DYNAMIC DATA ANALYSIS OF COMPRESSOR ROTATING STALL
by
Frank Kushner
Senior Consulting Engineer
Eltiott Company
Jeannette, Pennsylvania
Frank Kushner is a Senior Consulting
Engineer for mechanical measurement
analyses at Elliott Company. He has 27
years experience with compressor and
turbine evaluation, predominantly with
respect to vibration and acoustics. Previous
engineering experience was four years at
Pratt and Whitney Aircraft's combustion
development section. He is a previous
author for the Ninth Turbomachinery
Symposium, along with ASME.
After obtaining a B. S.M. E. degree (1965) from Indiana Institute
if Technology, Mr. Kushner received his M. S.M.E. degree (1968)
'rom Renssalaer Polytechnic Institute. He is a registered
0rofessional Engineer in the State of Pennsylvania and also a
nember of the ASME and the Vibration Institute.
<\BSTRACT
Techniques for rotating stall verification and analysis of detri­
nental effects are described. Majority of dynamic pressure data
Jresented herein are from centrifugal compressors, including one
mit that required field modification. Data from dynamic pressure
Jrobes, along with rotor vibration are scrutinized for two sources
Jf rotating stall, the impeller itself and the diffuser.
In many cases, the number of stall cells is greater than one,
.vhich is verified to have negligible reaction forces on the r otor­
Jearing system. However, when there is one stall cell per 360
legrees, unbalanced loads can be greater than the machine can
.vithstand, thereby dictating design alterations. Use of dynamic
Jressure probes is shown to be highly beneficial for more complete
malysis.
Various techniques for changing rotating stall characteristics ,
ncluding forcing stall into a multiple cell structure, are discussed.
�esults are given for some methods, and others having potential
rre also described, with suggestions for testing verification. The
;everity of rotating stall is another issue to be addressed, relating to
.vhen economics outweigh the need for change.
Axial compressor data are also presented, with somewhat
lifferent analyses, especially on blading. For a unit in FCC service,
lynamic pressure probe data are presented for both shop tests and
'or field surge line definition. Pressure pulsations are shown to
Jrovide an excellent precursor to full surge flow reversal, which
:an be much more detrimental if not properly controlled.
NTRODUCTION
Requirements for comprehensive data analysis of machinery
ypically include the three major parameters of amplitude,
'requency, and phase angle. Accurate conclusions can often be
nade with low risk for rotating stall if phase angle data are not
tvailable, as those made by Fulton and Blair [ 1] . Another example
s subsynchronous rotor vibration at a natural frequency due to
71
change in variables such as aerodynamic cross coupling, described
in numerous publications. As in synchronous rotor vibration, phase
angle for compressor rotating stall can be a determining factor to
solve problems or test new designs. Multiple dynamic pressure
probes can be used to ascertain relative phase angles and inherent
stall propagating speed, as explained in the Appendix.
Test cases such as those described herein can offer updated trend
analyses to preclude the need for pressure transducers in some
cases of problem solving. By contrast, the need for them in evalu­
ations of new designs is highlighted. These data can parallel
computational fluid dynamics (CFD), which requires accurate
boundary conditions, confirmed with testing [2] .
Results will b e given herein for several cases o f compressor
dynamic pressure measurements:
• An open inducer centrifugal impeller, which was shown to be
free of rotating stall at surge inception, thus verifying that blade
excitation was due to surge
• Single-stage test rig data on a covered impeller to verify the
cause of rotor vibration on a high pressure reinjection compressor
• Two impeller s developed for aerodynamic performance
improvements that were shown to have unacceptable stall charac­
teristics showing need for modifications
• An axial compressor for which surge control line could be
defined with increased confidence, especially relative to rotating
blade reliability
Severity of rotating stall can also be evaluated; a method is given
herein to eliminate concerns for severe problems, and theory is
presented for future test verifications of another method.
Continued use of techniques described can also assist in advance­
ments in surge control for reliability and cost savings.
OPEN INDUCER CENTRIFUGAL IMPELLER
A field failure of blading on a large combustion air compressor
was analyzed to show that the most probable cause of high cycle
fatigue was continuous surge. The compressor has a single stage,
employing an open inlet, with a design pressure r atio near 2.0 and
tip speed near 1100 ftlsec. Failures occurred shortly after contrnis­
sioning, during which questionable flow and pressure fluctuation
sensing was utilized in defining incorrect setpoints for automatic
surge controls. A cross section shown in Figure 1 gives initial
location of dynamic pressure probes for failure analy sis. Probes
were used for shop tests completed on both an original blade
design and redesigned impeller, and also during recontrnissioning
in the field. It was shown that redesign may not have been
necessary, but offered additional reliability.
In the meantime, an original spare rotor was used for production,
but probes were installed for a more comprehensive definition of
the surge control line. Probe installation was not optimum, but stall
was found with a small increase in rotor vibration prior to surge,
sufficient to obtain accurate setpoints. Subsequent test instrumen­
tation for pressure pulsation included the following:
72 PROCEEDINGS OF THE TWENTY-FIFTH TURBOMACHINERY SYMPOSIUM

PRESSURE PULSATIONS AT 2.5 HZ

4400 RPM

8: INLET PROBE X: 2 5 Hz y: 2 16.349 mPSI

300
mPSI

LinMag
30
mPSI
/di v

n A

\... .tJM� lll:] "Jo/1.. ·"' " -'" ]-"' .IIIVI I�

0
PSI
OHz AVG: 78 200Hz

Figure 3. Spectrum Showing 2. 5 Hz Pulsation for Open-Inducer

Impeller.

times rotor speed. However, going lower in flow caused a large

change in dynamic pressure as shown in Figure 4 at probes located
Figure I. Cross Section of Compressor Showing Initial Locations
upstream and above the inducer leading edge. Using various points
of Pressure Probes.
that gave differences around the circumference, another Fourier
5/ 16-24 TO DEPTH SHOWN analysis of the dynamic data gave an approximate force variation
. 38¢ X 45" CHAM.
for flow reversal also shown in Table 1 . This showed that the
blading could be subjected to large numbers of severe cyclic forces
for excessive running time immediately prior to or in surge. In
order to give utmost reliability, impellers were designed with zig­
zag damping pins (patent applied for) shown in Figure 5. These
would overcome the most probable cause of failure, continuous
surging, if it occurred again.

\.... .03R X . 03 DEEP THO. RELIEF PRESSURE FLUCTUATION AT MINIMUM FLOW

PRIOR TO OPENING DISCHARGE VALVE

Figure 2. Adapter for Dynamic Pressure Probes

A: INOUCER
700
mps 1
Flush mounted, AC-coupled piezoelectric transducers with 0.5
·•-:;o
•

Hz to> 1 0 KHz frequency response, two microsecond rise time, m

Real l"'l -..:
100 II" Ill
1 00 mv/psi sensitivity, and high signal to noise ratios mpsi . . ... l IIIII" .•.
/div I IIlii � 11o�A.i,
• Adapters shown in Figure 2, along with seals and clamp nuts for '111 '11 " IP.. T P�' ,[,
the probes -300 I'IW..IJ .1111 lloi'UI
mps1 . ... llll'l''f'
These ensure no extraneous natural frequencies to contaminate 8: INLET
Os 15.9844s
data, either from gas modes or structural effects. In addition, 600
mpa 1
multiple probe circumferential angles were utilized in case data
indicated a high number of stall cells. See Appendix. Real Ill
100 I'� Till 1'1111' 1"\
Example of pulsation data in the inlet is given in Figure 3, on the mps 1 'fT "l"''..
/d1v
verge of surge. The component at 2.5 Hz only occurred just below I'�

peak discharge pressure, and was found to be purely axial, similar
to a mild part volume surge with zero circumferential phase angle.
Amplitudes were sufficiently high and electrically noise free that
besides giving incipient surge points also provided an additional
alarm signal for the control room. Eddy current probe and
accelerometer monitors were modified in turn, including band pass
filters.
Shop verification tests also involved checking the inlet just
upstream of the inducer for instantaneous circumferential static
pressure variations, in about 20 degree increments. Even without
any blade-damaging type of rotating stall being found for the
original and redesigned stronger impeller, the concern was that the
discharge volute caused a serious maldistribution of loading at the
compliant area of blading. Data shown in Table 1 verified that up
to and at the incipient surge point, Fourier harmonic analysis gave
negligible excitation in the frequency area of concern, above three
-400
mpai
OS 15.9844s
Figure 4. Time-Trace Identifying Large Pressure Change at
Inducer and That Upstream of Open Impeller.
REINJECTION COMPRESSOR IMPELLER TESTING
An impeller design with extensive experience produced subsyn­
chronous response at a frequency varying from 70 to 80 percent of
rotating speed. This occurred only when approaching the surge
fl ow points, similar to that described by Fulton and B lair [ 1] .
Difference evaluation did not show the cause, s o there was impetus
to do a special rig test. Moreover, this was the first time the manu­
facturer experienced subsynchronous vibration on a unit with these
characteristics . In fact, there were also never any known cases of
 DYNAMIC DATA ANALYSIS OF COMPRESSOR ROTATING STALL 73

keep flow above that where forced vibrations occurred. Since

bearing modifications including damper bearings were analytical­
ly shown to give negligible benefits for vibration amplitude, the
impeller design was modified. Verification of the rotor/bearing
design was also shown by insignificant amplitude at natural fre­
quencies over the entire performance m ap from aerodynamic or
seal cross coupling effects.
RElNJECTION COMPRESSOR LOAD TEST
STALL AT 30 SECS. WITH SURGE AT 90 SECS.

Figure 6. Waterfall of' Rotor Vibration 1vith Suhsynchronous

Component for Reinjection Compress01:

While redesign was done and impellers were being manufac­

tured, a closed-loop rig test was clone for the original stage design.
Figure 5. Open-Inducer fmpeller with Zig-Zag Damping Pins. It was recognized from previous analyses that the cause was most
likely a one-cell rotating stall clue to an impeller, [7] thru [9].
However, the rig-tested impeller always exhibited three or two
Table 1. Calculated Harmonic Excitation Forces on Open-Inducer cells . Dynamic pressure probes were installed in both the inlet and
Blades. diffuser near the impe!Ier. Response at blade passing frequency
(BPFJ for normal 11ow is shown in Figure 7, while pulsation
[mplied Force Variation From Avemge amplitude during three-cell stall is in Figure 8. Rotor response
(% - Peak to Peak) changes for the rig were negligible confirming that forces are
b alanced from the peak pulsations, 120 degrees apart. Time traces
Speed Using Dynamic for phase angle calculation are given in Figures 9 and 1 0. A
I Harmonic Using Static Probes Probes summary is given in Table 2 for one of the test sequences, as air
equivalent tip speed was increased.
At Design With Inlet With l<'low R134A GAS - 4480 RPM
POINT 26
Flow Stall Reversal

A: DIFFUSE tL....__,_x" 1 . 568 kHz Y: 87.0103 mosi

1 2.28 6.48 5.8 100
mps1
2 1.86 6.27 4.8
B.P.F,
3 0.47 1.92 14.4
4 0.30 0.50 3.2
5 0.34 0.85 4.6 Lin Mag

6 0.23 0.81 3.1

10
mpsi
7 0.11 0.62 0.4
/div
-·

8 0.10 0.87 1.0

low-frequency stall similar to others' reported experiences [ 1, 3, 4,

and 5]. However, potentially damaging amplitudes described by
Lynghjem, et al., [6] required the design to be modified. Rotor sub­
synchronous vibration at part load is shown in Figure 6. Response 0 � �

psi
at rotor/bearing first critical frequency was extremely low, so that OHz AVG. 100 3"2kHz

this was concluded to be a forced response, most likely one-cell

rotating stalL Note that the subsynchronous component starts just Figure 7. Normal Spectrwnfor Reinjection Compressor Impeller.
below rotor speed, then decreases in frequency. This characteristic
will be further expounded on. Field tests showed that vibration The rig test did give evidence that the impeller was the cause of
levels might be harmful especially if automatic controls failed to rotating stalL Using an abracl able seal at the impeller eye did not
74 PROCEEDINGS OF THE TWENTY-FIFfH TURBOMACHINERY SYMPOSIUM

AT INITIATION OF STALL Table 2. Test Variation for Impeller Stall.

PRESSURE PULSATIONS AT 1B4 HZ

REINJECTION COMPRESSOR IMPELLER

A: DIFF. PROBE X: 1B4 Hz Y: 72.793 mosi
200
mps1 RIG ROTATING STALL DATA

EOUIVALENT SIA!J. s::rAIJ,_ STALL SPEED/

TIPSPEED FREQUENCY � ROTORSPEEP

LinMag
20
mpsi
/div

B.P.F 300 143 3 47.7 85

400 191 3 63.7 85

II
500 3 76. 81

WI. �t� A A A n 600 258 3 86. 77

0 Ill\ {"'JVV�-�-,/1)\,.., ���1\J\ ,A, .JL

PSl
OHz AVG. 1B :3.21<Hz STALL COULD ONLY BE HELD IN WITHOUTSURGE AT 300 AND 400FT/SEC.

STALL COULD NOT BEFOUND AT 720FT/SEC.

Figure 8. Spectrum for Rotating Stall of Reinjection Compressor

Impeller. change characteristics. There were some small stator differences in
the rig as compared to the compressor, which was also inspected to
be as designed and not much different than previous compressors
AT INITIATION OF STALL, WITH SOME B.P.F.
PULSATIONS AT 184 HZ, 1BO DEG. PHASE ANGLE with similar staging. However, the differences do remain as a likely
cause for why the actual compressor had one cell, rather than two
A: INLET P �OBE or three cells as in the rig. The most likely cause of one-cell
250 rotating stall was deduced to be due to a predominant one per
mpsi
revolution variation in the impeller itself. Note that the frequency
I"" c/'¥
Real
50 \1� ,J'I V\ ll"'lll'h IO'IAII1 ll'o..
relative to a stationary point was decreasing as the flow was
mpsi ...... ... Jl' ... /i ,I\ .. ft.l \IL .,. decreasing. In other words, initially the rotating stall frequency
/div • rTL II'
relative to impeller blades is zero, then increased to near 20 percent
- 250 of speed. Relative change in frequency correlated with compressor
mpsi
Os 31.2195ms surge testing, Figure 6. The rig-tested impeller supports this
B: INLET A so· hypotheses for the three and two-cell stall; data such as in Figure
300
mpsi 1 1 showed a higher amplitude at two and three per revolution than
at one times speed. More support is found in [7], where in Figure
., .AI
'
I"Y
Real
50 I.,.. Jr. !'" J\11_\., -� ..., lrl. 6 of their tests showed a four per revolution predominant peak, and
mpsi �'MIW 'II'" ... ''!'\. IPI tlM,N' '_11\, .tl' 'lLA
/diV ''I'
I , .. '""" 1'1' typically four stall cells for inducer stall, even with intentional
nonuniform stationary sources.
- 200
mpsi AT NORMAL FLOW AT BOOO RPM
Os :31.2195ms PREDOMINANT TWO PER REV. PULSATION

Figure 9. Three-Cell Stall Time-Trace at Inlet of Reinjection A: INLET P ROBE X: 266 Hz Y: .BIU 6 mD li
B. B
Impeller; Probes 60 Degrees apart. mps i

LinMag
AT INITIATION OF STALL, WITH SOME B.P.F. BOO
PULSATIONS AT 1B4 HZ, 135 DEG. PHASE ANGLE ups i II
/div Ill II 1\

A: DIFF. PROBE BOO '\IJ' 1.-' .f\ _v:

400 upsi
•v
�w
mpsi 20Hz AVG: 16 420Hz
M1 • 4. In B: DIFF P ROBE' X: 66_ Hz Y: 23.94 55 mD 1i
11'1 I\ I -� 1111 Ill .1111 30
,. lflriJI ' II lVI 1n
VIIJI .fll"
Real
100 Ill II/I J.IV Lilt IIII ',r1111 1 mpsi 21(
mpsi Ulll 'Jll Ill II
/div i IR lilA lllr ' LinMag 3X
3
-600 mpei lX II
mpsi /div
Os 31.2195ms Jl
B: DIFF. AT 45' "IN'\, '"-f\1'
0 �"-'""' """" 11\,
400 psi
mps i 20Hz AVG: 16 420Hz
All � .n n AI .�
Real If! I\ I� .!'W� lA lrVl/1,
100 II� JH � ntr llllllfl uv
Figure 11. Typical Low-Frequency Spectra for Reinjection
mps i ·�· 1 ... 'U II IlllN. rv IU\11 Compressor Impeller.
/div • II l.r .. 'U

-600 Rig tests could not produce one-cell stall by changing size or
mps1 rate of discharge valve closure, nor did variations in diffuser width,
OS 31. 2195ms
eye seal, gas composition, or pressure. A last test with a vaned
Figure 10. Three-Cell Stall Time-Trace at Diffuser of Reinjection diffuser design eliminated impeller rotating stall, but gave an unac­
Impeller; Probes 45 Degrees apart. ceptable flow range.
 DYNAMIC DATA ANALYSIS OF COMPRESSOR ROTATING STALL 75

Incidence angle changes at the impeller inlet analytically forced angles at the design flow point. W hen off design, the vanes would
rotating stall to a much lower fl ow, below that of previous experi­ be at a different angle than the fl ow, but effects on efficiency were
ence with actual surge . Gas production plans for the compressor expected to be small, since there were only two vanes, 1 80 degrees
did not require rig confirmation, as critical-path delivery of new apart. Retesting verified efficiency changes at normal fl ows were
impellers was almost complete for commi ssioning. In addition, it small, but effect on rotating stall was dramatic. One-cell impeller
still could have been two-cell or three-cell stall in the rig. Surge stall at 65 to 70 percent of running speed was eliminated, along
and rotating stall occurred in the field just about simultaneously with rotor subsynchronous vibration. At low flow, stall frequency
only during control line definition with rotor vibration reduced to near 80 Hz was mild. A waterfall plot is shown in Figure 1 3 , where
acceptable levels, precluding bearing or other damage. two cells were verified by phase angle measurement, giving a prop­
agating speed near 30 percent of rotor speed.
MID-FLOW COVERED IMPELLER RIG TEST
NITROGEN - 7800 RPM
Following design, a rig confirmation test was done on an STALL INITIATION AT PREDOMINANT 80 Hz
impeller with a change in blade profiles to obtain efficiency
improvements. Again dynamic pressure probes were used in both
the inlet and diffuser to assist in surge/stall definition. The same rig
was utilized as for the reinjection impeller test described above, so
that small nonuniform flow from stationary components should
give similar effects. At tip speeds equivalent to operation with air
below 1 000 ft/sec, a one-cell rotating stall was found prior to surge.
This stall was confirmed by CFD analysis to be due to the impeller.
Near 1 000 ft/sec equivalent speed, the same stall propagating at 65
percent of rotor speed was quickly followed by a diffuser stall,
traveling near three percent speed, but with two cells. Rotor
vibration shown in bottom trace of Figure 12 only increased for the
one-cell stall (at 50 Hz), but not for the two-cell stall (at 4.5 Hz) .
Away from stall, pulsation at once per revolution was predominant,
giving an indication of one-cell tendency. This is in sharp contrast
to the previous rig test for the reinjection compressor which did not
�50�H�z----���
-
619 . 995
mSec
have one-cell stall. As rotor speed increased, only a strong two-cell
diffuser stall without rotor vibration was found. The frequency
increased as flow was reduced, contrary to that for impeller stall. Figure I3. Initiation of Stall for Mid-Flow Impeller with Stabilizer
Vanes.
RS34A - 4!580 RPM
POINT 32

MIXED FLOW COVERED IMPELLER RIG TEST

A: IIUJ PIUE )( : 10 H2 Y: ... _ .. , g,. m�
400
mp• 1 4,5 HZ
A comprehensive description of this impeller and rotating rig
test is given by Hohlweg and Boal [2] including CFD analysis and
L.inMag aerodynamic testing. Additional information is given herein to
40
mpai expand on stall measurement and subsequent mitigation.
/div

l<jo> Original Design

0
"'-"
pai
OHZ AVG: HI 400HZ At all equivalent tip speeds up to 900 ft/sec, a one-cell rotating
B: IMP. VI ><· 15J:L Hz V: oa_gg lUI mo l>•
200
stall causing subsynchronous rotor vibration was found, see Figure
mmila 1 4 . Stall propagating speed range was 75 to 80 percent of rotor
speed, implying the impeller to be the likely source. This conclu­
L. 1nMag
20 sion was supported by CFD analysis, e .g, Figure 1 5 , discussed in
mmila
/div 19
[2]. Pressure peak pulsation levels shown in Figures 16 & 17 were
high, on the order of five percent of average pressure . Since pulsa­
II
mila
0
,., tions were somewhat distorted, the discharge volute could have
OHZ A.VGI: HI 400HZ been the cause. The inlet was ruled out by using a flow straighten­
er downstream of the guide vanes in the inlet connection. Tests
Figure I2. Pulsation and Vibration Spectra During Stall of Mid­ were also made with a wider diffuser, and with a change in
Flow Impeller and Diffuser. impeller axial position, giving the same results.
Analy sis also showed that there was a definite large component
The same impeller was then tested with a vaned diffuser, which at one times rotor speed, as compared to higher harmonics, e.g.,
sometimes reduces the flow range of an impeller design. Flow at Figure 18. As fl ow was decreased towards stall, the one per rev
diffuser stall was higher, i .e . , above that at which impeller stall had component was usually not as significant by comparison, e special­
occurred. Had this been the only test, impeller stall would not have ly at the inlet, but the one-cell stall persisted. Onset of stall shown
been discovered. This diffuser stall propagated faster than for the in Figure 19 was sudden, typically building up to full amplitude in
vaneless diffuser, probably due to the presence of diffuser vanes, in several cycles, les s than 30 milliseconds.
the range of 14 to 1 7 ·percent of rotating speed. Stall propagating
Stabilizer Vane Tests
speed increased as flow decre ased. The number of stall cells was
either three or two, with negligible effect on rotor vibration. With succe s s found for the mid-flow impeller, stabilizer vanes
The vaned diffuser was removed and a design utilizing two sta­ were again designed and tested. In this case since a volute was
bilizer vanes in the diffuser was tested. The vanes were shaped to being utilized, one of the vanes was used to guide the fl ow to the
only guide the flow in the diffuser at the calculated log-spiral flow volute tongue, and the second vane was located 1 80 degrees
76 PROCEEDINGS OF THE TWENTY-FIFTH TURBO MACHINERY SYMPOSIUM

MIXED FLOW IMPELLER - UEQ - 900 FT/SEC MIXED FLOW IMPELLER - UEQ � 900 FT/SEC
ONE CELL ROTATING STALL @ 77% DF ROT. SPEED ONE CELL ROTATING STALL @ 214 HZ

A: ROTOR VIB. X: 216 Hz Y: 152.059 mmiloo A: INLET B

400 1.2
mmilpp psi
lX II
/V [V
LinMag
40
Real
200
mmilpp SIAI.l. mps1 rJ ri f 11. II)
'It' 1\ nofll I �,.C
/div /div
''ij l/" �""II V" U' ,} ' v � " II'
0
..._
-BOO
milpp f>.
mps1
5Hz AVG: 5 405Hz Os 15.6097ms
B: DIFF. C X: 216 Hz Y: 931.144 mosi B: INLET A
1 1
ps1 psi

LinMag \nl
,Nf'l II\ I
Real
100 200
v' 1
mpsi mps l -� .J>f" ' � ill
/div /di v "\ /1,, '�Ill 1/\\. "" 1.!' VI(

0 1
psi psi
5Hz AVG. 5 405Hz Os 15.6097ms

Figure 14. Spectra Showing Rotor Vibration and Diffuser

Pulsations. Figure 16. Time-Trace for Inlet Pulsations at Stall.

CFD Analysis of Mixed Flow Impeller

Relative Velocity Vectors, Streamtraces
MIXED FLOW IMPELLER - UEQ = 900 FT/SEC
Mid-Channel Surface ONE CELL ROTATING STALL @ 77% OF ROT. SPEED

! Normal Flow ! A: DIFF. D

2.5
Psi
A.
Real 'lfVI/\1\ nJVlfVIfi All IV\Ilfl. .R!.
'"1
500 lA . "' "I.
mpsi Vt, 01' IV "
/div IV\, "VJ' '\ , Rill
''I
-2.5
PB1
OS 15.6097ms
B: DIFF. C
2.5
psi

Real 1\ Ill\ N' 'VI .nn, lA&

500 "\, �� ,/V'V !.-.. 1\ '\, .. IAI :lo.t
'
mps1 Ill ,1\/' ·�, vv�
JL 'I
/div Vrv'V V'
·v
-2.5
ps i
Os 15.6097ms

I Stalled Flow I Figure 17. Time-Trace for D(ftitser Pulsations at Stall.

MIXED FLOW IMPELLER - UEQ = B O O FT/SEC

DISCHARGE VALVE OPEN

A: DI FF. �:===�=-X Y: 7 9
4 _: J-�-·--_-_-· 1-::
-·-,-·.J:g
- -- - ._ t-----3- 9l1_
y--f---t- ---t
- j- . __
mo/-s·i--J
mpsi" --
�---t---4--- ��-t----+---1----t-- +---�---l --

Figure 15. CFD Analysis Showing Relative Velocity Streamlines at

Mid-Channel.

opposite. Test results were successful in that rotating pressure

50 Y: 37.209
pulsation at normal speeds was greatly reduced, on the order of 80
c______ )t_i;1
Hz
- .l1lllfL-
percent, and surge occurred just about simultaneously. In fact, near
- - --- --
optimum design speed, surge frequency near 1 1 H z was found ..
LinMag
prior to rotating stall as shown by the peak-hold plots in Figure 20. 4
In this case, stabilizer vanes did not fully overcome the one-cell
mpsi
/div
�-:ir
v
-- 1-- --

IV'\.
v
-
f--· r--
pattern. In addition, the once per revolution pressure pulsation was
still dominant;. implying that the impeller effects were controlling. 0 -:::---
psil.,-- -
Rotor vibration was also greatly reduced, comparing Figure 2 1 to OHz AVG: 23 B O O Hz
Figure 1 4 . When stall frequency occmred, it was predominantly on
only part of the 10 to 1 1 Hz, low frequency surge pulse cycle as Figure 18. Normal Spectra at Diffuser and Inlet.
 DYNAMIC DATA ANALYSIS OF COMPRESSOR ROTATING STALL 77

MIXED FLOW IMPELLER : ONE-CELL STALL MIXED FLOW IMPELLER DURING SURGE
INITIATION @ 2.79 SECS.; DECAY @ 3.15 SECS. TWO SPLITTER VANES - UEG • B O O FT/SEC

A:INLE � 6 R�O�B�E�----, A: ROT VIS

300
X: 181 Hz Y: 38. 7i 6 m llnn
0
mpsi mmilpp lX

Real
LinMag
-50 \) 30
mmilpp
3.245 /div
Sec

0 b&_
milpp ""- ,..,._.. .......
5Hz AVG. 110 805Hz
B: INLET 8 X: LSi Hz Y· 9 .d7i" mn ,;
400
mps 1 Hz

�
0
2.75 ps 1
SecL ------------------------------ � 5Hz AVG. 110 805Hz
--- �� - � � 7�
1 24 . 8 7 9�m s
05

Figure 21. Peak-Hold Spectra with Stall Following Surge.

Figure 19. Time-Trace Waterfall for Onset of Rotating Stall.
MIXED FLOW IMPELLER AT START OF SURGE
TWO SPLITTER VANES - UEG • BOO FT/SEC
shown in Figure 22. The amplitude at stall frequency was also
broad-banded especially in the normal speed range. Note that the A: INLET A
surge pulses in Figure 22 are in phase, verifying an axial motion. It 1. 2
ps i
was hoped that the stabilizer vanes would also at least give the . ... Ill
... •
same efficiency as without them, due to some guiding into the Real
20 0 Ill m. 11'11
volute. Results showed an actual performance improvement so that mps i�
/div
• .-. Iloilo. If" 'I. ..... II ·1.
'\
vanes can be useful even if rotating stall is eliminated by other "II. 1t. .,,
means. -eo 0
mps 1
OS 999.0234ms
8: INLET B
1. 2
MIXED FLOW IMPELLER AT SURGE INITIATION ps i
TWO SPLITTER VANES - UEG • B O O FT/SEC " ..
Real .� •• I• Ill
200 __IL _A _ll __ft "
A: ROT VIB )(• 247 H2 Y: 70 417 mmilllJl mps 1 ...... .... -- ..... 1r 1 II'� .,
300 lX /div Ill!' _.llo ���. -� .. '\
mmilpp
� l, '\
-eo0 II. 'I'
LinMag mps 1
30 Os 999.0234ms
mm1lpp
/div
Figure 22. Time-Traces at Inlet Showing In-Phase 10Hz Pulses.
0
milpp IV J\.
5Hz AVG: 42 805Hz Shop tests of initial axial compressors with controlled diff usion
8: INLET 8 X: i1 �7 Y: l43.0 71 mosi
200 airfoils included dynamic pressure measurements. The only detri­
mpsi mental rotating stall that was found was during startup if the
adjustable vanes were not fully closed, similar to older NACA 65
LinMag
20 type blading. At normal speeds, setting the surge point showed no
mpsi
/div adverse effects of stall. An unusual case of a more recent unit for
FCC service with a blank first row for future uprate was analyzed
0
psi
using dynamic pressure probes at rotor blade tips of various stages.
5Hz AVG: 42 805Hz Data shown in Figure 23 were extremely useful, as initial tests with
fully open, adjustable guide vanes produced pulsations following
Figure 20. Peak-Hold Spectra Prior to Rotating Stall. surge recovery. Surge pressure is the low frequency trace, and
rotating stall frequency is shown during time of recovery. This stall
persisted after surge as the discharge valve was being open. Rotor
AXIAL COMPRESSOR STALL MEASUREMENTS
vibration was not affected, as there were two stall cells traveling at
Consideration of rotating stall has been much more crucial for 60 percent of rotor speed. As flow was somewhat higher than
industrial axial compressors, let alone those in jet engines . It is design specification, guide vane opening could be limited to a
well known that blade fatigue can occur if natural frequencies are value that had a more normal surge, such as shown in Figure 24. A
equal to a maj or harmonic of rotating stall frequency, relative to a normal surge can produce extremely high pulsation, impact loads,
blade. For example, with propagating stall speed of 33 percent of shock waves, etc., so that occurrences must be limited using
blade rotating speed, the sixth harmonic of one-cell stall frequency reliable anti-surge automatic controls.
can excite a rotating blade if its fundamental mode is at four times The same probes were used for assistance in field commission­
rotor speed. L ikewise, six stall cells at the same propagating speed ing with blow-off valve operation prior to production. The first
and amplitude would give much more excitation, since the first point on the performance map gave a long surge pulse time and a
harmonic would be the excitation source. Thus, it can be important single surge could be ascertained by stopping valve closure more
to define number of stalls and severity, unless it is for an off design quickly as compared to the shop test. Valve controls in the field
transient such as shutdown. gave ability to step the closure in 0. 1 percent increments. Thus, a
78 PROCEEDINGS OF THE TWENTY-FIFTH TURBOMACHINERY SYMPOSIUM

AXIAL COMPRESSOR SHOP TEST, SURGE AND STALL AXIAL COMPRESSOR FREQUENCY SPECTRUM !! SURGE
WITH ORIGINAL OPEN AO�USTABLE VANE SETTING ROTATING STALL �UST BEFORE FLOW REVERSAL

A: ROW 1!! OIE6R 'ES B: ROW 7 x· 32 Hz Y· 86!..6 4 mosi

25 , ....... 2
psi --.... psi

Real
5
psi ·vv
1'\
/div .,....
"\. ....... LinMag
200 B.P.F,
-25 mpsi
psi /div
Os 1.99Bs
B: ROW 1!! on:r.o"'
SfAU.
0
PSl l,
"""'\
Real
2.5 J.
psi .h
/div ...,. A 'JV'Y"'.
v� io\1\ AA LilA A. vvv· ·v

-25 0 \ ./ h.. Jl
psi psi r-
OS 499. 5117ms OHZ AVG: 111 3.2kHZ

Figure 23. Time-Trace at First Row During Surge and Recovery. Figure 25 . Spectra Showing One-Cell Pulsation at Middle Row.

AXIAL COMPRESSOR SHOP TEST AXIAL COMPRESSOR FREQUENCY SPECTRUM

SURGE WITH FULLY OPEN AO�USTABLE VANES NORMAL OPERATING CONDITIONS - 3600 RPM

A:ROW 1 !! 0 IFGIHS A: ROW 1 X: .376 kH Y: .947 4 OS

30 3
PSl psi
'.F.
Real LinMag
5 300
psi / mpsi
/div /div
� / ./
-20 it 0 "-
psi \ psi
Os 7.99228 OHz AVG. 10 3.2kHZ
B:ROW 14 OII'Om: B: ROW 14 X: .2U3 kH Y: .703 7 OS
10 2
psi A " psi B.P.F.
\ 1/ / '-
fVV '
Reel LinMag
2.5 \,. J 200
psi mpsi
/div /diV

....
-15 0
psi psi
Os 7.9922s OHZ AVG. 10 3.2kHZ

Figure 24. Time-Traces at First and Last Rows with Multiple Figure 26. Normal Spectra at Front and Rear Rows.
Surges.
AXIAL COMPRESSOR FREQUENCY SPECTRUM
WITH ACOUSTIC PULSATION FROM DISCHARG E PIPE
trace of rotating stall could be found as shown in Figure 25 for
open vane settings. Even though this was one fell, it was not detri­
A: ROW 1 x· 376 kH Y· 766 )2 DS
mental, partly due to low sensitivity of the rotor/bearing system. 2 ..
Harmonics of stall frequency were also negligible in the range of psi

frequencies that could excite blade natural frequencies. Away from LinMag
surge points, pulsations were only at normal blade pass frequen­ 200
mpsi
cies, Figure 26, and stall point settings gave optimum operational /div
control line data. R
0 II
An added value of dynamic pressure probes was that commis­ psi
sioning also showed an acoustic resonance. It was sensed as well OHz AVG. 10 3.2kHz
B: ROW 14 X: 432 Hz Y· 256 5 3 mo ;i
with high levels at the discharge pipe and was audible, so that there 3
ps i
was concern that it could be propagating upstream at a level that
could excite the blades. Data verified frequency changed with LinMag B.P.F

speed of sound. Levels at the last rotating row plotted in Figure 27 300
mps i
showed that it was a standing acoustic wave at 432 Hz and could /div
not cause blade excitation for the calculated number of waves.
0
Amplitudes were much lower for the other probe in the last row, ps i
OHz AVG: 10 3.2kHz
showing that a standing acoustic wave is the case , rather than some
odd rotating stall. Figure 27. Spectra with 432 Hz Noise at Last Row.
DISCUSSION OF SEVERITY AND STALL MffiGATION

Relative to blade loading affects on fatigue, pulsation measure­ calculations can be generated to set limits on nonsynchronous rotor
ments can give values to be used for forced response analysis. vibration; as it is generally a forced, stable mechanism. For a given
Rotor vibration examples could also be used to determine whether element, severity should be a function of flow raised to the third
 DYNAMIC DATA ANALYSIS OF COMPRESSOR ROTATING STALL
power; but for the same equivalent tip speed, would increase
directly with power. For example, a reduced pressure performance
test at correct equivalent tip speed showing a minor amplitude of
0.3 mil) p-p vibration could be as high as 1 .2 mil)p- for four times
t
the flow at full field conditions, and still be accepta le if flow is to
the left of the control line. Also, to be factored in would be the
frequency experienced relative to the rotor/bearing system natural
frequency. If test conditions give a frequency much different than
proj ected field conditions, dynamic stiffness_ would also be used to
adjust calculations.
A pattern from centrifugal impeller testing emerged in that one­
cell rotating stall correlated with indication that one per rev
pulsation was higher than other harmonics.
Thus, a potential method is planned for testing wherein a
multiple cell structure can be forced to occur. Hopefully, this idea,
used for patent application, will compliment the use of stabilizer
vanes and diffuser vanes.
CONCLUSIONS FROM TESTING
• Measurements using dynamic pressure probes are useful in iden­
tifying the true nature of stall inception, propagation and effects on
system surge definition. Other flow and pressure instrumentation
should be used in conjunction with audible noise, sensing of
vibration, speed fluctuations, and load changes at peak head, etc.
• A volute stage can be properly designed to give negligible alter­
nating blade loading on highly-loaded open inducer impellers,
without damaging static pressure nonuniformity away from stall.
• Data show that centrifugal impeller stall frequency (propagating
speed) decreased as fl ow is reduced, opposite to that for diffuser
stall. Future tests should eventually better identify cause and effect
relative to sources giving improved designs and easier modifica­
tions for problem-solving.
•Additional advances in CFD analytical techniques can be bench­
marked using dynamic pressure probe data.
• Use of diffuser stabilizer vanes can eliminate concern for one­
cell rotating stall caused by centrifugal impellers, and give
efficiency improvements for volutes. Normal diffuser vane designs
could also be used to change characteristics, generally only if flow
range limitation is not a severe detriment.
• Data for centrifugal compressors also showed that predominate
one per revolution pulsations may be an indicator of propensity for
one-cell, in lieu of multiple-cell rotating stall. Only one-cell stall
can give significant unbalanced loads to cause rotor vibration.
• Surge tests, especially for the axial compressor showed extreme
pulsation levels, once again highlighting the concern for limiting
occurrences. Adjusting discharge valve with dynamic pressure
probes for surge point definition can be useful in defining true
setpoints for automatic controls , minimizing number of severe
surges . Setpoint data are best quickly logged and flow increased to
remove any hysterisis.
• A procedure such as described for rotating stall severity calcula­
tions could save the industry from performing unnecessary full
load tests for well-damped sy stems, along with identifying
potential costly field problems.
• Dynamic pressure probes can be used for an added monitoring
method for critical machinery; advances in data analysis should
permit operation closer to surge, giving more flexibility and oper­
ational efficiency.
NOMENCLATURE
rotor operating speed, Hz
stall propagating speed in direction of rotor speed, Hz
number of rotating cells
79
f8 first harmonic of stall frequency measured at a stationary
point, Hz
fr first harmonic of stall frequency relative to each rotating
blade, Hz
'i>s measured phase angle between stall cells , degrees
cl>m installed angle between stationary probes, degrees
a tolerance on installed angle between probes, degrees
� tolerance on phase angle measurement, degrees
APPENDIX
Aspects of Rotating Stall and Its Measurement
Compressor surge is the well known system instability succinct­
ly described by Den Hartog [ 1 0] , and later by Japikse [ 1 1].
Sometimes a more localized phenomenon, rotating stall, can be
found just before or simultaneously with surge. Generally, stall is
at the point where pressure rise peaks in one or more components
and starts to give a positive slope on the system pressure vs flow
curve. A sketch to indicate cells of low pressure alternating
circurnferentially is shown in Figure 28 with those cells higher
than the average pressure. These revolve at £08 , some fraction of
rotor speed ror, almost always in the same direction from a station­
ary viewpoint. Relative to each rotating blade, the cells are
propagating backwards at a speed of (ror -£08) . Thus sections of
higher flow in tum provide more flow into blade areas that just had
experienced a low flow condition. A steady state with this pattern
can exist prior to in-phase reversal (surge). Each blade experiences
a peak pressure at a rate of n multiplied by (ror - £08); but any
one-cell condition would give a net fluctuating force on the rotor at
frequency of f8•
For stationary. measurements in a casing near the rotating
component (s), dynamic probes can be used to determine number
of cells and relative amplitudes , including harmonics for
waveforms, not purely sinusoidal. Usually, two probes are used
with one giving a circumferential reference for phase angle mea­
surements. If only one probe is used, a frequency of f8 is obtained,
but the number of cells and their propagating speed can be in
question.
A phase angle measurement value near zero would show an
axial pulsation, which would indicate a local or full surge type flow
reversal. Usually a phase angle of± 1 0 degrees for the second
probe can be easily detected even for low amplitudes using
frequency response functions (FRFs) from two-channel fast
Fourier transform (FFf) analy ses. Typical projected results are
shown in Table 3 for selected separation angles of the two probes.
A separation much less than 4 5 degrees could give questionable
data in that pulsation frequency could really be surge, near zero
degrees. With consideration of accuracy, 45 degree probe separa­
tion, installed to ± 2.5 degrees, can determine one to five cells, as
shown for Case B in Table 4 using Equation ( 1 ) .
(1)
Other factors t o consider:
Measured amplitudes should also be about the same for each
•
probe at a given location.
•Instrumentation, especially filters must be checked for phase
measurement errors.
Following equations also apply :
(2)
(3)
Examples 1 and 5 in Table 5 show that there is some small risk
that instead of one cell, there are nine cells . For more accuracy, a
80 PROCEEDINGS OF THE TWENTY-FIFTH TURBOMACHINERY SYMPOSIUM

ONE-CELL STALL Table 3. Stall Number Determination for Separation Angle of Two
Probes.

Implied Nnmber
Probe Separation Measured Phase Anlde , of Cells
(degrees) (degrees)

180 180 1,3,5,7, •.•

360 2,4,6,8, ••.

90 90 1,5,9,...
180 2,6,10,

0
••.

270 3,7,11, .•.

360 4,8,12,...

60 [60] [1],7,...
120 2,8,...
180 3,9, ...

240 4,10,...
300 5,11,...
360 6,12,...

45 [45] [1],9,...
90 2,10,...
135 3,11,...
180 4,12,...
225 5, 13,...
TWO-CELL STALL 270 6,14,...
315 7,15,...
360 8,16,...

Table 4,. Accuracy for Probe Spacing of 45 Degrees.

. Range of Measured Implied

Phase Angle No. of Stall Cells
(degrees)

0
� CaseB
350-10 350-10 0
30-60 32.5.57.5 1
70-110 75-105 2
110-160 117.5.152.5 3
150 • Z10 160.200 4
190.260 202.5-247.5 5
230.310 245.295 6
270-0 287.5 • 342.5 7
310.5 0 ' 330.30 8
350-100 12.5.77.5 9
30-150 55-125 10

Figure 28. Sketch for One and Two Rotating Stall Cells.
third probe spaced 60 degrees from the reference probe gives a
match if it shows near 60 degrees measurement needed for one
cell; see bracketed values in Table 3 . Nine stall cells would require
this probe to indicate 1 80 degrees. However, rotor vibration also
found during stall would add to certainty that there is only one stall
cell, which gives unbalanced forces on the rotor as shown in Figure
28 at stall frequency, f8• Likewise, if only one probe is used and the
frequency is the same as rotor subsynchronous vibration, one cell
can also be safely implied.
Case A. a= 5•; � = 10 Degrees
Case J1 a= 2.5"; � = 10 Degrees
Examples 3 and 5 in Table 5 could show concern for an axial
compressor or open (non-covered) inducer type impeller, e.g., the
frequency relative to blading for Example 3 is approaching three
per revolution; the second harmonic at 300 Hz could especially be
near a fundamental blade mode. Excitation at rotating stall could
add to other sources, especially critical if the blade mode is also at
a harmonic of rotor speed. Again, more probes at different spacing
could be necessary for convincing analysis.
 DYNAMIC DATA ANALYSIS OF COMPRESSOR ROTATING STALL 81

Table 5. Examples of Rotating Stall Analysis. 6. Lynghjem, A., Svendsen, 0., and Underbakke , H., 'The Offshore
Application of a Dual-Mode Inj ection Centrifugal Compressor
Two Probes 45 Degrees Apart and Improvements to Rotating Stall,'' ASME 96-GT-322
( 1 996).
Example No. 1 2 3 4 5 7. Ariga, 1., Masuda, S., and Ookita, A., "Inducer Stall in a
Centrifugal Compressor With Inlet Distortion," ASME 86-GT-
Rotor Operating Speed -Hz 60 60 60 60 60 1 39 ( 1 986).
8 . Van Den Braembussche, R., "Surge and Stall In Centrifugal
Measured Frequency -Hz 45 84 30 6 45
Compressors," VKI Lecture S eries 1 984-07-Flow In
Centrifugal Compressors, von Karman Institute for Fluid
Measured Phase Angle -Degs. 45 90 135 45 45 Dynamics, Rhode Saint Genese, B elgium (May 1 984).

Number of Cells 1 2 3 1 9 9. Frigne, P. and Van D en Braembussche, R., "Distinction

Between Different Types of Impeller and Diffuser Rotating
Cell Rotating Speed -Hz 45 42 10 6 5 Stall In a Centrifugal Compressor with Vaneless Diffuser,"
(Percent of Operating Speed) 75 70 17 10 8 ASME Journal of Engineering for Gas Turbines and Power,
106, pp. 468-474 (April 1 984).
Rotating Blade Excitation 1 0 . Den Hartog, J. P., "Mechanical Vibrations," pp. 29 1 -292,
(1st Harmonic Frequency) -Hz 15 36 150 54 495 Fourth Edition, New York, New York: McGraw-Hill ( 1 956).
1 1 . Japikse, D . , "Stall, Stage Stall, and Surge,'' Proceedings of the
Tenth Turbomachinery Symposium, Turbomachinery Labo­
REFERENCES
ratory, Texas A&M University, College Station, Texas ( 1 9 8 1 ) .
1. Fulton, J. W. and Blair, W. G., "Experience with Empirical
Criteria for Rotating Stall In Radial Vaneless Diffusers," ACKNOWLEDGMENTS
Proceedings of the Twenty-Fourth Turbomachinery Assistance is greatly appreciated from all those at Elliott
Symposium, Turbomachinery Laboratory, Texas A&M Company in obtaining and analyzing the data presented, especial­
University, College Station, Texas ( 1 995). ly those in the Advanced Technology group. A special thanks is
2. Hohlweg, W. C. and B oal, C. F. , "Design Analysis and Test of given to Ken Greene, Bill Hohlweg, B ob Strickland, Ron Aungier,
a Mixed Flow Centrifugal Impeller," ASME 95-WA/PID-5 Chuck B oal and John Beaty, and to Penny Montgomery for prepa­
( 1 995). ration. Professor George E. S mith of Tufts University also
provided excellent consultation on data gathering and analysis for
3. Ferrara, P. L., "Vibrations in Very High Pressure Centrifugal
the open-inducer impeller.
Compressors,'' ASME 77-DET- 1 5 ( 1 977).
4. Shannon, R., 'The Stall Zone," Orbit Magazine, pp. 1 6-2 1 ,
B ently Nevada Corporation, Minden, Nevada (June 1 995).
5. Sorokes, J. M., Kuzdzal, M. J . , Sandberg, M. R., and Colby, G .
M . , "Recent Experiences I n Full Load Full Pressure Shop
Testing of a High Pres sure Gas Inj ection Centrifugal
Compressor," Proceedings of the Twenty-Third Turbo­
machinery Symposium, Turbomachinery Laboratory, Texas
A&M University, College Station, Texas ( 1 994).
82 PROCEEDINGS O F TH E TWENTY-FIFTH TURBOMACHINERY SYMPOSIUM