Automatic efficiency optimization of an axial compressor with adjustable inlet guide vanes

Experimental investigations are performed in a three-stage low-speed axial compressor with variable inlet guide vanes (IGV) and adjustable stators. The characteristics of the compressor, especially the efficiency and stall margin, are analyzed in design and off-design operation conditions by adjusting stagger angles of IGV and stators as well as changing the rotational speed. The experimental results show that the off-design performance of the multistage axial compressor is improved by restaggering of IGV and stators related to rotational speed. Considering the background of engineering applications, digital signal processing (DSP) technique is used to realize online adjustment of stagger angles according to the corresponding relations between incidence angles of rotor and rotational speed.

Numerical and experimental investigation of the shock-vane interaction in a transonic compressor

The internal losses in the tip clearance region strongly influence the compressor performance and its operational range. Previous research proved that passive wall treatments with circumferential grooves in axial compressors effectively increase the compressor stall margin. The vortex generated inside the circumferential grooves creates a resistance to the flow that leaks into the tip clearance region of the compressor. However, most works found in the literature on circumferential grooves in axial compressors deal only with high-performance single-stage axial compressors. Therefore, there is a need to investigate and analyze the behavior of circumferential grooves in a multi-stage environment. In the present work, a passive wall treatment with circumferential grooves was implemented in a multi-stage axial compressor. Different configurations of circumferential grooves were created at the casing of the first and second rotor rows used in a four-stage axial flow compressor. Numerical simulations were performed to evaluate the influence of the circumferential grooves on the performance of a multi-stage axial compressor. The results obtained after the simulations for the different circumferential groove configurations were compared with the results obtained for the compressor without casing treatment (smooth wall) for different rotational speeds. Furthermore, the complete compressor map characteristics were simulated for the different casing treatment configurations, and the results were compared with the compressor characteristics of the smooth wall case. The passive wall treatment with circumferential grooves produced changes in the multi-stage axial compressor flow field, especially in the tip clearance region, improving the compressor stability mainly for part load speeds.

The interaction between wakes of an adjacent rotor-stator or stator-rotor blade row pair in an axial turbomachine is known to produce regular spatial variations in both the time-mean and unsteady flow fields in a frame relative to the upstream member of the pair. This paper examines the influence of such changes in the free-stream disturbance field on the viscous losses of a following blade row. Hot-wire measurements are carried out downstream of the outlet stator in a 1.5-stage axial compressor having equal blade numbers in the inlet guide vane (IGV) and stator rows. Clocking of the IGV row is used to vary the disturbance field experienced by the stator blades: the influence on stator wake properties is evaluated. The magnitude of periodic fluctuations in ensemble-average stator wake thickness is significantly influenced by IGV wake-rotor wake interaction effects. The changes in time-mean stator losses appear marginal.

Computational fluid dynamics (CFD) of industrial-scale, axial compressor geometries has traditionally been performed using steady state methods such as the mixing plane approach. With the surge in the development of large-scale, massively-parallel computing platforms, fully 3D unsteady approaches are rapidly growing in popularity. The fully 3D, unsteady approach involves building a full 3D domain for each blade row, and then coupling the stationary and rotating domains using a sliding interface. In the literature, there are various methods for solving this 3D unsteady problem, such as the Unsteady Reynolds Averaged Navier-Stokes (URANS) and the Detached Eddy Simulation (DES) methods. While these methods are well documented for a variety of real-world problems, there have been limited efforts to compare the effectiveness of these methods for fully 3D, unsteady turbomachinery problems. In this study, the first stage of an industrial-scale axial compressor was simulated using: i) the URANS approach, and ii) the DES approach. The compressor geometry consisted of an inlet housing, inlet guide vanes (IGV), a rotor, and a stator. The RANS model for both simulations was the k-epsilon model. For both of these cases, sliding mesh interfaces were located between the IGV and rotor, and between the rotor and stator. The results of the URANS and DES approaches were time-averaged and their predictions were compared. Throughout the study, our goal was to provide important insights into the performance of the URANS and DES approaches, and to highlight the essential differences.

Non-axisymmetric end wall profiling is now a well established design methodology in axial flow turbines, used principally to improve their aerodynamic efficiency by reducing secondary loss. However, profiled end walls (PEWs) have yet to find an in-service application in a gas turbine compressor. This two-part paper presents the results of a number of studies, both experimental and computational, into the potential aerodynamic benefits of applying PEWs in axial flow compressors. The second paper describes an investigation into PEWs as a means of suppressing stator hub corner stall. An in-house design optimisation system (SOPHY) was applied to a typical embedded stator row in a multi-stage HP compressor. This enabled a new PEW geometry to be defined which is shown to be an effective alternative to 3-D aerofoil shaping in controlling stator hub corner stall. The results of this new study and of the work described in the first paper have been combined in a further investigation. PEWs were applied to an HPC with purely 2-D blading, which exhibited extensive stator hub corner stall at off-design conditions. CFD analysis showed that stator hub corner stall was successfully suppressed by the PEWs. It is concluded that PEWs can significantly affect the end wall flow field and have similar effects on corner stall as 3-D blading. The potential for improving the performance of axial flow compressors using PEWs is discussed. To successfully achieve any such improvements, extensive computational resources that are dedicated to design optimisation will be required.

Over the years it has been speculated that the performance of multi-stage axial flow compressors is enhanced by the passage of a wake through a blade row prior to being mixed-out by viscous diffusion. The link between wake mixing and performance depends on the ability to recover the total pressure deficit of a wake by a reversible flow process. This paper shows that such a process exists, it is unsteady, and is associated with the kinematics of the wake vorticity field. The analysis shows that the benefits of wake total pressure recovery can be estimated from linear theory and quantified in terms of a volume integral involving the deterministic stress and the mean strain rate. In the limit of large reduced frequency the recovery process is shown to be a direct function of blade circulation. Results are presented which show that the recovery process can reduce the wake mixing loss by as much as seventy percent. Under certain circumstances this can lead to nearly a point improvement in stage efficiency, a nontrivial amount.

The main investigation subject considered in this paper is axial compressor model stage K1002L. Three simulation models were designed: Scheme 1 – inlet stage model consisting of IGV (Inlet Guide Vane), rotor and diffuser; Scheme 2 – two-stage model: IGV, first-stage rotor, first-stage diffuser, second-stage rotor, EGV (Exit Guide Vane); Scheme 3 – full-round model: IGV, rotor, diffuser.Numerical investigation of the model stage was held for four circumferential velocities at the outer diameter (Uout=125,160,180,210 m/s) within the range of flow coefficient: ϕ = 0.4 – 0.6. The computational domain was created with ANSYS CFX Workbench.According to simulation results, there were constructed aerodynamic characteristic curves of adiabatic efficiency and the adiabatic head coefficient calculated for total parameters were compared with data from the full-scale test received at the Central Boiler and Turbine Institution (CBTI), thus, verification of the calculated data was carried out. Moreover, there were conducted the following studies: comparison of aerodynamic characteristics of the schemes 1, 2; comparison of the sector and full-round models.The analysis and conclusions are supplemented by gas-dynamic method calculation for axial compressor stages.

Numerical simulations were carried out with the purpose of investigating the effect of applying circumferential grooves at axial compressor casing passive wall treatment to enhance the stall margin and change the tip leakage flow. The tip leakage flow is pointed out as one of the main contributors to stall inception in axial compressors. Hence, it is of major importance to treat appropriately the flow in this region. Circumferential grooves have shown a good performance in enhancing the stall margin in previous researches by changing the flow path in the tip clearance region. In this work, a passive wall treatment with four circumferential grooves was applied in the transonic axial compressor NASA Rotor 37. Its effect on the axial compressor performance and the flow in the tip clearance region was analyzed and set against the results attained for the smooth wall case. A 2.63% increase in the operational range of the axial compressor running at 100%N, was achieved, when compared with the original smooth wall casing configuration. The grooves installed at compressor casing, causes an increase in the flow entropy generation due to the high viscous effects in this gap region, between the rotor tip surface and casing with grooves. These viscous effects cause a drop in the turbomachine efficiency. For the grooves configurations used in this work, an efficiency drop of 0.7% was observed, compared with the original smooth wall. All the simulations were performed based on 3D turbulent flow calculations using Reynolds Averaged Navier-Stokes equations, and the flow eddy viscosity was determined using the two-equation SST turbulence model. The details of the grooves geometrical dimensions and its implementation are described in the paper.

There are a number of performance indices for a turbomachine on the basis of which its strength is evaluated. In the case of axial compressors, pressure ratio, efficiency and stall margin are few such indices which are of major concern in the design phase as well as in the evaluation of performance of the machine. In the process of improving the blade design, 3D blade stacking, where the aerofoil sections constituting the blade are moved in relation to the flow. Tilting the blade sections to the flow direction (blade sweep) would increase the operating range of an axial compressor due to modifications in the pressure and velocity fields on the suction surface. On the other hand, blade tip gap, though finite, has great influence on the performance of a turbomachine. The present work investigates the combined effect of these two factors on various flow characteristics in a low speed axial flow compressor. The objective of the present paper is thereby confined to study the collective effects of sweep and tip clearance without attempting to suggest an outright new design. In the present numerical work, the performance of Tip Chordline Sweeping (TCS) and Axial Sweeping (AXS) of low speed axial compressor rotor blades are studied. For this, 15 computational domains were modeled for five rotor sweep configurations and three different clearance levels for each rotor. Through the results, 20°AXS rotor is found to be distinctive among all the rotors with highest pressure rise, higher operating range and less tip clearance loss characteristics. TCS rotors produced improved total pressure rise at the low flow coefficients when the tip gap is increased. Hence there is a chance that an “optimum” tip gap exists for the TCS rotors in terms of total pressure coefficient and operating range, while AXS rotors are at their best with the minimum possible clearance.

Ventricular assist devices (VAD) are designed to provide circulatory support to patients suffering from advanced-stage heart failure. While not pulsatile, the advantages of continuous axial flow VADs include a compact size and low mechanical failure rate. However, being compact, they operate at high speed, resulting in adverse effects, such as hemolysis caused by high flow shear and thrombosis formation in stagnant regions are common and threaten the successful use of the device. While state-of-the-art computational fluid dynamics (CFD) is widely used in designing these devices, detailed high-resolution experimental measurements of the flow within them are not readily available in the literature. Such experimental data is crucial for understanding the flow inside the VAD and its interaction with blood cells as well as for validating the CFD predictions. The present study investigates the flow inside a 1:1 exact replica of a VAD – ReliantHeart HeartAssist5®. This 12mm diameter device consists of an inlet guide vane (IGV), a rotor and a stator. However, unlike in the real machine, the rotor is driven by a thin shaft that penetrates through the center of the IGV. Refractive index-matching is used to facilitate optical measurements. Hence, all the blades and housing of the pump are made of transparent acrylic. The working fluid is a mixture of water, sodium iodide and glycerin, which matches the refractive index of acrylic, and the kinematic viscosity of blood. Performance tests have been carried out at speeds ranging from 7000 to 9000 RPM. Trends of the results are consistent with those of the actual machine. While scaled data for the pressure rise across the rotor at different speeds collapse, the total head rise across the entire machine does not. High-resolution 2D PIV measurements with vector spacing of 30μm have been conducted in meridional planes of the rotor passage at several blade orientations. They have been performed at 8000RPM and flowrate of 4.5L/min, consistent with physiological requirements. They show that near the rotor front end, the flow in the tip region is dominated by the tip leakage vortex (TLV), associated blockage effects, and very high turbulence level. The upstream end of this domain remains aligned with the leading edge, implying that blades persistently dissect the remnants of a previous TLVs. Interaction of the hub boundary layer with the blades also generates secondary flows. Downstream of the helical section of the rotor, the axial flow is high near the hub and low in the outer part of the passage due to leakage flow-related blockage. Hub boundary layer separation occurs upstream of the stator, generating a large circumferential vortex that occupies nearly half of the rotor span. The complexity of the flow structure and turbulence in this machine would be a challenge to model.

This paper traces the development of three-phase induction motor controls using the Semikron advanced integration (SKAI) power electronics system. The SKAI was developed for hybrid and electric vehicles and integrates all the components of a three-phase inverter. As such, it promises to deliver significant cost savings. The SKAI utilizes a digital signal processor (DSP) controller. However, Semikron does not supply the necessary software for the DSP controller. The DSP used in the controller is manufactured by Texas Instruments. Texas Instruments provides an array of DSP programming utilities. This paper discusses aspects of programming and testing the DSP controller

Variability in stator vanes is a widely used technique to improve the stability and efficiency of axial flow compressor in gas turbine engines. Most of the modern aircraft jet engines use variable stator vanes in both low pressure and high pressure compressors primarily for off-design performance. This study discusses in detail about the effect of stator variability in a three stage low pressure axial compressor at design and off-design conditions. Computational flow analysis were carried out for the three stage low pressure compressor with variability in inlet guide vane and first stage stator blade. Detailed investigation on flow physics was carried out in rotor blade passages with stator variability. At off-design speeds, the reduction in flow velocity is lower than the reduction in blade tip speed. This leads to mismatch in flow angles and inlet blade angles causing high incidence and large flow separation in blade passage. This results in poor aerodynamic stability of the axial compressor at off-design speeds. In this study, aerodynamic performance of compressor is evaluated from 70% to 100% design speeds with different stagger angle setting of inlet guide vane at each speed. Further, to improve 2nd stage rotor performance, variability was introduced in 1st stage stator blade and performance was evaluated. Compressor test results are compared with CFD data for design and off-design speeds.

Ambient air temperature plays significant role in performance of a Gas Turbine. Frequently Gas Turbines in electrical power generation are single rotor and are directly coupled to the Electrical Generators. These machines normally operate 8,000 hours per calendar year under the 100% load. The control of the combustion air flow is achieved by modulating compressor Inlet Guide Vanes (IGV). The single shaft axial compressor consumes as a rule of thumb more than 50% of turbine useful expansion work. Axial compressor is high-volume, moderate discharge pressure machine. Its power demand to discharge ambient air to the turbine combustion system is very dependent on ambient conditions such as pressure, temperature and relative humidity. The optimization of the axial compressor aerodynamic loading under various ambient conditions is therefore mandatory. During the hot and humid summer days, especially from the noon time to 6:00 PM, the demand for the power is at its maximum. This Paper describes selection, design and installation of the Inlet Air Cooling System. (IACS). The selected IACS is fine water mist, FOG. FOG System (FS) was selected because of its efficiency and because the clean water was available. FS incorporates Fog Generating Skid (FGS) and Fog Curtain (FC). FC is comprised of lateral lines with equally spaced. FOG Nozzles (FN). The FN is specially designed to generate individual “Fog Cones” that efficiently dissipate the water particles in the space. Fine water particles are atomized by incoming air in the Inlet Air (IA) duct. The homogenous mixture of FOG and IA is required to enhance the water mist particles evaporation process. In cases when the FS works in tandem with Evaporative Cooler (EC) most of the FOG particles are “injected” into the compressor suction. The injected FOG particles start to evaporate during the IA compression process. The water evaporation process simultaneously causes cooling of the IA being compressed. The result is reduced compression work and improved performance of GT.

Rotating stall is a primary constraint for the performance of axial flow compressors. This paper establishes a necessary and sufficient condition for a quadratic feedback controller to locally stabilize the critical equilibrium of the uniform flow at the inception of rotating stall. The explicit condition obtained in this paper provides an effective synthesis tool for rotating stall control.