the potential to reduce loss sources caused by distorted inflow.

Considerations and complications with "first principles" dynamic modelling of industrial compressors

Readily available processing hardware and "off-the-shelf" (OTS) simulation software has made "high fidelity" first principles models of both steady and transient states, for both axial and centrifugal industrial compressors, relatively easy to construct. These high-fidelity models are finding their way into "real-time. digital twin" performance monitors, front-end engineering design, and post-design – pre-construction compressor performance evaluation. The compressor models are useful for reliably demonstrating the compressor and – to some degree, based on the complexity of the model – process response to various operating conditions. Once the model is constructed, it is trivial to run a "what-if" analysis of compressor performance to answer questions related to (a) recommendations or validation of the recycle/vent valve size and actuation speed, (b) general piping layout and sizing around the compressor, (c) and hot gas bypass requirements, to name a few. This paper takes a practical approach in discussing the compressor and process parameters necessary for building these dynamic "high-fidelity" industrial-compressor models. We identify compressor inputs and compressor responses that are faithfully modeled by first-principle equations available in the simulation software and those that typically require a compromise between an "ab initio" and data-fitting approximation. We discuss the simulation's tendency to overstate pressure excursions during surge events and understate the compressor operation in the "stonewall" region. We also discuss using the simulator software's compressor-stage enthalpy calculations to predict and quantify the compressor train reverse rotation. We use our broad experience and understanding of the compressor operation and simulation and our experience with the AVEVA™ Dynamic-Simulation "OTS" simulation software as the basis for this discussion.

Effect of housing size on the performance of a centrifugal compressor for turbocharger application: An experimental and numerical study

Currently, engine downsizing through turbocharging is widespread in the automotive industry to improve fuel economy and emissions. The engine downsizing demands compact and high performance centrifugal compressors for turbochargers. A compressor contains mainly an impeller and housing, which often uses a vaneless diffuser and an overhanging volute. High-speed flow from the impeller is decelerated in the diffuser and volute, to recover static pressure for boosting the engine. The volute flow characteristics and pressure recovery depend on the housing size, which determines the overall compressor performance and size. This study evaluates the effect of four different housing sizes viz., baseline, 12% scaled up, and 12% and 20% scaled-down geometrically, through experimental and numerical analysis. The experiments are conducted using different housing sizes with a given impeller to measure the compressor pressure ratio and efficiency. Also, steady-state numerical simulations are performed to examine the flow mechanisms causing pressure losses due to changes in housing size. Then, the simulation is also done for different volute surface roughness levels in each housing to establish its effect on compressor performance. From the results, it is found that there is no marked change in compressor efficiency between the baseline and 12% scaled-up housing. Whereas, the scaled-down housings (12% and 20%) showed efficiency drop of about 2–5 percentage points at near-choke flow rate. The CFD analyses of these scaled down housings with reduced cross-sectional area indicated substantial increase of meridional velocity, which results in higher swirl velocity in the volute causing more pressure losses. Besides, the increased volute surface roughness is realized to cause extra pressure loss due to higher wall shear stress. It amounts to additional efficiency reduction of 0.5–1 percentage points at the same near-choke flow.

Effect of housing surface roughness on the performance of a centrifugal compressor for turbocharger: Experimental and numerical study

Centrifugal compressor plays a vital role in the performance of a turbocharger. The compressor contains an impeller and housing, including the vaneless diffuser and a volute. The high-speed flow from the impeller is diffused in the diffuser and volute, before being delivered to the engine. Hence, the housing flow characteristics affect the compressor performance and operating range. Generally, housing has noticeable surface roughness, especially in the volute. This study evaluates the effect of the volute surface roughness on the compressor performance by experimental and numerical analysis. The experiments are conducted for three different volute surface roughness levels to measure the overall compressor pressure ratio and efficiency. The uncertainty in the efficiency for experimental results is within ±0.5% pts. Also, steady-state numerical simulations are performed to analyse the flow mechanisms causing pressure losses. Then, a numerical analysis is done to understand the effect of roughness of the diffuser hub and shroud walls on the compressor performance. From the experimental results, it is found that the increase in the roughness level of the volute from the smooth surface by circa 900% and 1400% shows a significant reduction in the compressor efficiency at the design speed (N) and off-design speeds (0.87 and 1.13 N). The reductions of efficiency are about 0.5%–1% pts at the near surge point, 1%–1.5% pts at the peak efficiency point and 2%–2.5% pts at the near choke flow point. The CFD analyses show significantly higher near-wall turbulence and wall shear resulting in additional pressure losses. Also, it is found that the pressure losses are more sensitive to roughness of the diffuser shroud-wall than that of the hub-wall. On the other hand, the diffuser hub-wall roughness increases the radial momentum in the diffuser passage which suppress the flow separation at low flow rates.