Axial Compressor

PEMP
RMD510
Design of Axial Flow Compressor-1
Session delivered by:

Prof Q.
Prof. Q H.
H Nagpurwala
05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 1

PEMP
Session Objectives
RMD510
• To learn design procedure for

axial compressor stages
• To calculate flow properties
across the blade rows and to
determine velocity triangles
• To determine number of stages
• To determine annulus area from
inlet to exit

PEMP
Multistage Axial Flow Compressor RMD510

PEMP
Velocity Triangles RMD510
Two-Dimensional Approach
U : Peripheral velocity at the
mean blade height in a
tangential plane
Ca : axial component
Cw : whirl or tangential
component
p

PEMP
Compression Process on T-S Diagram RMD510

PEMP
Euler Turbine Equation RMD510
W k ddone per unit

Work i mass fl
flow rate or S ifi W
Specific k
Work

W  U 2 C w2  U 1C w1 
For U2 = U1, and Ca1 = Ca2 = Ca, we can write
W  U(C
( w2  C w1 )
 UCa( tan α2  tan α1 )
 UCa( tan
t β1  tan
t β2 )
Also
U
 tan  1  tan β1 (1)
Ca
U
 tan
t α2  tan
t β2 (2)
Ca
PEMP
Euler Turbine Equation RMD510
The input energy is absorbed usefully in raising the pressure,

temperature and velocity of the air and wastefully in overcoming
various frictional losses.
W  C p ΔTos  UCa( tan β1  tan β 2 )
UCa
ΔTos  ( tan β1  tan β 2 )
cp
And, if C3 = C1
UCa
ΔTos  ΔTs  ( tan β1  tan β 2 )
cp
γ
 ΔT os  γ- 1
s = stage isentropic efficiency
ratio, R s  1  η s
Total pressure ratio 
 T o1 
T01= inlet stagnation temperature

PEMP
Work Done Factor RMD510
• Radial distribution of axial

velocity is not constant along
the
h height
h i h off the
h blade.
bl d
• The velocity profile settles
down in the fourth stage.
stage
• Axial velocity distributions
from first to fourth stage are
shown in the figure.

PEMP
Work Done Factor RMD510
Work
W kDDone FFactor is
i the
h ratioi off the
h actuall workk absorbing
b bi
capacity of the stage to its ideal value as calculated from the Euler
turbine equation.
q
W  UC a tan β1  tan β 2 
For a given rotor
 U U  C a tan α1   C a tan β2  blade,, α1 and β2 are
almost constant
 U U  C a tan α1  tan β 2 
Hence, less work is done at the region where Ca is high and the
actual temperature rise is given by
λUC a
ΔTos  ΔTs  ( tan β1  tan β 2 )
cp
 is the work done factor,
factor which is less than unity.
unity Its value may range from 0.96
0 96
at the first stage to about 0.85 at the fourth and subsequent stages.

PEMP
Degree of Reaction RMD510
Degree off R
D Reaction,
i R is
R, i defined
d fi d as the
h ratio
i off the
h static
i enthalpy
h l rise
i
in the rotor to the static enthalpy rise in the whole stage.
ΔT A ΔTA : Static temperature rise in the rotor
R
ΔT A  ΔT B ΔTB : Static temperature rise in the stator
Since c p T0 s  c p Ts

W  c p  ΔTA  ΔTB   c p ΔTs
 UCa tan β1  tan β2 
 UCa( tan α2  tan α1 )
Also, C p ΔTA  UCa( tan α2  tan α1 )-
1 2
2

C2  C12 
It can be shown that
Ca
R  1 ( tan α2  tan α1 )
2U
PEMP
Symmetrical Blading RMD510
By adding equations (1) and (2)

2U
 tan α1  tan β1  tan α 2  tan β2
Ca
C  2U 2U 
R a    tan β1  tan β2 
2U  Ca Ca 
Ca
 tan β1  tan β2 
2U
1 U
If R  then tan β1  tan β 2 
2 Ca
From equation (1) & (2) • It is assumed that  = 1
α1  β 2
• Since  cannot be 1, the degree of
β1  α 2 reaction achieved will be slightly
different from 0.5
05
This results in symmetrical
velocity triangles across the rotor
Un-symmetrical Blading
PEMP
RMD510
R > 50% ; β2 > α1 R < 50% ; β2 < α1
If R > 0.5, then β2 > α1 and If R < 0.5, then β2 < α1 and the
the velocity diagram is velocity diagram is skewed to
ske ed to the right
skewed i ht. The static the left. The stator enthalpy
enthalpy rise in the rotor (and pressure) rise exceeds
exceeds that in the stator (this that in the rotor.
i also
is l true
t for
f the
th static
t ti
pressure rise).
PEMP
Polytropic Efficiency RMD510
Small Stage or Polytropic Efficiency of Compressor
Polytropic
y p efficiency y is the
efficiency of a compressor stage
operating between infinitesimal
pressure differential P. It is
used in comparing the
performance of two compressors
having the same pressure ratio
b operating
but i at different
diff
temperature levels.
In multistage
g compressors,
p the
polytropic efficiency is used in
defining the isentropic efficiency
of individual stages.

PEMP
Polytropic Efficiency RMD510
Relation between Polytropic Efficiency and Isentropic Efficiency

of a compressor
0.9 p= 0.9
 1
0.8  p2  
Isentropic p= 0.8
08    1
efficiency, c  p1 
0.7
c   1 1
 p2    p
  1
p= 0.7
0.6  p1 
Pressure ratio, p2/p1
Variation of small stage (polytropic) efficiency of compressor

with pressure ratio

PEMP
Polytropic Index RMD510
P l
Polytropic
i index
i d n is
i defined
d fi d suchh that
h
 1 1 n 1  1 n
 or p  
 p n  n 1
 1  p
T2  p2 
From
o co
consideration
s de at o of
o small
s a stage efficiency
e c e cy   
T1  p1 
 1 
T  p2 
'
F id
For ideall compression
i process   
2
T1  p1 
Stage
g ppolytropic
y p efficiency
y can now be written as
 1 n   1 ln  p2 p1 
p   
 n 1  lnT2 T1 

PEMP
Blade Loading Criteria RMD510
De Haller Number
V2
 0.72 for rotor
V1
C3 for stator
 0.72
C2
Lieblein’s Diffusion Factor

V2 Vw s
D  1 
V1 2V1 c
 cos 1  cos 1 s
D  1    tan 1  tan  2  for incompressible flow
 cos  2  2 c
D > 0.4-0.45 (at rotor tip) ; > 0.6 (at rotor hub)
PEMP
Design Procedure RMD510
1. Make appropriate assumptions about the efficiency, tip speed, axial

velocity and related parameters
2. Size the annulus at inlet and outlet of the compressor
3. Calculate the air angles required for each stage at the mean diameter
4. Choose a suitable vortex theory and calculate the air angles at various
radii from root to tip
5. Check for blade stresses, rate of diffusion and Mach number levels
6. Choose incidence angles, solidity, blade thickness, etc. from cascade data.
Estimate deviation angles. Calculate blade metal angles
7. Choose suitable aerofoil shape.
p Generate and stack blade sections from
hub to tip
8. Evaluate the compressor performance through empirical relations or CFD
analysis or experiments

PEMP
Design of Axial Flow Compressor RMD510
Task: To design an Axial Flow Compressor assuming that the

compressor has no inlet guide vanes
Design Data
• Sea level static conditions : pa =1.01 bar, Ta = 288 K

• Compressor
p ppressure ratio : 4.15
• Air mass flow rate : 20 kg/s

PEMP
Design Process RMD510
The complete design process for the compressor will encompass

the following steps:
• Choice of rotational speed and annulus dimensions
• Determination of number of stages, using an assumed efficiency
• Calculation
l l i off the
h air
i angles
l for
f eachh stage at the
h mean radius
di
• Determination of the variation of the air angles from root to tip
• Investigation of compressibility effects
• Selection of compressor blading, using experimentally obtained cascade
data
• Check on efficiency previously assumed, using the cascade data
• Estimation of off-design performance
• Rig testing

PEMP
Design Process (… contd.) RMD510
In practice, the process of design will be one of continued

refinement, coupled with feedback from other groups such as:
 Designers of the combustion system
 Designers of turbine module
 Material specialists
 Mechanical designers
 Stress analysts
 Experts in rotor dynamics
 Experts in bearings and lubrication system
 Personnel responsible for fabrication and assembly

PEMP
Rotational Speed and Annulus Dimensions

RMD510
Assume from previous experience

• Tip speed: Ut = 350 m/s
• Axial velocity Ca= 150 m/s and no IGV at inlet so that there will be
no whirl component of velocity at inlet (see figure in next slide to
understand the effect of IGV)
• Hub/tip diameter ratio ~ 0.4 to 0.6 at the entrance
 For a specified annulus area the tip radius will be a function of
the hub-tip ratio
 For a fixed blade speed, the rotational speed will also be a
function of hub-tip ratio
• Thus the designer has a wide range of solutions and must use
engineering judgment to select the most promising one

PEMP
Inlet Relative Mach Number RMD510

PEMP
Mass Flow Continuity RMD510
To satisfy continuity:
rt
 r 
2

m   1 AC a1   1 rt 1   r
2
  C a1
  rt  
rr
m
rt 
 
2
πρ1C a1 1  rr rt 
2
rt : Tip radius ; rr : Root radius

PEMP
Compression Process on T-S Diagram RMD510

PEMP
Rotational Speed RMD510
At sea level static conditions

sea-level conditions, T01= Ta= 288 K
K. Assuming no loss in intake
intake,
p01= pa = 1.01 bar.
C1  C a1  150 m / s (C w1  0)
150 2
T1  288  3
 276 .8 K
2 * 1.005 * 10
  1 3.5
T   276.8 
p1  p01  1   1.01   0.879bar
 T01   288 
100 * 0.879
1   1.106kg / m 3
0.287 * 276.8
20 0.03837
rt 2  
  
 *1.106 *150 1  rr rt 2 1  rr rt 2 
p , Ut , is related to rt byy Ut = 2  rt N,,
The tipp speed,
350
and hence if Ut is chosen to be 350 m/s, then N
2 rt
PEMP
Variation of N with Radius Ratio RMD510
• rt and N are evaluated over a range of hub-tip ratios

• Results are given in the following table :
rr rt N
rt m  s
rev
0.40 0.2137 260.6

0.45 0.2194 253.9
0.50 0.2262 246.3
0.55 0.2346 237.5
0.60 0.2449 227.5

PEMP
Turbine Data RMD510
• We need to consider the turbine to which this compressor could be

coupled.
• Let us say a turbine designed for this purpose has a speed of 250
rev/s and the outer radius of the turbine inlet is 0.239m
• Referring to the table above,
above a hub-tip
hub tip ratio of 0.50
0 50 would give a
compatible compressor tip radius of 0.2262 m although the rotational
speed is 246.3 rev/s.
• There was nothing sacrosanct about the choice of 350 m/s for the tip
speed, and the design could be adjusted for a rotational speed of 250
rev/s.
• With the speed slightly altered, then
Ut = 2  *0
0.2262
2262*250
250 = 355.3
355 3 m/s

PEMP
Hub -Tip Radius Ratio RMD510
• For a simple engine of the type under consideration, there would be

no merit in using
g a low hub-tip
p ratio; this would merelyy increase the
mismatch between the compressor and turbine diameters, and also
complicate both the mechanical and aerodynamic design of the first
stage.
g
• On the other hand, using a high hub-tip ratio would unnecessarily
increase the compressor diameter and weight.
• But it should be realized that the choice of 0.50 for hub-tip ratio is
arbitrary, and merely provides a sensible starting point.
• Later considerations
id i following
f ll i detailed
d il d analysis
l i could
ld cause an
adjustment, and a considerable amount of design optimization is
called for.

PEMP
Inlet Mach Number RMD510
• At this stage it is appropriate to check the Mach number relative to the rotor
tip at inlet to the compressor.
• Assuming g the axial velocity
y to be constant across the annulus,, which will be
the case where there are no inlet guide vanes, the relative velocity
2
V1t  U12t  Ca21  355.32  150
50 2 ,
and V1t= 385.7 m/s
a RT1   1.4 * 0.287 * 1000 * 276.8  331.0m / s

V 385.7
M1t  1t   1.165
a 331.0
• Thus, the relative Mach number at rotor tip is 1.165 and the first stage is
transonic; this level of Mach number should not present any serious problem.

PEMP
Annulus Dimensions at Exit RMD510
• Hub-tip ratio = 0.50

• Tip radius = 0.2262m
• Root radius = 0.1131m
• Mean radius = 0.1697m
 To estimate
i the
h annulus
l dimensions
di i at exit
i from
f the
h compressor, it
i will
ill
be assumed that the mean radius is kept constant for all stages.
• The compressor
p delivery
yppressure, p02 = 4.15*1.01= 4.19 bar
 To estimate the compressor delivery temperature, it will be assumed
that the polytropic efficiency of the compressor is 0.90.
n 1
• Then
 p02  n
(n  1) 1 0 .4
T02  T01    *  0.3175
p
 01  n 0.90 1.4
so that T02= 288.0 (4.15)0.3175= 452.5K

PEMP
Annulus Dimensions at Exit (… contd.) RMD510
• Assuming that the air leaving the stator of the last stage has an axial velocity
of 150 m/s and no swirl, the static temperature, pressure and density at exit
can readily be calculated as follows:
150 2
T2  452.5  3
 441.3K
2*1.005*10
γ
3.5
 T2  γ 1  441.3 
p2  p02    4.19   3.838bar
 T02   452.5 
100* 3.838
ρ2   3.03kg/m 3
0.287* 441.3
Please note: Suffix 1 stands for inlet of

the compressor and suffix 2 stand for
outlet of the compressor. Do not mix
with the accompanying figure which is
shown
h ffor a stage.
t

PEMP
Annulus Dimensions at Exit (… contd.) RMD510
The exit annulus area is thus given by

A2 = 20/3.031*150 = 0.0440 m2
With rm= 0.1697 m, the blade height at exit, h, is given by
0.044 0.044
h   0.0413m
2rm 2 * 0.1697

PEMP
Annulus Dimensions RMD510
• The radii at exit from the last stator are then

rt = 0.1697 + (0.0143/2) = 0.1903 m
rr = 0.1697 - (0.0143/2) = 0.1491 m
• At this point we have established the rotational speed and the
annulus dimensions at inlet and outlet, on the basis of a constant
mean diameter.
• To summarise
N = 250 rev/s rt = 0.2262 m inlet
Ut = 355.3
355 3 m/s rr = 0.1131
0 1131 m
Ca =150 m/s rt = 0.1903 m
rm = 0.1697 m ((constant)) rr = 0.1491 m outlet

PEMP
Annulus Dimensions RMD510
Many stages
Casing
Inlet 0.2262
0 2262 m Exit
Mean
0.1697m radius 0.1903 m
0.1131 m Hub 0.1491m
Compressor Axis

PEMP
Estimation of Number of Stages RMD510
• Assumed polytropic efficiency is 0.90.

• Th
The overall
ll stagnation
t ti temperature
t t rise
i through
th h the
th
compressor is 452.5 - 288 = 164.5 K.
• The stage temperature rise Tos can vary widely in different
compressor designs, depending on the application and the
importance or otherwise of low weight: values may vary
f
from 10 to 30 K ffor subsonic
b i stages andd may beb 45
4 K or
high performance transonic stages.
• Rather choosing a value random Tos can be estimated
al e at random,
based on the mean blade speed.

PEMP
U = 2*  * 0.1697 * 250 = 266.6 m/s

• We will adopt the simple design condition Ca1= Ca2= Ca throughout
the compressor, so the temperature rise is given by
UCa tan t 2 
t 1  tan U Cw2  Cw1 
Tos  
cp cp
With a purely axial velocity at entry to the first stage,
stage in the absence
of IGVs,
U 266.6
tan 1  
Ca 150
1  60.640
Ca 150 U
V1    305.9m / s
cos 1 cos 60.64
PEMP
• In order to estimate the maximum possible deflection in the rotor,

we will apply the de Haller criterion V2 / V1> 0.72. On this basis the
minimum allowable value of V2 = 305.9*0.72 = 220 m/s, and the
corresponding rotor blade outlet angle is given by
Ca 150
cos  2   ,  2  47.010
V2 220
PEMP
• Using this deflection and neglecting the work-done factor for this crude
estimate
266.6 * 150(tan 60.64  tan 47.01)
Tos  3
 28 K
1.005 * 10
• A temperature rise of 28 K per stage implies 164.5/28 = 5.9 stages. It is
likely that the compressor will require six or seven stages; and in view
off the
th influence
i fl off the
th work-done
kd factor,
f t seven is i more likely.
lik l
• An attempt will, therefore, be made to design a seven-stage compressor.

PEMP
Stage Temperature Rise RMD510
• With seven stages and an overall temperature rise of 164.5 K

the average temperature rise is 23.5 K per stage. It is normal
to design for a somewhat lower temperature rise in the first
and last stages.
• A good starting point would be to assume T0  20 K for
the first and last stages, leaving a requirement for
remaining stages as T0  25K
• Having determined the rotational speed and annulus
dimensions, and estimated the number of stages required, the
next step is to evaluate the air angles for each stage at the
mean radius. It will then be possible to check that the
estimated number of stages is likely to result in an acceptable
d i
design.

PEMP
Air Angles at Mean Radius RMD510
Stage-by-stage design:
From the velocity triangles, we get
Cw1  Ca tan 1 Cw 2  Cw1  Cw
• For the first stage 1 = 0 because there are no inlet guide vanes.
• The stator outlet angle for each stage, 3 , will be the inlet angle 1 for
the following rotor.
• Calculations of stage temperature rise are based on rotor considerations
only, but care must be taken to ensure that the diffusion in the stator is
kept to a reasonable level.
• The work-done factors will vary through the compressor and
reasonable values for the seven stages would be 0.98 for the first stage,
0.93 for the second,, 0.88 for the third and 0.83 for the remainingg four
stages.

PEMP
Design of Stages 1&2 RMD510
First stage
2nd and 3rd stage with 7-stage axial compressor

symmetric blading
PEMP
Design of Stage 1 RMD510
• Recalling the equation for the stage temperature rise in

terms of change in whirl velocity ΔCw= Cw2 - Cw1, we have
c p T0 1.005 * 103 * 20

Cw    76.9m / s
U 0.98 * 266.6 β1
V1 Ca
• Since Cw1= 0,
0 Cw2= 76.9
76 9 m/s and hence U
tan β1= U/Ca = 266.6/150 = 1.7773

β1 = 60.640

PEMP
Design of Stage 1(… contd.) RMD510
U  Cw2 266.6  76.9

tan  2    1.264,  2  51.670
Ca 150
C 76.9
tan  2  w2   0.513, 2  27.140
Ca 150
The velocity diagram for the first stage therefore appears as

PEMP
• The deflection in the rotor blades is β1 - β2= 8.980 , which is modest.

The diffusion can readily be checked using the de Haller number as
follows:
V2 Ca / cos  2 cos 1 0.490

    0.790
V1 Ca / cos 1 cos  2 0.260
• This value of de Haller number indicates a relatively light

aerodynamic loading, i.e, a low rate of diffusion. It is not necessary
to calculate the diffusion factor at this stage, because the de Haller
number g gives an adequate
q preliminary
p y check.
• After the pitch chord ratio (s/c) is determined from cascade data, the
diffusion factor can be calculated readily from the known velocities.

PEMP
• At this point, it is convenient to calculate the pressure ratio of the stage

(P03/P01)1, the suffix outside the parentheses denoting the number of the stage;
and then the pressure and temperature at exit which will also be the values at
i l t to
inlet t the
th secondd stage.
t
• The isentropic efficiency of the stage is approximately equal to the polytropic
efficiency of the compressor, which has been assumed to be 0.90, so we have:
3.5
 P03   0.90* 20 
   1    1.236
 P01 1  288 
P03 1  1.01*1.236  1.249bar
T03 1  288  20  308K

PEMP
• We have finally to choose a value for the air angle at outlet from the
stator row, 3 ,which will also be the direction of flow, 1 , into the
second stage.
• Here it is useful to consider the degree of reaction. For this first stage,
with the prescribed axial inlet velocity, C3 will not equal C1 (unless 3 is
made zero) whereas our equations for R were derived on the assumption
of this equality of inlet and outlet velocities. Nevertheless, C3 will not
differ markedly from C1, and we can arrive at an approximate value of R
b using
by i equation
ti
C w 2  C w1 76.9
R  1  1  0.856
2U 2 * 266.6
• The
Th degree
d off reaction
ti isi high,
hi h but
b t this
thi is
i necessary with
ith low
l hub-tip
h b ti
ratios to avoid a negative value at the root radius. We shall hope to be
able to use 50 percent reaction stages from the third or fourth stage
onwards,
d andd an appropriate
i t value
l off R for
f the
th secondd stage
t may be
b
about 0.70.
PEMP
• For the second stage, Tos = 25 K and  = 0.93 and we can determine
1 and 2 using equations
0.93* 266.2*150
25  3
( tan β1  tan β2 )
1.005*10
tan 1  tan  2  0.6756
Ca
and from R  tan β1  tan β 2 
2U
2U
150
0.70  (tan 1  tan  2 )
2 * 266.6
tan 1  tan  2  2.4883
PEMP
Design of Stage 2 (… contd.) RMD510
• Solving these simultaneous equations we get

1  57.7  and  2  42.19
• Finally, using equations
U U
 tan α1  tan β1  tan
t α 2  tan
t β2
Ca Ca
1  11.06 and  2  41.05

• The whirl velocities at inlet and outlet are readily found from
the velocity diagram,
diagram
Cw1  Ca tan α1  150 tan 11.06  29.3m/s
Cw 2  Ca tan α 2  150 tan 41.05  130.6m/s
PEMP
• The
Th required
i d change
h in
i whirl
hi l velocity
l it isi 101.3
101 3 m/s,
/ comparedd with
ith
76.9 m/s for the first stage; this is due to the higher stage temperature
rise and the lower work-done factor. The fluid deflection in the rotor
bl d has
blades h increased
i 15 51. It
d to 15.51 h 3 for
I appears that f theh fi
first stage
should be 11.06. This design gives a de Haller number for the
second-stage rotor blades of cos57.70 /cos42.19 = 0.721, which is
satisfactory.
• With the stator outlet angle for the first-stage stator now known, the de
H ll number
Haller b for
f the
th first-stage
fi t t stator
t t would
ld be
b
C3 cos 2 cos 27.15
   0.907
C2 cos 3 cos11.06
implying a small amount of diffusion. This is a consequence of the high

degree of reaction in the first stage.
stage

PEMP
The velocity diagram for the second stage appears as shown in the Figure
and the outlet pressure and temperature become
3 .5
 P03   0.90* 25 
   1    1.280
 P01  2  308 
P03 2  1.249*1.280  1.599 bar
T03 2  308  25  333 K
PEMP
• At this point we do not know 3 for the second stage, but it will be
determined from the fact that it is equal to 1 for the third stage.
• ItI iis useful
f l to point
i out that
h the
h degree
d off reaction
i isi directly
di l related
l d to
the shape of the velocity diagram. It is known that for 50 percent
reaction the velocity diagram is symmetrical.
• Writing Cwm= (Cw1+Cw2)/2, degree of reaction can be rewritten in the
form R = 1-(Cwm/U).
• When Cwm/U is small, and the corresponding reaction is high, the
velocity diagram is highly skewed; the high degree of reaction in the
first stage is a direct consequence of the decision to dispense with inlet
guide vanes and use a purely axial inlet velocity.
• The degree of reaction is reduced in the second stage, and we would
eventually like to achieve 50 percent reaction in the later stages where
the hub-tip ratios are higher.
PEMP
• Using a stage temperature rise of 25K and a work-done factor of 0.88, an

attempt will be made to use a 50 percent reaction design for the third stage.
• P
Proceeding
di as before
b f
ΔTos C p 25*1.005*103
tan β1  tan β2    0.7140
λUCa 0.88* 266.6*150
2U 0.5* 2* 266.6
tan β1  tan β2  R   1.7773
Ca 150
• Yielding 1  51.24 and  2  28.0.

• The corresponding
p g value of the de Haller number is given
g byy
cos51.24/cos28.0 = 0.709.
• This is rather low, but could be deemed satisfactory for a preliminary design.
It is instructive
instructive, however,
however to investigate the possibilities available to the
designer for reducing the diffusion.

PEMP
• One possibility
O ibilit is
i to
t consider
id changing
h i the th degree
d off reaction,
ti butb t it is
i found
f d
that the de Haller number is not strongly influenced by the degree of reaction
chosen; as R had a value of = 0.70 for the second stage it might appear that a
suitable value for the third stage might be between 0.70
0 70 and 0.50.
0 50
• Repeating the above calculations for a range of R, however, shows that R = 0.55
results in a further decrease of the de Haller number to 0.706; For a specified
axial
i l velocity,
l i the h required
i d diff
diffusion
i iincreases with
i h reaction
i . A dde H
Haller
ll
number of 0.725 can be achieved for R = 0.40, but it is undesirable to use such a
low degree of reaction. A more useful approach might be to accept a slightly
lower temperature rise in the stage,
stage and reducing ΔTos from 25 K to 24 K while
keeping R = 0.50 gives
tan β1- tan β2 = 0.6854
• Yielding β1 = 50.92 , β2 = 28.63 and a de Haller number of 0.718, which is
satisfactory for this preliminary design.
• Other
O h methods
h d off reducing
d i the h aerodynamic
d i loading
l di include
i l d increases
i in
i blade
bl d
speed or axial velocity, which could readily be accommodated.
PEMP
• With a stage temperature rise of 24 K, the performance of the

third stage is then given by
3.5
 p03   0.90* 24 
   1    1.246
 p01 3  333 
 p03 3  1.599*1.246  1.992 bar
b
T03 3  333  24  357 K
• From the symmetry of the velocity diagram α1 = β2= 28.63 and
α2 = β1= 50.92.
• The whirl velocities are given by
Cw1=150 tan 28.63 = 81.9 m/s
Cw2=150 tan 50.62
50 62 =184.7
=184 7 m/s

PEMP
Design of Stage 4, 5 and 6 RMD510
• A work-done factor of 0.83 is appropriate for all stages from the fourth
onwards, and 50 percent reaction can be used.
• The
h design
d i can be
b simplified
i lifi d by
b using
i the
h same mean diameter
di velocity
l i
diagrams for stages 4 to 6, although each blade will have a different
length due to the continuous increase in density.
• The seventh and final stage can then be designed to give the required
overall pressure ratio. It is not necessary to repeat all the calculations
for stages 4-6
4-6, but it should be noted that the reduction in work-done
factor to 0.83, combined with the desired stage temperature rise of 25K,
results in an unacceptably low de Haller number of 0.695.
• Reducing the stage temperature rise to 24 K increases the de Haller
number to 0.705, which is considered to be just acceptable for the
ppreliminaryy design.
g

PEMP
Design of Stage 4, 5 and 6 (… contd.) RMD510
• P
Proceeding
di as before,
b f
24 * 1.005 *103
tan 1  tan 2   0.7267
0.83 * 266.6 * 150
266.6
tan 1  tan 2  0 .5 * 2 *  1.7773
150
• Yielding β1 = 50.38 (= α2) and β2 = 27.71 (= α1). The
performance of the three stages can be summarized
below:
stage
g 4 5 6
p01(bar) 1.992 2.447 2.968
T01(K) 357 381 405
( 03/p
(p / 01) 1 228
1.228 1 213
1.213 1 199
1.199
p03(bar) 2.447 2.968 3.560
T03(K) 381 405 429
p03- p01(bar) 0.455 0.521 0.592

PEMP
Design of Stage 4, 5 and 6 (… contd.) RMD510
• It should be noted that although each stage is designed for

the same temperature rise, the pressure ratio decreases with
stage number; this is a direct consequence of the increasing
inlet temperature as flow progresses through the compressor.
The ppressure rise,, however,, increases steadily.
y

PEMP
• At entry to the final stage the pressure and temperature are 3.560 bar
and 429 K. The required compressor delivery pressure is 4.15*1.01 =
4.192 bar. The p
pressure ratio of the seventh stage
g is thus ggiven byy
 p03  4.192
    1.177
 p01  7 3.560
• The temperature rise required to give this pressure ratio can be
determined from
3 .5
 0.90Tos 
1    1.177
 429 
giving Tos  22.8 K
• The corresponding air angles, assuming 50 percent reaction, are then
β1 = 50.98 (= α2), β2 = 28.52 (= α1) with a satisfactory de Haller
number of 0.717.
0 717

PEMP
• With a 50 percent reaction design used for the final stage, the fluid
will leave the last stator with an angle α3 = α1 = 28.52, whereas
ideally the flow should be axial at entry to the combustion chamber
chamber.
The flow can be straightened by incorporating vanes after the final
compressor stage and these can form part of the necessary diffuser
at entry to the combustion chamber.
chamber

PEMP
Comments RMD510
• All the preliminary calculations have been carried out on the basis
of a constant mean diameter.
• Another
A h problem
bl now arises:
i a sketch,
k h approximately
i l to scale,
l off
the compressor and turbine annuli shows that the combustor will
have an awkward shape, the required changes in flow direction
causing additional pressure losses.

PEMP
Comments RMD510
• A more satisfactory solution might be to design the compressor for a

constant outer diameter.
• The use of a constant outer diameter results in the mean blade speed
p
increasing with stage number, and this in turn implies that for a given
temperature rise, ΔCw is reduced. The fluid deflection is correspondingly
reduced with a beneficial increase in de Haller number.
• Alternatively, because of the higher blade speed, a higher temperature rise
could be achieved in the later stages ; this might permit the required
pressure ratio
i to be
b obtained
b i d in i six
i stages rather
h than
h seven.
• Note that the simple equations derived on the basis of U = constant are
then not valid
valid, and it would be necessary to use the appropriate values of
U1and U2 ; the stage temperature rise would then be given by λ(U2Cw2-
U1Cw1)/Cp.
• Compressors which use constant inner diameter, constant mean diameter
or constant outer diameter will all be found in service.
PEMP
Comments RMD510
• The
Th use off a constant inner
i diameter
di is
i often
f found
f d in
i industrial
i d i l units,
i
permitting the use of rotor discs of the same diameter, which lowers the
cost.
• Constant outer diameter compressors are used where the minimum
number of stages is required, and these are commonly found in aircraft
engines.
engines
• The compressor annulus of the Olympus 593 engine used in Concorde
employs a combination of these approaches; the LP compressor annulus
has a virtually constant inner diameter, while the HP compressor has a
constant outer diameter.
• The accessories are packed around the HP compressor annulus and the
engine when fully equipped is almost cylindrical in shape, with the
compressor inlet and turbine exit diameters almost equal. In this
application,
li ti frontal
f t l area is
i off critical
iti l importance
i t because
b off the
th high
hi h
supersonic speed.
PEMP
Olympus 593 Mk 610 Engine RMD510
Compressor: Axial –
7 high pr. stages;
7 low pr. stages
Turbine: 1 low pr.
stage; 1 high pr.
stage
Weight: 3180 kg
Length: 7.11m
Diameter: 1.21m
Concorde aircraft Thrust: 170kN

PEMP
Session Summary RMD510
• The design procedure for multistage compressor is explained.

• The calculation of annulus area and importance of hub and tip
flares are explained.
• Detailed procedures for estimation of number of stages and
blade velocity triangles are presented.

Axial Compressor

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Axial Compressor

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PEMP

Design of Axial Flow Compressor-1

Session delivered by:

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 1

• To learn design procedure for

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 2

Multistage Axial Flow Compressor RMD510

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 3

Velocity Triangles RMD510

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 4

Compression Process on T-S Diagram RMD510

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 5

Euler Turbine Equation RMD510

W k ddone per unit

Euler Turbine Equation RMD510

The input energy is absorbed usefully in raising the pressure,

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 7

Work Done Factor RMD510

• Radial distribution of axial

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 8

Work Done Factor RMD510

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 9

Degree of Reaction RMD510

Since c p T0 s  c p Ts

Symmetrical Blading RMD510

By adding equations (1) and (2)

R > 50% ; β2 > α1 R < 50% ; β2 < α1

Polytropic Efficiency RMD510

Small Stage or Polytropic Efficiency of Compressor

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 13

Polytropic Efficiency RMD510

Relation between Polytropic Efficiency and Isentropic Efficiency

Pressure ratio, p2/p1

Variation of small stage (polytropic) efficiency of compressor

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 14

Polytropic Index RMD510

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 15

Blade Loading Criteria RMD510

Lieblein’s Diffusion Factor

Design Procedure RMD510

1. Make appropriate assumptions about the efficiency, tip speed, axial

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 17

Design of Axial Flow Compressor RMD510

Task: To design an Axial Flow Compressor assuming that the

• Sea level static conditions : pa =1.01 bar, Ta = 288 K

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 18

Design Process RMD510

The complete design process for the compressor will encompass

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 19

Design Process (… contd.) RMD510

In practice, the process of design will be one of continued

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 20

Rotational Speed and Annulus Dimensions

Assume from previous experience

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 21

Inlet Relative Mach Number RMD510

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 22

Mass Flow Continuity RMD510

rt : Tip radius ; rr : Root radius

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 23

Compression Process on T-S Diagram RMD510

05 @ M.S. Ramaiah School of Advanced Studies, Bengaluru 24

Rotational Speed RMD510

At sea level static conditions