Experimental and Numerical Analysis of Different Volutes in a Centrifugal Compressor

In a centrifugal compressor the flow around the diffuser is collected and led to the pipe system by a spiral-shaped volute. In this study a single-stage centrifugal compressor with three different volutes is investigated. The compressorwas first equipped with the original volute, the cross-section of which was a combination of a rectangle and semi-circle. Next a new volute with a fully circular cross-section was designed and manufactured. Finally, the circular volute wasmodified by rounding the tongue and smoothing the tongue area. The overall performance of the compressor as well as the static pressure distribution after the impeller and on the volute surface were measured. The flow entering the volute was measured using a three-hole Cobra-probe, and flow visualisations were carriedout in the exit cone of the volute. In addition, the radial force acting on theimpeller was measured using magnetic bearings. The complete compressor with thecircular volute (inlet pipe, full impeller, diffuser, volute and outlet pipe) was also modelled using computational fluid dynamics (CFD). A fully 3-D viscous flow was solved using a Navier-Stokes solver, Finflo, developed at Helsinki University of Technology. Chien's k-e model was used to take account of the turbulence. The differences observed in the performance of the different volutes were quite small. The biggest differences were at low speeds and high volume flows,i.e. when the flow entered the volute most radially. In this operating regime the efficiency of the compressor with the modified circular volute was about two percentage points higher than with the other volutes. Also, according to the Cobra-probe measurements and flow visualisations, the modified circular volute performed better than the other volutes in this operating area. The circumferential static pressure distribution in the volute showed increases at low flow, constant distribution at the design flow and decrease at high flow. The non-uniform static pressure distribution of the volute was transmitted backwards across the vaneless diffuser and observed at the impeller exit. At low volume flow a strong two-wave pattern developed into the static pressure distribution at the impeller exit due to the response of the impeller to the non-uniformity of pressure. The radial force of the impeller was the greatest at the choke limit, the smallest atthe design flow, and moderate at low flow. At low flow the force increase was quite mild, whereas the increase at high flow was rapid. Thus, the non-uniformityof pressure and the force related to it are strong especially at high flow. Theforce caused by the modified circular volute was weaker at choke and more symmetric as a function of the volume flow than the force caused by the other volutes.

The performance and the characteristic field of a centrifugal compressor

Tässä työssä tarkastellaan radiaalikompressorin puristusprosessiin liittyvä peruslaskenta. Ilmankosteuden vaikutukset laskentaan huomioidaan ja kompressorin tunnuskenttä esitellään tässä työssä. Esimerkkinä lasketaan pisteitä kompressorin tunnuskentästä.

Performance Improvement of Centrifugal Compressor Stage with Pinched Geometry or Vaned Diffuser

Centrifugal compressors are widely used for example in refrigeration processes, the oil and gas industry, superchargers, and waste water treatment. In this work, five different vaneless diffusers and six different vaned diffusers are investigated numerically. The vaneless diffusers vary only by their diffuser width, so that four of the geometries have pinch implemented to them. Pinch means a decrease in the diffuser width. Four of the vaned diffusers have the same vane turning angle and a different number of vanes, and two have different vane turning angles. The flow solver used to solve the flow fields is Finflo, which is a Navier-Stokes solver. All the cases are modeled with the Chien's k – έ- turbulence model, and selected cases are modeled also with the k – ώ-SST turbulence model. All five vaneless diffusers and three vaned diffusers are investigated also experimentally. For each construction, the compressor operating map is measured according to relevant standards. In addition to this, the flow fields before and after the diffuser are measured with static and total pressure, flow angle and total temperature measurements. When comparing the computational results to the measured results, it is evident that the k – ώ-SST turbulence model predicts the flow fields better. The simulation results indicate that it is possible to improve the efficiency with the pinch, and according to the numerical results, the two best geometries are the ones with most pinch at the shroud. These geometries have approximately 4 percentage points higher efficiency than the unpinched vaneless diffusers. The hub pinch does not seem to have any major benefits. In general, the pinches make the flow fields before and after the diffuser more uniform. The pinch also seems to improve the impeller efficiency. This is down to two reasons. The major reason is that the pinch decreases the size of slow flow and possible backflow region located near the shroud after the impeller. Secondly, the pinches decrease the flow velocity in the tip clearance, leading to a smaller tip leakage flow and therefore slightly better impeller efficiency. Also some of the vaned diffusers improve the efficiency, the increment being 1...3 percentage points, when compared to the vaneless unpinched geometry. The measurement results confirm that the pinch is beneficial to the performance of the compressor. The flow fields are more uniform with the pinched cases, and the slow flow regions are smaller. The peak efficiency is approximately 2 percentage points and the design point efficiency approximately 4 percentage points higher with the pinched geometries than with the un- pinched geometry. According to the measurements, the two best geometries are the ones with the most pinch at the shroud, the case with the pinch only at the shroud being slightly better of the two. The vaned diffusers also have better efficiency than the vaneless unpinched geometries. However, the pinched cases have even better efficiencies. The vaned diffusers narrow the operating range considerably, whilst the pinch has no significant effect on the operating range.

Design of a Test Stand for a Centrifugal Compressor

The goal of the Master’s thesis is to design a test stand for a centrifugal compressor. Different theoretical aspects of flow parameters measurements and test rigs built for the similar purposes in other research units are described in the theoretical part of the work. The process of components selection and the description of chosen components are given in the second part of the thesis. Besides measuring and control stages, the designed test stand has a closed-loop piping, an aftercooler and a surge tank. Overview and layout of the test rig is presented in the last chapter of the work.

Computational and Experimental Analysis of Flow Field in the Diffusers of Centrifugal Compressors

Centrifugal compressors are widely used for example in process industry, oil and gas industry, in small gas turbines and turbochargers. In order to achieve lower consumption of energy and operation costs the efficiency of the compressor needs to be improve. In the present work different pinches and low solidity vaned diffusers were utilized in order to improve the efficiency of a medium size centrifugal compressor. In this study, pinch means the decrement of the diffuser flow passage height. First different geometries were analyzed using computational fluid dynamics. The flow solver Finflo was used to solve the flow field. Finflo is a Navier-Stokes solver. The solver is capable to solve compressible, incompressible, steady and unsteady flow fields. Chien's k-e turbulence model was used. One of the numerically investigated pinched diffuser and one low solidity vaned diffuser were studied experimentally. The overall performance of the compressor and the static pressure distribution before and after the diffuser were measured. The flow entering and leaving the diffuser was measured using a three-hole Cobra-probe and Kiel-probes. The pinch and the low solidity vaned diffuser increased the efficiency of the compressor. Highest isentropic efficiency increment obtained was 3\% of the design isentropic efficiency of the original geometry. It was noticed in the numerical results that the pinch made to the hub and the shroud wall was most beneficial to the operation of the compressor. Also the pinch made to the hub was better than the pinchmade to the shroud. The pinch did not affect the operation range of the compressor, but the low solidity vaned diffuser slightly decreased the operation range.The unsteady phenomena in the vaneless diffuser were studied experimentally andnumerically. The unsteady static pressure was measured at the diffuser inlet and outlet, and time-accurate numerical simulation was conducted. The unsteady static pressure showed that most of the pressure variations lay at the passing frequency of every second blade. The pressure variations did not vanish in the diffuser and were visible at the diffuser outlet. However, the amplitude of the pressure variations decreased in the diffuser. The time-accurate calculations showed quite a good agreement with the measured data. Agreement was very good at the design operation point, even though the computational grid was not dense enough inthe volute and in the exit cone. The time-accurate calculation over-predicted the amplitude of the pressure variations at high flow.

Computational Analysis and Optimization of Real Gas Flow In Small Centrifugal Compressors

Small centrifugal compressors are more and more widely used in many industrialsystems because of their higher efficiency and better off-design performance comparing to piston and scroll compressors as while as higher work coefficient perstage than in axial compressors. Higher efficiency is always the aim of the designer of compressors. In the present work, the influence of four partsof a small centrifugal compressor that compresses heavy molecular weight real gas has been investigated in order to achieve higher efficiency. Two parts concern the impeller: tip clearance and the circumferential position of the splitter blade. The other two parts concern the diffuser: the pinch shape and vane shape. Computational fluid dynamics is applied in this study. The Reynolds averaged Navier-Stokes flow solver Finflo is used. The quasi-steady approach is utilized. Chien's k-e turbulence model is used to model the turbulence. A new practical real gas model is presented in this study. The real gas model is easily generated, accuracy controllable and fairly fast. The numerical results and measurements show good agreement. The influence of tip clearance on the performance of a small compressor is obvious. The pressure ratio and efficiency are decreased as the size of tip clearance is increased, while the total enthalpy rise keeps almost constant. The decrement of the pressure ratio and efficiency is larger at higher mass flow rates and smaller at lower mass flow rates. The flow angles at the inlet and outlet of the impeller are increased as the size of tip clearance is increased. The results of the detailed flow field show that leakingflow is the main reason for the performance drop. The secondary flow region becomes larger as the size of tip clearance is increased and the area of the main flow is compressed. The flow uniformity is then decreased. A detailed study shows that the leaking flow rate is higher near the exit of the impeller than that near the inlet of the impeller. Based on this phenomenon, a new partiallyshrouded impeller is used. The impeller is shrouded near the exit of the impeller. The results show that the flow field near the exit of the impeller is greatly changed by the partially shrouded impeller, and better performance is achievedthan with the unshrouded impeller. The loading distribution on the impeller blade and the flow fields in the impeller is changed by moving the splitter of the impeller in circumferential direction. Moving the splitter slightly to the suction side of the long blade can improve the performance of the compressor. The total enthalpy rise is reduced if only the leading edge of the splitter ismoved to the suction side of the long blade. The performance of the compressor is decreased if the blade is bended from the radius direction at the leading edge of the splitter. The total pressure rise and the enthalpy rise of thecompressor are increased if pinch is used at the diffuser inlet. Among the fivedifferent pinch shape configurations, at design and lower mass flow rates the efficiency of a straight line pinch is the highest, while at higher mass flow rate, the efficiency of a concave pinch is the highest. The sharp corner of the pinch is the main reason for the decrease of efficiency and should be avoided. The variation of the flow angles entering the diffuser in spanwise direction is decreased if pinch is applied. A three-dimensional low solidity twisted vaned diffuser is designed to match the flow angles entering the diffuser. The numerical results show that the pressure recovery in the twisted diffuser is higher than in a conventional low solidity vaned diffuser, which also leads to higher efficiency of the twisted diffuser. Investigation of the detailed flow fields shows that the separation at lower mass flow rate in the twisted diffuser is later than in the conventional low solidity vaned diffuser, which leads to a possible wider flow range of the twisted diffuser.

Insulation System in an Integrated Motor Compressor

A high-speed and high-voltage solid-rotor induction machine provides beneficial features for natural gas compressor technology. The mechanical robustness of the machine enables its use in an integrated motor-compressor. The technology uses a centrifugal compressor, which is mounted on the same shaft with the high-speed electrical machine driving it. No gearbox is needed as the speed is determined by the frequency converter. The cooling is provided by the process gas, which flows through the motor and is capable of transferring the heat away from the motor. The technology has been used in the compressors in the natural gas supply chain in the central Europe. New areas of application include natural gas compressors working at the wellheads of the subsea gas reservoir. A key challenge for the design of such a motor is the resistance of the stator insulation to the raw natural gas from the well. The gas contains water and heavy hydrocarbon compounds and it is far harsher than the sales gas in the natural gas supply network. The objective of this doctoral thesis is to discuss the resistance of the insulation to the raw natural gas and the phenomena degrading the insulation. The presence of partial discharges is analyzed in this doctoral dissertation. The breakdown voltage of the gas is measured as a function of pressure and gap distance. The partial discharge activity is measured on small samples representing the windings of the machine. The electrical field behavior is also modeled by finite element methods. Based on the measurements it has been concluded that the discharges are expected to disappear at gas pressures above 4 – 5 bar. The disappearance of discharges is caused by the breakdown strength of the gas, which increases as the pressure increases. Based on the finite element analysis, the physical length of a discharge seen in the PD measurements at atmospheric pressure was approximated to be 40 – 120 m. The chemical aging of the insulation when exposed to raw natural gas is discussed based on a vast set of experimental tests with the gas mixture representing the real gas mixture at the wellhead. The mixture was created by mixing dry hydrocarbon gas, heavy hydrocarbon compounds, monoethylene glycol, and water. The mixture was chosen to be more aggressive by increasing the amount of liquid substances. Furthermore, the temperature and pressure were increased, which resulted in accelerated test conditions. The time required to detect severe degradation was thus decreased. The test program included a comparison of materials, an analysis of the e ects of di erent compounds in the gas mixture, namely water and heavy hydrocarbons, on the aging, an analysis of the e ects of temperature and exposure duration, and also an analysis on the e ect of sudden pressure changes on the degradation of the insulating materials. It was found in the tests that an insulation consisting of mica, glass, and epoxy resin can tolerate the raw natural gas, but it experiences some degradation. The key material in the composite insulation is the resin, which largely defines the performance of the insulation system. The degradation of the insulation is mostly determined by the amount of gas mixture di used into it. The di usion was seen to follow Fick’s second law, but the coe cients were not accurately defined. The di usion was not sensitive to temperature, but it was dependent upon the thermodynamic state of the gas mixture, in other words, the amounts of liquid components in the gas. The weight increase observed was mostly related to heavy hydrocarbon compounds, which act as plasticizers in the epoxy resin. The di usion of these compounds is determined by the crosslink density of the resin. Water causes slight changes in the chemical structure, but these changes do not significantly contribute to the aging phenomena. Sudden changes in pressure can lead to severe damages in the insulation, because the motion of the di used gas is able to create internal cracks in the insulation. Therefore, the di usion only reduces the mechanical strength of the insulation, but the ultimate breakdown can potentially be caused by a sudden drop in the pressure of the process gas.

New computer software for defining the three-dimensional geometry for a centrifu- gal compressor impeller

In this thesis, a computer software for defining the geometry for a centrifugal compressor impeller is designed and implemented. The project is done under the supervision of Laboratory of Fluid Dynamics in Lappeenranta University of Technology. This thesis is similar to the thesis written by Tomi Putus (2009) in which a centrifugal compressor impeller flow channel is researched and commonly used design practices are reviewed. Putus wrote a computer software which can be used to define impeller’s three-dimensional geometry based on the basic geometrical dimensions given by a preliminary design. The software designed in this thesis is almost similar but it uses a different programming language (C++) and a different way to define the shape of the impeller meridional projection.

Numerical simulation of rotor-stator interaction and tip clearance flow in centrifugal compressors

The effect of the tip clearance and vaneless diffuser width on the stage performance and flow fields of a centrifugal compressor were studied numerically and results were compared to the experimental measurements. The diffuser width was changed by moving the shroud side of the diffuser axially and six tip clearances size from 0.5 to 3 mm were studied. Moreover, the effects of rotor-stator interaction on the diffuser and impeller flow fields and performance were studied. Also transient simulations were carried out in order to investigate the influence of the interaction on the impeller and diffuser performance parameters. It was seen that pinch could improve the performance and it help to get more uniform flow at exit and less back flow from diffuser to the impeller.

Radiaalikompressorin valinta hiilivetyteollisuudessa

Tutkimuksen tavoitteena oli selvittää hiilivetyteollisuudessa käytettävien radiaali-kompressorien ominaisuuksia, toimintaympäristöjä, turvallisuusasioita, etuja ja rajoitteita. Tämän lisäksi selvitettiin vaihtoehtoisia yleisesti käytettyjä menetelmiä radiaalikompressorien simuloimiseksi. Työssä tutkittiin myös kaupallisten mitoitusohjelmien soveltuvuutta laitesuunnittelun tueksi Neste Jacobs Oy:ssä. Työn kirjallisuusosassa käsiteltiin radiaalikompressorien toimintaympäristöjä, säätötapoja sekä näistäja muista tekijöistä aiheutuvia rajoitteita ja vaatimuksia. Kirjallisuustutkimuksen perusteella laadittiin tarkistuslista asioista, jotka tulee selvittää ennenvarsinaista radiaalikompressorien mitoittamista. Soveltuvaakaupallista kompressorien mitoitusohjelmaa ei tutkimuksessa löytynyt. Tämän vuoksi työn kokeellisessa osassa laadittiin Excel-laskentataulukko, joka perustuu yhteen kirjallisuusosassa esitettyyn mitoitustapaan. Laaditun laskentataulukon soveltuvuutta kompressorien esivalintaan testattiin vertailemalla ohjelman mitoituksia Neste Jacobs Oy:llä käytössä olevaan mitoitusohjelmaan ja toiseen työssä esitettyyn mitoitus-menetelmään. Lisäksi Excel-laskentataulukon ja Neste Jacobs Oy:n ohjelman mitoituksia verrattiin todellisen, käytössä olevan kompressorin suunnittelu- ja operointiarvoihin. Lisäksi tutkimuksessa arvioitiin laaditun laskentataulukon käytettävyyttä, rajoitteita ja kehitysmahdollisuuksia. Saatujen tulosten perusteella työssä laadittu laskentataulukko soveltuu sellaisenaan Neste Jacobs Oy:n radiaalikompressorien simulointiin.

Radiaalikompressorin spiraalivirtauksen numeerinen mallinnus

Diplomityössä mallinnetaan numeerisesti radiaalikompressorin spiraalin virtaus. Spiraalin tarkoituksena radiaalikompressorissa on kerätä tasaisesti virtaus diffuusorin kehältä. Spiraaliin on viime aikoina kiinnitetty enemmän huomiota, koska on havaittu, että kompressorin hyötysuhdetta voidaan parantaa spiraalia optimoimalla. Spiraalin toimintaa tarkastellaan kolmella eri massavirralla. Työn alussa käsitellään spiraalin toimintaperiaatteita. Numeerisena ratkaisijana käytetään Teknillisessä korkeakoulussa kehitettyä FIN-FLO -koodia. FINFLO -laskentaohjelmassa ratkaistaan Navier-Stokes yhtälöt kolmeulotteiselle laskenta-alueelle. Diskretointi perustuu kontrollitilavuus menetelmään. Työssä käsitellään laskentakoodin toimintaperiaatteitta. Turbulenssia mallinnetaan algebrallisella Baldwin-Lomaxin ja kahden yhtälön Chienin k-e turbulenssimalleilla. Laskentatuloksia verrataan Lappeenrannan teknillisessä korkeakoulussa tehtyihin mittauksiin kyseessä olevasta kompressorin spiraalista. Myös eri turbulenssimalleilla ja hilatasoilla saatuja tuloksia verrataan keskenään. Laskentatuloksien jälkikäsittelyä varten ohjelmoitiin neljä eri tietokoneohjelmaa. Laskennalla pyritään saamaan lisäselvyyttä virtauksen käyttäytymiseen spiraalissa ja erityisesti ns. kielen alueella. Myös kahden eri turbulenssimallin toimivuutta kompressorin numeerisessa mallinnuksessa tutkitaan.

Study of a vapor-compression air-conditioning system for jetliners

Most modern passenger aeroplanes use air cycle cooling. A high-speed air cycle is a reliable and light option, but not very efficient. This thesis presents research work done to design a novel vapour cooling cycle for aeroplanes. Due to advancements in high-speed permanent magnet motors, the vapour cycle is seen as a competitive option for the air cycle in aeroplanes. The aerospace industry places tighter demands on the weight, reliability and environmental effects of the machinery than those met by conventional chillers, and thus modifications to conventional design are needed. The thesis is divided into four parts: the initial screening of the working fluid, 1-D design and performance values of the compressor, 1-D off-design value predictions of the compressor and the 3-D design of the compressor. The R245fa was selected as the working fluid based the study. The off-design range of the compressor was predicted to be wide and suitable for the application. The air-conditioning system developed is considerably smaller than previous designs using centrifugal compressors.

Kompressoriyksiköiden mekaaninen kunnonhallinta

Kunnossapidon kuluista suurimman osan aiheuttavat koneiden ennakoimattomat rikkoutumiset ja niiden tuomat tuotannonpysäytykset. Kunnossapidon suunnitelmallisuutta ja vikojen ennustettavuutta pyritään parantamaan erilaisin kunnonvalvonnallisin keinoin. Havaitsemalla alkava vikaantuminen ajoissa ja seuraamalla sen kehittymistä luodaan mahdollisuus korjaustoimenpiteiden ja -ajankohdan hallittuun suunnitteluun ja tätä kautta kustannussäästöihin. Tässä työssä on tutkittu kompressoriyksiköiden (kaasuturbiini ja keskipakokompressori) ja niiden apulaitteiden kunnossapidon menetelmiä, niiden hyödynnettävyyttä sekä mahdollisuuksia kehittää mekaanista kunnonhallintaa. Työssä päädyttiin johtopäätökseen, että käytettävien menetelmien hyödynnettävyydessä on kehitettävää. Kunnonvalvonnan ohjeistuksia tarkennettiin vastaamaan tämän päivän tavoitteita. Todettiin myös, että värähtelynvalvontaan perustuva kunnonvalvontajärjestelmä soveltuu hyvin kompressoriyksiköiden kunnonvalvonnan järjestelmäksi. Värähtelynvalvontaan perustuva kunnonvalvontajärjestelmä luo mahdollisuuden turvallisen käyttöajan ennustamiseen. Kunnonvalvonnan kehittämisen ja käyttövarmuuden parantamisen kannalta jatkotutkimuksen tekeminen kompressoriyksiköiden mekaanistenlaitteiden turvallisen käyttöajan ennustamiseksi on perusteltua.

Radiaalikompressorin aerodynaaminen suunnittelu

Tämän diplomityön tavoitteena on ollut suunnitella radiaalikompressori. Aluksi on tutustuttu radiaalikompressorissa tapahtuviin ilmiöihin, jonka jälkeen radiaalikompressori on suunniteltu. Reunaehtoina suunnittelussa olivat toimilaitteelta saatava teho 250 kW ja sen suurin pyörimisnopeus 500 Hz. Esisuunnittelu on tehty Virtaustekniikan laboratoriossa kehitetyllä CentriFlow-ohjelmalla. Juoksupyörän muoto on suunniteltu viskoosittomilla 2D-malleilla. Juoksupyörän muodon suunniittelussa on käytetty kaupallista AxCent-ohjelmaa. Juoksupyörän muoto on tarkistettu laskennallisen virtausdynamiikan avulla. Virtausmallinnuksessa käytettiin FinFlo-ohjelmaa. Suunnittelun ja mallinnuksen pohjalta valittiin kolme erilaista juoksupyörää valmistukseen.

Optimization of centrifugal separation of Ó-lactalbumin and ¿̐ư-lactoglobulin

Selostus: Ó-lactalbumiinin ja ¿̐ư-lactoglobuliinin sentrifugointierotuksen optimointi