Numerical Simulation of Surge in Turbocharger Centrifugal Compressor: Influences of Downstream Plenum

Abstract

Surge is an important instability seriously affecting compression systems. This paper presents a numerical simulation of surge flow phenomenon inside a turbocharger centrifugal compressor with a vaneless diffuser. The compressor was discharged into a plenum and the effect of the plenum on surge behavior of the compressor system was investigated. The entire geometry of the compressor, including the impeller, vaneless diffuser, volute housing and downstream plenum, were included in the simulation. Three-dimensional Reynolds averaged compressible Navier–Stokes equations were solved with the k–ε turbulence model using commercial software CFX and two different sizes of plenum were studied. A new plenum model is proposed which allows temporal variation of temperature inside the plenum. The numerical technique employed to set up CFD (computational fluid dynamics) with such an unstable flow system are described. The results show that when the plenum volume was nearly doubled, the dominating frequency of the system suddenly dropped from 72Hz to 23Hz. During the surge cycle, the compressor characteristic (pressure ratio ν mass flow curve) showed distinct differences. With the smaller plenum, the characteristic showed random traces with little global backflow at the compressor inlet, while with the larger plenum, clear surge cycles are displayed with strong global backflow at the inlet. The flow fields of the two systems are presented as functions of time and show distinct differences. In the case of the smaller plenum, the circumferential flow field inside the impeller is non uniform, showing influences of rotating stall, while in the case of the large plenum, the circumferential uniformity returns and the flow field behaves quasi-steadily during the surge cycle. With the larger plenum, the volute flow synchronises with the inlet mass flow oscillation in time and a completed vortex break down occurs at every volute cross section, but with the smaller plenum the synchronisation disappears and vortex break down only occurs partially at the centers of some volute cross sections.