See discussions, stats, and author profiles for this publication at: https://www.researchgate.net/publication/245493930 The Development of Centrifugal Compressor Impeller Article in International Journal for Computational Methods in Engineering Science and Mechanics · June 2009 DOI: 10.1080/15502280903023165 CITATIONS READS 9 1,024 2 authors: C. Xu Ryoichi S. Amano University of Wisconsin - Milwaukee University of Wisconsin - Milwaukee 58 PUBLICATIONS 325 CITATIONS 367 PUBLICATIONS 1,352 CITATIONS SEE PROFILE Some of the authors of this publication are also working on these related projects: Internal Cooling of Gas Turbine Blades View project Energy in water and wastewater treatment View project All content following this page was uploaded by C. Xu on 12 November 2014. The user has requested enhancement of the downloaded file. SEE PROFILE This article was downloaded by: [University of Connecticut] On: 28 October 2014, At: 12:12 Publisher: Taylor & Francis Informa Ltd Registered in England and Wales Registered Number: 1072954 Registered office: Mortimer House, 37-41 Mortimer Street, London W1T 3JH, UK International Journal for Computational Methods in Engineering Science and Mechanics Publication details, including instructions for authors and subscription information: http://www.tandfonline.com/loi/ucme20 The Development of a Centrifugal Compressor Impeller a C. Xu & R. S. Amano a a University of Wisconsin-Milwaukee , Milwaukee, WI, USA Published online: 11 Jun 2009. To cite this article: C. Xu & R. S. Amano (2009) The Development of a Centrifugal Compressor Impeller, International Journal for Computational Methods in Engineering Science and Mechanics, 10:4, 290-301, DOI: 10.1080/15502280903023165 To link to this article: http://dx.doi.org/10.1080/15502280903023165 PLEASE SCROLL DOWN FOR ARTICLE Taylor & Francis makes every effort to ensure the accuracy of all the information (the “Content”) contained in the publications on our platform. However, Taylor & Francis, our agents, and our licensors make no representations or warranties whatsoever as to the accuracy, completeness, or suitability for any purpose of the Content. Any opinions and views expressed in this publication are the opinions and views of the authors, and are not the views of or endorsed by Taylor & Francis. The accuracy of the Content should not be relied upon and should be independently verified with primary sources of information. 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Amano Downloaded by [University of Connecticut] at 12:12 28 October 2014 University of Wisconsin-Milwaukee, Milwaukee, WI, USA An impeller is one of the key components of industrial centrifugal compressors and turbochargers. Aerodynamic and structure designs of the impeller are critical to the success of the whole compressor stages. The requirements for efficiency and operating range of industrial centrifugal compressors and turbochargers have been increased dramatically compared with the situation in the past. The efficiency of a newly developed, low-pressure-ratio centrifugal compressor has reached the possible level of the machine. However, the efficiency level of an intermediate- and high-pressure ratio machine still has gaps between the current state-of-the-art and possible level. The challenge for centrifugal compressor design is to keep the efficiency level at state-of-the-art and increase the compressor operating range. Increase of the compressor operating range without sacrificing compressor peak efficiency is difficult to achieve. The product globalization requires one product design, which can be used in all locations. In some counties, due to the technology differences, electricity frequency variations could be 10%. Turbocharger compressors work at different rotational speeds for the majority of the time. The compressor impeller rotating speeds change in certain ranges. The impeller rotating speed variation makes the impeller structure design more challenging. In this study, a full-3D impeller was designed to optimize impeller aerodynamic performance and structure characteristics. Keywords Impeller, CFD, FEA INTRODUCTION Centrifugal compressors have a wide application in industrial, aerospace, and automobile industries. In a centrifugal compressor the flow enters the compressor axially and then turns in the radial direction out from the impeller. The flow then enters a radial annular vaned or vaneless diffuser. The flow exit from the diffuser needs a volute or collector to deliver the flow to the next stage or send it to the next components [1–3]. The basic components of the radial compressor are shown in Fig. 1. Unlike an axial compressor or fan [4, 5], the work input for a centrifugal compressor is almost independent of the nature of the flow. A centrifugal compressor can be designed with much higher De Address of correspondence to R. S. Amano, University of Wisconsin-Milwaukee, Milwaukee, WI 53201, USA. E-mail: amano@ uwm.edu Haller number than an axial compressor can achieve. So it is possible for a centrifugal compressor to have a much higher stage pressure ratio than axial ones. Centrifugal compressors have wide applications for a mass flow rate less than 10 kg/s [1, 5]. The small flow centrifugal compressors have wide applications in turboshaft aircraft engines, turbochargers, and industry. However, being in a low-power class, these compressors need to be inexpensive to manufacture and operate, requiring that the compressor be a simple design having fewer parts and relatively large tolerance. Moreover, the five-axis machine is now a common tool for impeller machining, but most other parts should be fabricated by using other types of machining to reduce the manufacturing costs. The turbomachinery industry is increasingly interested in using optimization procedures that enable enhanced compressor efficiency and widen operating ranges. During the compressor development, designers always compromise between a peak attainable efficiency and an overall operating range [6]. Compressor design normally starts with a meanline program at each individual operating point on a map, then throughflow calculation is performed, and finally the impeller, diffuser, and volute are designed. In this study, a recently developed turbomachinery viscous optimal method [7, 8] for axial machines was further extended to a centrifugal compressor design [9]. The main focus of this study lies in the development of a small flow compressor where flow coefficient φ = Q/N/D3 = 0.145. Q, N, and D are the volume metric flow (m3 /s), rotational speed (rps), and impeller tip diameter (m). The design pressure ratio and the flow rate are 3.65 and 0.75 kg/s, respectively, at the design condition. The total to static efficiency required to be higher than 84% and the stability operating range (SB) great than 38%. The compressor design employs a global optimization viscous process for achieving efficiency and stability targets [8]. Good surge margins were achieved without use of a variable geometry for a stable operation. Special attention has been paid to the tip clearance profile to permit large clearance without too much lost efficiency during the impeller design. The compressor developed in this study consists of three major parts: an impeller, low solidity diffuser, and volute. In this study, particular attention was paid mainly to impeller design and analyses. 290 291 THE DEVELOPMENT OF A CENTRIFUGAL COMPRESSOR IMPELLER TABLE 1 Main design information of the test compressor Shaft speed N = 60000 rpm Impeller outlet radius R2 = 82.90 mm Out blade angle β2 = 55◦ Downloaded by [University of Connecticut] at 12:12 28 October 2014 Impeller blade number Zi = 19 Diffuser inlet radius R3 = 88.70 mm FIG. 1. Centrifugal compressor. A variable speed centrifugal compressor impeller with a compound lean blade was developed [9, 10]. The newly developed impeller defines a blade pressure side that extends from the leading edge to the trailing edge and is convex near the leading edge and flat near the trailing edge. The impeller was leaned opposite to rotation at the inlet portion and leaned back at exit. The clearance between impeller and casing is non-uniform, defined by a high-order equation. The flow and structure analyses were performed. Some basic performance tests and structure modal tests were performed. The analyses agreed with test results. EXPERIMENTAL STUDY Two impeller designs were installed with the same diffuser and scroll stage. The experimental studies were performed in the Centrifugal Compressor Development Laboratory. The performer test and data acquisition procedures were based on the ASME performance test procedure [11]. The test compressor consists of: inlet pipe, impeller, vaneless diffuser, low solidity vaned diffuser, vaneless diffuser, and volute as shown in Fig. 1. The test circuit is an open loop testing system as shown in Fig. 2. The flow rate is regulated by a butterfly valve located at the discharge pipe of the compressor. The main dimensions of the test compressor are listed in Table 1. Reference [9] provides more details for the test compressor. The test uncertainty for the flow rate is less than 2% at 95% confidence level. The head and efficiency uncertainties were kept under 2.2% and 2.5%, respectively, with the same confidence level based on the system uncertainty analyses [9]. The performance characteristic was tested through five total temperature and total pressure measurements at the inlet of compressor and discharge of the volute exit cone for both impellers. Due to the motor system problems after running the traditional impeller performance test, the off-design point test for a new full-threedimensional impeller was not able to performance. Only design Mass flow rate m = 0.77 kg/s Impeller outlet width b2 = 7.85 mm Design pressure ratio π = 3.60 Numbers of diffuser vanes Zd = 9 Volute inlet radius R5 = 170.00 mm point performance was tested for a full-three-dimensional impeller. More testing for off-design point performance will be conducted after fixing the motor problem. For determining the static pressure ratio, five pressure transducer taps were mounted on the circumferentially distributed wall at discharge of volute exit cone, which were used to measure the pressure. The mass flow was measured by using an ASME [10] nozzle located at the end of the discharge pipe. The tip clearance of the impeller at tip was measured with an alumina pin. The design tip running clearances at inlet and exit are about 0.2 mm and 0.1 mm, respectively. The performance test results are discussed in the CFD calculation section. For comparing the structure analyses with the experimental results, vibration tests were performed for the full 3D impeller utilizing a LDV (Laser Doppler Velocitmeter) and an impact hammer. A calibrated impact hammer was used to excite the impeller at different points and the resulting frequency and mode shape were measured by fast Fourier transform (FFT) and circular sampling of the part. Post processing yields a spectral response pattern and mode shape. The frequency test results are reported in the following section. FIG. 2. Test rig of a single stage compressor. Downloaded by [University of Connecticut] at 12:12 28 October 2014 292 C. XU AND R. S. AMANO FIG. 3. FEA boundary conditions and meshed for different impeller blades. FEA AND MODAL ANALYSES In a modern centrifugal compressor, due to increased requirements of compressor performance, the blade thickness has a trend to reduce. This can be achieved by the selection of better material and conducting more detailed finite-element analysis (FEA). Finite element analysis is a powerful tool to help find correction factors that make more cost-effective, simplified analyses as accurate as possible [12]. Stress analyses of the centrifugal impeller wheel during the design stage helps diagnose possible design problems and avoid failure. The finite element method can identify high-stress locations as well as vibrations in the centrifugal compressor impellers. Integration optimization between FEA and CFD is more popular in industry for turbomachinery designs [7,8]. Optimizations guided design changes that improved the integrity of the compressor. In this study, a preprocess BLADEPROTM [13] was used for Ansys [14] solver. The preprocess allows the user to specify Radial (R), Tangential (T), and Axial (A) boundary conditions for cover-face nodes for both static (single-blade steady stress) and dynamic (modal) analyses as shown in Fig. 3. A.B.C., R.B.C., and R.A.B.C. in Fig. 3 represent Axial constrain boundary condition, Radial constrain boundary condition and Radial and Axial constrain boundary conditions. The temperature and pressure profiles on the blade were calculated based on the CFD analyses. After generating the mesh and setting boundary conditions, the stress and modal analyses were performed. The material properties such as Youngs Modulus, material density and Poisson’s ratio and thermal properties such as coefficient of thermal expansion were selected from BLADEPROTM material database (Ti-6A1-4v Titanium Alloy). Calculations were performed on a Dell Precision 490 personal computer. The calculation time for stress analysis was about 30 seconds. The calculation showed that overall von Mises stress is similar for both full three-dimensional blade and traditional threedimensional design, those of which are the cases without bow and compound lean features. The von Mises stress contours near the impeller bore area were enlarged and are shown in Fig. 4. The max stress near bore area is about 82.4 ksi for the fully 3D blade and is about 82.3 ksi for traditional blade. It is shown that the bore stress does not change too much for both designs. The von Mises stress contours near the root of the trailing edge is shown in Fig. 5. As shown in Fig. 5, the maximum von Mises stress for the full 3D blade is a little higher than the cases for traditional blades. This is because the full 3D blade trailing edge stiffness may be smaller than a traditional blade. Less stiffness will cause more deflection and increase the stress. However, all the von Mises stress level is well below the yield strength of the material. The maximum von Mises stress for full 3D blade peak stress near the leading edge is about 64ksi and is about 52ksi for the traditional design as shown in Fig. 6. Leading edge FIG. 4. von Mises stress contour near bore area for different impeller blade designs. Downloaded by [University of Connecticut] at 12:12 28 October 2014 THE DEVELOPMENT OF A CENTRIFUGAL COMPRESSOR IMPELLER 293 FIG. 5. von Mises stress contour near trailing edge for different impeller blade designs. stress mainly depends on how much material near the leading edge area is used. The full 3D blade design has more material near the leading edge area due to the compound lean and bow. Additional material increases the centrifugal force during the rotation and causes higher stress. However, the maximum stress near the root of the leading edge for both designs is far below yield strength. It is shown that both designs meet the stress requirements. After stress analyses were completed, an at-speed modal analysis was performed in which a single-blade steady stress analysis was first performed to include the stress stiffening effects in frequency prediction. Stress stiffening effects from a single-blade stress analyses were carried over into the frequency calculation. At-speed modal analysis performs frequency prediction at a given shaft speed where both the “stress stiffening” and “spin softening” effects are included in frequency prediction. A cyclic sector can be modeled using two options: the reduced order model (ROM) and the full cyclic model. ROM uses super-elements for frequency prediction whereas the full cyclic model uses all the elements in the cyclic sector for frequency prediction. The full wheel method is used when there is a non-cyclic structure; for example, a wheel with unequal group lengths. The full cyclic model uses all the elements in the cyclic sector for frequency prediction. In this study, an at-speed full cyclic modal analysis was performed on a Dell Precision 490 personal computer after stress analyses. Modal analyses for each case took about 2500 seconds. The interference diagram is a plot of Frequency vs. Nodal Diameter that is used to identify potential resonance situations FIG. 6. von Mises stress contour near leading edge root for different impeller blade designs. Downloaded by [University of Connecticut] at 12:12 28 October 2014 294 C. XU AND R. S. AMANO FIG. 7. Interference diagram for different impeller blade designs. [15]. Each mode is represented by a dot on the interference diagram. The impulse lines in the interference diagram were constant speed lines corresponding to high and low limits of the running speeds of the machine. Intersection of this constant speed line with one or more dots indicates potential resonance conditions. The modal analyses results are plotted in the form of interference diagram as shown in Fig. 7. It can be seen that the traditional design can not meet frequency margin requirements (5%) at mode 39 due to the excitations of nine diffuser vanes. The full 3D wheel did not change the blade hub and shroud profiles and thickness; however, it successfully meets the frequency margin requirements. The frequency prediction accuracy is dependent on the mode shape and level of the frequency; simple modes like 1st bending FIG. 8. Sketch of the computational mesh. Downloaded by [University of Connecticut] at 12:12 28 October 2014 THE DEVELOPMENT OF A CENTRIFUGAL COMPRESSOR IMPELLER 295 FIG. 9. Convergent history of RMS mass. and torsion can be predicted more accurately than higher complex modes. The full three-dimensional blade mode calculations are more difficult than traditional three-dimensional blades. For validating the calculations, the modal testing for a full 3D wheel was conducted. It can be seen that the calculation results agree with the measurements. FIG. 10. Comparison of the performance curves. CFD CALCULATIONS The single stage compressor, from inlet pipe, impeller, vaned diffuser, vanless diffuser and volute, is computationally analyzed using a Navier-Stokes solver on a fully 3-D viscous turbulent flow solver CFX10.0. The geometrical discretization of the compressor stage is made for the computational analysis. FIG. 11. Tip relative Mach number distribution near shroud. Downloaded by [University of Connecticut] at 12:12 28 October 2014 296 C. XU AND R. S. AMANO FIG. 12. Relative Mach number contour near suction side of the blade. FIG. 13. Relative Mach number contour near pressure side of the blade. Downloaded by [University of Connecticut] at 12:12 28 October 2014 THE DEVELOPMENT OF A CENTRIFUGAL COMPRESSOR IMPELLER FIG. 14. Relative Mach number contour near mid plan between the blades. FIG. 15. Static pressure contour near suction side. 297 Downloaded by [University of Connecticut] at 12:12 28 October 2014 298 C. XU AND R. S. AMANO FIG. 16. Static pressure contour near pressure surface. FIG. 17. Radial velocity contour near suction surface. Downloaded by [University of Connecticut] at 12:12 28 October 2014 THE DEVELOPMENT OF A CENTRIFUGAL COMPRESSOR IMPELLER 299 FIG. 18. Radial velocity contour near pressure surface. Structure hexahedral cells are generated to define all parts of the compressor as shown in Fig. 8. The meshed size for inlet pipe, impeller, diffuser, and volute are 29,940, 597,902, 497,314 and 768,543 nodes, respectively. The interface surface between inlet-impeller and impeller-diffuser is modeled by using the frozen rotor method, i.e. the relative orientation of the two interface components across the interface is fixed. The calculation of the downstream surface of the interface plan was based on the average mixing plane approach. The calculation assumed to be converged when RMS of flow, pressure, and turbulence parameters smaller than the 7th order of original errors as shown in Fig. 9. The turbulence model is one of the factors to determine the success of the CFD analyses. Different turbulence models were tested for single stage centrifugal compressor flow calculations [16]. It is shown that both k-ε two equations and zero equation turbulence models provided reasonably good results, as shown in Fig. 10. The turbulence model used in this study is based on a zero equation model; only an algebraic equation was used to calculate the viscous contribution from turbulent eddies. The inlet boundary conditions were enforced by using the total pressure and total temperature. The flow entering the pipe is assumed to be normal to the inlet surface. The outlet boundary condition was applied by using a variable static pressure proportional to the kinetic energy at the outlet. The flow rate of the compressor is changed by modifying the static pressure to kinetic energy ratio at the outlet condition, which simulates different closing positions of the butterfly valve employed in the tests. In the calculation, no-slip boundary conditions were imposed over the impeller blades, diffuser airfoils, and all solid walls. The calculations were performed in an HP 8000c workstation. The time steps used in the calculation were set to 5.0 × 10−5 seconds at near surge and 5.0 × 10−4 seconds at other conditions. The calculation was assumed to be convergent when the ratio between the sum of the residuals and the sum of the fluxes for a given variable in all the cells is reduced to at least six orders of magnitude. Intensive grid size dependence tests were carried out [9] and overall compressor performance was compared with different mesh sizes. The final mesh size was set when the mesh size increased; the mass flow rate changed less than 0.5%. Two types of turbulence models, standard k-ε two equation and zero equation turbulence models, were used to calculate the compressor performance for traditional impeller. The results are plotted in Fig. 10. It is shown that the compressor developed by this research has a wide operating range of 40% with high efficiency in all operating conditions. It is shown that both turbulence models provided good predications for compressor efficiencies and head coefficients compared with the test, except the compressor operated near choke. For the compressor operated near choke, computations overpredicted the performance compared with tests. For full 3D design, the calculation shows a little performance advantage, better efficiency and head at the same flow conditions, compared with traditional impeller design. However, the tests near design flow show that there are no significant benefits for both efficiency and head coefficients near design point. The test showed a little benefit near choke and surge operations. To reduce the test tolerances, a few repeated tests were performed and similar results were obtained. Upon further inspecting the impellers, it was found that the impeller surface finish is about 6.3 micrometers near hub and about 3.2 300 C. XU AND R. S. AMANO Downloaded by [University of Connecticut] at 12:12 28 October 2014 FIG. 19. Relative flow angle contour at blade exit. micrometers on the blades. Because the calculations assumed that all walls on the impeller are a smooth wall, the friction loss estimations may be smaller than the test impeller. When a compressor is operated at a near design condition, both full 3D impeller and traditional impeller have no massive separation; the friction loss for the full 3D impeller is larger than the traditional blade due to bowed and lean features increasing the wet area. Further examination of the impeller calculations at design point for the compounded lean 3D impeller and conventional impeller showed that the total to total efficiency for 3D impeller and traditional impeller were 93.33% and 92.99%, respectively. It can be seen that the gain of the efficiency for 3D design is about 1/3%. This performance gain in the impeller becomes less significant for a whole stage. If the test part surface finish is not very high, the effect of the performance due to a 3D design will be washed out by frictional loss. The tip relative Mach number contours near the tip of the impellers for both full 3D and traditional designed impeller are shown in Fig. 11. It is shown that the traditional design leading edge area had a relatively larger Mach number compared with the full 3D design impeller. This may indicate that the full 3D design had a smaller portion of the flow passing through the blade tip range. It is favorable for impeller FIG. 20. efficiency if it shows a smaller flow in the tip high loss range. This is one of the reasons why the full 3D design shows a better efficiency. The relative Mach number contours near the suction surface, pressure surface, and mid-span plans are shown in Figs. 12, 13, and 14. It can be seen that the compounded lean blade has a relatively larger high Mach number area than the conventional blade near the suction side of the blade in the middle of the flow path. At a near inlet area the full 3D design depicts a smaller high Mach number area than the traditional impeller design. On the pressure side, the low Mach number region of the full 3D impeller is smaller than the conventional design. Mid-span Mach number distributions also show that a full 3D design provides more uniform Mach number distributions. The uniform Mach number distributions would benefit the compressor performance. The static pressure contours near the pressure and suction side are shown in Figs. 15 and 16. The static pressure contours show that the traditional blade has less static pressure rise compared with a lean blade. Figures 17 and 18 show the relative radial velocity contour near suction and the pressure surface of the impeller blade, respectively. It is shown that there is a larger high radial velocity region for the traditional impeller both near Secondary velocity contour at blade exit. THE DEVELOPMENT OF A CENTRIFUGAL COMPRESSOR IMPELLER 301 Downloaded by [University of Connecticut] at 12:12 28 October 2014 FIG. 21. Relative Mach number contour at blade exit. the suction and pressure side at about 50% of the flow path location of the impeller. It also shows that this higher velocity region is also closer to impeller shroud for traditional blade impeller. It is interesting to point out that the radial velocities near the shroud at 50% flow path location drop very fast near the impeller exit. At the impeller exit, the radial velocities near shroud are very low. The flow angle contour at blade exit plan in Fig. 19 shows that the compounded lean full 3D blades design provides a more uniform exit angle distribution. The larger angle flow area is smaller for the full 3D design. This characteristic will benefit the vaned diffuser performance. This allows a 3D design to get a little more efficiency compared with a traditional design. The secondary flow contour at the exit of the impeller is shown in Fig. 20. It is shown here that both designs give a single vortex structure and the main secondary flow center is located near the suction side of the blade. In the traditional design, the vortex center is located closer to the shroud side and also shows much stronger secondary flows. The relative Mach number distribution in Fig. 21 shows that the regions for both high and low Mach number areas are larger for the traditional design. It indicated that the flow is less uniform at the impeller exit for traditional design. CONCLUSIONS In this study, a new full 3D centrifugal impeller was designed and analyzed for both structure and flow. Calculations showed that a full 3D blade is both advantageous in a structure vibration and an aerodynamic performance. The test results show that the full 3D impeller did not show any significant benefits in performance near the design point due to the increase in friction losses on the surface of the bowed blades, whose surface area is greater than that of the conventional impeller. In cases of near surge and choke, full 3D impeller separation is reduced in the bowed blade impeller so that the stagnation pressure ratio and efficiency are increased. Structure analyses showed that the bowed blade could change the impeller into higher order modes separations. Natural frequencies of the impeller had View publication stats different values compared with the traditional blade. This feature offers benefits that previously have not been reported in the literature. REFERENCES 1. D. Japikse, Centrifugal Compressor Design and Performance, Concepts ETI, White River Jct., VT, 1996. 2. N.K. Amineni, A. 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