Thesis (MScEng)--Stellenbosch University, 2014. / ENGLISH ABSTRACT: Turbomachinery plays an important role in the efficiency of power generation and combustion processes used in the automotive and aerospace industries. The potential for fulfilling future energy needs has been identified in both civilian and military applications, for example micro gas turbines (MGTs) used in unmanned aireial vehicles (UAVs). The goal of this thesis was to build a performance testing facility for small-scale centrifugal compressors, for use in MGTs. The objectives of this study were mainly achieved through experimental work. In addition to the experimental work, numerical simulations using computational fluid dynamics (CFD) software were performed to substantiate the experimental results. The project methodology followed the process whereby a compressor performance map is constructed from experimental data and compared to map obtained from theoretical data. The test facility consists of a turbocharger fitted with an experimental compressor section. The turbocharger turbine is driven by unheated compressed air. Sensors, data acquisition and ancillary equipment required to perform performance test measurements, were obtained and installed on the test facility. Performance curves at three different rotational speeds were successfully obtained for the experimental compressor. When compared to the CFD results there was good qualitative agreement, although deviations in the results increased with rotational speed. In addition a second impeller design was tested which correlated well with the theoretical data. / AFRIKAANSE OPSOMMING: Turbomasjinerie speel 'n belangrike rol in die doeltre endheid van kragop- wekking en verbrandingsprosesse wat in die motor- en lugvaartbedryf gebruik word. Die potensiaal om in toekomstige energiebehoeftes te voorsien is in beide burgerlike en militêre toepassings uitgewys, byvoorbeeld mikrogastur- bines (MGT's) wat in onbemande vliegtuie (OLV's) gebruik word. Die doel met hierdie tesis was om 'n prestasietoetsfasiliteit vir kleinskaalse sentrifu- gale kompressors te bou wat in MGT's gebruik kan word. Die doelstellings van hierdie studie is hoofsaaklik deur eksperimentele werk behaal. Daarbe- newens is numeriese simulasies met gebruikmaking van sagteware vir bereke- ningsvloeidinamika (BVD) gedoen om die eksperimentele resultate te staaf. Die projekmetodologie volg die proses om 'n kompressorprestasiekaart uit eks- perimentele data op te stel en dit te vergelyk met 'n kaart wat uit teoretiese data bekom is. Die toetsfasiliteit bestaan uit 'n turboaanjaer wat met 'n eksperimentele kompressordeel toegerus is. Die turboaanjaer se turbine word deur onverhitte druklug aangedryf. Sensors, dataverwerwing en bykomstige toerusting, wat benodig is om prestasietoetsmetings mee te doen, is bekom en op die toetsfasiliteit geïnstalleer. Prestasiekrommes is vervolgens by drie verskillende omwentelingsnelhede suksesvol met die eksperimentele kompres- sor bekom. In vergelyking met die BVD-resultate was daar goeie kwalitatiewe ooreenstemming, ofskoon afwykings in die resultate vergroot het namate die omwentelingspoed toegeneem het. Daarby is 'n tweede stuwerontwerp getoets wat goed met die teoretiese resultate korreleer.

This thesis constitutes detailed computational investigation on ow through the passages of a centrifugal compressor used for turbocharging applications. Given the dynamic nature of operation of the turbocharger, it becomes necessary to under- stand the ow that occurs within the blade passages and its e ect on performance. CFD is an established computational technique wherein the ow is dissected to fun- damental levels and a detailed picture is presented, application of this technique with limited and diverse sense towards understanding of ows through a turbocharger compressor has been successfully carried out by many before. This work presented attempts to address many of the lacuna reported and carries forward the work of several researchers to ll in the gaps. The complexity of the geometry of the blade shape poses many challenges in model- ing within the virtual space, an e ective way to overcome the obstacles is presented as a part of this work. Grid generation of the impeller and casing are discussed and adaptive approach is followed with generation of hexahedral grids for the impeller whereas tetrahedral for the casing. Since the grids of the impeller and its casing are di erent, ways of interfacing between the two domains in a CFD environment is discussed. An industry standard implicit 3D RANS solver was used to carry out the simula- tions. The importance of use of boundary conditions for the domain at unsteady operating points is presented in detail. On the choice made for turbulence model that governs the validity of the solution obtained, an extensive literature survey of the relevant topic as applicable for centrifugal compressors is presented and logic of the choice made for the present work is discussed. Menter's two equation SST-k! model emerges as the clear choice to be used even though the di erence in perfor- mance predictions by other turbulence models are insigni cant. Dynamics of ow at optimum design point, surge and choke of the compressor are presented in detail. With the geometry modeled with a tip clearance and the casing included within the simulation environment, it can be seen that the performance predicted is closer to actual at all operating points. A study of behavior of the compressor at extreme o design points is carried out and it can be seen that it depicts the trends that are seen in experimental works available in open literature. The distortion of pressure within the vaneless di user and the inviscid nature of the ow within the volute space are e ectively captured and an in depth analysis is carried out to uncover new patterns. A parametric study involving important geometric features such as the tip clearance and wrap angles are conducted leading to discovery of anomalies. The work summarizes to point out that the investigation carried out with the CFD simulations comprehensively leads to uncovering of ow dynamics within a complex system such as the centrifugal compressor within the limits of numerical analysis.

Thesis (MScEng)--Stellenbosch University, 2011. / ENGLISH ABSTRACT: Stellenbosch University participated in a project to re-design the compressor section of a diesel locomotive turbocharger. Tests conducted on the prototype compressor showed possible rotating stall in the diffuser section before the designed higher pressure ratio could be achieved. When approaching the higher pressure ratio, the compressor inlet trunk started to rhythmically collapse (due to suction), the engine shook and bellows of black smoke were exhausted by the engine. It was decided to simulate the prototype compressor's operation by using the 1-D theory of Aungier (2000) and to perform a 3-D CFD analysis of the compressor using FINE/Turbo of NUMECA International. A veri cation process was followed to show the accuracy of the 1-D and 3-D modelling methods using two well-known centrifugal compressor test cases found in the literature, namely the O-Rotor by Eckardt (1975, 1976, 1980) and the "Radiver" open CFD test case by Ziegler et al. (2003c). Results from the models were compared to available experimental results and the accuracy was found to be su cient to investigate the prototype compressor's impeller and diffuser. Both prediction methods con rmed separation in the vaned di user across the entire operating ow range of the prototype compressor at the design impeller speed. The 3-D method identi ed supersonic ow at the vaned diffuser inlet at the operating point and also predicted a smaller operating range than originally anticipated. Both the 1-D and 3-D methods also predicted impeller blade stall over the entire operating ow range at the design impeller speed. A recommendation was made to redesign the impeller and diffuser of the prototype compressor. / AFRIKAANSE OPSOMMING: Die Universiteit van Stellenbosch het deel geneem aan 'n projek om die kompressor gedeelte van 'n diesel lokomotief se turbo-aanjaer te herontwerp. Toetse uitgevoer op die prototipe kompressor het moontlike roterende wegbreking in die diffuser seksie uitgewys voordat die ontwerpte hoër drukverhouding bereik kon word. Toe die hoër drukverhouding genader is, het die kompressor inlaatpyp begin ritmies inmekaar vou (as gevolg van die suig aksie), die enjin het geskud en wolke swart rook is deur die enjin uitgeblaas. Die besluit is geneem om die prototipe kompressor se werking te simuleer met behulp van die 1-D teorie van Aungier (2000) en om ook 'n 3-D berekenings vloeimeganika (BVM) analise op die kompressor uit te voer met behulp van FINE/Turbo van NUMECA Internasionaal. 'n Veri kasieproses is gevolg om die akkuraatheid van die 1-D en 3-D modelle te illustreer met behulp van twee welbekende sentrifugaal kompressor toetsgevalle beskikbaar in die literatuur, naamlik die O-Rotor deur Eckardt (1975, 1976, 1980) en die "Radiver" oop BVM toetsgeval deur Ziegler et al. (2003c). Resultate van die modelle is vergelyk met beskikbare eksperimentele resultate en die bevinding is gemaak dat die akkuraatheid genoegsaam is om die prototipe kompressor se rotor en diffuser te ondersoek. Beide voorspellingsmetodes het wegbreking bevestig in die gelemde diffuser oor die hele werksbestek van die prototipe kompressor teen die ontwerp rotorspoed. Die 3-D metode het supersoniese vloei by die gelemde diffuser se inlaat by die bedryfspunt geïdenti seer en het ook 'n kleiner werksbestek voorspel as wat vroeër verwag is. Beide die 1-D en 3-D metodes het ook wegbreking in die rotor oor die hele werksbestek teen die ontwerp rotorspoed voorspel. 'n Voorstel is gemaak om die rotor en diffuser van die prototipe kompressor te herontwerp.

Thesis (MScEng)--Stellenbosch University, 2011. / ENGLISH ABSTRACT: Turbomachines are exposed to several environmental factors which may cause failure of components. One of these factors, high cycle fatigue, is often caused by blade utter. This thesis forms part of a project of the European Seventh Framework Programme (FP7), called project Future. Project Future is doing theoretical and experimental investigation into the occurrence of utter in turbomachinery. The objective of this thesis was to evaluate the effectiveness of a gas injection system as a means of exciting vibrations on the rst stage rotor blades of a compressor. Unsteady simulations of the excitation velocity perturbations were performed in the Computational Fluid Dynamics (CFD) software, Numeca FINE/Turbo. Experimental testing on the in-house Rofanco compressor test bench, using one prototype of the 15 injector system, provided data that was used to implement boundary conditions and to verify certain aspects of the unsteady simulation results. The simulation results revealed the following: the injector bypass frequency was so dominant that the excitation frequency was hardly detectable in the majority of cases. Furthermore, several secondary frequencies were consistently present. The injector bypass frequency, as well as the secondary frequencies, occurred as a result of the convolution of Fast Fourier Transforms. While the injector bypass frequencies can theoretically be eliminated, it will not be possible to eliminate the secondary frequencies from the blade response. In conclusion, according to the CFD results, it will not be possible to excite a single excitation frequency by making use of a nite number of gas injector vibration exciters. / AFRIKAANSE OPSOMMING: Turbomasjiene word onderwerp aan verskeie omgewingsfaktore wat falings van komponente kan veroorsaak. Een van hierdie faktore, naamlik hoëfrekwensie vermoeidheid, word onder andere veroorsaak deur lem adder. Hierdie tesis is deel van 'n projek in die Sewende Europese Raamwerk Program (European Seventh Framework Programme - FP7), projek Future. Projek Future doen teoretiese en eksperimentele ondersoek na die voorkoms van lemfl adder in turbomasjienerie. Die doelwit van hierdie tesis was om die effektiwiteit van 'n gasinspuiter vibrasie-opwekkingstelsel te evalueer, deur gebruik te maak van onbestendige simulasie in die berekenings vloei-meganika sagtewarepakket, Numeca FINE/Turbo. Eksperimentele toetswerk op die plaaslike Rofanco kompressortoetsbank, met 'n prototipe van die 15 inspuiter stelsel, het inligting verskaf wat gebruik is om die inlaattoestande te spesi seer en simulasieresultate te korreleer. Die simulasieresultate het getoon dat die frekwensie waarteen 'n lem by die inspuiters verbybeweeg, so prominent is, dat dit in die meerderheid van gevalle baie meer prominent is as die opwekkingsfrekwensie. Verder was daar ook deurgaans 'n aantal sekondêre frekwensies teenwoordig. Die teenwoordigheid van die inspuiter verbybeweeg frekwensie en die sekondêre frekwensies is die resultaat van die konvolusie van Vinnige Fourier Transforme. Alhoewel dit in teorie moontlik sal wees om die inspuiter verbybeweeg frekwensie te elimineer, is dit onmoontlik om die sekondêre frekwensies uit die lem vibrasie te elimineer. Ter opsomming, volgens die berekenings vloei-meganika resultate, is dit nie moontlik om met 'n stelsel van 'n eindige aantal inspuiters, 'n enkele vibrasie frekwensie op te wek nie.

Thesis (PhD)--Stellenbosch University, 2012. / ENGLISH ABSTRACT: This dissertation is basically a summary, with some interpretation, of published research by the author. The scope is limited to the fields of turbo-machinery, computational fluid dynamics and solar chimney power plants. The main contribution in the field of turbo-machinery in general is in the development of a through-flow method that automatically satisfies mass conservation. Concerning fan design, the contributions are the realization of the importance of the exit kinetic energy in the determination of the efficiency of rotor-only axial flow fans, and the quantification of the effect of off-axis inflow into cooling system fans on their performance. In the field of centrifugal fans and compressors an original, unifying model for the prediction of slip factor was developed. To investigate accident scenarios in closed cycle gas turbine nuclear reactors, all possible operational modes of multi-stage axial compressor operation caused by flow and rotation direction were investigated experimentally and computationally. Spanning the fields of turbo-machinery and solar chimneys, the basic theory of solar chimney turbines was developed, showing that high turbine efficiency was possible. In the field of solar chimneys, an original thermodynamic approach was developed to predict the main relationships that govern solar chimney performance, and to solve the through-flow equations for non-ideal systems with losses. Equations for the accurate determination of all the thermodynamic variables in a solar chimney as dependent on chimney height, wall friction, additional losses, internal drag and area change were derived and solved. Coefficients of wall friction, bracing wheel loss and exit kinetic energy were determined experimentally, and empirical equations were developed to predict the loss coefficient of the collector to turbine transition section and and the turbine inlet flow angle. A simple power law approach allowed the calculation of the optimal turbine pressure drop in solar chimney power plants. A comparison of two sets of equations used to calculate the heat fluxes into, inside and leaving the solar collector, resulted in similar air temperature rises in the collector, and similar produced power. It turned out however that the optimal flow for minimal turbine pressure drop was dependent on the heat transfer models. Investigation of the performance of various solar chimney turbo-generator layouts using analytical models and optimisation techniques showed that the optimal number of turbines varies with plant size, but the individual turbine size, the number of blades and even the efficiency remains close to constant. It was found that the cost of a turbogenerator system, however, varies significantly with size. A joint paper with several German universities and institutions did a comparative cost analysis of solar chimney power plants / AFRIKAANSE OPSOMMING: Hierdie verhandeling is basies ’n opsomming, met interpretasie, van gepubliseerde navorsing deur die outeur. Die omvang is beperk tot die gebiede van turbomasjinerie, berekeningsvloeidinamika en sonskoorsteenkragstasies. Die hoof bydrae op die gebied van turbomasjinerie in die algemeen is in die ontwikkeling van ’n deurvloeimetode wat outomaties massabehoud bevredig. Wat waaierontwerp betref is die bydrae die besef van die belangrikheid van die uitlaat kinetiese energie in die bepaling van waaierbenuttingsgraad, en die kwantifisering van die effek van af-as invloei in verkoelingswaaiers op hulle gedrag. Op die gebied van sentrifugaalwaaiers en -kompressors is ’n oorspronklike, samevattende model vir die voorspelling van glipfaktor ontwikkel. Om ongeluk-scenario’s in geslote kringloop gasturbine kenreaktors te ondersoek is al die moontlike werksmodusse veroorsaak deur vloei en rotasie rigting van ’n multistadium aksiaalkompressor eksperimenteel en numeries ondersoek. As brug tussen turbomasjinerie en sonskoorstene is die basiese teorie van sonskoorsteenturbines ontwikkel met die aanduiding dat hoë turbine benuttingsgraad moontlik is. Op die gebied van sonskoorstene is ’n oorspronklike termodinamies benadering ontwikkel om die hoofverwantskappe te voorspel wat sonskoorsteen gedrag bepaal, en om die deurvloei vergelykings op te los vir nie-ideale stelsels met verliese. Vergelykings vir die akkurate bepaling van al die termodinamiese veranderlikes in ’n sonskoorsteen soos afhanklik van skoorsteenhoogte, wandwrywing, bykomstige verliese, interne sleur en oppervlakte verandering is afgelei en opgelos. Koëffisiënte vir wandwrywing, verstywingswiel-verlies en uitlaat kinetiese energie is eksperimenteel bepaal, en empiriese vergelykings is ontwikkel om die verlieskoëffisiënt van die kollektor-tot-skoorsteen oorgang en die turbine inlaatvloeihoek te bepaal. ’n Eenvoudige magswet benadering het dit mootlik gemaak om die optimum turbine-drukval in sonskoorsteen aanlegte te bepaal. ’n Verglyking van twee stelle vergelykings om warmtevloede in, binne en uit die sonkollektor te bereken het gelei na soortgelyke temperatuurstygings en gelewerde drywing. Die optimale vloei vir maksimum drywing was egter afhanklik van die warmteoordrag modelle. Ondersoek van die gedrag van verskeie turbo-generator uitlegte, deur gebruik van analitiese modelle en optimeringstegnieke het getoon dat die optimale aantal turbines wissel met aanleg grootte, maar die individuele turbine grootte, die aantal lemme en selfs die benuttingsgraad bly feitlik konstant. Daar is egter gevind dat die koste van ’n turbogenerator stelsel beduidend wissel met grootte. ’n Gesamentlike artikel met verskeie Duitse universiteite en instansies het ’n vergelykende koste analise van sonskoorstene gedoen.

Approved for public release, distribution unlimited / Steam leakage from an aircraft carrier catapult is sometimes ingested into the aircraft engines upon launch which may induce compressor stall. Investigation of this phenomenon is of particular interest to the Navy with its new F35C, the aircraft carrier variant of the joint strike fighter. The single engine configuration of the F-35C makes this aircraft particularly vunerable to steam-induced stall. The present study examined both throttle-induced stall and steam-induced stall in a compressor at 90% and 95% speed through the use of 9 Kulite and 2 hot-film pressure transducers. The use of Fast Fourier Transform waterfall plots of the transient data before and during stall proved invaluable in determining stall precursors as well as the mode of rotor stall. In addition, a new computational fluid dynamic model was designed using CFX-5 software to represent a single blade passage of the compressor rotor, in order to predict compressor performance. The computed results were compared to experimental results gathered at various throttle settings. An accurate model will enable researchers to predict compressor performance for various and multiple gases. / Outstanding Thesis

Diante do expressivo aumento do número de refinarias de petróleo, bem como, com a crescente modernização das tecnologias de processo, englobando também o ramo petroquímico e de fertilizantes, notou-se que o consumo de energia de compressores centrífugos e suas eficiências tornaram-se de suma importância. Uma consequência desta nova realidade, está na necessidade de melhoria dos métodos estimativos para pré-dimensionamento e performance destas máquinas, o que necessariamente implica em uma previsão precisa de sua eficiência politrópica. Além disso, tais métodos devem também estimar as dimensões básicas de cada seção de compressão. A maior parte da literatura atual, versando sobre compressores centrífugos, tipo multiestágio, não está atualizada no que diz respeito à estimativa de eficiências politrópicas, quando comparadas com as eficiências alcançadas por compressores de fornecimento recente. Sendo assim, o principal objetivo da presente dissertação foi estimar um compressor centrífugo multiestágio, utilizando métodos adequados de cálculo. Isto implicou em comparar três métodos de estimativas, refletindo três procedimentos clássicos de cálculo, normalmente utilizados. Após pesquisa foram identificados três métodos, dois otimizados recentemente e um terceiro de abordagem mais antiga, proveniente de alguns fornecedores de compressores. Os métodos em análise são: Método das relações de Semelhança Otimizado por Sandberg (2016), Método de Lüdtke (2004), com correções propostas por Busaid e Pilidis (2016) e finalmente o Método dos Expoentes Politrópicos (N-Method), apresentado por Gresh (2001) e editado novamente em Gresh (2018). Os dois métodos mais recentes, embora baseados em diferentes critérios, apresentam estimativas de desempenho, dentro de uma precisão razoável, quando comparada aos dados reais de teste, enquanto que o método mais antigo, apresenta desvios significativos. Nesta dissertação, serão estimados seis casos reais de compressores, cujos resultados serão comparados aos estimados pelos três métodos de cálculo. Analisando os métodos, à luz dos desvios indicados nas tabelas para os seis casos, pode-se afirmar que o Método Simplificado e Corrigido de Lüdtke foi o que apresentou melhores resultados. O desvio relativo máximo apresentado foi na potência de eixo, cujo valor foi de 5,1%. Considerando o Método de Sandberg, verifica-se a partir dos desvios listados nas tabelas, que não cumpriu com o limite de aceitabilidade no tocante à potência no eixo para dois dos casos estudados. Entretanto, com exceção a estes dois casos, o método mostrou-se bastante satisfatório. Finalmente, analisando o Método dos Expoentes Politrópicos, citado por Gresh (2018), pode-se dizer que este método só foi aceitável para dois casos. Para os demais, segundo os desvios indicados nas tabelas, o método mostrou-se inadequado devido a desvios significativos na sua eficiência politrópica. / With the crescent number of modern fertilizer plants and hydrocracking process units in oil refineries, the consumption of energy and consequently the efficiency of centrifugal compressors were made of paramount importance in present day. A consequence of this new reality is the necessity of improvement of the methods that estimate the polytropic efficiency of these compressors. Furthermore, new methods also need to predict the basic geometric parameters of each machine. On the other side, most of the literature, which deals with polytropic efficiencies, is not up to date with the values performed by modern compressors. The main scope of present work is to provide background information and present a comparison between two up to date methods and a third classical old method, based on different approach, but capable to predict the performance and sizing of multistage centrifugal compressors. The methods under analysis are: Sandberg (2016) Optimized Similarity Method, Lüdtke\'s Method (2004), with corrections proposed by Busaid and Pilidis (2016) and finally the Politropic Exponent Method (N-Method), presented by Gresh (2001) and edited again in Gresh (2018). Both the newer methods present good agreement with the values performed by several compressors, as demonstrated when these methods are adopted, whilst the old method presents some deviations, mainly in the gas power. In this paper, six real cases will be estimated by the three methods and compared against supplier data; the results will be justified. Analyzing the methods, in respect of the deviations indicated in the tables for the six cases, it can be stated that the Simplified and Corrected Method of Lüdtke was the one that presented the best results. The maximum relative deviation presented was in the brake horsepower, whose value was of 5.1%. Considering the Sandberg Method, it can be verified from the deviations listed in the tables, that it did not meet the limit of acceptability regarding power on the axis for two of the cases studied. However, with the exception of these two cases, the method was quite satisfactory. Finally, analyzing the Politropic Exponents Method, quoted by Gresh (2018), it can be said that this method was only acceptable for two cases. For the others, according to the deviations indicated in the tables, the method proved to be inadequate, due to significant deviations in its polytropic efficiency.

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 1981. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND ENGINEERING. / Includes bibliographical references. / by Michael S. Idelchik. / M.S.

Thesis (Ph.D.)--Massachusetts Institute of Technology, Dept. of Aeronautics and Astronautics, 1981. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND AERO / Includes bibliographical references. / by Saeed Farokhi. / Ph.D.

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