Taking up a characteristic

of a centrifugal compressor
with an adjustable inlet guide grid

University Duisburg-Essen
Faculty for engineering sciences
Department of mechanical engineering
Turbomachinery
Prof. Dr.-Ing. F.-K. Benra
Table of contents

1 Introduction 2

2 Theoretical bases 3
2.1 Velocity-triangle of the compressor stage..................................................................... 3
2.2 Compressionwork, internal efficiency .......................................................................... 3

3 Characteristic curves und controlling of compressors 4

3.1 Theoretical and measured characteristic curves............................................................ 4
3.2 Regulation ..................................................................................................................... 5
3.2.1 Regulation by changing the rpm ....................................................................... 6
3.2.2 Suction throttle regulation................................................................................. 6
3.2.3 Regulation by blowing off or Umblasen?? ....................................................... 7
3.2.4 Regulation by adjustable installations within the compressor .......................... 7

4 Description of the plant 9

4.1 General operational data................................................................................................ 9
4.2 Components of the plant ............................................................................................... 9

5 Measuring instruments 11
5.1 Measuring point plan................................................................................................... 11
5.2 Measuring methods and –instruments......................................................................... 12
5.2.1 Temperature measurement .............................................................................. 12
5.2.2 Volume flow rate measurement ...................................................................... 12
5.2.3 Pressure measurement ..................................................................................... 12
5.2.4 Speed measurement......................................................................................... 13

6 Investigational procedures

7 Interpretation of test results 15

7.1 Evaluation of the measured values under test conditions ........................................... 15
7.2 Conversion on reference conditions ............................................................................ 16
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List of used symbols

Symbol Meaning Unit

Ad Cross section of the orifice opening m2

AD Tubing cross section m2
A* Closest flow passage area m2
c Absolute speed m/s
cp Specific heat capacity kJ/Kg K
g Gravitation m/s2
h Enthalpy kJ/kg
l Height of the liquid column m
m Aperture ratio -
M Mach number -
n Number of revolutions min-1
n Polytropic exponent -
p Pressure bar
P Drive power kW
R Gas constant kJ/kg K
T Temperature K
u Circumferential speed m/s
V& Volume flow rate m3/s
ω& Relative speed m/s
y Specific flow work J/kg
z geodetic height m
α Flow coefficient -
ε Expansion number -
κ Isentropic exponent -
η Efficiency -
ρ Density kg/m3
π Pressure ratio -
φ Vapor %

Indices

dyn Dynamic portion

m Meridional component, mechanical
Mot Drive
ref Reference condition
red Reduced
t Total size
u Circumferential component
 2

1 Introduction

In Turbomachineries the continuous current of the fluid gets energy extracted which is
supplied to the shaft as mechanical energy (Turbopowermachine). Otherwise mechanical
energy is supplied by the shaft to the rotor which submits it to the fluid as pressure- or kinetic
energy (Turboworkmachine).

The centrifugal-compressor is a Turboworkmachine in which the pressure-heightening is

achieved by converting of kinetic energy. The process of compression happens in radial
streamed rotors and stators.

Fig. 1.1 shows the areas in which several compressor-types are used. You can see that radial-
compressors are used for volume flow rates from 1500 to 400000 m3/h and for pressures till
500 bars. In dependence of flow rate and pressure-ratio they are carried out in several
arrangements, e.g. singlestaged - multistaged, singleflow - multiflow.

The purpose of centrifugal-compressors in modern techniques is varied. They are used for

• Compressed-air plant

• Charging of internal combustion engine

• As compressors in gasturbineplants

• As an so called process-compressor for unit-operations

• As cooling fan

Fig. 1.1: Operative ranges of several compressor-types

They are used for operative ranges, which means for several combinations of ratings like
pressure-ratio, mass flow, efficiency et cetera. The relation between these parameters can be
displayed in a characteristic diagram. In this experiment it is your task to determine a
characteristic of a centrifugal-compressor and compare it with the one given by the
manufacturer.
 3

2 Theoretical bases
2.1 Velocity-triangle of the compressor stage

The task of a compressor stage exists in the continuous compression of the incoming fluid..

Fig. 2.1: Velocity-triangle at the rotor

The streaming fluid reaches the entry of the bladed wheel with an absolute speed c1. The
current can be with or without a spin. You can adjust this by the diffuser plate (stator). The
current is influenced owing to the rotation of the bladed wheel. The fluid streams into the
channel with a relative speed which depends on the vectors of the velocity-triangle. (Pic. 2.1)

The energy conversion in a rotary grid of turbo machinery is described with the help of the
kinematic main equation.

M ⋅ω
1. Shape ∆ht = a = = u2 cu 2 − u1cu1
m&
c22 − c12 u22 − u12 ω22 − ω12
2. Shape ∆ht = a = + +
2 2 2

2.2 Compressionwork, internal efficiency

The work which is converted in turbo machinery corresponds to – within the condition of an
adiabatic change of state – the complete enthalpy difference between the plane in front of the
first bladed wheel and behind the last one. (This derives from the 1. Axiom for stationary
flow-processes)

By setting ahead an isentropic change of state and looking upon the fluid as an ideal gas, the
following term derives:
κ −1
 
κ   pt 2  κ 
(∆ht ) s = RTt1   − 1
κ −1  p
 t1  
(How to derive this should be known by every student!)

At a change of state, the change of the total enthalpy is given by:

∆ht1,2 = c p (Tt 2 − Tt1 )
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The ratio between isentropic and real difference of the total enthalpy is equal to the definition
of the total isentropic efficiency:
( ∆h ) ( ∆ht )s
(ηtV )s = t s = or
∆ht1,2 c p (Tt 2 − Tt1 )

κ −1
 
  p  κ
Tt1  t2
− 1
 pt1  
 
(ηtV )s =
(Tt 2 − Tt1 )
Finally we get the term for the necessary output to run the machine:
m& ∆ht1,2 V& ρ∆ht1,2
P= =
ηm ηm

3 Characteristic curves und controlling of compressors

3.1 Theoretical and measured characteristic curves

The theoretical curve of a compressor can be derived from the velocity triangles. A spin-free
inflow is to be present. Furthermore we take the assumption of equal cm (which is
characterizing for the flow rate) at entry and exit.

Fig. 3.1 shows the dependence of the volume flow to the velocity triangles directly. The angle
of flow β2 is decisive.

Fig. 3.1: Velocity triangle at exit of the rotor

The straight line yth (Pic. 3.2), which is derived by this, is only correct for an infinite number
of blades, which means it is a theoretical straight line. If you look upon a limited number of
blades the lift of delivery is reduced about ∆yz.

The friction losses ∆yr cause a further sinking of the characteristic curve, which becomes the
larger, the higher the flow rate is. The collision losses, which result from an unfavourable
incident flow of the profile nose, are considered by ∆yst. The collision losses become the
larger the further away by the design point the machine is operated. Finally the clearance
losses cause a further shift of the characteristic around ∆V, which causes an additional waste
of the efficiency. The execution of this view for different numbers of revolutions makes
predicting the characteristic diagram for a machine possible.

In a characteristic diagram pressure ratio, efficiency or enthalpy characteristics are laid above
massflow, volumeflow or flow rate characteristics. For this, the entrance sizes must be kept
constant. A characteristic shows the dependence for constant number of revolutions,
mentioned above.
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Fig. 3.2: Theoretical compressor characteristic

The operating point of a machine is given by the consumer. As you can see in Fig 3.2, it’s the
intersection between the compressor and plant characteristic.

For practice, a stable instrument range of a compressor is from great importance.

Fig. 3.3: Compressor- and Plant-characteristics

The stable work area is marked at smaller volume flow rates by the pumping border and at
larger volume flow rates by the sip border.

3.2 Regulation
The regulation of turbo machinery divides itself into two main areas:

I. The static controller action:

Here the possible regulatory interventions and their economy are examined to connection with
the machine.

II. The dynamic controller action:

This field covers the temporal sequence of the control procedure. Of special meaning are
layout and reaction as well as the stability of the controlling system. The dynamic behaviour
 6

of the compressor plant and its components (Pipings, radiator, valves, etc...) at fast load
changes has to be known. These changes result in the case of driving on and off as well as in
the case of incidents (Breakdown of the electricity mains). If a fast switch-off takes place, the
drain valve must open, in order to prevent the pumping of the compressor.

In the following example (Fig. 3.4) the change of the operating points is presented as a
function of the opening-time t of the valve.

Fig. 3.4: Dynamic properties of a compressor at a fast switch off

As you can see, the operating points for the times t=2s and t=1,6s – for smaller volume flow
rates - are beyond the stability range. To avoid a pumping of the compressor, a valve floating
time t<1,6s should be taken. According to the major tasks with the regulation of compressors
thereby problems have to be solved, for which also the characteristics of the consumers and
power supply units should be considered. The different controlling-procedures are examined
in the following terms.

3.2.1 Regulation by changing the rpm

Here the rpm are adapted to the required operating point for each case. A condition for this is
a drive, which is adjustable in the number of revolutions, because the drive must permit a
speed-regulation. The main advantage of regulation by changing the rpm consists of the fact
that the velocity-triangles in a wide field of the instrument range are similar to those, who are
present at the operating point. Thus a good efficiency is ensured for nearly all operating
points.

3.2.2 Suction throttle regulation

Through attach a throttle organ in the intake of the compressor the operating point can be
varied at constant number of revolutions. The intake pressure is lowered and behind the
compressor a lower pressure is automatically adjusted. Due to volume shifts, which can be
derived from the continuity equation, the separation phenomena at the pumping border are
shifted to smaller flow rates.
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Fig. 3.5: Regulation by suction throttle control

3.2.3 Regulation by blowing off or blowing back

A further possibility of the regulation can be achieved by blowing a subset off at the
compressor-exit. If this subset is led back to the intake, then one speaks of blowing back
regulation. Both procedures are strongly inefficient.

3.2.4 Regulation by adjustable installations within the compressor

Here losses are strongly reduced, by trying to adapt the machine to the operating-conditions.
This happens e.g. through:

a) By sliding a ring into the rotor inlet opening:

The current separates at the ring edge, and the available delivery volume is equivalent to a
smaller rotor.

Fig. 3.6: Regulation by adjustable ring

Although this procedure does not work loss-free, the inset is more economical than the
suction throttle control.

b) Pre-diffuser plate adjustment

With the help of an entrance control device the compressor is adapted to the operating
conditions in each case. The stator causes a change of the blow direction. On the basis of the
velocity triangles at the entrance the effect for the case of a current within a positive spin
should be described now. (Fig. 3.7)
 8

Fig. 3.7: Velocity triangles at the rotor inlet

On the assumption cm=const. the influence of the absolute speed c1 on the specific shovel-
work is clearly. The circumferential-component of c1´ becomes positive (positive spin), so that
the specific shovel-work
a = u2cu2 – u1cu1
becomes smaller.

This has the consequence that also the compression of the stage becomes smaller. Fig. 3.7
shows also the reverse effect for an incident flow with negative spin (cu1’’<0).

A throttle procedure is connected with dissipation, which has to be avoided as far as possible.

In the practical course attempt the regulation of the throughput takes place with the help of an
entrance control device as well as a throttle lying on the pressure-site of the piping. The flow
rate can be reduced or increased (in certain borders) by use of a pre-diffuser plate, whereby
the stability range is extended. Fig. 3.8 shows the characteristic diagram of a compressor with
an entrance control device.

Fig. 3.8: Diagram of a compressor with entrance control device

0°-position:
The guide vanes stand parallel to the incident-flow direction of the fluid.

Positive Spin:
This range extends from 0° to +80°. Here the flow rate can be reduced e.g. with constant final
pressure depending upon compressor-type up to 50% of the nominal quantity.

Negative Spin:
The usable range extends from 0° to for instance -30°. The flow rate and/or the pressure can
be reduced in limited extent. During over-regulation the current at the guide vanes tears off.
 9

This develops a turbulence, which leads to a substantial volume and pressure reduction which
reduces the efficiency.

4 Description of the plant

4.1 General operational data

The practical course attempt is done at a radial compressor of the type KG 3.32 of the
company DEMAG.

Design data of the compressor

Intake volume flow : 6500 m3/h

Sucking in temperature : 20° C
Intake pressure : 0,985 bar
Final pressure : 2,11 bar
Relative dampness : 70%
Clutch performance : 233 kw
Number of revolutions : 22340 U/min (=100%)

Speed ratio of the transmission : i = 7,446

As drive engine an electric motor of the company GARBE, LAHMEYER & CO. AG with the
following data is used:

Voltage : 400 V - DC voltage

Power input : 1070 / 1092 A
Number of revolutions : 0 – 1500 / 3000 U/min
Year of construction : 1980

4.2 Components of the plant

Fig. 4.1 is to illustrate how the individual components work together. Fig. 4.2 illustrates the
structure of the compressor.
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Fig. 4.1: Components of the plant

Fig. 4.2: Structure of the compressor-type KG 7

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5 Measuring instruments
5.1 Measuring point plan

In Fig. 5.1 the test range and the measuring point plan are represented. In the measuring point
plan of the plant the levels are registered, which should be measured. Level 1 marks the
condition of the air in the compressor entrance, Level 2 the condition in the compressor exit.
In level 3 an orifice plate (effect pressure procedure) for the determination of the flow rate is
used.

Fig 5.1: Test range and measuring point plan

In the levels specified above the following sizes are measured:

Level 1: - static pressure p1

- total temperature Tt1

Level 2: - static pressure p2

- total temperature Tt2

Level 3: - effect pressure ∆pBl

In addition the following sizes are necessary for interpretation of test results:

• Outside temperature T∞

• Ambient pressure p∞

• Engine speed n

The measuring instruments which are necessary for the collection of these sizes are described
in the next section.
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5.2 Measuring methods and measuring instruments

5.2.1 Temperature measurement

For the measurement of the temperatures 2 thermocouples are intended in the practical course
attempt.

The thermocouples are attached to an electronic measurer version plant, which converts the
measured thermovoltage into appropriate centigrades. These are brought on the screen of a
computer.

5.2.2 Volume flow rate measurement

The measurement of the flow rate takes place with the help of the effect pressure procedure
according to DIN 1952. A schematic representation for the measurement of the effect pressure
is given in fig. 5.2.

Fig. 5.2: Flow measurement by the effect compression procedure.

To the relationship between the flow and the measured effect pressure the equation applies:
2∆pOr
V& = αε Ad (5.1)
ρ
ε : Expansion number
α : Flow coefficient
∆pBl : Effect pressure
Ad : Cross section of the opening
ρ : Density
The effect pressure ∆pBl is measured with the help of one u-pipe-manometer filled with water.

The necessary data for the inserted standard orifice you can find in chapter 7.

5.2.3 Pressure measurement

The static pressure is measured in conventional way with the help of a Prandtlrohr and a u-
pipe-manometer downstream.

With the help of the u-pipe-manometer the difference between the static pressure and the
ambient pressure is measured. To the static pressure applies thus:
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p = (p - p∞) + p∞
= ∆p + p∞

(Note during the evaluation that ∆p1 is negative!)

The total pressure pt results from the following relationship:

pt = p + pdyn (5.2)

It shows up that the dynamic pressure pdyn is comparatively small at the speeds arising in the
practical course, so that total pressure and static pressure in good approximation can be
equated.

Pt = p

U-pipe-manometer:
The measured difference of pressure amounts for an equal-leg u-pipe-manometer, if the
density of air is neglected in relation to the density of the measuring liquid ρFl.

∆p = g l ρFl (5.3)

In the practical course attempt the u-pipe-manometers for the static pressure measurement are
filled with mercury. By the higher density of mercury opposite of water a larger pressure
range can be seized.

For the conversion of the read off liquid column in units of pressure see chapter 7.

5.2.4 Speed measurement

The engine speed nM is measured on optical way at the clutch between transmission and
electric motor. For this a giver and a counting device are available.

For calculating of the compressor number you need the following formula:

nV = nM ·i ; i = 7,446

Here i is the speed ratio of the transmission.

6 Investigational procedures
For the practical course a reference characteristic diagram is given, which was measured with
the following suction conditions:

Tref = 291 K pref = 1.1013 bar nM,ref = 2700 min-1

Since these conditions are present only in a few cases at the time of the execution of the
practical course attempts, it is, in order to receive comparable conditions in the compressor,
necessary, to keep some demands from the similitude theory. Under the condition that the
isentropic exponents at attempt- and reference conditions are equal, the change in status in the
compressor can be kept alike. Additional the demand after same Mach numbers and same
Reynolds numbers has to be fulfilled. For a practical course all these demands don’t have to
 14

be fulfilled except the Mach-similarity. The influence of the change of the Reynolds-number
has to be neglected. Mach-similarity is present, if with the circumferential speed of the
impeller formed Mach number at test conditions agrees with that of the reference condition.
M 1uV = M 1uref
u
= = konst. (T1 ≈ T2 )
κ ⋅ R ⋅ T1
or transformed
uV i ⋅ nM Tt1V
= =
uref i ⋅ nM ,ref Tt1ref

Thus the compressor number of nV results in the case of test conditions as reduced number of
revolutions to:
Tt1V
nV = i ⋅ nM = i ⋅ nM , ref
Tt1ref
The appropriate engine speed nM = nV must be determined before beginning of the attempt
i
(pocket calculator !!!).

Switching on of the engine on as well as the controlling of the engine speed takes place at the
control desk.

After starting the plant short time must be waited, until a stationary condition adjusted itself.

The adjusting of the operating points (Intersection of compressor characteristic and plant
characteristic) takes place via adjustment of the entrance control device and the throttle
attached on the pressure site.

The control device can be adjusted directly at the blower (manually) or by a by hand steered
motor drive.

Each group has the task during the attempt to determine the measured values for the
examination of the throttle characteristic with a firm position of the entrance control device.
The position of the entrance control device and the throttle positions which are necessary for
the determination of the throttle characteristic are given before the attempt.

For the later determination of the compressor characteristic the following sizes must be
measured and be registered into the prepared measurement-table.
Level 1: - static pressure p1
- total temperature Tt1
Level 2: - static pressure p2
- total temperature Tt2
Level 3: - effect pressure ∆pBl for calculating the volume flow.
In addition:
• Ambient pressure
• Intake pressure
must be measured.
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7 Interpretation of test results

7.1 Evaluation of the measured values under test conditions

• Temperatures
The total temperatures Tt1 and Tt2 are indicated on the screen of a computer directly in
centigrade.

The static temperatures result from the kinetic energies

c2
T = Tt −
2c p

Since the flow rates are relatively low in sucking and pressure pipe, these differences are
neglected during the further evaluation (T1 ≈ Tt1; T2≈Tt2).

• Pressure
The static pressure is determined for the respective level (chapter 5.2.3).

pi = ∆pi + p∞ i=1,2
To the total pressure P applies:
pti = pi i=1,2

• Flow rate
For the determination of the characteristics the flow rate at the compressor entrance (Level
1) is needed. In addition first the flow rate in level 3 is determined. Here it is to be
presupposed that the thermodynamic condition is identical in the levels 2 and 3 (p2=p3;
T2=T3). The flow rate V3 can be calculated by:
2∆pOr
V&3 = V&2 = αε Ad
ρ2
For the following effect pressure measurement in the practical course attempt a standard
orifice with the following values is used:
α = 0,70673
ε = 0,99568
Ad = (0,1892406 m)2 π/4

The density ρ2 before the orifice can be calculated with the help of the equation of state for
ideal gases:
p
ρ3 = ρ 2 = 2 , R=287 J/kgK
RT2
The flow rate at the compressor entrance Vt1 is determined according to the following
formula:
p ⋅T
V&t1 = V&2 ⋅ 2 t1
T2 ⋅ pt1
• Polytropic flow work
To the specific flow work applies under the condition of a polytropic change in status:
n
y polV = ⋅ R ⋅ (T2 − T1 ) ,
n −1
 16

Whereby the polytropic exponent should be constant and can be calculated by the following
formula:
ln ( p2 / p1 )
n=
ln ( p2 / p1 ) − ln (T2 / T1 )
• Polytropic efficiency
The polytropic efficiency η polV can be approximated by:

y polV
η polV =
∆h

n
= n −1 mit κ=1,4
κ
κ −1
7.2 Conversion on reference conditions

• State of reference

Tref = 291 K ; pref = 1,013 bar; nM,ref = 2700 min-1

• Polytropic shovel work

2
n 
y polref = y polV  M ,ref 
 nM 
• Volume flow rate
2
n 
V&ref = V&t1 ⋅  M , ref 
 nM 
• Efficiency
ηref = η polV
• Pressure ratio
n  nn−1 
from y polref = ⋅ R ⋅ Tref π ref − 1
n −1  

the pressure ratio derives to

n
 n −1  n −1
π ref =  y polref ⋅ + 1
 nR ⋅ Tref 

•Required power
y polref 1
PKref ≈ V&ref ρ ref ⋅
ηref ηm
pref
with: ρ ref = ; nM=0,98; R=287 J/kgK
R ⋅ Tref
 17

Bibliography
1. Adolph, Max: Strömungsmaschinen, Springer Verlag, Berlin/Hagen 1965
2. Prospects of the company GHH Sterkrade
3. Prospects of the company DEMAG: “Turboverdichter radialer Bauart”
4. Grahl, K.: Vorlesung Strömungsmaschinen I und II, Duisburg 1983
5. Dietzel, Fritz: Turbinen, Pumpen und Verdichter, Vogel Verlag Würzburg
6. Traupel, W.: Thermische Turbomaschinen, Regelverhalten, Festigkeit und dynamische
Probleme, Zürich 1986
7. Prospects of the company DEMAG, Einstufige Getriebe-Turbogebläse Typ KG
8. Bohl/Mathieu: Laborversuche an Kraft- und Arbeitsmaschinen Hanser Verlag,
München 1975

∆p = p - p∞
t∞ =
Level 1 Level 2
ELA- Throttle- Rpm
Position Positiom Tt1 ∆p1 Tt2 ∆p2 ∆pOr Not.
[°] [°] [min-1] [°C] [mbar] [°C] [mbar] [mbar]
1
2
3
4
5
6
7
8
9
10
11
12

Table 6.1: Measured values

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Evaluation lab test “CC”

The evaluation happens according to the data in chapter 7 of the practical course script. With
the help of the relations indicated there the table 7.1 can be filled out and thus the
characteristic can be drawn in illustration 7.1.
(ypolref(V) and/or ηpolV(V))

p∞ = [mbar]

Tt1 Tt2 p1 p2 ∆pOr V2 Vt1 ypolV n ηpolV Ypolref Vref Kref Pkref

[K] [K] [mbar] [mbar] [mbar] [m3/h] [m3/h] [kJ/kg] [kJ/kg] [m3/h] [kW]

10

11

12

Table 7.1: Calculated values

Fig 7.1: Spin characteristic diagram for radial compressors