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The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008 1

The Development of Centrifugal Turbo Compressor Stage


Using CFD

Kosprdová, Jindra1, Oldřich, Jiří2

1
Ing. ČKD NOVÉ ENERGO, a.s. Klečákova 1947, 190 02 Praha 9,
jindra.kosprdova@ckdenergo.cz, www.ckdnoveenergo.cz
2
Ing., CSc. ČKD NOVÉ ENERGO, a.s. Klečákova 1947, 190 02 Praha 9,
jiri.oldrich@ckdenergo.cz, www.ckdnoveenergo.cz

Abstract: This paper describes the procedure of development of centrifugal turbo compressor
flow passage using CFD. CFD simulation was used for fluid flow calculation in the flow
passage of centrifugal compressor stage. The investigated centrifugal compressor stage was
composed of 2D impeller blades, vaneless diffuser and return channel. The CFD simulation
was calculated by means of ANSYS CFX software. In terms of the results the geometric
modification of the flow passage was suggested and CFD simulation was again calculated.
This paper describes several solver settings for these simulations (mathematical and
physical). The geometric modification is described and the results of the CFD simulations are
also shown. The evaluation of suggested modification of flow passage of the investigated
turbo compressor is done as well.

Key words: CFD, compressor, centrifugal, efficiency, optimization

1 Introduction
The aim of this article is to inform the readers about the centrifugal turbo-compressor stage
optimization using the latest methods. The scheme of this optimization process is shown in
the figure 1. At the beginning the comparative analysis for existing compressor stage was
made. This CFD analysis was solved in terms of ANSYS CFX software. The CFD calculation
setting is described below and is the same both for the existing and for the optimized
compressor stage. In both cases we used quantitatively and qualitatively similar
computational grid. The results of the comparative analysis were, for their verification,
compared with the measurements that were made on the original stage. Pressure and
efficiency curves of the stage and loss and pressure recovery coefficient for return channel
were also compared. The results of this analysis are shown in the figures 2 – 5 together with
the results of the CFD analysis of the optimized stage. In the figure 2 we can see good
agreement of pressure curve between the comparative analysis and measurements. In terms of
efficiency curve we can also see good agreement but as the mass flow drops the deviation
rises. Concerning loss and pressure recovery coefficients, which describe the quality of return
channel, we can see much larger deviation. That’s why we will pay attention to this part of
compressor stage in the future. Over all we can say that this CFD analysis can be comparative
for evaluation of the geometry changes influence on the pressure and efficiency curve.
The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008 2

Existing Compressor 1
Stage Analysis
NREC AxCent, ANSYS
CFX

Optimization of Existing 2
Stage
NREC AxCent + iSight

Analysis of Optimized 3
Stage ANSYS CFX

Verification
Measurements of
Optimized Stage

Appropriate Concept of
Additional Changes

Fig. 1 Compressor optimization process

2 Optimization
The compressor stage which was optimized includes 2D impeller blades, vaneless diffuser
and vaned return channel. As mentioned earlier the goal of this project was the optimization
of the shape of the impeller blades and of the return channel vanes shape. Initially the
constraining requirements of the optimization were set. The Basic requirement was the
conservation of the meridional section (Fig. 6) and impeller outlet blade angle. There were
design requirements for the return channel vanes thickness (minimum blade thickness).
Besides the CFD analysis of the original compressor stage in the first step of this optimization
was also done the MST analysis of this stage by means of NREX AxCent software. The blade
loading, static pressure and relative velocity distributions were evaluated for impeller and
blade loading and absolute velocity for return channel. Results of this analysis can be seen in
The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008 3

the figures 7 – 9 (impeller) and 13 - 14 (return channel) in the comparison with the same
calculation for optimized compressor stage.

The impeller optimization was made by means of connection between NREC AxCent and
optimization software iSight. In this optimization we made changes in the impeller blade
angle distribution along the blade (without change in the exit blade angle) and we observed
the influence of this change on the blade loading calculated by means of the MST analysis.
We evaluated the difference between calculated blade loading and designed optimum blade
loading. The blade thickness was held constant. The optimization was made in two steps the
first approximation was done with Adaptive Simulated Annealing method and after this step
was used Modified Method of Feasible Direction. The comparison between the blade loading
for original and for the final design can be seen in the figure 7.
The optimization of return channel was made in terms of the results from MST calculation.
Initially inlet vane angle was changed in order to be the same as flow angle at appropriate
diameter. The comparison of the blade and flow angle for original and optimized compressor
stage is shown in the figure 15. Further, vane thickness in return channel was changed. We
observed the influence of these changes on absolute velocity and blade loading distribution.
The comparison of these distributions can be seen in figures 13 and 14.
After this optimization process detailed CFD analysis of this optimized compressor stage was
solved.

3 CFD Analysis
The CFD analysis was solved by means of ANSYS CFX software. The fully 3D,
compressible, viscous, turbulent analysis of the fluid (air) flow was solved. The
computational domain was periodically repeating segment of impeller, diffuser and return
channel. The solution was so made on the segment around one impeller blade and around two
return channel vanes. The angle was for both segments 40°. For rotor-stator interaction we
used “stage” interface. SST k-ϖ turbulent model was used because this model is suitable for
such an analysis. The relation between the state value was made by means of state equation of
ideal gas.
Computational grid was made by GRID-Pro software. The size (density) of the computational
grid was restricted by software and hardware equipment (only one CPU was used for the
calculation). The structured computational grid contains cca 360 000 cells in rotor and the
same value in stator in both cases (original, optimized).
The boundary condition at the inlet was always set as the total pressure and total temperature.
At the outlet static pressure boundary conditions for higher mass flows were set, for lower
mass flows the mass flow boundary conditions were set. The speed of revolution was also set.
Through the calculation the values of maximum residuals, pressure at the outlet eventually
mass flow, imbalances and efficiency were monitored. As the convergence criteria was set for
value of maximum residuals below 1e-4. At this value all other monitored parameters were
constant.
The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008 4

4 Definition of evaluation parameters


Blade to Blade loading
ws − w p
B 2 Bloading =
 ws + w p 
 
 2 
 
where:
ws [m / s] − Relative velocity at the blade suction side (in the case of return channel it is
absolute velocity)
w p [m / s ] − Relative velocity at the blade pressure side (in the case of return channel it is
absolute velocity)

Stage efficiency
p c7
log
p c0
η pol =
κ T
log c 7
κ −1 Tcb
where:
p c 7 - Outlet total pressure
p c 0 - Inlet total pressure
Tc 7 - Outlet total temperature
Tcb - Inlet total temperature

Loss coefficient Cp coefficient


p c (i ) − p c (i +1) p s (i +1) − p s (i )
K= Cp =
p c (i ) − p s (i ) p c (i ) − p s (i )

where:
p c (i ) - Total pressure near the return channel blade leading edge
p c ( i +1) - Outlet total pressure
p s (i ) - Static pressure near the return channel blade trailing edge
p s (i +1) - Outlet static pressure

5 Conclusions
To sum up we can say that the whole turbocompressor stage was improved. The changes of
geometry led to the improvement of pressure and efficiency curve (to higher position). It is
important to point out that the CFD analysis doesn’t contain the leakage and disc friction
losses. The flow character in return channel should be verified by the experimental
measurements and by the more detailed CFD analysis.

The calculations were done in ČKD NOVÉ ENERGO, a.s. as a part of project
“Research and Development of Flow Part of Centrifugal Compressor Stage” which was
carried out with financial support from Ministry of Industry and Trade of the Czech
Republic.
The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008
Fig. 2 Pressure Curve Fig. 3 Efficiency Curve
0.900
200000.000

190000.000 0.800

180000.000
0.700
170000.000
Outlet Total Pressure (Pa)

160000.000

Efficiency (-)
0.600

150000.000
0.500
140000.000

130000.000 0.400

120000.000
0.300
110000.000

100000.000 0.200
1.100 1.200 1.300 1.400 1.500 1.600 1.700 1.800 1.900 2.000 2.100 2.200 1.000 1.200 1.400 1.600 1.800 2.000 2.200
Mass Flow (kg/s) Mass Flow (kg/s)

original measurements original CFX opti CFX original measurements original CFX opti CFX

Fig. 5 Cp Coefficient
Fig. 4 Loss Coefficient
0.6
1

0.5
0.9

0.4
0.8

0.7 0.3

Cp Coefficient (-)
Loss Coefficient (-)

0.6
0.2

0.5
0.1

0.4
0
0.3 1.000 1.200 1.400 1.600 1.800 2.000 2.200

-0.1
0.2

-0.2
0.1

0 -0.3
1.000 1.200 1.400 1.600 1.800 2.000 2.200 Mass Flow (kg/s)
Mass Flow (kg/s)
original measurements original CFX opti CFX
original measurements original CFX opti CFX

5
The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008
fig. 7 Blade to Blade Loading
Fig. 6 Meridional section
1

0.8

0.6

0.4

0.2

B2B Loading (-)


0
0 10 20 30 40 50 60 70 80 90 100

-0.2

-0.4

-0.6

-0.8

-1
%M

original hub original shroud opti hub opti shroud OPTIMUM

fig. 8 Static Pressure obr. 9 Relative Velocity Distribution

150000 350

140000
300

130000
250

120000

Relative Velocity (m/s)


Static Pressure (Pa)

200
110000

100000 150

90000
100

80000

50
70000

60000 0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100

%M %M

6
original opti original pressure original suction opti pressure opti suction
fig. 10 Impeller Beta Distribution fig. 11 Return Channel Beta distribution

The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008
34

90

32
80

30
70

28
60

Beta (°)
Beta (°)

26
50

24
40

22 30

20 20
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
%R %M

original opti original opti flow angle

fig. 13 Return Channel Blade to Blade Loading


fig. 12 Thickness Distribution

2.5
20

2
18

1.5
16

B2B Loading (-)


Thickness (mm)

14

0.5

12

0
0 10 20 30 40 50 60 70 80 90 100
10
-0.5

8
-1

6
-1.5
0 10 20 30 40 50 60 70 80 90 100
%M
%M
original hub original shroud opti hub opti shroud
original opti

7
The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008 8

Fig. 15 Return Channe l Flow - Blade Angle

100

90

80

70

60
Angle (°)

50

40

30

20

10

0
0 10 20 30 40 50 60 70 80 90 100
%M

original flow angle opti flow angle original blade angle opti blade angle

fig. 14 Return Channel Absolute Velocity Distribution

250

200
Absolute Velocity (m/s)

150

100

50

0
0 10 20 30 40 50 60 70 80 90 100
%M

original pressure original suction opti pressure opti suction


The 20th International Conference on Hydraulics and Pneumatics, Prague, September 29 – October 1, 2008 9

Informace pro zpracovatele příspěvku (nepublikují se):


Použitý formát souboru s příspěvkem: Microsoft Word 2003
Údaje jednotlivých autorů pro zpracování autorského rejstříku:
Pořadí Příjmení Jméno Název organizace a stát Email
1 Kosprdová Jindra ČKD NOVÉ ENERGO, a.s., jindra.kosprdova@ckde
Česká republika nergo.cz
2 Oldřich Jiří ČKD NOVÉ ENERGO, a.s., jiri.oldrich@ckdenergo.
Česká republika cz

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