A centrifugal compressor is a mechanical machine with purpose to convert kineticenergy from a rotating impeller wheel into the fluid medium by compressingit. One application involves supplying boost air pressure to downsized internalcombustion engines (ICE). This allows, for a given combustion chamber volume,more oxygen to the combustion process, which is key for an elevated energeticefficiency and reducing emissions. However, the centrifugal compressor is limitedat off-design operating conditions by the inception of flow instabilities causingrotating stall and/or surge. These instabilities appear at low flow rates andtypically leads to large vibrations and stress levels. Such instabilities affectthe operating life-time of the machine and are associated with significant noiselevels.The flow in centrifugal compressors is complex due to the presence of a widerange of temporal- and spatial-scales and flow instabilities. The success fromconverting basic technology into a working design depends on understandingthe flow instabilities at off-design operating conditions, which limit significantlythe performance of the compressor. Therefore, the thesis aims to elucidate theunderlying flow mechanisms leading to rotating stall and/or surge by means ofnumerical analysis. Such knowledge may allow improved centrifugal compressordesigns enabling them to operate more silent over a broader operating range.Centrifugal compressors may have complex shapes with a rotating partthat generate turbulent flow separation, shear-layers and wakes. These flowfeatures must be assessed if one wants to understand the interactions among theflow structures at different locations within the compressor. For high fidelityprediction of the complex flow field, the Large Eddy Simulation (LES) approachis employed, which enables capturing relevant flow-driven instabilities underoff-design conditions. The LES solution sensitivity to the grid resolution usedand to the time-step employed has been assessed. Available experimentaldata in terms of compressor performance parameters, time-averaged velocity,pressure data (time-averaged and spectra) were used for validation purposes.LES produces a substantial amount of temporal and spatial flow data. Thisnecessitates efficient post-processing and introduction of statistical averagingin order to extract useful information from the instantaneous chaotic data. Inthe thesis, flow mode decomposition techniques and statistical methods, suchas Fourier spectra analysis, Dynamic Mode Decomposition (DMD), ProperOrthogonal Decomposition (POD) and two-point correlations, respectively, areemployed. These methods allow quantifying large coherent flow structures atvfrequencies of interest. Among the main findings a dominant mode was foundassociated with surge, which is categorized as a filling and emptying processof the system as a whole. The computed LES data suggest that it is causedby substantial periodic oscillation of the impeller blade incidence flow angleleading to complete system flow reversal. The rotating stall flow mode occurringprior to surge and co-existing with it, was also captured. It shows rotating flowfeatures upstream of the impeller as well as in the diffuser. / <p>QC 20171117</p>

Centrifugal compressors with high pressure ratio are widely used in small aircraft turbine engines and turbocharges. At high rotational speeds they have narrow stable operating region and commonly used impellers with back swept blades are not able to ensure requested stability. In order to achieve wider stable operating region, some other anti-surge measures can be used, such as an Internal Recirculation Channel (IRC) located in compressor impeller inlet. This thesis deals with an investigation of IRC influence on centrifugal compressor operational parameters. As a first, the various recirculation channel geometry was studied by using of CFD analysis on simplified computational models. Those geometry, which indicated best results in terms of mass flow and looses in channel were used for testing on a model test device. Subsequently the same geometry was tested on real centrifugal compressor in experimental turbine engine to verify influence of IRC on compressor performance map – pressure ratio and efficiency. Simultaneously the CFD analyses of IRC with a 3D model of compressor impeller were performed and results compared with those, gained from measurement on model and compressor. In addition the measurement of flow field downstream the recirculation channel outlet slot with using of 3-hole pressure probe was performed and compared with flow velocity profiles evaluated from numerical simulations.

The effects of impeller-diffuser interaction are investigated through numerically simulating the modified wedge vane profiles. Steady and time-accurate, 3D- viscous RANSsolver is used to perform flow field computations. The original design is modified to obtain better aerodynamic performance. Five morechanges are made to the leading edge profile of the new design, in order to assess different degrees of unsteadiness. These changes show that their contribution on stageefficiency is rather minor, while they have a huge reduction on blade loadings. Moreover, it is shown that the shorter radial distance of vaneless space does not necessarilymean an increased loading thanks to the eliminating in-phase fluctuations on pressureand suction sides. It is found that the impeller reacts to the upstream static pressure disturbance, whichis caused by the applied geometry change and its resultant flow field in the wedge diffuser, but not to the radial location of a certain profile. In addition, the results indicatethat the wedge diffuser aerodynamic performance is driven by time-averaged flow fieldbehaviour.

Turbochargers play an important role in increasing the energetic efficiency andreducing emissions of modern power-train systems based on downsized recipro-cating internal combustion engines (ICE). The centrifugal compressor in tur-bochargers is limited at off-design operating conditions by the inception of flowinstabilities causing rotating stall and surge. They occur at reduced enginespeeds (low mass flow rates), i.e. typical operating conditions for a betterengine fuel economy, harming ICEs efficiency. Moreover, unwanted unsteadypressure loads within the compressor are induced; thereby lowering the com-pressors operating life-time. Amplified noise and vibration are also generated,resulting in a notable discomfort. The thesis aims for a physics-based understanding of flow instabilities andthe surge inception phenomena using numerical methods. Such knowledge maypermit developing viable surge control technologies that will allow turbocharg-ers to operate safer and more silent over a broader operating range. Therefore,broadband turbulent enabled compressible Large Eddy Simulation (LES) cal-culations have been performed and several flow-driven instabilities have beencaptured under unstable conditions. LES produces large amounts of 3D datawhich has been post-processed using Fourier spectra and Dynamic Mode De-composition (DMD). These techniques are able to quantify modes in the flowfield by extracting large coherent flow structures and characterize their relativecontribution to the total fluctuation energy at associated. Among the mainfindings, a dominant mode was found which describes the filling and emptyingprocess during surge. A narrowband feature at half of the rotating order wasidentified to correspond to co-rotating vortices upstream of the impeller faceas well as elevated velocity magnitude regions propagating tangentially in thediffuser and the volute. Dominant mode shapes were also found at the rotatingorder frequency and its harmonics, which manifest as a spinning mode shapelocalized at the diffuser inlet. From the compressible LES flow solution one can extract the acoustic infor-mation and the noise affiliated with the compressor. This enable through datacorrelation quantifying the flow-acoustics coupling phenomena in the compres-sor. Detailed comparison of flow (pressure, velocity) and aeroacoustics (soundpressure levels) predictions in terms of time-averaged, fluctuating quantities,and spectra is carried out against experimental measurements. / <p>QC 20160406</p>

Pour les compresseurs axiaux et centrifuges, la minimisation du jeu, entre l’extrémité des aubes et le carter qui les entoure, augmente l’efficacité aérodynamique des turbomachines mais favorise également l’apparition de contacts structuraux. En présence du contact, les deux structures échangent de l’énergie et le système peut devenir instable lorsque ses fréquences propres, exprimées dans le même repère, sont égales. Nous verrons qu’il existe également la possibilité de créer des réponses forcées lorsque les harmoniques de la vitesse de rotation coïncident avec les fréquences propres de la structure fixe ou tournante. Dans les deux cas, les structures peuvent subir des endommagements assez importants. La maitrise de l’interaction aube-carter est donc logiquement un phénomène que les constructeurs de turbomachines doivent intégrer lors de la définition d’un moteur. Ainsi, dans l’étape de conception des compresseurs, il faut prévoir le comportement vibratoire du système en prenant en compte les phénomènes physiques les plus influents. Dans ce contexte, ce travail de recherche est focalise sur l’étude du comportement mécanique et thermomécanique résultant de l’interaction aube-carter entre un compresseur centrifuge (ou rouet) expérimental du premier étage de compression d’un moteur d’hélicoptère et son couvercle qui est recouvert d’un matériau abradable afin de réduire la sévérité du contact. L’objectif majeur des travaux présentes dans ce manuscrit est d’établir un scénario plausible pour expliquer les divers phénomènes présents lors du contact et de créer une base de données expérimentales, dans un environnement de laboratoire au travers d’un essai réaliste et maitrisé. Puis, il s’agit de confronter et valider les interprétations expérimentales sur un modèle numérique. Pour atteindre nos objectifs, nous avons utilisé un dispositif d’essai adapté afin de fournir des données fiables sur le comportement dynamique et thermomécanique en situation de contact aube-carter. L’analyse des résultats expérimentaux et numériques montre des évènements transitoires concomitants entre la structure fixe et tournante. Le contenu spectral des réponses est caractérise par la présence d’harmoniques de la vitesse de rotation et de sidebands, qui influencent le comportement dynamique du système lorsqu’ils coïncident avec les fréquences propres des structures. / In axial and centrifugal compressors, minimizing the clearance between the blade tips of the impeller and its surrounding casing increases the aerodynamic efficiency, but also the probability of contacts. An energy exchange is then produced between the two structures, leading to forced excitation of the natural modes and potentially to dynamical instabilities, such as interaction phenomena. In both cases, the structures suffer subsequent structural damages. Mastering blade-to-casing interactions is thus a phenomenon that turbomachinery manufacturers must incorporate into the design process of an engine. Compressor designers must predict the vibration behavior of the system, taking into account the predominant physical phenomena. In this context, this work focuses on the study of the dynamic and thermomecanichal behavior resulting from blade-to-casing interactions between a low-pressure centrifugal compressor (or impeller) and a casing lined with abradable coating. The main purpose of this work is to build a likely scenario to explain the various phenomena present when contact occurs, and the creation of a database for subsequent comparisons with numerical simulations. To achieve this, a test rig heavily instrumented has been used in order to better understand the influence of various physical phenomena (dynamic, wearing, heating). Analysis of experimental and numerical results shows transient events, characterized by a simultaneous increase in amplitude on both the rotating and stationary structures. The spectral content of the response highlights the presence of harmonics of the rotating speed and some sidebands aside from the main excited frequencies, which may cause the system to become unstable when they coincide with the natural frequencies of structures.

This research aims to assess the causes of inefficient and unstable operation of centrifugal compressors and turboexpanders in process gas applications in order to provide a solution for performance restoration and enhancement. It encompasses thermodynamic and flow evaluations to examine the efficiency and operating range improvement options of new units. Besides, this work is complemented by a technoeconomic analysis to provide a rounded outcome from these studies. In order to achieve the desired objectives, a novel integrated approach has been developed to assess the design and performance of multi-stage centrifugal compressors. The proposed systematic methodology involves five basic elements including evaluation of compressor selection, compressor sizing and casing structure, performance prediction at the design and off-design conditions, modelling of efficiency and head deterioration causes; and stage design evaluation. This will contribute towards evaluating the geometrical parameters of the new units’ designs at the early preliminary design phase, and thus, will be useful to identify the options for efficiency and operating range enhancements. For installed units, this approach can be implemented to assess the cause of inefficient and unstable operation by assessing the available operation data. A method was developed to predict the performance curve of multi-stage centrifugal compressor based on a stage stacking technique. This approach considers the advantages of Lüdtke and Casey-Robinson methods with an incorporation of a methodology for compressor selection and sizing to generate more accurate results. To emphasize the validity of the developed model, it has been evaluated for both low and high flow coefficient applications. The obtained results show a significant improvement in the estimated efficiency, pressure ratio, shaft power and operating range as compared with the existing methods. The centrifugal compressor is designed to run under various operating conditions and different gas compositions with the primary objective of high efficiency and reliability. Therefore, a new iterative method has been developed to predict the equivalent compressor performance at off-design conditions. This technique uses the performance parameters at design conditions as a reference point to derive the corresponding performance characteristics at numerous suction conditions with less dependency on the geometrical features. Through a case study on a gas transport centrifugal compressor, it was found that the developed approach can be applied for design evaluation on the expected variation of working conditions, and for the operation diagnosis of installed units as well. Furthermore, a parametric study has been conducted to investigate the effect of gas properties on the stage efficiency, surge margin, and compressor structure. The obtained results support the need for considering the gas properties variation when the off-design performance is derived. To evaluate the impact of internal blockage on the performance parameters, this study proposed an approach to model the effect of non-reactive deposits, which has been qualified using four operation cases and the obtained results are compared with the internal inspection findings from the stage overhauling process. This also covers the influential aspects of flow blockage on the technical and economic values. Since the main challenge here is to analyze the process gas composition in real time, the influences of the non-reactive deposits have been compared with the effect of the unanticipated gas composition change. Subsequently, it has turned out that the pressureratio parameter is not enough to assess the possibility of flow blockage and unexpected gas properties change. Moreover, it was observed that the stage discharge pressure was more sensitive to the fouled aftercooler comparing with suction and internal blockage. However, the effect of contaminated aftercooler on the surge point and discharge pressure and temperature of the upstream stage was found greater than its impact on the shaft power. Thus, a substantial surge margin reduction was detected when the first stage was operating with a fouled aftercooler comparing with the measured reduction as a result of unanticipated gas properties change. Furthermore, a larger pressure ratio drop was measured in the case of liquid carryover which revealed a more significant impact of the two phases densities difference comparing with the gas volume fraction (GVF) effect. The possibility of hydrate formation has been assessed using hydrate formation temperature (HFT) criteria. Additionally, this research highlights a number of challenges facing the selection of typical centrifugal stage design by assessing the contribution of design characteristics on the operating efficiency and stable flow range. Besides, an empirical-based-model was established to select the optimum impeller and diffuser configurations in order to make a compromise decision based on technical and economic perspective. It was concluded that there is no absolute answer to the question of optimum rotor and stator configuration. The preliminary aerothermodynamic evaluation exposed that the selection of the optimum impeller structure is governed by several variables: stage efficiency, pressure loss coefficient, manufacturing cost, required power cost, resonance frequency and stable operating range. Hence, an evaluation is required to compromise between these parameters to ensure better performance. Furthermore, it was argued throughout this study that the decision-making process of the typical stage geometrical features has to be based upon the long-term economic performance optimization. Thus, for higher long-term economic performance, it is not sufficient to select the characteristics of the impeller and diffuser geometry based on the low manufacturing cost or efficiency improvement criterion only. For turboexpanders, a simple and low cost tool has been developed to determine the optimum turboexpander characteristics by analysing the generated design alternatives. This approach was used in designing a turboexpander for hydrocarbon liquefaction process. Moreover, since the turboexpanders are expected to run continuously at severe gas conditions, the performance of the selected turboexpander was evaluated at different inlet flow rates and gas temperatures. It has turned out that designing a turboexpander with the maximum isentropic efficiency is not always possible due to the limitations of the aerodynamic parameters for each component. Therefore, it is necessary to assess the stage geometrical features prior the construction process to compromise between the high capital cost and the high energetic efficiency.

This thesis deals with a procedure for determining the complete processing of aerodynamic flow instabilities (rotating stall and surge) in a centrifugal compressor. At small flows the performance of a compressor system is limited by the surge line, which is caused by flow instabilities. Numerical solution is obtained using the method of transfer matrix. This system is simulated through several models with local resistances that represent the dissipation of pressure energy. Pulses are excitated in these models by the pressure jump placed before the centrifugal compressor. From the frequency-amplitude characteristics for the selected range of frequencies and flow the impedance characteristic of the compressor system is determined. We are looking for problematic frequencies in this characteristic that cause flow instabilities in the compressor system.

One elementary part of a centrifugal compressor is the volute, which is located downstream the impeller. Its purpose is to collect the flow and increase the static pressure by converting kinetic energy into potential energy. Despite its significant effect onto the design point and operating range of the compressor, the number of publications regarding this component is quite small. Therefore, a numerical optimization of the volute housing is performed in order to identify important geometric parameters and find an optimal volute geometry. For this purpose, a new density-based CFD solver for all Mach numbers is developed as well as an automated geometry generation tool for the volute housing. The results show, that a volute with an inlet eccentricity of 0.9 and a slightly lower radial volute channel offers the best compressor efficiency. Moreover, the actual cross-sectional shape of the volute has only a minor influence onto the performance. As a result, the isentropic efficiency could be improved by up to 2 % compared to the reference compressor model, in particular at high off-design flow rates. These results are a novelty in the scientific community and help to design more efficient compressors. / Das Spiralgehäuse eines Radialverdichters wird im Gegensatz zum Laufrad kaum in wissenschaftlichen Arbeiten untersucht. Um wichtige Geometrieparameter und Einflussfaktoren dieses Bauteils zu identifizieren, wird daher eine Optimierung mittels genetischer Algorithmen durchgeführt. Dazu wird zunächst ein dichte-basierter CFD-Löser entwickelt und validiert, um die komplexe Strömung in einem Radialverdichter mit hoher Genauigkeit simulieren zu können. Darauf aufbauend wird das Spiralgehäuse parametrisiert und ein Programm entwickelt, welches die komplexe Geometrie automatisiert erstellt. Durch die neuartige Kombination von numerischer Optimierung, automatisierter Geometrieerstellung und CFD-Simulation des Spiralgehäuses können erstmals Aussagen zur optimalen Geometrie sowie über Verlusteffekte für eine Vielzahl an Geomtrievarianten getroffen werden. Mit Hilfe dieses Wissens können sparsamere und effizientere Radialkompressoren für viele Bereiche des Maschinenbaus entwickelt werden.

<p>  </p> <p>As aviation fuel costs and consumption have continued to rise over recent decades, gas turbine engine manufacturers have sought methods to reduce fuel burn. Manufacturers plan to achieve this by reducing the specific fuel consumption of the machine by increasing the bypass ratio through a reduction of the diameter of the engine core. This presents an opportunity for implementing a centrifugal compressor as the final stage of the high-pressure compressor. The vaned diffuser in a centrifugal compressor stage maintains an integral role in determining the extents of the operating range as well as conditioning the flow for the downstream combustor. Thus, it is critical to understand the aerodynamics and performance of the vaned diffuser across the entire compressor operating range.</p> <p>This investigation focused on seven compressor operating points at the stage’s design corrected speed, which ranged from choked flow to the minimum mass flow rate before rotating stall. Steady-state and unsteady performance data were acquired to study the aerodynamics at each operating point as well as the steady-state performance of the vaned diffuser. Laser Doppler velocimetry, high-frequency pressure transducers, and additive manufacturing techniques were all implemented to acquire data in the research compressor.</p> <p>Unsteady velocity measurements were acquired in the vaneless space and were used to quantify the change in diffuser inlet incidence as the stage mass flow rate changes. The impeller exit jet and wake were compared at each operating point to understand the effect of these flow structures on the spanwise incidence profile. Steady-state performance metrics for the vaned diffuser were compared with the change in incidence to assess the effect of incidence on performance. Maximum static pressure recovery and minimum total pressure loss occurred at the maximum incidence operating point. </p> <p>The chordwise static pressure distribution is critical for health monitoring of the polymer, additive manufactured diffuser vanes. Steady-state and unsteady pressure measurements were acquired along the diffuser vane surface to assess the change in the aerodynamic lift force across the compressor operating range as well as the static pressure differential across the vane leading edge. The maximum unsteady lift on the diffuser vanes was up to 34% greater than the steady-state lift force. Unsteady static pressure differentials across the diffuser vane leading edge were similar to the steady-state values, but they were marginally greater across the entire examined operating range. These unsteady pressure measurements were acquired with high-frequency response pressure transducers installed along the diffuser vane surfaces. These transducers were also used to study the rotating stall and surge behavior of the investigated centrifugal compressor stage. This centrifugal compressor stage exhibits a spike-type rotating stall pattern at the onset of stage instability, which rapidly evolves into full flow reversal with several surge cycles. During these surge cycles, the diffuser vane leading edges are subject to a 20 psid static pressure differential. </p> <p>A computational model was used to predict the compressor flow at three different operating points. This model utilized the BSL-EARSM turbulence model, and it included surface roughness and an experimentally measured shroud thermal profile. The model accurately predicted the diffuser inlet flow angles near the shroud, but it predicted more radial flow near midspan. The diffuser vane leading edge static pressure differential was predicted within 1 psid at higher aerodynamic loading conditions. The differences between the computationally predicted and experimentally measured flow are attributed to difficulties associated with modelling the rate of mixing within the flow.</p>

The use of turbocharged Diesel engines is nowadays a widespread practice in the automotive sector: heavy-duty vehicles like trucks or buses, in particular, are often equipped with turbocharged engines. An accurate study of the flow field developing inside both the main components of a turbocharger, i.e. compressor and turbine, is therefore necessary: the synergistic use of CFD simulations and experimental tests allows to fulfill this requirement. The aim of this thesis is to investigate the performance and the flow field that develops inside a centrifugal compressor for automotive turbochargers. The study is carried out by means of numerical simulations, both steady-state and transient, based on RANS models (Reynolds Averaged Navier-Stokes equations). The code utilized for the numerical simulations is Ansys CFX.   The first part of the work is an engineering attempt to develop a CFD method for predicting the performance of a centrifugal compressor which is based solely on steady-state RANS models. The results obtained are then compared with experimental observations. The study continues with an analysis of the sensitivity of the developed CFD method to different parameters: influence of both position and model used for the rotor-stator interfaces and the axial tip-clearance on the global performances is studied and quantified.   In the second part, a design optimization study based on the Design of Experiments (DoE) approach is performed. In detail, transient RANS simulations are used to identify which geometry of the recirculation cavity hollowed inside the compressor shroud (ported shroud design) allows to mitigate the backflow that appears at low mass-flow rates. Backflow can be observed when the operational point of the compressor is suddenly moved from design to surge conditions. On actual heavy-duty vehicles, these conditions may arise when a rapid gear shift is performed. / Användningen av turboladdade dieselmotorer ärr numera utbredd inom bilindustrin: i synnerhet tunga fordon som lastbilar eller bussar ärr ofta utrustade med turbo-laddade motorer. En utförlig förståelse av flödesfältet som utvecklas innuti båda huvudkomponenterna hos en turboladdare, dvs kompressor och turbin, är därför nödvändig: den synergistiska användningen av CFD-simuleringar och experimentel-la tester möjliggör att detta krav uppfylls. Syftet med denna avhandling är att undersöka prestanda och det flödesfält som utvecklas i en centrifugalkompressor för turboladdare. Studien utförs genom nu-meriska simuleringar, både steady state och transient, baserat på RANS-modeller (Reynolds Averaged Navier-Stokes-ekvationer). Koden som används för de numeriska simuleringarna är Ansys CFX.   Den första delen av arbetet ¨ar ett försöka att utveckla en CFD-metod för att förutsäga prestanda för en centrifugalkompressor med hjälp av steady-state RANS-modeller. De erhållna resultaten jämförs sedan med experimentella observationer. Studien fortsätter med en analys av känsligheten hos den utvecklade CFD-metoden till olika parametrar: Inflytande av både position och modell som används för rotor-statorgränssnitt samt axiellt spel mellan rotor och hus på de globala prestationerna studeras och kvantifieras.   I andra delen utförs en designoptimeringsstudie baserad på Design of Experiments (DoE). I detalj används tidsupplösta RANS-simuleringar för att identifiera vilken utformning av ported shroud som minskar backflöde i kompressorn under en snabb minskning av massflöde och varvtal och därmed ger bättre prestanda i transient surge. På tunga fordon kan dessa förhållanden uppstå under växling.