Impeller Design Challenges on Integrally Geared Centrifugal Compressors

The integrally geared compressor, also known as a multi-shaft compressor, is a technology that has been around since the 1960s, but remains underdeveloped.  Usually seen in applications in the industrial gases industry, integrally geared compressors (IGCs) can range in size from small product machines to steam turbine driven high-horsepower, high-flow compressors for air separation plants.  These compressors modular construction principle, consisting of as many as eight different stages, allows for implementation in a large number of varied customer processes.  The main advantages of IGCs in the industrial gases industry is the compact design and smaller installation footprint, efficiency increases due to the use of multiple speeds for separate impellers, and overall lower operational and installation costs.

semi-open-impeller
Figure 1 – Semi-Open Impeller

One of the key design differences between the standard inline compressors and the IGCs is that the integrally geared compressor makes use of both closed AND semi-open impellers.  The reason for the use of open impellers in IGCs are the higher strengths due to better manufacturing techniques, speed of manufacture, and the inherent lower costs.  However, the main drawback to having an open impeller in your system is that in the event of impeller rub, the damage to the compressor would be significantly worse than with a closed impeller.

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Performance Effects of Axial Turbines & Compressors Due to Roughness Variations

As turbomachinery technology continues to advance in efficiency as well as overall power, many engineers want an estimate on how long these manufactured machines will operate.  Specifically, in high-temperature and high-flow turbomachinery applications, one of the main sources of performance degradation can be attributed to increases in surface roughness.  Gas turbine and compressor blades in particular experience a substantial amount of surface degradation over their lifetime.

gas turbine blade
Figure 1 – Gas Turbine Blade and Annulus Surface Wear (Source PowerMag)

There are many mechanisms that contribute to surface degradation in airfoils and annulus surfaces.  Foreign particles adhering to the material surface (or fouling) is generally caused by any increase in contaminants such as oils, salts, carbon, and dirt in the airflow.  Corrosion occurs when there is a chemical reaction between the material surface and the environment that causes further imperfections on the machine surfaces.  Additional mechanical factors such as erosion and abrasion will play a part in a machine’s surface degradation as well.

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Improving Turbine and Compressor Design Matching

Compressor-Turbine-MatchingOne of the most prominent steps of complete gas turbine design is turbine-compressor matching. There are three major components to a gas turbine: compressor, combustor, and turbine. Although all of the components are designed individually, each of the components needs to correspond within the same operating condition range since all are integrated into one cycle. Consequently, an optimal design of each component must fit the requirement of other component’s optimal parameters. Corresponding operating points for each component must be found at equilibrium with the engine, thus the overall performance of gas turbine can be reached within the defined range of parameters.

The idea behind component “matching” process is to find flow and work compatibility between corresponding components. Based on the mechanical constraints, gas generator speed and firing temperature of a gas turbine have limitations depending on: ambient temperature, accessory load and engine geometry. The match temperature chosen should be the ambient temperature which reach both upper limits at the same time.  Pressure ratio needed to allow a certain gas flow is also one of the most prominent parameters that has to be taken into consideration. Designers need to make sure that the gas flow through the power turbine from gas generator satisfy the pressure ratio needed for compressor power requirements. Gas generator can easily show an altered match temperature due to some conditions i.e: reduction in compressor efficiency (due to fouling, etc), change of thermodynamic properties of combustion product, gas fuel with lower or higher hearing value, etc. Match parameters of an engine could also be altered by changing the flow characteristics on the first turbine nozzle.Turbine-Compressor

Using characteristic map/curve as well as thermodynamic relationships of turbine and compressor, calculations can be performed to identify the permitted operating range. It must be taken into consideration that all calculated value must match the value from map data.

Trying to find the fastest solution for this step? SoftInWay’s turbine-compressor matching feature in AxSTREAM could help you cut engineering time and simplify the process. Combining performance maps of turbine and compressor, making it easier for the user to determine points of joints operations.

Take a look into AxSTREAM’s to learn more about this.

Reference:

https://www.grc.nasa.gov/www/k-12/airplane/ctmatch.html
http://cset.mnsu.edu/engagethermo/components_gasturbine.html
http://turbolab.tamu.edu/proc/turboproc/T29/t29pg247.pdf
http://scholarcommons.sc.edu/cgi/viewcontent.cgi?article=3255&context=etd
Turbine Compressor Matching Compatibility Mode Document

Variable Speed Compressor for HVAC and Refrigeration.

Even though energy consumption for HVAC and refrigeration system is considerably smaller than most technology applications, energy savings is still desired for many reasons: cleaner technology, saving cost, fuel economy and many more. Improvements in insulation, compressor efficiency and optimization of the cycle can be implemented to achieve better performance. Installation of variable speed drives is one way to optimize the potential of HVAC system.

Refrigeration

Although has been implemented to various HVAC components, variable-speed drive is considerably still one of the “newer” advancements in the compressor industry. These devices are able to precisely control the motor speed and trim/balance systems. Variable speed control compressor gives end-users the comfort of matching the speed to what is needed at the time; giving precise temperature control with less cycling and longer run times. With longer run times, the technology also helps to remove moisture and relative humidity during the summer; or on the other hand during the winter by increasing the speed of compressor, system are able to deliver hotter air.

Compared to fixed compressor, where there are only two options for end-users to set: maximum capacity or completely off; variable speed drives gives the end-user an ability to adjust power output to compressor. The technology also comes with the benefit of less energy wasted from off and on cycle, precise load matching and low amp gradual compressor motor startup; therefore, improving the efficiency on certain conditions.

Compressor

Coupling variable speed drives to centrifugal compressor alter the behavior of the component. Although, not always requiring smaller energy (i.e at or near full load) compared to fixed speed compressor, installation of VSD could really benefit the users in terms of power consumption (i.e at part lift), to optimize even further implementation of both compressor types would benefit both conditions.

Want to learn more? Design your most efficient compressor using AxSTREAM

Reference:

Variable Speed Air Compressor

Reduction In Power Consumption Of Household Refrigerators By Using Variable Speed Compressors

The Impact of Variable-Speed Drives on HVAC Components

Heat pump and refrigeration cycle

 

Design Considerations in Turbochargers (Part 1 – Incidence)

A turbocharger (TC) has to provide a required pressure ratio for efficient combustion and operation of an internal combustion engine (ICE). The turbocharger consists of a turbine and a compressor sides on the same shaft. The turbine utilizes the energy of exhaust gases while the compressor forces the air into the engine. The compressor with a wide operating range is a strict requirement in the automotive industry because the unit has to operate across all of the ICE regimes.

Even though any compressor has a design point, the ability to operate at low and high mass flows is critical for TC compressors. To satisfy the operating range requirement, a designer tries increasing mass flow at choke and decreasing mass flow at surge. This is quite a challenge. For smaller mass flow rates, the impeller outlet and diffuser should be optimized. The choice of a vaneless diffuser is always justified by increased flow range at the cost of efficiency.

To increase the right-most mass flow limit, a designer optimizes the compressor inlet. The common practice is to design blades with large inlet metal angles. Increase in inlet angles open larger area for the flow to pass. This, in turn, leads to large incidence angles at design point. Therefore, many TC compressors are designed with large positive incidence in the design point. The incidence angle increases for every speedline going toward the surge line. Incidence distribution on a TC compressor map is shown in the figure below. It is equal to +12 deg (with respect to tangent) in the design point.

Fig. 1 Incidence on the TC compressor map
Fig. 1 Incidence on the TC compressor map

Glossary:

Blog - incidenceDesign point: An operating condition where a compressor reaches maximum efficiency

Compressor Map: Pressure versus mass flow characteristic at different rotational speeds and isoefficiency contours

Speedline: Dependence of pressure on mass flow rate for a given shaft speed

Surge: Left-most point on a compressor map for a given shaft speed

Choke: Right-most point on a compressor map for a given shaft speed

Incidence: The difference between inlet flow and metal angles. If an incidence is small, the flow has less resistance to enter the impeller.

Source: http://www.turbobygarrett.com/turbobygarrett/compressor_maps

Beyond the Clouds in No Time

We can all agree that airplanes are cool, and rockets are awesome, but when combined, the result is even better! Besides getting engineers to jump up and down for this revolutionary concept, Reaction Engines Ltd applied it to an actual SABRE engine concept.

SABRE stands for Synergistic Air-Breathing Rocket Engine and one typically does not associate “Air-Breathing” with “Rocket.” which makes this engine a one of a kind to reach new heights (literally). Let’s dig into the geeky technical specs of the engine while going through some quick history of this revolutionary single stage to orbit propulsion system.

SABRE Engine
Source: Reaction Engines

SABRE is an evolution of Alan Bond's series of liquid air cycle engine (LACE) and LACE-like designs that started in the early/mid-1980s under the HOTOL project. Upon termination of HOTOL funding, Bond formed Reaction Engines Ltd. SABRE is currently being developed for hypersonic flights and runs on a combined cycle; the precooled jet engine configuration is used in the air-breathing phase of the flight until air becomes scarce and speed critical. From this moment on the engine switches to its close cycle rocket mode to bring the Skylon airplane to orbit (2 engines are mounted on the aerospace plane).

The air-breathing mode (below Mach ~5 and about 25 km altitude which is about 20% of the orbital velocity and altitude, respectively) works almost like a regular jet with one major difference being the apparition of a new component, first discussed in 1955; the air precooler which is placed behind the translating axisymmetric shock inlet cone that slows the air to subsonic speeds inside the air-breathing engine using 2 shock reflections. The precooler is “capable of cooling incoming air (without liquefying it, from around 1000°C) to −150°C (−238°F), to provide liquid oxygen (LOX) for mixing with hydrogen to provide jet thrust during atmospheric flight before switching to tanked LOX when in space." This precooler also allows a considerable reduction of the thermal constraints of the engine which then requires “weaker” and much lighter materials that are a necessity when reaching orbital velocities and altitudes. With compressors working more efficiently with a colder fluid, and the incoming air already highly compressed from the flight speed and shock waves, the fed pressure in the combustion chamber is around 140 atm. When in rocket mode, the inlet cone is closed and liquid oxygen and liquid hydrogen are burned from on-board fuel tanks for the remaining 80% of velocity and climb required to reach orbit.

Source: Reaction Engines

On a very recent note, feasibility studies conducted by the U.S. Air Force Research Laboratory were successfully passed in 2015.

Although the application of the SABRE engine is destined for orbital use, its cousin (Scimitar) has been designed for the environmental-friendly A2 hypersonic (top speed higher than Mach 5) passenger jet for 300 rushed passengers (about 3 times more than the Concorde) under the LAPCAT (Long-Term Advanced Propulsion Concepts and Technologies) study founded by the European Union.

When dealing with such high speeds, noise becomes a real constraint and flying above inhabited areas is restricted, which is why specific aerial routes are designed. According to Alan Bond, the A2 design could fly subsonically from Brussels International Airport into the North Atlantic, reaching Mach 5 across the North Pole and over the Pacific to Australia in about 4.6 hours, with a price tag similar to what you would pay for business class these days. This speed would heat the body of the craft so that windows are not an option because the appropriate thickness would represent a considerable weight. It is therefore thanks to flat panel displays showing images that you would be able to enjoy the scenery.

Blog - plane 2
Source: www.salon-de-l-aviation.com

When one talks about high-velocity flight it is difficult not to think of the French Concorde that operated between 1976 and 2003 and could travel at Mach 2.04 (limited by thermal constraints due to the material used) using the Scramjet technology; scramjet standing for “supersonic combustion ramjet”. This allowed a New York City to Paris flight in less than 3.5 hours instead of 8 hours with a conventional jet.

Blog -220px-Concorde_Ramp
Source: http://www.concordesst.com/powerplant.html

The principle of this technology is to compress air with shock waves under the body of the aircraft before injecting the fuel (the Concorde’s intake ramp system can be seen on the figure on the right).

Due to the high inefficiency of this technology at low speeds, afterburners are used from take-off until reaching the upper transonic regime.

Keeping in mind that the heating of the Concorde’s body due to friction could make it expand by as much as close to a foot, it becomes easy to understand one of the reasons why high altitudes (scarcer air and therefore lesser aerodynamic resistance) are chosen for such high flight velocities; the Concorde cruising altitude was around 56,000 ft and would be decreased when sun radiation levels were becoming too high. On a side note you can keep an eye out at Charles de Gaulle airport in Paris (France) for a Concorde displayed outside.

Oh and did I forget to mention that the turbomachinery parts on the SABRE engine are currently being designed in the AxSTREAM suite??

SoftInWay Case Study

Turbochargers in Formula 1

The history of turbochargers in Formula 1 is pretty fascinating. Turbochargers were initially introduced in 1905, applied to large diesel engines in the 1920’s and found their way into commercial automobiles in 1938. However, it took a few more decades for the turbochargers to be used in Formula 1 car racing.

When Renault decided to enter the sport in 1977, they started their engines based on the novel turbocharger concept. As one would expect, their first design suffered from constant reliability problems through all the races it competed in. As Renault focused their development entirely on the engine, the car’s aerodynamics worsened; it suffered a huge turbolag under acceleration, and when the boost finally triggered the tires were not able to handle it [1]. “So the engine broke and made everyone one laugh”, Jean-Pierre Jabouille, the driver, admitted in an interview. At the time, everyone was looking at the turbo engines as something that no one would ever hear about again.

MMR, twin turbocharged GT500 V8 engine, from Mustangs Daily [3].
MMR, twin turbocharged GT500 V8 engine, from Mustangs Daily [3].
From theJUDGE13 [2].
From theJUDGE13 [2].
 

 

 

 

 

 

Continue reading “Turbochargers in Formula 1”

Innovation in Aerospace: Aircraft Compressor Design

Aerospace - croppedOur next webinar is on Thursday, April 30th! Are you an engineer involved in the Aerospace Industry and its latest development, a manager interested in improving the performance of your aircraft engines, or a student interested in the future of aerospace and the current climate of the industry? You should attend! During the webinar, we will be taking a close look at the most recent trends and developments of compressors in aircraft engines with a focus on the key factors for the successful development of aircraft engines.

Key factors for the successful development of aircraft engines include technological viability, performance, and re-usability. As one of the industry’s most high-technology products, aircraft engines require innovation in manufacturing and especially in design. They also face the need for continuous development in their technical capabilities in terms of achieving not only higher efficiencies and reliability but also safety and environmental legislation.

Continue reading “Innovation in Aerospace: Aircraft Compressor Design”

Innovative Boost of Larger Internal Combustion Engines

The last few decades have brought with them a dramatic increase in the development and use of turbochargers in automobiles, trains, boats, ships, and aircrafts. There are several reasons for this growth, including rising demand for fuel efficiency, stricter regulations on emissions, and advancements in turbomachinery design. Turbochargers are appearing more and more and are replacing superchargers.

turbocharger
Turbocharger

 

Turbochargers are not the only turbomachinery technology growing in popularity in the marine, automobile, and railroad industries. Organic Rankine Cycles are being applied to take advantage of the exhaust gas energy and boost engine power output. ORCs, a system for Waste Heat Recovery, improve the overall efficiency of the vehicle, train, or boat, and reduce specific emissions.

As the size of the engines we consider increases, there is more heat available to recuperate, and more potential WHR systems to use. For instance, we can consider different combinations of these systems with both non-turbocharged and turbocharged engines. We are able to design and compare engine boost system combinations, with and without a turbocharger, with and without a blowdown turbine, and with and without a WHR system, at the cycle and turbine design levels.

In our upcoming webinar, we will do just that. We will design different combinations for larger ICEs and compare the results. This webinar will also cover introductions to these systems and application examples for supplementary power production systems in the automotive and marine industries.

We hope you can attend! Register by following the link below.

[su_button url=”http://www2.softinway.com/automotivewebinar” target=”blank” radius=”round” icon=”icon: arrow-right”]Register[/su_button]

 

TBT Webinar: Centrifugal Compressor Design: Can You Really Avoid Choke and Surge?

It’s Throwback Thursday and we are sharing another of our past webinars! This week’s is called Centrifugal Compressor Design: Can You Really Avoid Choke and Surge?

video2

Surge and choke are inherent, sophisticated phenomena in centrifugal compressor operation. They limit the operational range of any centrifugal compressor and cause severe damage to the machine if it is in surge condition. Several books cover the development of centrifugal compressor surge and choke models that can be applied in compressor control systems in order to avoid surge and choke; while these methods focus retroactively, there are some proactive methods that can be applied during the design phase of the machine. Continue reading “TBT Webinar: Centrifugal Compressor Design: Can You Really Avoid Choke and Surge?”