Introduction to Machinery Analysis

Flow Instabilities
Flow Path in a Centrifugal Compressor
 Flow Path Contribution

Return Diffuser
channel with channel
guide vanes with guide
(stall region) vanes (stall
region)

Shroud disc Impeller tip

clearance (Kxy) clearance (-Kxx)

Hub disc
clearance (Kxy) Impeller eye
seal (Kxy)

Shaft/shroud
disc seal (Kxy)

Impeller inlet (stall region) Center labyrinth seal with shunt holes (Kxy & Cxx)
Seals
Angled tooth
Plain bushing seal Stepped seal
labyrinth seal

See through
Tapered seal Staggered seal
labyrinth seal
Seals

m xx m xy  x  c xx c xy  x  k xx k xy  x   f x  where (m,c,k)xy = -(c,m,k)yx

             
m yx m yy  y  c yx c yy  y  k yx k yy  y   f y  and (m,c,k)xx = (c,m,k)yy

Labyrinth seal cavity

Seals - Inlet Swirl
Inlet swirl ratio or velocity ratio is the ratio between the tangential velocity
of the gas at the entrance to the seal divided with the velocity of the rotor
surface

v gas , tan K xy
v rat  wrat 
v rotor   C xx
Calculated Stiffness Coefficients Calculated Damping Coefficients Whirl Frequency Ratio

600.0 1.00

500.0 0.80 2.0

400.0
0.60 1.5

Kxy/N*Bxx (dim)
300.0
0.40
N*s/mm
N/mm

1.0
200.0
0.20
100.0 Bxx 0.5
Kxx
0.00 Bxy
0.0 Kxy
0.00 0.50 1.00 0.0
0.00 0.50 1.00 -0.20
-100.0 0.00 0.50 1.00
-0.5
-200.0 -0.40
Inlet swirl (dim)
Vrat (dim) Vrat (dim)
Process Condition
 Fluid or Aero Dynamics Stability

t al l
rS
Isentropic Head / Pressure Differential

lle
pe
Im Rotordynamic Instability
ne
Li
e
rg

ll
Su

ta
rS
se
ff u

ll
Wa
Di

n e
Sto

Flow
Stall
Impeller Rotating Stall

• Flow attempts to maintain

continuity by “blocking”
some vanes
• Partial flow reversal

• Unbalanced radial forces
• Lateral shaft excitation
• Frequency below running
speed, as cells rotate
slower than impeller

Stall cell rotating

at 70 - 90 % of 
Impeller Rotating Stall

C out
 0.5
Cin
 inlet  12 0
Cout
Cm
 blade

U
Cin
Rotating Stall

• Rotating stall when 2 > 12°

• Several critical locations:

– Return channel
– Diffuser
– Impeller
Flow Induced Vibration
• Unstable flow in pumps or compressors (surge, stall etc.) will generate sub-
synchronous vibrations which can be correlated with measurements of flow,
pressure, etc.
– Surge will show up as a lift of the noise floor, normally below 20%
running speed
– Rotating Stall is normally located close to or at surge
• Diffuser, appears from 5% to 20% running speed, with possible harmonics
depending on the number of stall cells
• Impeller, appears from 65% to 90% (95%) running speed, can line up as a
harmonic of a weak diffuser stall
• Abrupt (interaction between impeller tip and diffuser), appears intermediate
of diffuser and impeller rotating stall
– Stall is often taken as surge and it is difficult to make any protection
against it, due to its sudden appearance

• Blade / vane passing frequencies can resonate with acoustic or structural

natural frequencies.
 Trip due to Flow Instability
Performance map
240

Stability
220 Line

200

180
HP [kJ/Kg]

160

140
7000

120 6600
6300
100 5900
Trip Path 5600
80 5200
4900
4 6 8 10 12 14 16 18 20 22
3
Flow [m /kH]