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Centrifugal Compressors
Class 13
1
Centrifugal Compressor Design
• Geometry
• Rothalpy
• Impeller Design Considerations
– Eye – Inducer
– Slip
• Diffuser Design Considerations
• Volute Design Considerations
2
Centrifugal Compressor Components
3
Centrifugal Compressor Components
Collector scroll and vanes may be
replaced with vaneless diffuser
4
Centrifugal Compressor Components
Centrifugal compressor= impeller+diffuser
Geometrical Definitions
5
Centrifugal Compressor Design
6
Centrifugal Compressor Design
• In class we defined "Rothalpy" for rotors:
−
2
C2
UCW2 2
U 2
U
=
I+ U
h =
h+− =h0
r
e
l−=c
on
s
t
a
nt
2g
J 2
gJ2
gJ 2 g
J
• Since across the impeller I1=I2 then the change in swirl velocity U
(
W2
− 2
WU)(2
−U2
) See result shown late
−
hh = 1 2
+2 1
J r is Example 1
2 1
2
gJ 2g
=
W=
h
U
0C
2[
U
2=
gH
f
o
rp
um
p
s
]
7
8
Centrifugal Compressor Design: T.E.
Back
Forward
10
Centrifugal Compressor Design: T.E.
• Radial T.E.
– Ideal no-slip view
– Increased Cr/Wr for same U do
es not change Cu or work
– T02/T01 unchanged with increa
sed Cr
11
Centrifugal Compressor Design: T.E.
• Backward T.E.
– Increased Cr/Wr for same U dec
reases Cu or work
– T02/T01 decreases with increas
ed Cr
– Stable side of compressor map
12
Centrifugal Compressor Design: T.E.
• Forward T.E.
– Increased Cr/Wr for same U incr
eases Cu or work
– T02/T01 increases with increas
ed Cr
– Unstable side of compressor ma
p
13
Centrifugal Compressor Design: T.E.
Radial T.E.
14
Centrifugal Compressor Design: T.E.
15
Centrifugal
Compressor
Design: T.E.
Centrifugal Compressor Design: L.E.
• Prewhirl [in the direction of rotation] added from added upstream g
uide vanes
• In high PR compressors, may be necessary to provide prerotation t
o reduce high relative inlet velocity. Also reduces incidence / reduc
es twist lower bending stresses
• Vane radial design impact on inducer
– Free vortex Cu 1/r: high incidence at low rh/rt designs
– Forced vortex Cu rn
Wo
Wn
18
Review: Axial Compressor Slip
• Slip: flow does not leave impeller at metal angle
• Carter's Rule:
m(1 −2)
= n
m& n Constants
19
Centrifugal Compressor Slip
• Slip: flow does not leave impeller at metal angle [even for inviscid f
low] – due to less than perfect guidance from blade.
• If absolute flow enters impeller with no swirl, =0.
• If impeller has swirl (wheel speed) , relative to the impeller the flo
w has an angular velocity - called the relative eddy [from Helmh
oltz theorem].
• Effect of superimposing relative eddy and through flow at exit is on
e basis for concept of slip.
20
Relative eddy Relative eddy with throughflow
Centrifugal
Compressor
Slip
Axial Compressor Slip
22
Axial Compressor Slip
23
Centrifugal Compressor Slip
• "Slip" (Deviation) Reduces Swirl & Work
=C/
C U
2 U
2i
dea
l
*
2 i
s
t
he
i
de
a
l
r
el
a
t
i
ve
fr
a
m
ee
x
i
tf
l
o
wa
ng
l
e
s=
Vsl
ipv
el
oci
t =u
yW2−W
u
2i
=
Cu
2i−
Cu
2
Vs
W W
C = =
UiU
r
tan
2
*
tan
2
• Slip Factor
=1−
V/U s 2
24
Centrifugal Compressor Slip
• Several Correlations for Centrifugal Impeller Slip Factor
=−
c
o1
s/
2*
−
1
Weisner 1 2
1
0
.
Z7
(1− t
an *
) Z0
.
7
2 2
Stodola
=−
cos2*
−
as Z
1
Z
(
1 −2t
a n)
*
2
1
Z
1
=−
0.
63 0
−
.
63
Stanitz
1 1
Z
(1−2tan *
2) Z
w
h
er
e =
Z#o
fi
mpe
l
le
rv
an
es
and2=
Cr
2/U2
N
o
t:2=
e Cr
2/U2
i
sl
i
ke=
Cx/
U f
ora
xi
al
s
A
l
sof
orm
an
yp
ro
bl
ems
1−t
an
1 2
*
2 25
Centrifugal Compressor Design
• In general, with possible prewhirl Cu10
=
W
C
−
p
T
0
2T
0
1=
U
C
2−
U
U
2C
1
U=
1U
2−
U
C
1
U1
C 02−T01=
pT U2−U
1CU1
p −1
03
=1+ c (T
R−)
1
p
01 T01
26
Centrifugal Compressor Design
• Impeller Performance Effects:
a
d=
a
i
d
e
c
t
u
a
l
a
w
l
w
o
r
o
k
t
o
r
k
t
f
l
o
f
u
i
d
l
u
id
(
h
=
0
(
−
3
h
0
3
h
0
−
)
1
i
dl
e
a
hU
0
1
=
p
/
0
) 2
C
U2
W
c=C
U
u
2 2 n
op
re
wh
i
rlC
u
1=0
=
c
pT
0−
2T0
1
p03 T03ideal −1 T03 −1
= =1+c −1
p01 T01 T01
U2 2 −1
=1+c
p 01
cT 27
Centrifugal Compressor Design
Backward sweep
29
Centrifugal Compressor Design
A
1 =r2
−r
T H
2
=
0.1252
−0.06252
=0.038m2
2rN 2rHN
UT−eye = T
=216m ps UH−eye = =108m ps
60 60
−1 T−eye −1 H−eye
U U
T−eye =tan =59.560
H−eye =tan =40.390
1x
C 1x
C
W
T1 = C
1
2
+U2
T1 = 129.962
+2162
=250mps
W
M1−relative = T1
=0.747
RT 1
31
Centrifugal Compressor Design
• Example #2: Dixon 7.1
– A radial vaned centrifugal impeller is required to provide a sup
ply of pressurized air to a furnace. The specification requires t
hat the fan produce a p0 rise equal to 7.5 cm of water at a vol
umetric flow rate (Q) of 0.2 m3/s.
– The fan impeller is made from [Z=30] thin sheet metal vanes, t
he ratio of the passage width to exit height=2 and r=0.1.
– Assume ad=0.75, m=0.95, slip can be estimated from Stanit
z correlation
– Assume R=287 J/(kg-C), p01=101.3 bar, T01=288K
– Assume
=
p
1/
0
1(
R
T
0
1=
)
15
0
/
(•
2
8
7=
2
9
3
)1
.
1
8
9k
g3
/
m
32
Centrifugal Compressor Design
1- Determine the impeller vane exit speed
p / p
ad = 0 = 02
UC
2 U2 U2
C 1.98 1.98 Stannitz
= U2 =1− =1− =0.934 21.98
U2 Z 30
p0 =gH=1.21
x 03•9.81•0.075=882.96N/m2
p0 882.96
U2 = = =47.66m/s
1.189•0.934•0.75
2- Determine the volumetric flow rate
C
Q=AannulusCr =Cr 2
rb=U r 2rb=Ur2rb
U
b 1 b
= = b=r/Z
s 2 2r/Z
Q=U0.12rr/Z
2 Q Z 2 0.2•30
D=2r= = =0.505m
0.2U 0.2•47.66 33
Centrifugal Compressor Design
2- Determine the volumetric flow rate cont’d
R
ot
ati
ona
lsp
ee
d
=2/
U D=•
24
7.6
6/0
.5
0 =8
518.7
5ra
d/s
ec
6
0
N=
• =1
802
re
v/m
i
n
2
No swirl m
WQ2
U1
.1
8
9•
0
.
2•
0.
9
34•
4
7
.2
6
6
==2
P = =
5
31
.
1
W
m0
.
95 0
.9
5
Q1
/
2
Q1/
2
1
88
.7•
50.
21
/2
= 3 = = =
s
(
gH /
4
) (
p/) (
0
3
/
4
8
82
.
96/
1.1
8
93
)/
4
0.
593
r
ad
1
/
2
NQ 60 6
0
= 3 =
= •= =
N
s
(
gH)/
4 s
2
0.
593
2
5
.
26
7
re
v/
m i
n 0
.
84r
ad/
se
34
c
Axial vs. Radial Machines
35
Diffuser Design: Sta. 23
• Rotation Effect on Diffuser Pressure Rise
36
Centrifugal Compressor Design
Example #3: Will work through design of each component separately
Centrifugal Compressor & Diffuser
Given
Find
a) Velocity diagram & flow properties at impeller inlet
b) Velocity diagram & flow properties at impeller exit
c) Velocity diagram & flow properties at diffuser exit
d) Adiabatic total to static efficiency at rotor & diffuser
e) Adiabatic total to total efficiency at rotor & diffuser
U2 1439.8966
1 − c o s1/ 2 [ 2* ] Slip Factor 0.9177
= 180 ; W e is n e r 2* = b a c k s w e e p Vs 118.4382
0 .7
Z A2 13.1947
V s = U 2 [1 − ] A2 = D 2b2 Poly Exp't 0.3175
Guess Pt2 56.1893
G u e s s p 0 2 th e n c a lc u la te Tt2 794.3942
−1 delta ho 66.0946
p o ly Cu2 1149.2347
T 0 2 = 5 1 9 ( p 0 2 / 1 4 .7 ) h 0 = c p (T 02 − T 01 ) Wu2 -290.6620
Wu2i -172.2238
C U 2 = g J h0 / U 2 WU 2 = CU 2 − U 2 Cr 298.3004
C 1187.3177
W U 2 id e a l = W U 2 + V s C r 2 = W U 2 id e a l / ta n [ 2* ] T 677.0886
180 P2 32.1208
rho 0.1280
C 22 −1
T2 = T02 − p 2 = p 0 2 (T 2 / T 0 2 ) flow 3.5000
2 gJc p error 0.0000
Pr t-t 3.8224
2 = p 2 /( R T 2 ) Tr 1.5306
m 2 = 2 A2C r 2 c h e c k w ith m 1 Eta - ad 87.98%
−1 Pr t-s 2.1851
Pr −1 Eta - ad 47.16%
P r = p 02 / p 01 T r = T02 / T01 ad =
Tr −1 Alpha2 75.4492
180 a2 1275.5646
2 = s in − 1 [ C U 2 / C ] M2 39 0.9308
Centrifugal Compressor Design: Sta. 2
Impeller Exit Velocity Diagram
350
300 U2
Vs Wu2i
Cu2
250
Cr2
200
2*
150
C2
100 W2
50
0
-50 150 350 550 750 950 1150 1350 1550
W −
W2U−
2 2 2 2
U
−
h
2h=
1
1
+ 1
2
=+
4.
463
5
.5
6
2g
J 2gJ 40
Centrifugal Compressor Design
• Impeller Performance:
– Clearance .3
b2
– Multi-stage usually shrouded because axial location (and the
refore, ) difficult to control
41
Diffuser Design: Sta. 23
• Basic Parameters
h = height of 2D diffuser
Y = entrance width
L = Length
B = entrance boundary layer blockage
W = inlet velocity
h
• Rotation Number
h
rT U
R= = 2
1
o
W
1 WW
2 2
42
Diffuser Design: Sta. 23
43
Radial Diffuser Performance: Sta. 23
• Pressure coefficient [compressor-type definition]
P−P P− P
C=3 2
f
orl
ows
pe
e=
d 3 2
−
p
P P 1 2
0
2 2
2C
2
2
2
C −
2 2
CC
A
=I =2 = −
p
2 3 2
n
c
om
p
re
s
s
ib
l
y:Cp
i 1
C
pi C2
A
3
2
r
fi=−
2
f
orc
on
st
antb
:Cpd
i
f 1
r
3
44
Rotation Reduces Diffuser Pressure Rise
1.00
0.80
0.60
Pressure
Coefficient
0.40
Ideal Cp
0.20 Ro=.000
Ro=.006
Ro=.029
0.00 Ro=.039
-0.20
1.00 1.25 1.50 1.75 2.00 2.25 2.50 2.75 3.00 3.25
Area Ratio
45
Diffuser Issues
Jet Flow
Appreciable Stall
No Stall
46
Radial Diffuser Design: Sta. 23
• Diffusers for Centrifugal Impellers:
47
Radial Diffuser Design: Sta. 23
• Diffuser reduces velocity & swirl
• Diffuser Configurations:
48
Vaneless Diffuser Performance: Sta. 23
• Vaneless Diffuser: removes swirl of fluid by increasing radius
Cu
r Cu = r2 Cu2 tan = constant
Cr
1
Cu tan = tan2
r 2
49
Vaneless Diffuser Performance: Sta. 23
• Swirl angle
Reduced by friction
50
Vaneless Diffuser Performance: Sta. 23
• Flow trace for vaneless, incompressible diff
user
dr rd
dt = =
Cr Cu
C u dr
d =
Cr r
r
− 2 = tan ln
r2
52
Centrifugal Compressor Design: Sta. 23
p 3 = p 2 + C p diff [ p 02 − p 2 ] Diffuser
D2 P3 41.7482
CU 3 = CU 2 assum ing 2 = 3 Cu3 672.0671
D 3 diff
G uess 3 C r 2 = C U 3 / tan[ 3] Guess Al3 77.4467
180 Cr3 149.6501
C3 688.5269
C 32
C3 = C 2
U3 +C 2
r3 T3 = T 02 − T3 754.9461
2 gJc p rho3 0.1493
Area 3 22.5629
3 = p 3 /( R T3 ) A3 = D 3 diff b 2 Flow 3.5000
Error 0.0000
check m 3 = 3 C r 3 A3 = m 1
Po3 49.8952
−1
p 03 = p 3 (T 02 / T3 ) Pr t-t 3.3942
Eta ad t-t 0.7875
−1
P r3 − 1
P r3 = p 03 / p 01 T r = T 02 / T 01 ad = Pr t-s 2.8400
Tr − 1 Eta ad t-s 0.6548
53
Vaned Diffuser Design: Sta. 23
• Vaned Diffusers
– Steifel 1972
54
Vaned Diffuser Design: Sta. 23
• Diffuser Performance
56
Vaned Diffuser Design: Sta. 23
• Throat Blockage Drives Effectiveness
57
Vaned Diffuser Design: Sta. 23
• Throat Blockage Driven by diffusion between blade exit and throat
58
Volute and Vaneless Diffuser: Sta. 34
• Impeller, Vaneless Diffuser, and Volute
59
Volute: Sta. 34
Radius
characteristic
of volute
is Rv
– Pressure Loss
– Space requirements
– Flow Uniformity
61
Volute Design
62
Volute Design
• Common design practice is to maintain simple conservation of a
ngular momentum along mean streamline in volute [r=rV]
63
Volute Design
• The Best Volute Design is Not Perfect
64
Volute Design
3 u3 =(r3 +rvol )Cu−vol
-Constant angular momentum: rC
-Since rv varies,volute flowvaries. At volute flowis: m= mtotal /360
-Circular volute area: Avol =rvol
2
360 r3 +rvol
2
b rvol r3 Cu3
For incompressible flows : 2 =
r3 360 r3 r3 +rvol Cr3
2
b rvol rvol
or 2 cot3 1+ =
r3 360 r3 r3
65
Volute Design
b
−1
rvol b
Solving the quadratic = cot 3 1 + 1 + 2 cot 3
r3 r3 360 r3 360
1 P Cu Cr
2
Radial static pressure gradient in volute : = − Cr
r r r
rC
Letting : rV = r3 + rvol Cu−vol = 3 u3
r3 + rvol
From mass conservation (rCr = constant), Volute exit radial velo
city is arbitrary and ca
Crvol = Cr 3 / 2 Cr = Cr 3 / 2 n be changed to optim
ize diffusion.
r = rvol (
CVol = Crvol + Cu−vol
2
)
2 1/ 2
then = −
rv r3 + rv r3 + rv rv
r C 2 r Cr 3
2
pvol = p3 + 3 u3 vol −
r3 + rvol r3 + rvol 2 66
Volute Design
Theequations for pvol ,po-vol ,rv all apply for all from0to3600.
67
Volute Design
Volute Exit
p 3 , T 3 c o n d itio n s a t e x it o f d iffu s e r
3 = p 3 /( R T 3 ) "C" 0.0076
rv/r3 0.1311
T 0 3 = T 0 2 , C U 3 , C r 3 fr o m d iffu s e r e x it rv 1.3449
D d iff − e x it rV 11.6049
r3 = Cuv 594.1787
2 Crv 74.8250
b 3 = w id th o f d iffu s e r Cv 598.8716
Pv 42.8861
rv o l / r3 rV o l = rv o l + r3 Pov 48.6634
CU 3
C U − vol = fr o m a n g u la r m o m e n tu m Pr t-s 2.9174
rV o l / r3 Eta t-s 0.6744
C r − v o l = C r 3 / 2 fr o m ???
Pr t-t 3.3104
p = 3
2 ( rv o l / r3 − 1 )
− C r − vol
2 Eta t-t 0.7685
C U − vol
g rv o l / r3 a3 1346.9071
M3 0.4446 68
Volute Design
Volute Exit Compressible Solution in Volute
69
Volute Design
Volute Radius vs Circumference
Volute Radius -
12.0
11.5
in.
11.0
10.5
10.0
0 90 180 270 360
Circumference - Degrees
Pressure vs Circumference
Volute Mean Flow
Pressure - psia
50
48
Ptv
46
44 Psv
42
40
0 90 180 270 360
Circumference - Degrees 70