Computational Analysis of Centrifugal Compressor Surge Control Using Air Injection

School of Aerospace Engineering
Computational Analysis of Centrifugal

Compressor Surge Control Using Air
Injection
Alexander Stein, Saeid Niazi and Lakshmi Sankar
Georgia Institute of Technology
Supported by the U.S. Army Research Office Under the Multidisciplinary
University Research Initiative (MURI) on Intelligent Turbine Engines
High Performance Computer Time was Provided by the Major Shared
Resource Center of the U.S. Army Engineer Research and Development
Center (ERDC MSRC).
Outline of Presentation
Objectives and motivation
Background of compressor control
Introduction of numerical tools
Configuration and validation results
DLR high-speed centrifugal compressor (DLRCC)
Off-design results without control

Surge analysis
Off-design results with air injection control

Steady jets
Pulsed jets
Conclusions and recommendations

2
Motivation and Objectives

Use CFD to explore and
understand compressor stall
and surge
Sur
ge
Lim
it
Lines of
Constant
Rotational
Speed
Choke
Limit
Apply CFD to compare lowspeed and high-speed

configurations
Desired Extension
of Operating Range
Total Pressure Rise
Develop and test control

strategies (air injection) for
centrifugal compressors
Lines of
Constant
Efficiency
Flow Rate
Motivation and Objectives

Compressor instabilities
can cause fatigue and
damage to entire engine
What is Surge?
Mild Surge
Deep Surge
Mean
Pressure Operating Point
Rise
Pressure
Rise
Peak
Performance
Limit Cycle
Oscillations
Flow Rate
Flow Rate
Flow
Rate
Period of
Mild Surge Cycle
Time
Period of Deep
Surge Cycle
Flow
Rate
Flow
Reversal
Time
How to Alleviate Surge

Diffuser Bleed Valves
Pinsley, Greitzer, Epstein (MIT)
Prasad, Neumeier, Haddad (GT)
Bleed Valves
Movable Plenum Wall

Gysling, Greitzer, Epstein (MIT)
Movable
Plenum Walls
Guide Vanes
Dussourd (Ingersoll-Rand Research Inc.)
Air Injection
Murray (CalTech)
Weigl, Paduano, Bright (NASA Glenn)
Fleeter, Lawless (Purdue)
Guide Vanes
Air-Injection
Numerical Formulation (Flow Solver)

Reynolds-averaged Navier-Stokes equations in finite volume
representation:
qdV Ei Fj Gk n dS Ri Sj Tk n dS
q is the state vector.

E, F, and G are the inviscid fluxes (3rd order accurate). R, S,
and T are the viscous fluxes (2nd order accurate).
A one-equation Spalart-Allmaras model is used.
Code can handle multiple computational blocks and rotorstator-interaction.
7
Boundary Conditions (Flow Solver)

Periodic boundary
at clearance gap
Solid wall boundary

at impeller blades
Solid wall boundary
at compressor casing
Inflow
boundary
Periodic
boundary
at diffuser
Solid wall boundary

at compressor hub
Periodic boundary
at compressor inlet
Outflow boundary
(coupling with plenum)
Outflow Boundary Condition (Flow Solver)

Plenum chamber
up(x,y,z) = 0
pp(x,y,z) = const.
isentropy
.
mt
ap, Vp
Conservation of mass and

isentropic expression for
speed of sound:
dp p
.
mc
dt
2
ap
Vp
c m
t)
(m
Outflow boundary
DLR High-Speed Centrifugal Compressor

Designed and tested
by DLR
High pressure ratio
AGARD test case
40cm
10
DLR High-Speed Centrifugal Compressor

24 Main blades
30 Backsweep
Grid 141 x 49 x 33 (230,000
nodes)
A grid sensitivity study was
done with up to 1.8 Million
nodes.
Design Conditions:
22,360 RPM
Mass flow = 4.0 kg/s
Total pressure ratio = 4.7
Adiab. efficiency = 83%
Exit tip speed = 468 m/s
Inlet Mrel = 0.92
11
Validation Results (Design Conditions)

Static Pressure Along Shroud
Static Pressure/Total Pressure, p/p
0 ,
Excellent
agreement
between CFD
and experiment
CFD Fine Grid
2.5
CFD Baseline Grid

Exp (Time Mean)
2
1.5
1
0.5
0
0
0.2
0.4
0.6
Meridional Distance, s/smer
0.8
Results indicate
grid
insensitivity
=> Baseline
Grid is used
subsequently
12
Off-Design Results
Performance Characteristic Map
5.5
D C
Total Pressure Ratio
Computational and
experimental data
are within 5%
B
A
4.5
Fluctuations at
3.2 kg/sec are 23
times larger than
at 4.6 kg/sec
4
Experiment
3.5
CFD
3
2
2.5
3.5
4.5
Mass Flow (kg/sec)
13
Off-Design Results (High-Speed)

10
0
Pressure Rise Fluctuations (%)
Large limit cycle

oscillations develop
near surge line
10
0
20
20
20
10
10
20
30
30
Mass Flow Fluctuations (%)
C: 3.4 kg/sec
20
10
0
10
20
10
10
20
30
20
30
D: 3.2 kg/sec
20
10
0
10
20
30
B: 3.8 kg/sec
20
10
10
30
A: 4.6 kg/sec
20
Performance Characteristic Map
20
20
10
10
20
30
30
20
10
10
14
Off-Design Results (High-Speed)

Mass Flow Fluctuations
Mild surge
cycles develop
Surge amplitude
grows to 60% of
mean flow rate
Surge frequency = 90 Hz
(1/100 of blade passing frequency)
15
Air Injection Setup

Casing
0.04RInlet
Impeller
Compressor
Casing
RInlet
Compressor
Face
Rotation Axis
Systematic study:
injection rate and yaw angle
were identified as the most
sensitive parameters.
Related work: Rolls Royce,
Cal Tech, NASA Glenn
/MIT,
Injected Fluid
Sheet
Yaw Angle
Main Flow
16
Air Injection Results (Steady Jets)

Different Yaw Angles, 3% Injected Mass Flow Rate
yaw = 45 deg
yaw = 7.5 deg
yaw = -15 deg
Optimum yaw angle

of 7.5deg. yields best
result
3.5
3
2.5
-25
2
10
20
30
Rotor Revolutions, t/
Positive yaw angle is

measured in opposite
direction of impeller
rotation
40
0
25
Amplitude (%)
Reduction in Surge
Mass Flow (kg/sec)
4.5
-20
50
75
100
0
20
Yaw Angle (Degree)
40
60
17
Air Injection Results (Parametric Study)

Optimum:
Surge amplitude/main flow = 8 %
Injected flow/main flow = 3.2 %
Yaw angle = 7.5 degrees
An optimum yaw angle exists.

A reasonable amount (~3%) of injected air is sufficient to suppress surge.
18
Nondim. Surge Fluctuations (%)
Air Injection Results (Pulsed Jets)

100
With Phase Angle

Adjustments
Surge fluctuations
decrease as long as
the injection phase
was lagged 180 deg.
relative to the flow
=> suggests feedback
control
Without Phase
Angle Adjustments
50
50
100
0
inj ( t )
m
flow
m
10
15
Rotor Revolutions,
t
20
25
reduction in external
air requirements by
50% (compared to
steady jets)
0.015 0.015 sin(surge t )
19
Nondim. Surge Fluctuations (%)

1.5% injected mass
is sufficient to
suppress surge
15
10
5
High-frequency jets
(inj = 4surge)
perform better than
low-frequency jets
(inj = surge)
0
5
10
15
0
10
15
Rotor Revolutions,
t
20
inj ( t )
m
0.015 0.015 sin( 4surge t )
m flow
20

Vorticity Magnitudes Near Leading Edge Tip
Increased amounts
of mixing enhance
the momentum
transfer from the
injected fluid to the
low-kinetic energy
particles in the
separation zone
600
Low-Frequency Jets
High-Frequency Jets
No Jets
Vorticity Magnitude
500
400
300
200
Numerical
Probe
100
Jet
0
0
t/2, Rotor Revolutions
21

Shear Stresses Near Leading Edge Tip
High-frequency
actuation leads to
significantly larger
shear stress levels.
0.001
Low-Frequency Jets
High-Frequency Jets
0.0009
0.0008
Produce smaller but

intense turbulent eddies.
xy, Shear Stress
0.0007
0.0006
Enhances the mixing at

small length scales.
0.0005
0.0004
Area of
Interest
0.0003
0.0002
Jet
0.0001
0
0
2
3
t/2, Rotor Revolution
22
Conclusions
A Viscous flow solver has been developed to
obtain a detailed understanding of instabilities in centrifugal compressors.
determine fluid dynamic factors that lead to stall onset.
Steady jets are effective means of controlling surge:

Alter local incidence angles and suppress boundary layer separation.
Yawed jets are more effective than parallel jets.
An optimum yaw angle exists for each configuration.
Pulsed jets yield additional performance enhancements:

Lead to a reduction in external air requirements.
Jets pulsed at higher frequencies perform better than low-frequency jets due
to enhanced mixing at small length scales.
23
Recommendations
Perform studies that link air injection rates to surge amplitude via
a feedback control law.
Use flow solver to analyze and optimize other control strategies,
e.g. inlet guide vanes, synthetic jets, casing treatments.
Employ multi-passage flow simulations to study rotating stall
and appropriate control strategies.
Study inflow distortion and its effects on stall inception.
Improve turbulence modeling of current generation
turbomachinery solvers. Analyze the feasibility of LES methods.
24

Computational Analysis of Centrifugal Compressor Surge Control Using Air Injection

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