round off the number of stages to the nearest whole number, then recalculate the

pressure coefficient, , using

if the pressure coefficient just calculated is within 5 % of the original value of 0.29,
then proceed using the calculated pressure coefficient and the assumed value of
mean blade velocity as the final value. Continue to the speed calculation. If the
pressure coefficient is higher than 5 %. add an additional stage to the compressor
and again calculate the pressure coefficient using Equation 6.16.
If the pressure coefficient is now, or was in an earlier step, 5 % under the 0.29
value, calculate a new mean blade velocity using the rounded-off number of stages
and the original pressure coefficient, 0.29. Use the calculated blade velocity in the
subsequent step for compressor speed.
Calculated the speed
In order to calculate the speed, a mean blade diameter must be established, and to
calculate the mean diameter, a tip diameter is needed. The first step is to calculate
the tip diameter.
where
tip diameter, inches
hub diameter, inches
inlet flow, cfm
mean blade velocity, fps
then calculate a mean diameter, in inches:
before proceeding, make sure the hub tip ratio is within the minimum limit of 0.67.
If satisfactory, continue with the speed calculation. If the value is unsatisfactory,
repeat the previous steps with an alternate frame choice:
where
shaft speed, rpm
the speed must not exceed the speed given in Figure 6-9 for the selected hub
diameter. Calculate the last stage volume using the following:
where
last stage inlet volume, cfm
pressure ratio across the compressor
isentropic compression exponent
Using Equation 6.16, calculate a stage tip diameter. Then check the hub tip ratio
against the maximum value, 0.9. If the value is greater, the last stage blading is
getting too short and probably the only solution is to use a smaller frame.
The guidelines presented are simplified and may not be sufficient for all
applications. This does not mean that an axial cannot be used, because the vendors
can perform a much more complex analysis and change factors that simplified chose
to hold constant. Undoing some of these values is probably beyond the score of
most of the users. The best way to interpret a potential application is that an extra
measure of care might be exercised when going out for bid. This can generate
additional questions concerning the vendor's proposal.
To complete the sizing, calculate the discharge temperature using the Equation 4.6
from Chapter 4.
where
discharge temperature, ºF
inlet absolute temperature, ºR
inlet temperature, ºF
adiabatic efficiency
Calculate the shaft horsepower, using Equation 4.7 from Chapter 4. Read the
mechanical losses from Figure 6-9
where
weight flow of the gas in the compressor, lb/min
total adiabatic head, ft-lb/lb
Example 6-1
Size an axial compressor for air service using the procedures outlined in the
chapter. The following conditions are given:
Molecular weight:
Isentropic exponent:
Compressibility:
Inlet temperature:
Inlet pressure:
Discharge pressure:
Weight flow:
Step 1. Use Equation 2.5 to calculate the specific gas constant.
R=
r=
Convert temperature to absolute.
Step 2. Substitute into Equation 2.10 and, using the conversion constant of 144
in2/ft2, calculate the inlet volume.
Select the frame size (hub diameter, dh) using Figure 6-9. At the inlet volume value,
a 44 frame is selected with a maximum speed of 3150 rpm.
This frame has a 44- inch hub diameter.
Step 3. To calculate the number of stages. the overall head is required. The head is
calculated using Equation 2.70 and rp=60/23=2.61 for the pressure ratio.
Then using Equation 6.12 and the pressure coefficient, =0.29 and um=720 fps
given in the chapter.
This value is rounded to the next whole number, 7. Recalculate using Equation 6.13
and the number of stages.
Since the is within 5% of the target value of 0.29, then use the mean blade
velocity, um=720 fps, as a final value and proceed with the sizing.
Step 4. Calculate the tip diameter using Equation 6.17.
Check the hub-to-tip ratio, dh/dt. If greater than 0.67, continue. If not, go back to
Step 2 and try another frame size.
This is greater than the stated limit, proceed to the next step.
Step 5. Calculate a mean diameter in preparation for calculating the compressors
speed. Use Equation 6.18.
Calculate the speed using Equation 6.18.
The speed just calculated is less than the maximum speed of 3150 given for the
frame and is therefore acceptable.
Sept 6. Calculate the last stage volume using Equation 6.20.

Using Equation 6.14 calculate the last stage tip diameter.

Check the last stage hub-to-tip ratio. It should be less than 0.9. If a problem is
encountered with meeting this ratio, select another frame. If one frame exceeds the
lower limit and the alternative choice exceeds the higher limit, multiple cases may
be needed. The casing passing the lower hub-to-tip limit of 0.67 should be selected,
except with the pressure ratio varied until the high limit of 0.9 can be met. The
balance of the compression could be compressor by the procedure outlined in
Chapter 5, the speed of the axial can be assumed to the centrifugal speed. This
would permit a charge temperature of the axial.
Calculate the last stage hub-to-tip ratio.
This value is less than the limit of 0.9. Proceed to the next step.
Step 7. Calculate the discharge temperature using the efficiency stated of 0.85 and
Equation 4.6.
Step 8. Calculate the shaft horsepower using Equation 4.7 and the mechanical
losses from Figure 6-9 at the frame selection. Use the efficiency =.85 as
recommended.
Application Notes
The axial compressor is a highly refined, sophisticated compressor. It is capable of
very high efficiency, to the point that some of the designers feel there is no area of
improvement left. As efficiency gets higher, the margin left between the ideal and
current design makes each point much more difficult to achieve. Most of the
development activity has centered on higher velocities, and the development of
cascade data at the higher Mach numbers. The development are more significant in
aircraft engines where power-to-weight (size) ratio has a greater impact. The
technology, however, is being applied to the land-based axial compressor. While the
cost is probably one of the more significant factors retarding the application growth.
The higher Mach number stages are more expensive to manufacture, somewhat
offsetting the savings of having fewer stages. Gas turbines seem to be using the
newer technologies as their size capabilities are increased.
Because the axial is a sophisticated compressor, it tends to chow its "blueblood" at
times, in lack of ability to cope with common plant problems such as fouling. The
sophisticated airfoils, while capable of such nice high efficiency performance, have a
real problem with dirt. It does not have to be polymers or other chemical reactions
of the kind that cause problem with the centrifugal, but rather it can be ordinary
atmospheric air. Some of the tendency to foul be averted by changing the reaction
at the expense of efficiency. This has not been completely successful, however, due
to the complex modes in which fouling takes place. The best solution is filtration,
which is attended by an increase in inlet pressure drop. The filtration should be of
the dry type. Moisture, even a high humidity, can make whatever dirt does pass
through the filter stick to the blading. On-stream washing has been successful in
some cases, but must be carefully done and is somewhat of a trial-and-error
method, until an operable mode is established. An alternative to washing is the use
of organic abrasives. These have been reported as an effective and low-cost method
of cleaning up this type of build-up.
Larger axial compressors have a physical space problem with the inlet nozzle,
requiring a departure from the conventional round flanged nozzle customarily used
in centrifugal application. This means either custom engineered rectangular duct
work supplied by the user or an off-machine transition piece. For atmospheric
suction compressors, where the inlet is connected to a nearby filter housing, this is
not a serious problem.
Inlet startup have been recommended for other compressors covered in the earlier
chapters. If the point has not been made yet, it should be with the axial
compressors. Considering that most of the cost of the compressor is in the hundreds
of vulnerable blades just waiting to be hit by some foreign object, it should be
obvious that some protection is needed until the piping has been proven to be clear
and clean.