Compressor Stage Research Articles

Advanced methods for assessing flow physics of the TU Darmstadt compressor stage: Uncertainty quantification of RANS turbulence modeling

Abstract In this paper we quantify the turbulence modeling uncertainty for the transonic TU Darmstadt (TUDa) compressor. The present work applies the Eigenspace Perturbation Framework (EPF), as it is the only published physics-based framework capable of addressing the model-form uncertainty in turbulence closure modeling. To sample from the possible solution space and obtain the modeling uncertainty, we perform simulations perturbing the eigenvalues of the Reynolds stress tensor in addition to simulations using an unperturbed turbulence model. We show, that the shape of the Reynolds stress tensor ellipsoid has significant impact on the evolution of turbulence, flow separation, vortex systems, shock-boundary layer interaction and finally the overall performance of the compressor. We compare the estimated uncertainties with available measurements and transitional Delayed Detached-Eddy Simulations (DDES). This allows us to assess the confidence of the chosen turbulence model and to evaluate the sharpness and coverage of the resulting uncertainty bounds. Thus, the EPF is comprehensively validated and suggestions for its future applicability with respect to turbomachinery components are made.

Effect of tip injection on performance of highly loaded helium compressor in high-temperature gas-cooled reactor

As one of the representatives of the fourth-generation advanced nuclear reactor, the continuous development and application of high-temperature gas-cooled reactor (HTGR) technology has promoted the technical progress of the whole nuclear energy field. Helium compressor is one of the core components of HTGR. The highly loaded helium compressor effectively solves the disadvantages of the low single-stage pressure ratio and numerous stages of the traditional helium compressor. But it also brings a more complex tip-leakage flow. Tip injection, which is an active control method, can effectively control the tip clearance leakage and inhibit the development of the leakage vortex. This paper analyses the effects of axial deflection angle and injection pitch angle on the rotor performance of a highly loaded helium compressor via numerical simulation and validates them via experiment. Results show that the leakage vortex can be blown to the pressure surface of the adjacent blade by proper axial deflection angle to reduce the vorticity of the leakage vortex. The injection pitch angle directly affects the intensity of the leakage vortex during its initiation and development. When the axial deflection angle is 60° and the injection pitch angle is 20°, the adiabatic compression efficiency and total pressure ratio increase by 0.554 % and 0.160 % respectively under the design condition, and by 0.822 % and 0.162 % respectively under near-stall conditions.

Design and Stability Study of a Distortion-Tolerant Axial Compressor Based on an Alternating Stator Layout

To effectively suppress flow separation in the corner regions of a compressor, improve aerodynamic performance, and enhance distortion tolerance, this study focuses on a single-stage high-load transonic axial flow compressor and introduces a novel and effective unconventional stator design known as an alternating stator (AS) vane layout. This study examines the relationship between the AS layout and the flow separation in the corner regions from a fluid dynamics perspective and investigates the enhancement effects of different AS designs on the compressor's aerodynamic performance and stability margin (SM). Numerical investigations indicate that the alternating layout scheme, which is developed by locally adjusting the inlet geometric angle of the stator vanes, can effectively improve the aerodynamic performance and stability of the compressor. Compared to the original compressor design, the scheme with a 12° adjustment in the blade tip's geometric angle significantly increases both the total pressure ratio and efficiency. This scheme also enhances the SM by 34.69%. With this alternating layout, the novel stator arrangement induces differentiation in the flow field structure among adjacent passages. Internally, an alternating separation forms at the top and root corner regions of the adjacent stator passages, effectively preventing extensive flow separation from occurring at the top or root corner regions of the compressor and thereby delaying a compressor stall. When this design is applied to the compressor stage with inlet distortion conditions, the AS scheme with a 12° adjustment in the blade tip's geometric angle effectively improves the compressor's aerodynamic performance and distortion tolerance and holds significant potential for expanding the stable operating range of the compressor with inlet distortion conditions. Relative to the original design, the SM of the AS compressor can be increased by 83.09%.

Examination of a Surge Suppression System Designed for a Centrifugal Compressor System

Centrifugal compressors are used in many areas of industry, for example from natural gas transportation to superchargers of internal combustion engines and compressor stages of aircraft engines to the air compression equipment of the rapidly expanding fuel cell powered systems. With regards to each field of usage of compressors, reliable operation is an important criteria for the operation of the compressor, in addition for ensuring a continuous and adequate medium supply. This process is easier to implement if the equipment is used in terrestrial applications, where these engines can be operated in closely stationary conditions, because there isn’t any sudden change in environmental parameters, so these engines could be well optimized by their geometrical design for reaching its maximum efficiency. In vehicle industry, but especially in the case of aerial applications, the task is much more complicated, because the operation of the compressor is determined by the current operating states of the engine, but here at least the conditions of the air supply are almost the same. In the case of aircraft, the operation of the compressor is determined not only by the current operating state of the gas turbine engine, but also by the attitude of the aircraft. For this reason it is necessary to investigate the unstable operating conditions of centrifugal compressors and to develop equipment which is suitable for eliminating these affects.

On Intake–Compressor Interactions Within an Integrated Propulsion System

Abstract The integration of a propulsion system into the airframe can contribute to the overall aircraft performance and is beneficial for military applications due to a reduction of the aircraft radar cross section. On the other hand, engine integration calls for serpentine engine intake systems in which generally combined pressure-swirl distortions are provoked, which affect the performance of the propulsion system. The military engine intake research duct was designed to provoke a large-scale flow separation as well as a combined pressure-swirl distortion. The serpentine research duct is tested in both a remote- and close-coupled setup with the Larzac 04 turbofan engine to assess the aerodynamic interactions between the flow within the intake duct and the compression system. The upstream effect of the compression system on the steady-state duct flow is within the range of expectations. Less is known from the open literature with regard to the unsteady character of the flow in such a setup. Three distinct unsteady flow phenomena caused by the serpentine shape of the duct are identified up- and downstream of the low pressure compressor in the remote-coupled setup. An additional distinct low frequency unsteadiness is provoked with a configuration which features vortex generators for flow control. All phenomena are largely attenuated by the upstream effect of the compressor in the close-coupled setup. Nonetheless, the surge margin is massively reduced due to the inflow distortion and stall cells within the first stage of the low pressure compressor are visualized at high thrust settings of both the remote- and close-coupled setup, which are expected to impact the durability of the compression system.

Development and Assessment of a Miniaturized Test Rig for Evaluating Noise Reduction in Serrated Blades Under Turbulent Flow Conditions

The implementation of serrated stator blades in axial compressor and fan stages offers significant advantages, such as enhanced performance and reduced noise levels, making it a practical and cost-effective solution. This study explores the impact of serrated blade design on noise reduction under specific engine operating conditions. A small-scale experimental test setup with a turbulence-inducing grid was designed for testing multiple grid sizes in order to identify the most promising configuration which replicates rotor–stator interaction. Numerical simulations and early experimental tests in an anechoic chamber using a four-blade cascade configuration at an airflow speed of 50 m/s revealed a small but notable noise reduction in the 1–6 kHz range for a partially matched grid–blade geometry. Serrated blades demonstrated an overall sound pressure level reduction of 1.5 dB and up to 12 dB in tonal noise, highlighting the potential of cascade configurations to improve acoustic performance in gas turbine applications.

Study Of Tandem Rotor Dual Wake Interaction With Downstream Stator Under Unsteady Numerical Approach

Abstract This paper highlights the intricate rotor-stator interaction between a tandem bladed rotor and a single-bladed stator in the light of unsteady numerical simulations. A low speed tandem bladed compressor stage has been conceptualized and experimentally validated against targeted performance goal. With the evident pressure rise capability of the tandem bladed compressor stage, it becomes obligatory to investigate the rotorstator interaction owing to its dominant effect on overall stage performance. The multi-passage rotor-stator unsteady simulations have been performed using blade transformation methods in ANSYS CFX. Due to the presence of two highly loaded rotor blades, the tandem rotor exhibits peculiar rotorstator interaction in terms of multiple wake impingement on the stator. Incorporating tandem blading on the rotor instead of the stator (which is more common) constricts the design envelope in terms of choice of blade axial overlap and percentage pitch. The variation of aerodynamic loading from hub to tip for both the rotor blades results in spanwise varying wake strength. The initially distinct wake structures merge resulting into a thicker wake. Additionally, the rotor blades are highly loaded in the tip region which results in the complex interaction between end-wall boundary layer and tip leakage flow. Cumulatively, these conditions constitute a challenging aerodynamic field for the downstream stator. The study focuses on the qualitative interaction between the rotor wakes and blockage with the downstream stator and put forwards some aspects of the tandem rotor-single stator stage design especially for core compressors of aero engine application.

Understanding the Flow Field in a Highly Loaded Tandem Compressor Cascade

Abstract Large flow turning in compressor cascades with single airfoils requires an effective control of the boundary layer growth under the diffusing flow. An alternative approach consists of distributing the loading over two subsequent airfoils, using a so-called tandem blade, to, in some measure, restart the boundary layer before flow separation occurs. It is, however, not always clear whether the benefits of the two-blade setup justify the additional manufacturing complexity. The present work explores the tandem blade concept using a gradient-based optimization method to produce an efficient, highly loaded compressor cascade blade directly. A comparison between two-dimensional single and tandem configurations is first presented to clarify the benefits of one over the other. The geometry is optimized for each concept using a gradient-based optimization technique to improve the pressure loss coefficient at multiple operating points for a given flow-turning constraint. While the optimized single and tandem blade designs have similar performance, the lower solidity of the latter provides a lighter compressor stage for the considered operating range. A three-dimensional tandem compressor cascade based on the two-dimensional study is then optimized to account for secondary flows. The aerodynamic performance and the operating range are assessed and compared, along with a study of the physical phenomena surrounding the tandem configuration. The resulting geometry presents similar non-conventional features observed during the two-dimensional study that exploits the flow mechanism of two-airfoil configurations.

Analysis of The Flow-Field Distorsions Induced by Pneumatic Pressure Probes In Test Bench Experiments On Centrifugal Compressors: Are We Testing Right?

Abstract Experimental testing at the test rig still plays a key role in the development of new centrifugal compressor designs for industrial applications. Although a wide set of different probes is used as per common practice, the overall impact of the probes? dimensions on the stage performance and rangeability is often assumed to be negligible. In this study, we aimed at quantifying the intrusiveness effects of pneumatic pressure probes on the flow-field inside a vaned diffuser using a model stage of an industrial centrifugal compressor, for which different experimental setups were tested at the University of Florence test rig. Performance and rangeability were initially assessed using a conventional set of pneumatic probes inserted in the flow path. Then, comparative analyses were realized through dedicated tests by either removing all probes at the diffuser inlet or introducing only a single pressure probe in the upstream section and varying its angular position in the measuring section. Experiments revealed an impact of upstream probes much higher than expected, with a decrease in efficiency and a substantial reduction of stall margin. Moving from this experimental evidence, accurate 3D CFD simulations of the entire stage were carried out including the actual geometry of the probes for two probes configurations and three operating points. Simulations highlighted the effect probes? wakes on downstream vanes and the induced blockage effect, which both appear in line with experimental evidence. As a handout, a recommendation on the optimal probe positioning is suggested.

Upgraded one-dimensional code for the design of a micro gas turbine mixed flow compressor stage with various crossover diffuser configurations

Abstract Micro Gas Turbine (MGT) designers often have the need for a design tool, capable of rapidly providing feasible design options. The upgrade of such an existing MATLAB® based mixed flow compressor design application (1D App) is discussed. In MGT engines, diffuser design largely influences the compressor stage performance. Crossover diffusers provide superior efficiency and pressure ratio performance compared to legacy type diffusers, albeit at the expense of operating range. The reduced operating range attributed to single vane crossover diffusers can be alleviated by splitter vane, tandem vane, and combined configurations. Therefore, the 1D App is updated to allow the user the ability to design these additional crossover diffuser configurations. Performance results are verified using Numeca/FINE™ Turbo CFD software. It is shown that the upgraded 1D App provides predicted performance results within 1 % of CFD results for both total-to-total efficiency and pressure ratio.

Uncertainty quantification based on active subspace dimensionality-reduction method for high-dimensional geometric deviations of compressors

Compressors are inevitably exposed to diverse geometric deviations from manufacturing errors and in-service degradation. Consequently, the evaluation of performance uncertainties becomes of utmost importance for compressors in engineering application. However, the presence of high-dimensional and strongly nonlinear geometric deviations poses significant challenges in efficiently and accurately assessing the performance uncertainties of compressors. This study proposes an active subspace-based dimensionality-reduction method for high-dimensional uncertainty quantification (UQ) of compressors. Based on the active subspace (AS) method, a dimensionality-reduction high-precision artificial neural network is raised to solve the dimension disaster problem for high-dimensional UQ. Additionally, a data-driven approach is used to calculate the gradient of the quantity of interest, addressing the issue of high computational cost during the AS dimensionality reduction process. Furthermore, the Shapley method is applied to explore the influence mechanism of geometric uncertainties on performance deviations of compressors. The UQ of one transonic compressor stage at design point and near stall point is conducted by the proposed method. The findings show that the original 24-dimensional uncertainties are reduced to three-dimensional uncertainties by using this method. Consequently, the required sample size is reduced by 75% while maintaining almost unchanged model accuracy. The findings reveal that the sweep and stagger deviation of the rotor are key uncertainties on the performance of the compressor. The dispersion in efficiency is attributed to variations in shock wave position and intensity, while the dispersion in total pressure ratio is primarily affected by changes in rotor work capacity. Moreover, the dispersion at near stall is 50% higher than that at design point. Therefore, when studying UQ, it is important to pay closer attention to the performance dispersion at near stall conditions.

Insights Into Turbocharger Centrifugal Compressor Stability Using High-Fidelity CFD and a Novel Impeller Diffusion Factor

Abstract Turbocharger technologies are widely applied in the modern automotive industry to meet increasingly stringent carbon emission standards. To support the continuous enhancement of these tactics, delivering improvement to the performance and stability of turbocharger compressors at low mass flow rate regimes is of paramount importance. The present paper investigated the stability of a turbocharger compressor stage equipped with a ported shroud, using high-fidelity CFD simulations. It was found that the recirculated flow passing through the ported shroud device had primary influence on the flow condition in the vicinity of the impeller tip region (80% to 100% span). This discovery facilitated the definition of a modified impeller diffusion factor (DF), which was applied to the CFD results for three different compressor geometry configurations to lead to the provision of quantitative metrics for impeller stability. Furthermore, the observed change in the limiting impeller DF along the compressor surge line indicated that the dominant components governing the instability of the entire stage had switched, i.e., the stalling behavior of the compressor stage had transitioned from impeller dominated stall to vaneless diffuser dominated stall. Additionally, the limiting impeller DF clearly showed that one of the compressor configurations with a change in the hub endwall recess around the rear of the impeller improved the impeller stability by 3%. By comparison, another configuration with a change to strut geometry in the ported shroud recirculation channel reduced the impeller stability by 10%.

Modelling carbon capture from power plants with low energy and water consumption using a novel cryogenic technology

Global warming mitigation requires modern energy generation technology to integrate low-cost carbon capture techniques. Despite volumes of research on the latter, the significantly high unit energy (MWh) of capture and high water consumption, do not enable any current carbon capture techniques to be adopted at a scale. To address this problem, we theoretically explore a novel low-cost carbon capture technology (NLCCT). In this paper, a detailed thermodynamic analysis of the effects of the operating conditions and parameters of NLCCT, such as the initial feed gas concentration, compressor intercooler temperature, number of compressor stages, efficiencies of the compressors, and turbines, ambient temperatures on the energy consumption for CO2 capture (ECC) is carried out with a view to obtain costs much lower than current techniques. The study identifies the inlet feed concentration, turbine and compressor efficiencies, and compressor intercooler temperatures (heat transfer effectiveness) as the significant parameters. For a drop of 20 % efficiency, the ECC was found to increase by 40 %, and for an increase in inlet CO2 feed concentration from 4 % to 10 %, the ECC was found to decrease by 31 %. Considering the effect of intercooler temperatures, the ECC increases by 25 % when the intercooler temperature is raised by 6 K. The effect of ambient conditions was also analyzed and observed that for an increase of 27C in the ambient temperature, the ECC would rise by 15 %.

Improving near-stall performance of axial flow compressors using variable rotor tandem stage. A steady analysis

This paper investigates the idea of substituting the first stage of a conventional axial-flow compressor and its inlet guide vane (IGV) row with a variable rotor tandem (VRT) stage to reduce the size and weight of axial-flow compressors. It is expected that a tandem stage gains higher pressure ratio than a conventional stage, and simultaneously, its variable stagger rotor provides more flexibility in handling unsteady phenomena at low mass flow rates. A three-dimensional numerical model based on Reynolds-Averaged Navier–Stokes equations is developed to conduct this investigation. To validate the numerical model, experimental tests are conducted on a tandem single-stage axial-flow compressor test bench in the Dana laboratory of Amirkabir University of Technology, to compare the performance map with numerical results. The validated numerical model is then employed to simulate the performance of both front and aft variable rotor blades. The proposed tandem stage effectively performs the IGV duty, suppresses instabilities at low mass flow rates, and eventually extends the compressor's stable operational range. This proves that a VRT stage is an efficient active surge-control system tool. The detailed survey of the three-dimensional flow field reveals that the aft tandem rotor blade stagger angle is more effective in increasing the stall margin and decreasing the minimum operational mass flow rate than the front row of blades. It is observed that when the aft blades rotate in the direction of decreasing the tandem blades' gap area, the flow momentum increases and causes the compressor stability at lower mass flow rates.

Investigation of mechanisms on leading edge vortex generation and suppression in vaned diffuser of a centrifugal compressor

This study numerically investigates the mechanisms for generating and suppressing the leading edge vortex (LEV) in a vaned diffuser of a centrifugal compressor, aiming to enhance the compressor's stable operating range. Detailed analyses focus on the mechanisms of the rotating stall and the initiation process of the LEV. Notably, the end wall contouring method is applied to vaned diffuser to suppress the LEV and improve diffuser stability. The suppression mechanisms of the LEV are examined to deepen the understanding of stability enhancement mechanisms. Results demonstrate that, under stall conditions, the vaned diffuser experiences two-cell rotating stalls moving opposite to the impeller rotation direction, each rotating at approximately 12% of impeller rotation speed. The formation of diffuser stall is attributed to a longitudinal vortex developing from the LEV and causing the passage blockage. The increasing spanwise distortion of leading edge (LE) incidence angles and circumferential distortion of static pressures at the diffuser inlet promote the evolution of the longitudinal vortex from LEV. The end wall contouring of vaned diffuser effectively enhances the compressor's stable operating range by 15.10% and 8.90% toward lower flow rate conditions for machine Mach numbers 1.3 and 1.2, respectively. At near-stall points, the end wall contoured diffuser reduces spanwise distortion of LE incidence angles and circumferential distortion of static pressures at the diffuser inlet, mitigates the LE flow separation and corner separation, suppresses the generation and development of the LEV, delays the onset of rotating stall in vaned diffuser, and thereby improves the stable operating range of centrifugal compressor stage.

Research on Effect of Endwall Contouring of Vaned Diffuser on Stable Operating Range of Centrifugal Compressor

Abstract The study investigates the impact of diverse endwall contouring strategies on the operational stability of a high-pressure ratio centrifugal compressor stage. Employing numerical simulation techniques, this study examines the implications of contoured wall positions, specifically convex profiles at the pressure side and/or concave profiles at the suction side, as well as asymmetric endwall contouring, on both stage performance and internal flow field within the centrifugal compressor. And the stability enhancement mechanism of endwall contouring is clarified. The results demonstrate that employing full circular contoured vaned diffusers on the hub-side wall can achieve a maximum improvement in stall margin of 15.10%. Additionally, the diffuser featuring solely convex profiles at the pressure side on the hub-side wall exhibits an augmented stall margin by 8.39%, with a reduction in performance loss at low flow rate conditions. The asymmetric endwall contouring improves stall margin by 8.39%, and mitigates the performance loss across the entire operating range. At the near-stall point, the contoured endwalls redirect fluid towards the suction side, thereby mitigating the incidence at the vane leading edge and attenuating the interaction between the impeller trailing edge vortex and the diffuser leading edge vortex. Moreover, concave profiles serve to accelerate the fluid on the suction side along the flow direction, thereby suppressing the corner separation and weakening passage blockages. Simultaneously, the advantages of endwall contouring in vane diffusers extend to the improvement in the circumferential non-uniformity of flow fields and the enhancement in diffuser stability.

Investigation of vaned diffuser endwall contouring technology for improving the stable operating range of a centrifugal compressor with an asymmetric volute

AbstractIn this study, nonaxisymmetric endwall contouring technology is employed as a passive control strategy to enhance the stable operating range of a centrifugal compressor with an asymmetric volute. The endwall contouring method is applied to the hub‐side wall of the vaned diffuser within a centrifugal compressor stage. Instead of utilizing a flat hub as the baseline diffuser, various diffuser configurations featuring hub‐side contoured endwalls are explored, with adjustments in the peak radial position and peak height of the convex and concave profiles. Numerical simulations are conducted to evaluate the performance of the centrifugal compressor stage with both the baseline and contoured vaned diffusers. The investigation explores the underlying flow control mechanisms and establishes the effective endwall contouring guidelines. The findings highlight the effectiveness of endwall contouring in enhancing the stable operating range of centrifugal compressors. Notably, a substantial enhancement of 15.1% in the stable operating range is achieved by employing the contoured diffuser with the peak radial position near the vane leading edge (LE) and the peak height at 20% of the vane height. The endwall contoured diffusers reduce the positive LE incidence angles to direct the fluid toward the suction side (SS), and increase the radial velocity near the SS to suppress the hub‐suction corner separations in the diffuser passages near the volute tongue. These improvements collectively contribute to the enhancement of diffuser flow characteristics. Finally, a set of effective endwall contouring guidelines is proposed to guide the endwall contouring design for enhancing the stable operating range of centrifugal compressors.

Numerical investigation of the potential of multi-row optimization of an axial compressor stage with a tandem vane stator

Numerical investigation of the potential of multi-row optimization of an axial compressor stage with a tandem vane stator

Experimental and Full-Annulus Simulation Analysis of the Rotating Stall in a Centrifugal Compressor Stage with a Vaned Diffuser

Experimental and Full-Annulus Simulation Analysis of the Rotating Stall in a Centrifugal Compressor Stage with a Vaned Diffuser

Sensitivity analysis and robust optimization to high-dimensional uncertainties of compressors with active subspace method

The performance of compressors often deviates significantly from the design value due to the substantial geometric deviations arising from manufacturing errors and in-service degradation. Robust design optimization (RDO) plays a crucial role in ensuring the high performance and reliability of compressors. The study proposes an active subspace-based dimensionality-reduction RDO method for high-dimensional uncertainties of compressors. By employing the active subspace (AS) method, a dimensionality-reduction artificial neural network (ANN) is raised to solve the "dimension disaster" problem for high-dimensional uncertainty quantification (UQ) analysis. Additionally, to decrease the computation cost of the original AS method, a data-driven method is utilized to calculate the gradient of the quantity of interest (QoI) within the AS dimensionality-reduction framework. Furthermore, Shapley method is applied to study the sensitivity of geometric variables and their variation direction on the mean and variance of the performance, and the robustness improvement method by only modifying key geometric variables based on Shapley results is discussed. The RDO of high dimensional geometrical uncertainties of a transonic compressor stage is studied by using this method. The results demonstrate a reduction from the original 24-dimensional uncertainties to a 4-dimensional space, achieved through this method. Consequently, the required sample size is reduced by 75 % while maintaining nearly unchanged model accuracy. Furthermore, the findings reveal that after RDO, the mean efficiency increases by 1.04 %, with a 42 % reduction in variance. Compared to RDO, which requires simultaneous optimization of all 24 geometric variables, the robustness improvement based on Shapley only necessitates modifying 4 key geometric variables, resulting in a substantial increase in both the mean and variance of efficiency.