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An analysis yields a model for energy transfer in compressor stages operating in the closed-throttle condition. The derivation indicates that three geometry parameters (hub/tip ration, aspect ration, and rotor blade setting angle) influence the values of pressure coefficient when the compressor flow is close to zero.
The results for in-plant full load testing of a 13.4 MW (18000 HP) gas turbine driven centrifugal compressor are presented and compared to analytical predictions of compressor rotor stability. Unique problems from both oil seals and labyrinth gas seals were encountered during the testing. The successful resolution of these problems are summarized.
Oil seals are commonly used in high speed multistage compressors. If the oil seal ring becomes locked up against the fixed portion of the seal, high oil film crosscoupled stiffnesses can result. A method of analysis for determining if the oil seals are locked up or not is discussed. The method is then applied to an oil seal in a compressor with subsynchronous vibration problems.
One example of excessive vibration encountered during loading of a centrifugal compressor train (H type compressor with HP casing) is discussed. An investigation was made of the effects of the dynamic load on the bearing stiffness and the rotor-bearing system critical speed. The high vibration occurred at a "threshold load," but the machine didn't run smoothly due to rubs even when it had passed through the threshold load. The acquisition and discussion of the data taken in the field as well as a description of the case history which utilizes background information to identify the malfunction conditions is presented. The analysis shows that the failures, including full reverse precession rub and exact one half subharmonic vibration, were caused by the oversize bearings and displacement of the rotor center due to foundation deformation and misalignment between gear shafts, etc. The corrective actions taken to alleviate excessive vibration and the problems which remain to be solved are also presented.
Compressor stall phenomena is analyzed from nonlinear control theory viewpoint, based on bifurcation-catastrophe techniques. This new approach appears promising and offers insight into such well known compressor instability problems as surge and rotating stall; furthermore it suggests strategies for recovery from stall. Three interlocking dynamic nonlinear state space models are developed. It is shown that the problem of rotating stall can be viewed as an (induced) bifurcation of solution of the unstalled model. Hysteresis effect is shown to exist in the stall/recovery process. Surge cycles are observed to develop for some critical parameter values. It is shown that the oscillatory behavior is due to development of limit cycles, generated by Hopf bifurcation of solutions. Both stable and unstable limit cycles are observed. To further illustrate the usefulness of the methodology some partial computation of domains of attraction of equilibria is carried out, and parameter sensitivity analysis is performed.
An analysis yields a model for energy transfer in compressor stages operating in the closed-throttle condition. The derivation indicates that three geometry parameters (hub/tip ratio, aspect ratio, and rotor blade setting angle) influence the values of pressure coefficient when the compressor flow is close to zero.
A comprehensive study of the three-dimensional turbulent boundary layer on a compressor rotor blade at peak pressure rise coefficient is reported in this paper. The measurements were carried out at various chordwise and radial locations on a compressor rotor blade using a rotating miniature 'V' configuration hot-wire probe. The data are compared with the measurement at the design condition. Substantial changes in the blade boundary layer characteristics are observed, especially in the outer sixteen percent of the blade span. The increased chordwise pressure gradient and the leakage flow at the peak pressure coefficient have a cumulative effect in increasing the boundary layer growth on the suction surface. The leakage flow has a beneficial effect on the pressure surface. The momentum and boundary layer thicknesses increase substantially from those at the design condition, especially near the outer radii of the suction surface.
A text program was conducted to determine the effects of certain shot-peening parameters on the fatigue life of the Ti-6Al-4V alloys as well as the effect of a demarcation line on a test specimen. This demarcation line, caused by an abrupt change from untreated surface to shot-peened surface, was thought to have caused the failure of several blades in a multistage compressor at the NASA Lewis Research Center. The demarcation line had no detrimental effect upon bending fatigue specimens tested at room temperature. Procedures for shot peening Ti-6Al-4V compressor blades are recommended for future applications.
The principal sources of vibration related reliability problems in high pressure centrifugal gas compressors are the re-excitation of the first critical speed or Resonant Subsynchronous Vibration (RSSV), and the forced vibration due to rotating stall in the vaneless diffusers downstream of the impellers. An example of such field problems is given elsewhere. This paper describes the results of a test program at the author's company, initiated in 1983 and completed during 1985, which studied the RSSV threshold and the rotating stall phenomenon in a high pressure gas compressor.
A multistage centrifugal compressor, in natural gas re-injection service on an offshore petroleum production platform, experienced subsynchronous vibrations which caused excessive bearing wear. Field performance testing correlated the subsynchronous amplitude with the discharge flow coefficient, demonstrating the excitation to be aerodynamic. Adding two impellers allowed an increase in the diffuser flow angle (with respect to tangential) to meet the diffuser stability criteria based on factory and field tests correlated using the theory of Senoo (for rotating stall in a vaneless diffuser). This modification eliminated all significant subsynchronous vibrations in field service, thus confirming the correctness of the solution. Other possible sources of aerodynamically induced vibrations were considered, but the judgment that those are unlikely has been confirmed by subsequent experience with other similar compressors.
The K1501 compressor, driven by a steam turbine, is used to transport synthetic gas in fertilizer plants of 1000 tons daily production. The turbo-compressor set, which had been in operation since 1982, vibrated rather intensely, and its maximum load was only about 95 percent of the normal value. Damaging vibration to pads and gas-sealing labyrinths occurred three times from 1982 to 1983 and resulted in considerable economic loss. From the characteristics of the vibration, we suspected its cause to be rotor instability due to labyrinth-seal excitation. But, for lack of experience, the problem was not addressed for two years. Finally, we determined that the instability was indeed produced by labyrinth-seal excitation and corrected this problem by injecting gas into the middle-diaphragm labyrinths. This paper primarily discusses the failure and the remedy described above.
A low-speed, medium loaded axial flow compressor stage is studied experimentally and theoretically. The flow compressor facility, composed of an inlet guide vane row, a rotor blade row, and a stator blade row, and the principles of the streamline curvature method (SCM) and the Douglas-Neumann cascade program are described. The radial distribution of the flow properties, the rotor blade static pressure distribution, and the lift coefficient and relative flow angle derived experimentally and theoretically are compared. It is determined that there is good correlation between the experimental flow properties and the SCM data, the Douglas-Neumann cascade program and experimental rotor blade static pressure data, and the experimental and theoretical lift coefficients only in the midspan region. Modifications to the SCM and the Douglas-Neumann cascade program in order to improve their accuracy are discussed.
This paper describes a preliminary study of a method for increasing compressor tolerance in circumferential distortion through asymmetric vane stagger control. The changes in vane stagger about the circumference are used to increase compressor pressure rise and flow capability over part of the annulus and decrease these over the rest. The average pressure rise and flow thus remain roughly constant but the velocity distortion is reduced (and can even be made zero). Calculations are carried out to show the magnitude of the vane motions that must be used, and it is found that significant increases in distoriton attenuation can be achieved with realistic vane swings. In addition, the asymmetric vane stagger scheme leads to a substantial decrease in stall pressure rise loss due to inlet total pressure distortion. This type of control strategy appears worthy of further investigation, both theoretical and experimental.
Rotor blade aerodynamic damping is experimentally determined in a three-stage transonic axial flow compressor having design aerodynamic performance goals of 4.5:1 pressure ratio and 65.5 lbm/sec weight flow. The combined damping associated with each mode is determined by a least squares fit of a single degree of freedom system transfer function to the nonsynchronous portion of the rotor blade strain gauge output power spectra. The combined damping consists of aerodynamic and structural and mechanical damping. The aerodynamic damping varies linearly with the inlet total pressure for a given equivalent speed, equivalent mass flow, and pressure ratio while structural and mechanical damping are assumed to be constant. The combined damping is determined at three inlet total pressure levels to obtain the aerodynamic damping. The third stage rotor blade aerodynamic damping is presented and discussed for 70, 80, 90, and 100 percent design equivalent speed. The compressor overall performance and experimental Campbell diagrams for the third stage rotor blade row are also presented.
A conceptual design for a real-time VLSI compressor capable of processing rate up to one gigabit per second is presented. This scheme is capable of providing a three-to-one distortion-free data reduction factor to both the High Resolution Imaging Spectrometer and processed SAR imaging data. The design uses a VLSI parallel/piplined architecture capable of processing at a real time rate. The design consists of a parallel array of VLSI compressor modules. Each module is built on a single customized VLSI chip using existing state-of-the-art semiconductor technology.
The available data on middle-stage research compressors operating near design point are used to derive simple empirical models for the spanwise variation of three-dimensional viscous loss coefficients for middle-stage axial compressor blading. The models make it possible to quickly estimate the total loss and deviation across the blade span when the three-dimensional distribution is superimposed on the two-dimensional variation calculated for each blade element. It is noted that extrapolated estimates should be used with caution since the correlations have been derived from a limited data base.
This paper reports results from investigations conducted to determine the effect of stage loading on endwall flows in a low speed axial flow compressor. These investigations consisted of two sets of measurements. The first set consisted of radial transverse of flow properties at the rotor inlet and exit, at five flow coefficients. These measurements are used to determine the boundary layer integral parameters. The displacement thicknesses at the rotor hub and tip agree reasonably well with Smith's (1970) correlation for multistage axial compressors. The second set consisted of measurements of static pressures on the rotor blade at four flow coefficients. From these measurements, lift coefficient is determined. Also, loss of lift coefficient near the tip is calculated, and is attributed mainly to the tip leakage flows.
Supersonic cascade wind tunnel results are presented for a linear, supersonic compressor cascade derived from the near-tip section of a high-throughflow axial flow compressor rotor over the inlet Mach number range of 1.30-1.71. Laser anemometry was used to obtain flow-velocity measurements showing the wave pattern in the entrance region. Attention is given to the unique-incidence relationship for this cascade, which relates the supersonic inlet Mach number to the inlet flow direction. An empirical correlation is obtained for the influence of the independent parameters of back pressure, axial velocity density ratio, and blade element performance.