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The Effect of Variable Geometry on the

Operating Range and Surge Margin of a
Centrifugal Compressor

A. WHITFIELD

F. J. WALLACE

R. C. ATKEY

University of Bath,
Bath, England

Two variable geometry techniques have been applied to a small turbocharger compressor,
with the objective of trying to move the peak pressure ratio operating point to lower flow
rates, thereby yielding a broad flow range map. Variable prewhirl guide vanes and variable
vaneless diffuser passage height have been studied separately. The results obtained with
both techniques are compared and the relative merits and demerits with respect to improved
flow range and isentropic efficiency penalties are considered.

Contributed by the Gas Turbine Division of The American Society of Mechanical Engineers for
presentation at the Gas "turbine and Fluids Engineering Conference, New Orleans, La., March 21-25, 1976.
Manuscript received at ASME Headquarters December 22, 1976.

Copies will be available until December 1, 1976.

THE AMERICAN SOCIETY OP MECNAPHCAL ENGINEERS, UNITED gikildiktERING CENTER, 345 EAST 47th STREET, NEW YORK, N.Y. 10017

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 The Effect of Variable Geometry on the
Operating Range and Surge Margin of a
Centrifugal Compressor
A. WHITFIELD F. J. WALLACE
INTRODUCTION
Interest in high output, high boost turbo-
charged diesel engines, coupled with specific
operating requirements such as hi _h torque backup,
good emission characteristics including absence
of smoke under "lugging" and transient conditions,
and rapid turbocha : ger response to changes in
load has led to renewed interest in variable
geometry turbocharging, and most leading manu-
facturers have built machines incorporating means
of varying the swallowing capacity of turbines
and the flow range of compressors (1). 1
The maximum efficiency cf radial flow
centrifugal compressors usually occurs to close
to the surge line and the desirability to match
engine operation close to this peak efficiency can
lead to insufficient flow margin during transient
operation. Techniques to reduce the surge flow
limit without adversely affecting compressor
performance at the design point are clearly
desirable. Variable geometry devices meet this
requirement as they can remain inactive when
design point peak efficiency is required and be
used only when surge is imminent.
Flow instabilities in centrifugal compressors
have been studied extensively using experimental
techniques, but due to the difficulties involved,
particularly with respect to gathering data withir
the rotating impeller, knowledge remains somewhat
superficial. No adequate theoretical approach
exists to satisfactorily predict the onset of
compressor instabilities. Experimental data
indicates that surge is usually preceded by
rotating stall in the vaneless diffuser or in the
impeller (2, 3, 4). Zones of stable operation
and mild surge regions have also been observed
between the onset of rotating stall and violent
audible surge. It is not clear whether or not
1 combustion chamber was used the fuel supply had
Numbers in parentheses designate Refer-
ences at end of paper.
L
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R. C. ATKEY
the diffuser and impeller must both stall before
violent surge occurs, but the bulk of the evidence
indicates the diffuser as a prime cause of surge.
Jansen (4) suggests that surge will occur when the
absolute flow angle from the radial direction
exceeds 75 deg, while Dean (5) has observed flow
angles as high as 80 deg.
In order to reduce the flow rate at which
surge occurs, it is clear that stalling in the
diffuser and impeller must be delayed. An experi-
mental investigation has been conducted which
permitted the variation of vaneless diffuser
passage depth, and the use of impeller prewhirl.
Significant changes in the surge characteristics
can be obtained by the introduction of prewhirl
provided the vaneless diffuser is not operated
close to its stall limit. By reducing the vaneless
diffuser passage depth the through flow velocities
can be increased and the absolute flow angle from
the radial direction decreased thereby reducing
the tendency for the diffuser to stall.
EXPERIMENTAL RIG
The general rig arrangement used to perform
the compressor tests is illustrated in Fig. 1.
Air was supplied to the turbine from a large
receiver maintained at constant pressure. Suf-
ficient air was available for turbine speeds up
to 50,000 rpm. For high speeds a Rolls-Royce
"Dart" combustion chamber was used and the turbine
inlet temperature maintained at approximately 400
C. Turbocharger speed was controlled by regulating
the air supplied from the dome valve. This was
done by means of a small regulating valve which
supplied a known pressure to the valve dome; the
dome valve then maintained the downstream pressure
equal to the dome pressure. In addition when the
to be regulated with a high pressure bypass valve.
 WTI EARN F LCK.■
NIC71.1 VALVE ORIFICE
PR(:•sURE
AIR
SUPPLY GATE
DOME
VALVe DART
VALVE
TURBINE (0mDusT■ow

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PRESSURE FUEL Ey - PASS
PRESSURE

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PU MP
OIL SUPPLY
DRAIN
LARGE
AIR
O IL
RECEIVER FLOW
Sy- PASS ORIFICE
CONTROL
VALVES

COOLER

LUSRICATINCI
OIL TANK

FILTER OIL
PUMP

Fig. 1 Experimental rig arrangement

Table 1 Details of Standard Radial Flow Impeller

Inlet hub radius R lh 11.05 mm

Inlet shroud radius Rlsh 33 mm
Hub/shroud radius ratio Rih/ish ° ° 355
Discharge radius R 2 47 mm
Discharge passage depth b 2 7.62 mm
Blade angle at shroud inlet Plsh -61.5 deg
Blade angle at discharge 0 deg
/32B

In general the air and fuel supplied were adjusted

so that the required speed was attained with a
turbine inlet temperature of 400 C. For the case
of 70,000 rpm the turbine inlet temperature was
allowed to increase to 500 C. The overall
dimensions of the compressor impeller are given
in Table 1.
The compressor performance, stagnation
pressure ratio and isentropic efficiency as func-
tions of mass flow rate and impeller speed, were
obtained by progressively reducing the compressor
flow rate by means of a throttle valve located
downstream of the compressor, while maintaining
the rotational speed constant. Each constant
speed characteristic was investigated from the
choked condition until the flow rate had been Fig. 2 Prewhirl mechanism
reduced sufficiently for very violent surge to
occur.
The compressor rotational speed was measured
by means of an inductive transducer located suction and delivery lines were used for tempera-
eccentrically in the hub of the prewhirl mechanism, ture measurement, while water or mercury manometers
Fig. 2. Thermocouples located in the compressor were used to measure suction and delivery static

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 Table 2 Specification of Diffuser Designs

Diffuser Dimension Radius Ratio at Area Ratio Overall

A (Fig. 3) End of Contraction at End of Area Ratio
mm Contraction

Standard 6.6 1.0 1.0 1.52

1 3.8 1.0 1.o 0.98
A 5.3 1.1 0.4 1.2
B 4.1 1.1 0.311 0.933
C 2.8 1.1 0.222 0.666
X 5.3 1.25 0.8 45 1.2
Y 4.1 1.5 0.755 0.933
z 2.8 1.76 0,666 0.666

t. ...,-, *so

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DIFFUSERS A, B. C

DIFFUSERS X ,Y, Z
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ANGLES III
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Fig. 3 Comparison of diffuser designs used
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pressures. The air mass flow rate was measured Fig. 4(a) Performance map with flat plate guide
with a BS. 1042 flow orifice, and by means of the vanes
known suction and delivery pipe areas the air
velocities were calculated. These velocities were
combined with the measured static pressures to
yield suction and delivery stagnation pressure from effect of possible prewhirl types on compressor
which the pressure ratio and isentropic efficiency performance, particularly any effects on the
were obtained. magnitude of the impeller incidence loss. Three
types of prewhirl were investigated in detail,
The Prewhirl Guide Vanes free vortex, forced vortex, and constant whirl
Prior to the actual design of the prewhirl angle with radius. The analysis was based on the
guide vanes a study was conducted to assess the familiar radial equilibrium approach (References

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While this preliminary design study indicated 1,0 ( 1 I
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initial blade designs were untwisted giving a

constant whirl angle with radius. This design Fig. 5 Performance with diffusers X, Y, and Z
was selected for ease of construction and the
ability to generate no prewhirl when rotated into
the axial position. Two vane designs were used,
Seven
S designs were tested: the first, designated
the first was a simple flat plate and the second
diffuser 1, was designed to yield a constant
curved with a camber angle of 40 deg. The vane
flow
f area with radius. The remaining six were
adjustment mechanism, Fig. 2, was designed to
grouped into two sets of three, diffusers A, B,
permit blade rotation of 40 deg. With the flat
plate vanes the mechanism was set to permit movement C all converged to a radius ratio 1.1 beyond
which the area increased linearly with radius,
from -20 to +20 deg, with the curved cambered
Table 2. Diffusers X, Y, Z each had a constant
blades movement from -5 to +35 deg, measuring
across the chord. angle of convergence with the flow area increasing
linearly from differing radius ratios, with
diffuser Z converging throughout. The overall
Vaneless Diffuser Designs
area ratios of diffusers A, B, and C being
The standard diffuser design as supplied by
identical to those of diffusers X, Y, and Z
the manufacturers consisted of a radial rear wall
respectively. The diffuser designs are shown on
as part of the bearing housing, and a radial front
Fig. 3 and Table 2 gives the detailed specifica-
wall with some initial convergence, to a radius
Lion.
ratio of 1.08, as part of the collecting scroll.
This initial convergence was not sufficient to cause
PRESENTATION AND DISCUSSION OF RESULTS
a reduction in the flow area, the flow area
increased throughout the diffuser but nonlinearly
The experimental performance map obtained
with radius up to the radius ratio of 1.08.
The standard vaneless diffuser was modified with the flat plate prewhirl guide vanes is
by attaching annular plates to the back face. presented in Figs. 4(a) and 4(b). Fig. 4(a)

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Fig, 6 Performance map with constant area diffuser

presents the pressure ratio as function of flow obse_vea.

rate and prewhirl angle for four impeller non- The performance map obtained with vaneless
dimensional rotational speeds, correspohdinw to diffusers X, F , and Z for impeller rotational
50,000, 60,000, 70,000 and 75,000 rpm, Results speeds of 40,000 and t=:0,000 rpm is presented in
are given for zero prewhirl and 20 deg of positive Fig, results were obtained with
and negative prewhirl. The points located at the diffusers A, and C. Roth diffusers A and X,
minimum flow rate for each operating line are with an overall area ratio of 1., showed an
those corresponding to the onset of violent increase in pressure ratio and efficiency over tnat
surge. The lines indicating the limit of stable obtained with the standard diffuser. The progres-
operation were drawn approximately through the sive r_.:.uction in the diffuser flow area has moved
peak pressure ratio point at which an increase the peak ratio point and the onset of flow in-
in the operating noise occurred. At a stabilities, to reduced flow rates in similar
flow rate a little below that for a peak pressure manner to that achieved with prewhirl. There is,
a sharp increase in air noise occurred, this however, a progressive reduction in efficiency
generally increased in magnitude as the flow rate level as diffuser flow area is reduced.
was reduced until finally very violent surge After the improvement in performance obtained
occurred. At the two upper speeds, with 20 deg with diffusers A and X, diffuser 1 was designed
of negative prewhirl, two "quiet" operating to yield approximately a constant flow area,
regions were readily detected. As the flow rate overall area ratio 0.97. The performance achieved
was reduced beyond the peak pressure ratio point with this diffuser is presented in Figs, 6(a)
a sharp increase in the noise level could be and O(b). At the lower impeller rotational
detected and the pressure ratio decreased. This speeds the peak pressure is slightly increased
was followed, on further reduction of the flow and moved to reduced flow rates. At the upper
rate, by a rising pressure ratio characteristic speed of 70,000 rpm, not only is the peak
and "quiet" operation, and ultimately by a decline pressure ratio moved to reduced flow rates, the
into violent surge. point of violent surge is also moved to reduced
The isentropic efficiency for two impeller flow rates. The diffuser modification has,
nondimensional rotational speeds are shown in therefore, improved the stable operating range by
Fig, 4(b). The introduction of 20 deg of positive approximately 30 percent with no significant
prewhirl has led to only a small reduction in the reduction in pressure ratio or efficiency.
peak efficiency. However, with 20 deg of negative The effect of variable diffuser design
prewhirl a reduction in efficiency is more readily is compared with that of prewhirl in Figs. 7(a)

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Fig. 7 Comparison of effect of variable diffusers

and prewhirl

and 7(b). Diffuser C, area ratio 0.666 yielded tially reduced than by the introduction of posi-

approximately the same overall pressure ratio as tive prewhirl. In addition the application of
that achieved with 20 deg of prewhirl applied to prewhirl to the constant area diffuser, diffuser 1,
the standard design. has led to an overall improvement of performance
The peak pressure ratio is moved to lower over that achieved with the standard design
flow rates by diffuser C than by the application thereby making the application of prewhirl more
of prewhirl; however the efficiency, Fig. 7(b), attractive.

is substantially reduced by the application of Clearly the standard diffuser used with

diffuser C. Prewhirl was also applied to the this compressor stage was not the optimum, and

stage configuration with diffuser 1, the constant the importance of diffuser design prior to the
area diffuser. This yielded both a reduction in application of prewhirl has been demonstrated.

the surge point flow rate and an increase in peak From the overall stage performance exhibited by

pressure ratio and efficiency over that obtained these tests the application of prewhirl to a stage

by the application of prewhirl to the standard with an optimum diffuser design will be aero-

design. This modified diffuser design, giving dynamically better than the application of variable

approximately a constant flow area, has not only diffusers in order to extend the operating range.

provided an increase in stable operating range However, the prototype prewhirl mechanism, Fig. 2,
over the standard design, but has also shown would add substantially to the total cost of the

itself to be more amenable to the introduction turbocharger unit, and it is possible that a
of positive prewhirl. fully variable vaneless diffuser design will be
less costly and more readily operated automatically.

CONCLUSIONS The feasibility of the variable diffuser design,
therefore, needs to be assessed further from a
The initial objective of this investigation cost point of view, and from its ability to be
was to assess the effect of vaneless diffuser operated automatically when located on an engine.
design on the surge margin of a turbocharger

centrifugal compressor, prior to the design of a REFERENCES
diffuser fully variable during compressor operation.

While the desired effect, of reducing the flow 1 Kemlin, S., "Turbocharger Line Covers
rate at which flow instabilities commence has been 150-500 HP Engine Range," Diesel and Gas Turbine
achieved, the efficiency levels are more substan- Progress, Jan.-Feb. 1969, p. 32.

Downloaded From: http://proceedings.asmedigitalcollection.asme.org/pdfaccess.ashx?url=/data/conferences/asmep/84020/ on 05/06/2017 Terms of Use: http://www.asme.org/abo

 2 Emmonds, H. W., Pearson, C. E., and 1971.
Grant, H. P., "Compressor Surge and Stall 6 Stanitz, J. D., "Design Consideration
Propagation," Transactions of ASME 1955, pp. 455- for Mixed Flow Centrifugal Compressors With High
469. Flow Rates Per Unit Frontal Area," NACA RME 53A15,
3 Amann, C. A., and Nordensen, G. E., 1953.
"The Role of the Compressor in Limiting Automotive 7 Coppage, J. E., Dallenbach, F., et al.,
Gas Turbine Acceleration," Centrifugal Compressors, "Study of Supersonic Radial Compressors for
Technical Progress Series, Society of Automotive Refrigeration and Pressurization Systems," WADC
Engineers, Vol. 3, 1961, p. 74. Tech Report 55-257, Dec. 1956.
4 Jansen, W., "Rotating Stall in A Radial 8 Whitfield, A., Wallace, F. J., and
Vaneless Diffuser," Transactions of ASE 1964, Vol. Atkey, R. C., "Experimental and Theoretical
86, Series A, p. 67. Performance of A Radial Flow Turbocharger
5 Dean, R. C., "On the Unresolved Fluids Compressor with Inlet Prewhirl," Proceedings of
Dynamics of the Centrifugal Compressor," Advanced the Institute of Mechanical Engineers, 1975.
Centrifugal Compressors, ASME Gas Turbine Division,

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