07 Innovative Centrifugal Compressor Design

European Workshop on New Aero Engine Concepts
Munich, 30 June 1 July 2010

Innovative Centrifugal Compressor
Design
NEWAC is an Integrated Project Co-funded by the European Commission within the Sixth Framework Programme
(2002-2006) under Thematic Priority 4 Aeronautics and Space.
L. Tarnowski
TURBOMECA groupe SAFRAN
INTRODUCTION
SP2 : IRA (Intercooled Recuperative Aero-engine)
Task 2.2.5 HP Centrifugal Compressor Design
The challenge is :
The challenge is :
to improve significantly the efficiency of a 2D flanked milled blades of a
state of the art centrifugal compressor with a high hub to tip radius ratio.
to maintain the initial stability range.
OVERVIEW OF THE IRA CONCEPT
The new design approach is applied to the last stage of compression (HP) of the
IRA engine concept
HP centrifugal compressor
PARTNER INVOLVED in Task 2.2.5
PBS
PBS and Turbomeca advanced studies are complementary :
Centrifugal compressor with a low hub to tip radius ratio.
Main work :
- Study of the rotor stator interactions.
- Focusing on an optimisation of the geometrical definition of the radial
diffuser captation zone.
TECHNICAL APPROACH
STEPS of DESIGN
Conventional 2D design of the centrifugal stage : rotor and stators
Advanced 3D design of the rotor (unchanged stators) :
- Identical meridional definition of the flow path
- Identical throat area
- Identical leading edge and trailing edge radius
- Identical leading edge and trailing edge radius
- Modification of the rotor blade angle
- Modification of the rotor blade thickness
Goals:
- To increase the efficiency of the 2D design by 0.8 pts
- To keep the stability of the 2D design
- To comply with the mechanical criteria
1D DEFINITION OF THE CONVENTIONAL DESIGN
Type of compressor:
HP compressor following an intercooler.
High hub to tip radius ratio of 0.8 (leading edge hub radius / Leading edge tip
radius).
Aerodynamic design point:
Aerodynamic design point:
Based upon the engine conditions: the mid-cruise flight.
HPC inlet pressure
HPC inlet temperature
HPC PR
HPC inlet mass flow
kPa
K
-
kg/s
129.8
302
7.13
27.72
Designed at ambient inlet conditions
Aero-thermodynamic data
HPC inlet pressure
HPC inlet temperature
kPa
K
101.325
288.15
Complementary data to estimate the efficiency
1D DEFINITION OF THE CONVENTIONAL DESIGN
Rotational speed rpm 12817
Technological data
Radial and axial tip gap
Roughness
Blade to hub radius
mm
m
mm
0.4
0.8 (compressor cover)
0.4 (rotor inducer)
0.8.(rotor exducer)
2
Geometrical data
Inlet hub radius
Maximum outer radius
Radial extension
mm
mm
-
193.5
1416
1.4
Efficiency and stability targets of the conventional design (1D estimate)
Isentropic efficiency pts 82.1
Surge margin (Kp
(*)
) pts 10
(*)Kp=(/ / / /W)
surge point
/(/ / / /W)
aero design point
with W the corrected mass flow and the total pressure ratio of the compressor stage.
DEFINITION OF THE CONVENTIONAL DESIGN
3D view of the 2D
flanked milled rotor and
its associated diffuser
3D DEFORMATIONS
The 2D blades geometry is modified step by step from hub to tip and along
the blade to blade channel.
The level of deformation from hub to tip, controlled by Bezier curves, is
directly applied to the blade surfaces.
This allows deformations as lean, bowed shapes, strong local curvatures,
The thickness of the blade is controlled under the same principles.
The thickness of the blade is controlled under the same principles.
Bowed Leading Edge
Strong curvatures at the Leading Edge
Types of Deformations
ASSESMENTS : 3D CFD calculations
The performances and the surge margin are estimated with 3D CFD
calculations.
Numerical features:
3D NS CFD code called elsA developed by ONERA.
Low Reynolds Number model for the boundary layer.
Code Name Elsa (ONERA)
Grid Size
3*10
6
nodes
Kind of Grid Block structured
Turb Model K-l Smith (2-eq)
CFD RESULTS
+1.6 pts
According to numerical predictions the final design is on target. With a factor of
achievement of 0.5, the efficiency is improved by 0.8 pts. This is achieved at
comparable surge margin.
CFD RESULTS
State of the art impeller
Advanced 3D impeller
Cross section views of the entropy distribution : about 50% down stream the
leading edge of the splitters
These pictures show the reduction of loss generation between the state of the art
design and the 3D improved version of the impeller by the reduction of secondary flows
(see the red circles).
TEST RIG
View of the fully instrumented test rig
Air Exit
Air Intake
TEST RIG
Manufacture of the test rig parts : Pictures of the instrumented diffuser
Diffuser of the centrifugal
compressor stage
Trailing edge of the 2D axial
diffuser
TEST RESULTS
Main test results with 3D impeller :
Increase of pressure ratio as predicted by CFD (+4% at given
mass flow)
Increase of efficiency (+0.9 pt at nominal speed, +1.5 at part
speed), pretty consistent with CFD prediction (factor of
speed), pretty consistent with CFD prediction (factor of
achievement varying between 0.6 to 1.0)
Slight deterioration of surge margin corresponding to the increase
of choke mass flow. Baseline surge line can be recovered without
any penalty on peak efficiencies by matching the radial diffuser
Sensitivity to running clearances unchanged
TEST RESULTS
2
2,5
I
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(
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)

3D design vs State of the art design : measured improvement of
efficiency
0
0,5
1
1,5
60 65 70 75 80 85 90 95 100 105 110
N' (%)
I
s
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t
r
o
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e
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g
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(
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)

CONCLUSION & OUTLOOK
Changing the way of design with massive use of 3D CFD calculations has
allowed to generate 3D blades for the rotor which brought an improvement
in efficiency better than the initial target (0.8 pt).
A tuning of the radial diffuser section has to be considered to get back to the
initial surge line.
Further investigation are necessary to understand the interaction between
the rotor and the stator to increase further more the overall efficiency of the
compressor stage.
Unsteady calculations will certainly be required to capture the flow features
and allow a more efficient design of the rotor and the stator.

07 Innovative Centrifugal Compressor Design

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European Workshop on New Aero Engine Concepts

Munich, 30 June 1 July 2010

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