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CentrifugalCompressors
Configuration Working BladeTypes
AxialFlowCompressors
Configuration BasicOperation
Efficiency CentrifugalCompressorPerformanceCurve
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
CentrifugalCompressors AxialFlowCompressors
LossesinCompressors Centrifugalcompressorsvs.AxialFlowCompressors
AdvantagesofAxialFlowCompressors AdvantagesofCentrifugalCompressors
Machinetoraisepressureofafluid Usesseveralenergytransformations
1. 2. 3.
Energyinputs:electricity,highpressuresteam,fuel
oil,compressedair,etc.
StaticElevation
Friction
3.
Pressure
4.
Velocity
Compressors - Classification
A. PrincipleofEnergyAddition 1. Kinetic
2.
PositiveDisplacement
Compressors -Classification
B. HowEnergyAdditionisAccomplished
C. GeometryUsed
Centrifugal Compressor
Rotating Impeller
II.
VoluteCasing:Singlecutwaterwhereflowis separated.Flowmovingaroundvolutecasing producesnetradialforcethatmustbecarriedby shaft&radialbearingsystem.Doubleortwin compressorvolutesproducenearradialsymmetry& balancethehydraulicradialloadsonpumpshaft DiffuserCasing:Morecomplexcasingarrangement consistingofmultipleflowpaths.Liquidentersthe nearestflowchannelinthecasing.Multiple cutwatersarethere,evenlyspacedaroundthe impeller.
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
AdvantageofDiffusercasing:Resultsinnearbalancingof
VELOCITY&PRESSURELEVELSOFFLUIDINA CENTRIFUGALPUMP
PRESSURE
VELOCITY
SUCTION
FLOWPATH
DISCHARGE
Therearethreeimpellervanetypesdefinedaccordingtothe exitbladeangles(DischargeVaneAngles) Impellerswithexitbladeangleequalto90degreesareradial vanes Impellerswithexitbladeanglelessthan90degreesare backwardcurvedor backwardswept Vaneswithexitbladeanglegreaterthan90degreesare knownasforwardsweptvanes Theforwardcurvedbladehasthehighesttheoreticalhead. Radialvanesrepresentacompromisebetweenmaxpressure ratio,maxefficiency&size
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
HEAD
RADIAL
BACKWARDCURVED
FLOWRATE
ratio onasingleshaft. Theenergytransferinasinglestageisverylimited (stagepressureratioofabout1.2) Buteaseofcombiningaxialflowstagesleadsto pressureratiosofupto6/1orevenhigher Thusaxialflowcompressorisconsideredasconsisting ofmanystages Singlestageisconsideredasafan Formostaircraft&industrialgasturbine,axialflow compressorisusedinpreferencetoradialflowtype
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Workingfluidinitiallyacceleratedbyrotorblades,then deceleratedinstatorbladeswherekineticenergy transferredinrotorisconvertedtostaticpressure Manystagesnecessaryforrequiredoverallpressureratio Flowalwayssubjecttoadversepressuregradient Processconsistsofseriesofdiffusionsinbothrotor& statorbladepassages Carefuldesignofcompressorbladingnecessarytoprevent wastefullossesandminimizestalling Flowreversalsmayoccuratmassflowconditionsdifferent frombladedesignconditions
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Efficiency
Isentropicefficiencyisratioofidealspecificwork
input,ortotalTrise,forgivenpressureratiotoactual Definitionofisentropicisadiabatic+reversible TotalTrise&powerinputtosustaingivenPratiois proportionaltoinlettotaltemperature Polytropicefficiency isisentropicefficiencyofan infinitesimallysmallcompressionstep,suchthatits magnitudeisconstantthroughout Isentropicefficiencyfallsaspressureratioisincreased forsamepolytropicefficiency
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Efficiency
Isentropic efficiency c c = (T03s T01)/(T03 T01)
zero.Itcorrespondstocentrifugalpressurehead producedbyactionofimpellerontheairtrapped betweenthevanes. AtpointB,efficiencyandpressureratioapproach maximumvalue.Furtherincreaseinmassflowwill resultinfallofpressureratio. Formassflowsgreatlyinexcessofdesignmassflow, airangleswillbewidelydifferentfromvaneangles leadingtobreakawayofair&fallinefficiency. Thepressureratiodropstounityat'C',whenthe valveisfullyopenandallthepowerisabsorbedin overcominginternalfrictionalresistances
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
between'A'and'B'couldnotbeobtainedduetoSurging. Surgingisassociatedwithsuddendropindeliverypressure& withviolentaerodynamicpulsationwhichistransmitted throughoutthemachine ForanyoperatingpointD onthepartofcharacteristicscurve havingapositiveslope,adecreaseinmassflowwillbe accompaniedbyafallindeliverypressure. Ifthepressureoftheairdownstreamofthecompressordoes notfallquicklyenough,theairwilltendtoreverseitsdirection andwillflowbackinthedirectionoftheresultingpressure gradient. Whenthisoccurs,thepressureratiodropsrapidlycausinga furtherdropinmassflowuntilthepoint'A'isreached,where themassflowiszero.
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
flowisretardedbyfrictionalforcesnearthevanes Tendencytosurgeincreaseswithnumberofdiffuser vanes Severaldiffuserchannelstoeveryimpellerchannel tendencyforairtoflowuponechannel&downanother (conditionsconducivetosurging) Onlyinonepairofchannelsthedeliverypressurewillfall &increaselikelihoodofsurging Thusnumberofdiffuservanesislessthanno.ofimpeller vanes Surgingisthennotlikelytooccur
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Itisanotherimportantcauseofinstability&poor performancewhichcanexistinthenominallystable operatingrange. A,B&Carethreeconsecutiveflowchannels Whenthereisnonuniformityinfloworgeometryof channelsbetweenvanesorblades,breakdowncanoccur inonechannel(saychannelB) AirdeflectsinsuchawaythatCreceivesfluidatreduced incidence&Aatincreasedincidence ChannelAstallswhichreducesincidenceinBenabling flowinthatchanneltorecover Rotatingstallmayleadtoaerodynamicallyinduced vibrationsleadingtofatiguefailuresinotherparts
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Thereisanadditionallimitationtotheoperatingrange, between'B'and'C'.Asthemassflowincreasesandthe pressuredecreases,thedensityisreducedandtheradial componentofvelocitymustincrease. Atconstantrotationalspeedthismeansanincreasein resultantvelocityandhenceanangleofincidenceatthe diffuservaneleadingedge. Atsomepointsay'E',thepositionisreachedwhereno furtherincreaseinmassflowcanbeobtainednomatter howwideopenthecontrolvalveis CHOKING Thispointrepresentsthemaximumdeliveryobtainableat theparticularrotationalspeedforwhichthecurveis drawn.
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
UnderidealconditionswhirlcomponentofV2 isequalto theimpellertipspeedU Duetoinertia,airtrappedbetweentheimpellervanes doesntmoveroundwiththeimpeller. Thisresultsinahigherstaticpressureattheleadingface thanthetrailingface. SlipFactor, takesintoaccountthiseffect; =Vw2/U Awidelyusedexpressionfor suggestedbyStanitzwhich isthemostsuitabletoradialvanedimpellers =1 (0.63/n) wherenisnumberofvanes
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Theoreticalworkdone:U2 Duetofrictionbetweencasingandaircarriedroundby thevanesandotherlosseslikewindage,actualwork inputisgreaterthantheoretical Powerinputfactor takesthisintoaccount actualworkdone=U2 Typicalvaluesfor liebetween1.035 1.04 StagnationTemperaturerepresentsthetotalenergyheld bythefluid. Noenergyisaddedinthediffuser,so,stagnation temperatureriseacrosstheimpelleristhatequaltothe wholecompressor.
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
inaxialdirection CombiningV1 vectoriallywithbladespeedU givesvelocityrelativetobladeVr1 atangle1 FluidleavesrotorwithrelativevelocityVr2 at angle2 Airleavingrotoratangle2 thenpassestostator whereitisdiffusedtovelocityV3 atanangle3 Typicaldesignissuchthat V3 =V1 &3=1
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
U/Vf =tan1 +tan1 U/Vf =tan2 +tan2 Powerinputisgivenby W=mcp(T02 T01) &W=mU(Vw2 Vw1) Theexpressioncanbeputintermsofvelocity&air anglestogive W=mUVf(tan2 tan1) orW=mUVf(tan1 tan2)
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Mustbesettomaximizeefficiencybyoptimisingspecific speed,keepingotherparameterswithintargetlevels Highestpressureratiofromasinglestageis9:1,andfrom twostages15:1 Owingtoductingdifficulties,unusualtousemorethan twocentrifugalstagesinseries Formaxefficiency,backsweepangleof40o ispractical Howeverthisresultsinincreaseddiameterforgivenmass flow&pressureratio
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
4. Pressureratio&no.ofstages
5. Backsweep
RimSpeed
Exducerrimspeedshouldnotexceedaround500m/s for aluminium&625m/sfortitanium
7.
ExducerHeight
Initiallysettoachievetargetrelativevelocityratiofrom inducertiptoexitof0.50.6 Thisshouldbeideallyoptimizedbyrigtesting
8.
ExitMachnumber&SwirlAngle
Wherebend&axialstraightenersareemployed,exitmach no.&swirlanglemustbelessthan0.2&10o Ifbend&axialstraightenersarenotemployed,swirlangle willbeoforderof50o
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
MeaninletMachnumber
Commonvaluesliebetween0.4 &0.6 Highestlevelforaeroenginesinsupersonicapplications
2.
TipRelativeMachnumber
Thehighesttiprelativemachno.willoccuronthefirststage Inletabsolutegasvelocitywillusuallybeaxial&maybe consideredconstantacrosstheannulus Conservative&ambitiousdesignlevelsare0.9 &1.3 Thelatterrequireshighdiffusionrelativetobladetoachieve subsonicconditions,whichincreasespressurelosses
3.
StageLoading
Measureofhowmuchworkisdemandedofthecompressoror stage Itistheenthalpyincreaseperunitmassflowofair,dividedby bladespeedsquared(Dimensionless)
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Pressureratio&numberofstages
Achievablepressureratioforgivenno.ofstagesgoverned
HadeAngle
Angleoftheinnerorouterannuluslinetotheaxial Ahadeangleofupto10o ,butpreferablylessthan50 maybe
usedforouterannulus Innerannuluslineangleshouldbekepttolessthan10o
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
AxialVelocity&AxialVelocityRatio
Axialvelocityratioistheaxialvelocitydividedbyblade speedonthepitchline Axialcomponentofvelocityisnormallykeptconstant throughoutthecompressor Axialvelocityratioisnormallybtw0.5 &0.75
7.
AspectRatio
Definedasheightdividedbyvaneorbladechord Typicaldesignlevelsare1.5 3.5
8.
ExitMachnumber&SwirlAngle
Mustbeminimizedtopreventdownstreampressureloss Machno.shouldntbehigherthan0.35 (ideally0.25) Exitswirlangleshouldbelessthan10O (ideally0)
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Losses in Compressors
FrictionalLosses
Majorportionofthelossesisduetofluidfrictioninstationaryand
Duringtheoffdesignconditions,thedirectionofrelativevelocityof
Losses in Compressors
Thisissometimesreferredtoasshocklosses. However,thewordshockinthiscontextshouldnotbe
confusedwiththeaerodynamicsenseofshock
Clearanceandleakagelosses
Certainminimumclearancesarenecessarybetweenthe
Losses in Compressors
Theleakagelossescompriseasmallfractionofthetotal loss. Theincidencelossesattaintheminimumvalueatthe designedmassflowrate. Theshocklossesarezeroatthedesignedflowrate. However,Incidencelossescomprisebothshocklossesand impellerentrylossduetoachangeinthedirectionoffluid flowfromaxialtoradialdirectioninthevanelessspace beforeenteringtheimpellerblades. Theimpellerentrylossisverysmallcomparedtoother losses. Thisiswhytheincidencelossesshowanonzerominimum valueatthedesignedflowrate.
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
ratio.Forex.atpressureratioof5:1,axialcompressor diameterwouldbehalfofcentrifugal Weightislessbecauseoflowerenginediameter Formassflowrates>5kg/s,axialflowcompressor hasgreaterisentropicefficiency Magnitudeofaboveadvantageincreaseswithmass flowrate Owingtomanufacturingdifficultiesthereispractical upperlimitofaround0.8mondiameterofcentrifugal impeller,hencemassflow&pressureratiocapability
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
compressorthismaytakebetweensixtotwelvestages Centrifugalcompressorsaresignificantlylowerinunitcostfor same massflowrate&pressureratio Atmassflowrates<5kg/sisentropicefficiencyisbetter,asinthis flowrangeaxialflowcompressorefficiencydropsrapidlyassizeis reducedduetoincreasinglevelsoftipclearance,bladeleading & trailingedgethicknesses Centrifugalcompressorissignificantlyshorterforgivenmassflow.This advantageincreaseswithpressureratio Exitmachno.willbelowerincentrifugalcompressor,hencereducing pressurelossesinthedownstreamduct CentrifugalcompressorsarelesspronetoForeignobjectdamage
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
weight&highefficiencyareessential Axialflowcompressorsaretheonlychoiceatlargesizes Centrifugalcompressorsdominatewhereunitcostis paramount,andatsmallsize. Thereasonforhighefficiencyinaxialcompressors:Thegas experienceslessdrasticchangesofdirectionasitprogresses throughthestagesofanaxialmachine. Thegeneralflowpathinanaxialcompressorisina predominantlyaxialdirection,withminorperturbationsthrough eachbladerow. Inthecentrifugalcompressor,therearetwo180degreesturns ineachstage,inadditiontoaspiralshapedpathintheradial planeofeachimpeller.Theshorter,straighterflowpathofthe axialresultsinlowerturbulenceandturninglosses
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
Summary
Compressorsaremachineswhichraisethepressureofafluid
usingvariousenergytransformations InCentrifugalCompressorspressurizationisachievedbythe actionofarotatingimpellerandsubsequentconversionof kineticenergyinstaticpressureheadinthediffuser. InAxialcompressors,pressureratioisachievedbypassingthe fluidthroughstagesofrotors&stators Optimumvaluesofsizingparametersforbothcentrifugaland axialflowcompressorswerediscussed Frictional,IncidenceandClearance&LeakageLossesfor compressorswerediscussed Bothcentrifugal&axialcompressorshavetheirownadvantages &limitationswhencomparedagainsteachother
FLOW THROUGH CENTRIFUGAL & AXIAL FLOW COMPRESSORS
References
GasTurbineTheory byH.I.H.Saravanamuttoo,G.F.C.
Acknowledgements
Iwouldliketoexpressmygratitude