07-PT12-Centri Comp-2 47 (Compatibility Mode)

PEMP
RMD510
Design of Centrifugal Compressor

Compressor-2
2
Session delivered by:

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

PEMP
Session Objectives RMD510
To introduce the delegates

g to
• the procedure for aerodynamic design of centrifugal
compressors based on specific speed
• numerical simulation of a typical centrifugal compressor
• presentation of compressor performance and flow
behaviour through impeller blade passages

PEMP
Schematic of Radial Compressor RMD510

PEMP
Notations RMD510
C1 : Absolute Velocity at entry

Whb,1 : Relative velocity at hub at entry
Wsh,
sh,1 : relative velocity at shroud at entry
uhb,1 : Peripheral velocity at hub
ush,1
h1 : Peripheral velocity at shroud
u2 : Peripheral velocity at exit
Cu,2 : Whirl
Whi l velocity
l it att exit
it
W2 : Relative velocity at exit

PEMP
Velocity Diagram – Radial Flow Impeller RMD510
Inlet velocity diagram Outlet velocity diagram

(Axial entry) (Radial exit)

Limiting Design Conditions
PEMP
RMD510
• Shroud relative velocity at impeller inlet, Wsh,1 should not

be very high .
W2
• de Haller ratio in impeller,  0.75
Wsh,1
(to minimise flow separation in impeller passages and consequently
to minimise losses)
• c,2
c 2 has strong
g effect on the stabilityy of a radial vaneless diffuser.
As a general rule, for vaneless and vaned diffusers
αc,,2  70
and, preferably, should be chosen to be 60° to 65° at design point.

Limiting Design Conditions
PEMP
RMD510
• The relative velocity ratio is beneficially increased for backswept

impellers.
• A smaller proportion of stagnation enthalpy rise is in the form of
velocity.
• Hence,
Hence polytropic efficiencies of backswept impellers are higher than
those of straight radial vanes (zero back sweep).
• However,, there is a reduction in max. ppossible work pper stage
g due to
 Reduction in work coefficient (~0.9 for radial impellers to 0.5 or less for
backswept impellers)
 Max. rotational speed of a backswept impeller should be lower than for a
radial impeller of the same tip diameter to contain stress levels
• Blade sweep back angles of up to 50
50º can be used,
used if there is no call for
maximum work per stage.
PEMP
Specific Work RMD510
From steady flow energy equation and Euler turbine equation

Wex  Win 1
 Δ12 h0  u 2Cu,2  u1Cu,1 
m gc
ce Wex = 0
Since
S
Win  T0 ,2  1
 c p T0 ,2  T0 ,1   c pT0 ,1   1  u2Cu,2  u1Cu,1 
m  T0 ,1  g c
Therefore  
 
 R p,c 
η
1 

 
 p   c p   
u2Cu,2  u1Cu,1   g c c pT0 ,1  0 ,2    1


 p0 ,1  
 

Slip Factor
PEMP
RMD510
 For most compressors, there is no inlet swirl and Cu,1 = 0

 To be able to use the relations in the previous slide, we need a relation
between U2 and Cu,2. This is given by the Wiesner’s
Wiesner s correlation for slip
factor
Cu,u 2 ,ac cos β2
σ w  slipfactor
li f t  ac
 1
Cu,2 ,tl Z 0.7
Z : number of blades
2 : Angle between radial direction and
tangent to the rotor blade at the periphery.
 It is desired to keep c,2 large, thus reducing C2

and Cr,2. But, this makes the downstream diffuser
prone to stall Hence c,2 is limited to 60º.
stall. Hence, 60º

PEMP
Number of Blades RMD510
 An
A iimportant quantity
i is
i the
h ratio
i off outlet
l tangential
i l flow
fl velocity
l i to
blade speed, Cu,2,ac / u2.
 If there is no swirl in the flow at rotor inlet
inlet, this ratio becomes loading
coefficient, .
-1
 Cu,2 ,ac   tan β2  1 
      ψ
 u2   tan αc,2  σ w 
 The number of blades and the blade

angle at exit are not totally independent.
independent
Number of blades
at periphery

Design Data
PEMP
RMD510
Given data:
Atmospheric Air = 1 bar, 300 K
Mass flow rate = 0.75 kg/s
Compressor stagnation-to-static
stagnation to static pressure ratio = 3:1
Choose a speed to give maximum efficiency
(polytropic,
(p y p , stagnation
g to static))
To find:
Rotor diameter
Blade axial width at outlet
rpm
PEMP
Number of Blades RMD510
Choose even number of blades,

so that half may be designated
‘Splitter Blades’.
Taking
a g intermediate
te ed ate loading
oad g
from range of number of blades
graph,
Z = 20 (10 being splitter blades)
2 = Blade angle at outlet is 45

Slip Factor and c,2
PEMP
RMD510
Slip Factor:
 Cu , 2,ac  cos 45
w     1 0.7
 0.8967
 Cu , 2,tl  20
Rotor Outlet Velocity Diagram:

Let us choose c,2 = 60º (suggested)
1
 Cu , 2,ac   tan  2  1 
       For zero swirl
 u2   tan  c , 2   w 
1
 tan 45  1 
      0.5908
 tan
t 60  0.8967 

PEMP
Optimum Specific Speed RMD510

total – statiic pressure ratio
Distribution n of total energy based on
Efficienc
cy
Specific speed, Ns (dimensionless)

Specific speed, Ns (dimensionless)

PEMP
Blade Peripheral Speed RMD510
Ch
Choose ti
an optimum ifi
specific
speed, Ns = 0.8.
The isentropic efficiency is read
as s,c = 0.83.
R cp
r 1
s c  R c p η p,c
ηs,c
r 1
p,c = 0.854
 R  1 
  
T0 ,2  p0 ,2    c p  η p,c 
 
  
T0 ,1  p0 ,1 
cp = 1009.1 J/kg.K
T0,2 = 432.55 K
Rodger’s data (1980)
PEMP
Blade Peripheral Speed RMD510
c p R  3.5165
Δh0  c p T0 ,2  T0 ,1   133754 J/kg
 Δh0  ψ u 2
133754
u 
2
2  u 2  475.81 m/s
0.5908
Cu , 2, ac    u 2  281 .11 m/s
Cu , 2 , ac
Cr ,2   162 .3 m/s
tan 60
Cu , 2, ac W2
C2   324 .60 m/s
sin 60
Outlet velocity triangle

PEMP
Rotational Speed RMD510
We have optimum specific speed

as 0.8 and have calculated the
enthalpy rise. To calculate the
rotational speed, N, we need the
inlet volume flow rate,, V1, also.
From Rodger’s charts, for max.
efficiency, Cx,1 / u2 is between 0.3
andd 0.4.
04
Let us choose
h an inlet
i l axial
i l
velocity of 185 m/s, in order to
estimate the static density.

Inlet Density
PEMP
RMD510
   
1
   
C cp   M 2
 
Inlet Mach number  0.6305  2 1  1 
can be obtained from g c RT 0 R  cp   
  2  1  
   R   
 
M  0.55
 c p  
  1  
    R  
 
ρ0  M 2

and static density from  1    1.1577
ρst c 
 2 p  1 
  R 
  
1105
ρ0 ,1   1.1616 kg/m 3
286.96  300
 ρst,1  1. k / 3
1 0034 kg/m

Velocity Function
PEMP
RMD510
Velocity Function vs
Mach Number for
Perfect Gases

PEMP
Rotational Speed RMD510
 0.75
V1  flow rate at inlet 
1.0034
 0.7445 m 3 /s
N 
60 N
s g c Δhh0 3 4
2π V
60  0.8  133754 
34
  61800 rpm
2π 0.7445
u2  60
R t diameter
Rotor di t ,d 2   147 mm
π  61800

PEMP
Blade Axial Width at Outlet RMD510
3.5165* 0 .9
p0 ,2  432.55 
  3.1838
p0 ,1  300 
 p0 ,2  318380 N/m 2 C
Comment:
p0 ,2 In the calculation of b2, the

ρ0 ,2   2.565 kg/m
g 3 effect of blade thickness and
R T0 ,2 blade boundary layer are
C2 ignored. This may result in
 0.9218 M 2  0.8311 flow separation in actual
g c R T0 ,2 machine. It is recommended
ρ0 ,2 to have a narrowing vaneless
 1.3822  ρst,2  1.8558 kg/m 3 space and the calculated b2
ρst,2 will
ill be
b suitable
it bl for
f the
th throat
th t
m  Cr,2 ρst,2 π d 2 b2 of this narrowed entrance.
0.75
b2   b2  5.39 mm
162.30 1.856    0.147
PEMP
Conditions for Flow Separation RMD510
Higher the back sweep, smaller is the

extent of flow separation in the
impeller.
impeller
Also, a lower limit of relative outlet-
to-inlet velocityy ratio W2 /W1 = 0.8 to
be used for prevention of separation
in rotors with subsonic inlet relative
Mach numbers ((Wsh,1 sh 1 /ast) and normal
Reynolds numbers (ast = sonic
velocity at static condition). This is a
more conservative value than the
0.71 suggested by Rodgers (1978). This graph is plotted for W,sh,1 = 60º and for
two values of c,2 = 60º and 70º. This range
covers the flow angles normally used in
design.

PEMP
Diameter Ratio RMD510
The inlet and outlet velocity diagrams give the following relation
between W2 / Wsh,1.
Wsh,1  u sh,1 sin α w,sh,1

W2  C r,2 cos α w,2
C r,2  Cu,2 tan αc,2
Cu,2  u 2  C r,2 tan α w,2
W2 sin α w,sh,1

Wsh,1 u sh,1 u 2 tan αc,2  tan α w,2 cos α w,2
d sh,1 sin α w,sh,1

d2 W2 Wsh,1 cos αw,2 tan i α w,2 
t αc,2  sin
Comments on Design
PEMP
RMD510
 The
h relative
l i outlet
l flow l W,2, is
fl angle, i a function
f i off blade l 2,
bl d angle,
and number of blades, Z.
 For pure radial impellers, W,2
W 2, is generally between 10
10º and 15
15º..
 For higher W,2, there is likelihood of separation.
 Hence,, radial impellers
p of veryy low specific
p speed
p have the diameter
ratio, dsh,1/d2, below the implied no-separation boundary of 0.38.
 Benefits of decreasing the design C,2 are:
 reduced likelihood of separation in the impeller
 less likelihood of flow instability in vaneless diffuser
 A low value of W,2 is given by small value of b2. The relative tip
clearance become large, increasing associated losses.
 C,2
C 2 values lower than 60
60º (e.g.
(e g 55
55º)) can be used when dsh,1
h 1/d2 must be
above 0.55.
PEMP
References RMD510
 Wilson D.G., Korakianitis Th. (1998) : “The design of high

efficiency turbomachinery and gas turbines
turbines”, Prentice Hall.
Hall
 Rohlik H.E. (1975): “Radial inflow turbines” (in turbine design
and application), vol.3, pp.31-58, also NASA Special Publication
SP 290.
 Rodgers C. (1980): “Specific speed and efficiency of centrifugal
impellers” (in Performance Prediction of Centrifugal Pumps and
impellers
Compressors), ed. By S. Gopalakrishnan et al., ASME, New
York, pp.592-603.

PEMP
RMD510
Case Study
Design of an Industrial Centrifugal

Compressor Impeller and Effect of Exit
Width Trim on its Performance

PEMP
Design of Centrifugal Impeller RMD510
IInput ddata
Mass flow rate (m) : 5.5 kg/s
Total Pressure ratio ((PR)) :4
Inlet ambient stagnation pressure (p01) : 101325 Pa
Inlet ambient stagnation temperature (T01) : 301 K
Polytropic efficiency (p) (Initial assumption) : 85%
Universal gas constant (R) : 287 J/kg K
Specific heat ratio ( ) : 1.4
E i blade
Exit bl d anglel (2) : 30o
Calculated data
D i speedd (N)
Design : 23000 rpm
Outer diameter of impeller (D2 ) : 407.5 m
Tipp speed
p (U
( 2) : 490.8 m/s
Inducer tip diameter (D1t ) : 220.7 mm
PEMP
Design of Centrifugal Impeller (… contd.) RMD510
Inducer hub diameter (D1hh ) : 75.6

75 6 mm
Blade angle at inducer hub (1h ) : 59.32 deg
Blade angle at inducer tip ( 1t ) : 30 deg
N b off bl
Number blades
d (Z) : 16
Slip factor () : 0.88
Exit blade width ((b)) : 20.24 mm
Flow angle at exit (2) : 71 deg


2
All velocity values are in m/s

PEMP
Design of Centrifugal Impeller (… contd.) RMD510
Impeller exit
geometric
parameters
Impeller Inlet
geometric
parameters

PEMP
Generation of Impeller Geometry RMD510
Impeller
pe e
(Outlet)
ANSYS BladeGen Layout
Blade
Hub Inducer
((Inlet))

PEMP
Definition of Impeller Exit Trim RMD510
Radial exit
Exit
width
trim
Design Case
Axial
entry Exit width trim Case
2D Blade Profile 3D Blade Profile

PEMP
Computational Model of Impeller RMD510
Compressor model imported

from ANSYS BladeGen to
Gambit after performing Flow domain discretisation
geometryy cleanupp
g g Gambit
using

Boundary Conditions
PEMP
RMD510
Hub
(wall) Blade surface (Wall)
Periodic blade
Pressure outlet Periodic outlet

Shroud
(wall)
Periodic inlet Pressure inlet

PEMP
Solution Procedure RMD510
The meshed model from Gambit is exported as .msh file and the
file is opened in FLUENT6.3.26
 Density based implicit solver

 Turbulence
T b l model:
d l Realizable
R li bl k-k  model
d l with
i h non-equilibrium
ilib i
wall functions
 Boundary conditions as per previous slide
 Solution is initialised using pressure inlet and pressure outlet
boundary conditions
 Back pressure is increased incrementally to obtain the
complete performance map from choke to stall

Compressor Performance
PEMP
RMD510
Compressor Performance Map

Compressor Performance Map
5.0 90.0
4.5 b 80.0
4.0 70.0 c b
Isentrropic efficiency %
3.5 c a
60.0
Pressure ratio
2.1 Lakh Cells

3.0 2.1 Lakh Cells a 50.0 3.35 Lakh Cells
2.5 3.35 Lakh Cells 4.88 Lakhs Cells
4.88 Lakh Cells 40.0
2.0
P
30 0
30.0
1.5
20.0
1.0
0.5 10.0
0.0 0.0
3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5
30
3.0 35
3.5 40
4.0 45
4.5 50
5.0 55
5.5 60
6.0 65
6.5
Mass flow rate (kg/s) m*sqrt()/
Mass flow rate (kg/s) m*sqrt()/
Based on the grid independence study, a grid of 4.88 lakh cells was selected
for numerical investigations

Compressor Performance
PEMP
RMD510
Static pressure ratio Vs Meridional distance
3.50E+05
3 00E+05
3.00E+05
sure ratio
2.50E+05
Choke Point (a)
2.00E+05 Design point (b)

Static press
Stall point (c)

1.50E+05
1.00E+05
5.00E+04
0.00E+00
0 02
0.2 04
0.4 06
0.6 08
0.8 1
Normalised Meridional distance
Static pressure variation along the normalised meridional

distance of baseline impeller

PEMP
Effect of Exit Trim RMD510
Compressor Performance Map Compressor Performance Map

50
5.0 90 0
90.0
4.5 80.0
4.0 70.0
Isentropic efficieny %
3.5
60.0
e ratio
3.0
Design Case 50.0
Design case
Pressure
2.5 10% reduced

d d width
idth
15% reduced width 10% reduced width
20% reduced width 40.0
2.0 25% reduced width 15% reduced width
30.0 20% reduced width
1.5 25% reduced width
20.0
1.0
10.0
0.5
0.0 0.0
3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5
Non dimensional Mass flow rate m*sqrt()/ Non dimensional mass flow rate m*sqrt()/
Normalised work coefficient vs Normalised flow coefficient

Maximum Total pressure ratio and Isentropic efficiency Vs
1.2 Exit width Trim (%)
4.4 90.0
work coefficient
1.0 88.0
4.2
86.0
0.8
al pressure
sentropic
4.0 84.0
cy (%)
Design case
0.6 82.0
3.8
Normalised w
10% reduced width
ratio
o
Maximum Tota
Maximum Is
efficienc
15% reduced width 80.0
0.4 20% reduced with 3.6
78.0
25% reduced width
3.4 76.0
0.2 Total pressure ratio
74.0
3.2 Isentropic efficiency (%)
72.0
0.0
0.0 0.2 0.4 0.6 0.8 1.0 3.0 70.0
All the Cases Normalised with 0% 10% 20% 30%
Designed compressor case Normalised flow coefficient Exit Trim width (%)

PEMP
Effect of Exit Trim RMD510
3.50E+05
3.00E+05
D i case
Design
pressure rise
2.50E+05 10% reduced width

15% reduced width
2.00E+05 20% reduced width
25% reduced width
1 50E+05
1.50E+05
Static p
1.00E+05
5.00E+04
0.00E+00
0 0.2 0.4 0.6 0.8 1
Normalised meridional distance
Static pressure variation along the normalised meridional distance at

a ggiven mass flow rate of 5.5 kg/s
g for all trim cases

PEMP
Analysis Planes RMD510
Meridional section Span wise section

VI
V
IV
90%
III 50%
II I
5%
Pitch
i h wise
i section
i
78% (Near Pressure

surface side))
30% (Near Suction
surface side)

PEMP
Relative Mach Number Contours RMD510
Baseline impeller Baseline impeller
Near suction Near pressure

surface surface
10% reduced exit

i 10% reduced exit
width impeller width impeller

surface surface

PEMP
15% reduced exit 15% reduced exit

width Impeller width Impeller
Near suction Near Pressure

surface surface


surface surface

PEMP

Near suction Near Pressure

surface surface
Baseline Impeller
Near blade tip

p ((90% from hub))

PEMP
10% reduced exit width 15% reduced

d d exit
it width
idth
impeller impeller
Near blade tip (90%

from hub) Near blade tip (90%
from hub)
20% reduced exit width 25% reduced exit width

impeller impeller
Near blade tip (90%

from hub) Near blade tip (90%
from hub))

PEMP
Baseline impeller 10% reduced

d d exit
it width
idth
impeller
Near blade tip (VI) Near blade tip (VI)
15% reduced exit width 20% reduced exit width

impeller impeller
Near blade tip (VI) Near blade tip (VI)

PEMP
25% reduced
d d exit
i width
id h iimpeller
ll
Near blade tip (VI)

PEMP
Conclusions from Case Study RMD510
 The compressors with 20% and 25% trim show marginal

increase in isentropic efficiency than the baseline case.
case
 The compressors with 10% and 15% trim show decrease in
isentropic
p efficiencyy than the baseline case.
 The work coefficients of all the trim cases are lower than the
baseline compressor.
 An existing centrifugal compressor can be trimmed to obtain
different pressure ratios at a given mass flow rate.

Session Summary PEMP
RMD510
This session has covered:

• A design methodology of centrifugal compressors based on
specific speed
• Calculation of geometric parameters of the impeller for given
specifications
• A case study highlighting the design procedure for centrifugal
impellers and evaluation of compressor performance with
different exit width trims through numerical simulations

07-PT12-Centri Comp-2 47 (Compatibility Mode)

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PEMP

Design of Centrifugal Compressor

Session delivered by:

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

Session Objectives RMD510

To introduce the delegates

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

Schematic of Radial Compressor RMD510

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

C1 : Absolute Velocity at entry

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

Velocity Diagram – Radial Flow Impeller RMD510

Inlet velocity diagram Outlet velocity diagram

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

• Shroud relative velocity at impeller inlet, Wsh,1 should not

10 @ M.S.Ramaiah School of Advanced Studies, Bengaluru 6

• The relative velocity ratio is beneficially increased for backswept

Specific Work RMD510

From steady flow energy equation and Euler turbine equation

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

 For most compressors, there is no inlet swirl and Cu,1 = 0

 It is desired to keep c,2 large, thus reducing C2

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

Number of Blades RMD510

 The number of blades and the blade

10 @ M.S.Ramaiah School of Advanced Studies, Bengaluru 10

Number of Blades RMD510

Choose even number of blades,

10 @ M.S.Ramaiah School of Advanced Studies, Bengaluru 12

Rotor Outlet Velocity Diagram:

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

Optimum Specific Speed RMD510

Specific speed, Ns (dimensionless)

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

Blade Peripheral Speed RMD510

Blade Peripheral Speed RMD510

Outlet velocity triangle

Rotational Speed RMD510

We have optimum specific speed

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Rotational Speed RMD510

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Blade Axial Width at Outlet RMD510

p0 ,2 In the calculation of b2, the

Conditions for Flow Separation RMD510

Higher the back sweep, smaller is the

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Diameter Ratio RMD510

Wsh,1  u sh,1 sin α w,sh,1

 Wilson D.G., Korakianitis Th. (1998) : “The design of high

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Design of an Industrial Centrifugal

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Design of Centrifugal Impeller RMD510

Design of Centrifugal Impeller (… contd.) RMD510

Inducer hub diameter (D1hh ) : 75.6

All velocity values are in m/s

Design of Centrifugal Impeller (… contd.) RMD510

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Generation of Impeller Geometry RMD510