Performance analysis and improvement of a high flow coefficient centrifugal compressor

Very high flow coefficient centrifugal compressor stages are mostly applied as the first stages of multistage compressors.The performance of this type of stages is critical to the entire centrifugal compressors,but surprisingly little related information is available in the open literature.A centrifugal compressor with high inlet flow coefficient of 0.2,presenting a narrow operating range and unstable running situation even at design speed during the test,is investigated here.To reveal flow details in this centrifugal compressor,numerical simulations have been carried out and indicate that excessive impeller flow diffusion results in the poor performance of this centrifugal compressor.With the same inlet flow coefficient,six redesign cases coming from an in-house one-dimensional analysis program are proposed together with impeller trimming and equal flow area design method for corresponding vaneless diffuser.Performance comparison among these redesign centrifugal compressors is presented and the most suitable one is recommended for test in the future.In addition,three redesign cases with lower inlet flow coefficient developed by means of flow trimming are shown in the end to satisfy potential application areas.Finally,the results in this study can provide valuable reference information for multistage centrifugal compressor design.     

Influence of volute distortion on the performance of turbocharger centrifugal compressor with vane diffuser

As the geometry of the volute of turbocharger compressor is non-axisymmetric,it causes a distortion at the outlet of the diffuser and influences the upstream components.A distortion model in which a pressure distortion was applied as outlet boundary condition was established to simulate the distortion induced by the volute.It turned out to be sufficient to impose a circumferentially asymmetric pressure distribution at the outlet of the diffuser to replace the volute.Based on the distortion model which was verified,the influence of the amplitude of the distortion on the performance of centrifugal compressor was studied in detail.The results show that the distortion severely harms aerodynamic stability of the investigated compressor.The larger the amplitude of the distortion,the worse the performance of the compressor.The distortion induced by asymmetric volute propagates to upstream components and causes local flow separation at part of diffuser and impeller,and then causes the compressor surge.When the amplitude of the volute distortion is 10%,the stable flow range of the centrifugal compressor decreases to near zero.To authors’knowledge,the relationship between the compressor performance and distortion amplitude is first obtained quantitatively,which provides evidence to improve the performance of turbocharger compressor by decreasing the distortion induced by asymmetric volute.     

含气率对导叶式离心泵内部流动的影响

为研究含气率对导叶式离心泵输送气液两相时内部流动的影响,基于延迟分离涡DDES(Delayed Detached-Eddy Simulation)湍流模型及Mixture多相流模型对导叶式离心泵进行非定常数值模拟,得到不同含气率下,模型泵内气相分布、压力分布、流线分布以及所选监测点压力脉动情况,并将数值模拟的外特性曲线与试验进行对比分析。结果表明:气相主要在导叶靠近蜗壳出口的流道、蜗壳靠近叶轮前盖板一侧以及出口段靠近隔舌一侧聚集;导叶出口处压力从靠近隔舌处沿顺时针方向逐渐减小;蜗壳隔舌至第Ⅰ断面内及出口段靠近隔舌侧均出现了回流区;蜗壳壁面从P₁点顺时针方向沿蜗壳至出口段静压值逐渐减小;随着含气率的增大,叶轮进口处低压区面积增大,导叶内压力降低;蜗壳出口段多个面积较小的回流区转变为几个面积较大的回流区;同一监测点静压值逐渐减小,隔舌处静压值受含气率的影响最大。     

进口导叶/叶轮/扩压器非定常相干的数值研究

在非零进口导叶预旋角度下,采用非定常的方法对进口导叶/叶轮/扩压器三部件之间非定常相干进行了数值模拟,研究了进口导叶/叶轮/扩压器三部件之间动静相干的机理。结果表明,叶轮由于受进口导叶尾流和扩压器势反冲效应的双重非定常影响,叶轮受非定常影响最小的区域出现在叶片50%弧长附近,最大的非定常影响出现在叶轮和扩压器之间的动静交界面上。当离心压缩机前带有进口导叶预旋时,扩压器受前面两部件的同时影响,扩压器叶片上的非定常变化沿流向比较均匀。     

Aerodynamic effects of impeller-diffuser axial misalignment in low-flow-coefficient centrifugal compressor

A numerical investigation on the aerodynamic effects of impeller-diffuser axial misalignment in the low-flow-coefficient centrifugal compressor is conducted through three-dimensional CFD analysis.The results show that the flow,especially near the diffuser inlet,is influenced by the axial misalignment obviously.When the impeller offsets to one side,the pressure at diffuser inlet close to this side will descend,and the vortex in the cavity on the other side will partially enter the diffuser and then result in the back flow.The performances of the stage and its components also change with the impeller-diffuser axial misalignment.There exists an optimum offset making the efficiency maximum at a given operating point.Furthermore,the effect of impeller-diffuser axial misalignment on the axial thrust is pronounced.The axial thrust is nearly increased linearly with the increase of axial misalignment.The aerodynamic effects of impeller-diffuser axial misalignment in the low-flow-coefficient centrifugal compressor behaves more remarkably at the large flow rate.To alleviate the aerodynamic effects of impeller-diffuser misalignment,a rounding in the meridional plane at the diffuser inlet can be applied.     

Experimental investigation of transient characteristics of mild surge and diffuser rotating stall in a centrifugal compressor with vaned diffuser

The centrifugal compressor is widely used for gas compression in various industrial fields such as aero-engine, gas turbine and turbocharger. However, the stable operating range is usually restricted by the occurrence of flow instability such as stall and surge. The paper experimentally examines the developing process of surge and stall occurring in a centrifugal compressor to advance the understanding on flow mechanism of flow instability. It is found that three types of pressure fluctuation can be observed at low flowrate region. At the critical point, the local stall firstly occurs in some specific diffuser passages and the enlarged local diffuser stall eventually induces the mild surge of compression system indicated by the sinusoidal pressure fluctuation. At lower mass flow rate, the diffuser stall cell begins to circumferentially propagate along the impeller rotating direction at 11% of rotor speed with the existence of mild surge. In comparative analysis of IGV pre-swirl angle on the occurrence of mild surge, the mild surge still occurs at the operating condition when the slope of the characteristic map of test stage is still obviously negative, in which the compression system is supposed to be stable in previous study. And a new suggested criterion for the prediction of mild surge is demonstrated that the occurrence of mild surge depends on the destabilization effect of downstream components about diffuser and volute. Combined with the experimental data, the streamwise distribution characteristic of diffuser stall can be used to develop the simplified model of lumped parameters for the analysis on the generation mechanism of the diffuser rotating stall. The quantitative investigation on the relation between the pressure-rise characteristic of subcomponents and the occurrence of mild surge and diffuser rotating stall not only advances the prediction of stability limit but also lays the theoretic foundation for controlling these unsteady behaviors to improve the operating range.     

逆向与正向结合的导叶式混流泵叶片系统反求设计

以某型混流式核主泵的叶轮叶片和导水机构叶片为研究对象,采用在逆向设计的基础上,正向设计校核迭代的技术来探索一条不破坏产品的前提下反求导叶式混流泵的复杂叶片系统的曲面几何数据方法。在不能获取叶片系统的完整曲面数据的情况下,采用叶片数字化设计方法建立沿回转流面上叶型曲线为参数线以便于修改控制的原始叶片系统的近似三维曲面几何模型,并将该模型与其他过流部件组成泵的全流道模型,在0.2~1.2Q_d（设计流量）范围进行泵的全流道流场数值模拟,预测计算出外特性,再与原泵的试验外特性对比,以评估反求的叶片系统流道曲面的准确性。工程应用实践表明,该方法既保证了反求精度又较好地解决了泵的叶片系统反求设计问题。     

径向导叶式多级泵单级叶轮切割的三维数值模拟

为探究径向导叶式压出室离心泵叶轮切割后性能的变化,基于N-S方程、标准k-ε湍流模型和SIMPLE算法对MD-280-42×4多级离心清水泵单级叶轮外径切割进行三维湍流数值计算,分析不同切割量下径向导叶式离心泵外特性和内部流动变化。结果表明:在设计工况(Q_d=0.078 m3/s)下,随着切割量的增加,径向导叶式离心泵的水力效率、轴功率均呈现下降趋势;在相同小流量工况下,随着切割量的增加,叶轮与导叶间隙和反导叶流道处流动损失逐渐减小,水力效率呈现上升趋势;在相同大流量工况下,随着切割量的增加,正反导叶流道流动均匀性受到较严重破坏,产生了较大的能量耗散,水力效率明显下降。       

节段式多级离心泵全三维湍流场的数值模拟

选取工业中常用的DF型多级离心泵作为研究对象,数值计算使用了FLUENT软件及其RNG k-ε湍流模型和多重参考坐标系,实现了节段式多级离心泵任意一整级（包括叶轮导叶在内）的全三维流场的数值模拟.模拟结果显示在叶轮出口与导叶入口衔接处,叶轮出流因受到导叶叶片头部的阻挡干扰,导致局部流体逆叶轮旋转方向运动.液流的静压值在正导叶出口附近达到泵级内最大值,进入反导叶后因沿程出现的水力损失静压值略有降低.计算结果得到了泵外特性实测值的验证.     

螺旋离心泵的双向流固耦合分析

基于Reynolds时均化N-S方程、标准k-ε两方程湍流模型, 以及结构响应的弹性体结构动力学方程, 采用多重坐标系法, 对螺旋离心泵清水介质时的内流场和结构动力学进行双向流固耦合全三维数值计算, 将计算结果与非流固耦合计算流场进行对比, 分析流固耦合作用对泵外特性及不同叶轮位置泵内压力场和速度场的影响。结果表明:采用双向流固耦合模式的扬程和效率预测值更接近试验值; 在小流量下流固耦合作用对外特性的影响较大, 而在大流量下对外特性影响较小; 流固耦合作用对压力场和速度场的影响主要集中在蜗壳扩散段, 对蜗壳其他部位和叶片影响较小; 在两种计算模式下蜗壳中截面压力分布出现明显差别, 并在叶片出口正对隔舌时压力分布出现突变。       

Numerical investigation of radial inflow in the impeller rear cavity with and without baffle

In typical small engines, the cooling air for high pressure turbine(HPT) in a gas turbine engine is commonly bled off from the main flow at the tip of the centrifugal impeller. The pressurized air flow is drawn radially inwards through the impeller rear cavity. The centripetal air flow creates a strong vortex because of high inlet tangential velocity, which results in significant pressure losses. This not only restricts the mass flow rate, but also reduces the cooling air pressure for down-stream hot components. The present study is devoted to the numerical modeling of flow in an impeller rear cavity. The simulations are carried out with axisymmetric and 3-D sector models for various inlet swirl ratio β_0(0–0.6), turbulent flow parameter lT(0.028–0.280) with and without baffle. The baffle is a thin plate attached to the stationary wall of the cavity, and is proved to be useful in reducing the pressure loss of centripetal flow in the impeller rear cavity in the current paper. Further flow details in impeller rear cavity with and without baffle are displayed using CFD techniques. The CFD results show that for any specified geometry, the outlet pressure coefficient of impeller rear cavity with or without baffle depends only on the inlet swirl ratio and turbulent flow parameter. Meanwhile, the outlet pressure coefficient of the cavity with baffle is indeed smaller than that of cavity without baffle, especially for the cases with high inlet swirl ratio. The suppression of the effect of centrifugal pumping and the mixing beween the main air which is downstream of the baffle and the recirculating flow of the vortex in the stationary cavity, which are caused by the use of baffle, are the underlying reasons that lead to the reduction of outlet pressure loss.     

基于大涡模拟的导叶式混流泵叶轮内压力脉动特性分析

为研究导叶式混流泵叶轮内部非定常压力脉动特性,在其叶轮进口截面及出口截面附近分别设置8个压力脉动监测点,采用大涡模拟方法(LES)对导叶式混流泵内全三维流道(进水管、叶轮、导叶及出水管)进行模拟,并对8个监测点进行压力脉动时域图和频域图的分析。结果表明:由于旋转叶轮旋转失速、脱流效应及静止导叶的干涉作用,叶轮出口处压力脉动系数幅值均大于进口处脉动系数幅值,且其最大压力脉动发生在叶轮出口处,脉动波衰减较慢;叶轮进、出口截面上监测点的压力脉动频率以叶轮叶频为主频次,且压力脉动主要频率为叶频的倍数。     

中压低温透平膨胀机增压端三维数值模拟

综合运用现代计算流体力学方法对某型号中压低温透平膨胀机增压端的三维定常黏性流场进行了数值模拟,详细研究了轮背间隙和密封腔内的刮削回流现象、动叶通道内的流场气动参数以及无叶扩压器内的流动特性对整机气动性能的影响。研究结果表明:气封齿和盖板缝隙内的局部射流是形成气封齿内旋涡旋向的主要因素;轴封槽内存在较大的旋涡且挂在齿尖上,这是由于齿尖区域的节流作用导致的;无叶扩压器和蜗壳通道内的流动具有很强的三维不均匀性,自蜗舌位置开始顺时针方向约45°范围内压力和温度都明显低于其他周向位置,影响了蜗壳的气动特性。数值计算结果为膨胀端的气动优化和改型设计提供了依据。     

低比转速离心泵驼峰稳定性及其影响因素研究

为了提高低比转速离心泵的效率,一般会将叶轮叶片出口角加大一些,但会引起H-Q曲线有驼峰,导致泵在小流量区运行不稳定。本文以国内某水泵厂生产的比转速为47的单级单吸式离心泵为研究对象,采用正交试验法选择叶轮出口边斜切比、出口角度、叶轮轴线倾斜角度、叶片包角、叶片进口边位置5个因素,每个因素采用4个水平,一共16个叶轮设计方案;针对每个方案进行数值模拟,得到其外特性曲线;利用极差分析法研究5个因素对特性曲线形状以及泵额定工况下扬程、效率的影响,得到影响特性曲线稳定性的因素主次顺序依次为叶片进口边位置、叶轮出口边斜切、叶轮轴线倾斜角度、出口角度、叶片包角;利用分析得到的结果得出叶轮的优化组合方案,对该方案进行数值模拟验证。结果表明:优化方案的H-Q曲线稳定且泵的扬程和效率分别提升2.2%和1.4%;从优化前后的叶轮流场中分析消除驼峰的机理,得到驼峰工况区内叶轮进口处的能量损失占据主导,进口边位置的前移减小进口处的能量损失,同时叶轮出口边斜切与轴面倾斜使叶轮出口处相对速度变化减小,“射流–尾迹”现象减弱甚至消失,损失大幅减小。     

Investigation of the spike-stall warning method using the blade passing signal

The vaned-diffuser usually brings compressor instability problems under the small flow rate, for instance the spike-type rotating stall phenomenon which restricts the operation range and may cause the trouble of blade fatigue. Since it is difficult to mathematically predict the spike-type stall for its randomness, finding out a practical method to warning this stall precursor appears to be meaningful. The paper explains the relationship between the spike-type precursor and the blade passing irregularity coefficient to analyze whether this coefficient is appropriate for the spike-stall warning inside a centrifugal compressor with the vaned-diffuser. The advanced wireless measurements were conducted on a 1.5 stages test centrifugal compressor to capture the unsteady behavior progressing from the design to stall inception within the region between the impeller trailing edge (TE) and diffuser leading edge (LE). The circumferential distribution of the blade passing irregularity has been quantitatively revealed. The steep increase of the blade passing irregularity at some “special locations”, which is responsible for the onset of the spike-type precursor, is highlighted. Also, to further understand the spike precursor inside the diffuser passage corresponding to the circumferential “special location” with maximum irregularity, the high-response transient measurement within this passage is presented. With the help of full-annulus computational fluid dynamics (CFD) simulation and the mathematical model, it is proved that the blade passing irregularity precisely reflects the flow characteristics during the spike precursor, which presents the guidance for this stall warning method.     

燃气轮机火焰筒双耳孔冷却特性的分析

为进一步提高燃烧室火焰筒的冷却性能,提出一种具有更高冷却性能的双耳孔型气膜冷却结构。采用数值模拟方法对比分析吹风比在0.67～2.01时,传统圆柱孔、扩散孔、收敛孔、双耳孔的流动传热和冷却特性。计算结果表明：与其他3种孔型相比,冷却壁面长径比在0～40时,双耳孔出口冷却气流在高温主流作用下形成的肾形涡对尺寸较小,强度较弱,对涡中心的间距较大,且冷却气流横向分布更广,壁面换热系数比更低,提高了气膜冷却性能。在吹风比为2.01时,与圆柱孔相比,扩散孔的流量系数提高了13.7%,展向换热系数比降低了1.5%;收敛孔的流量系数没有变化,展向换热系数比降低了2.7%;但双耳孔的流量系数却降低3.1%,展向换热系数比降低了11.25%。在吹风比为1.33时,与扩散孔和收敛孔相比,双耳孔的流量系数更低,在长径比小于40时,双耳孔的换热系数比最低,冷却效果最好。     

Turbocharger Noise Prediction Using Broadband Noise Source Model

The noise prediction of the turbocharger is studied. The broadband noise source model is employed to predict the near-field noise of the turbocharger. The 3D software Solidworks is adopted to establish the model blades and inlet of turbocharger compressor, then this 3D model is introduced into the software CFD to calculate the flow-field under different inlet shapes, different blades shapes and different clearances between casing and impeller. On the base of the above simulation, the broadband noise source model is employed to calculate and analyze the near-field noise. The calculation shows that compressor static pressure values and the sound power values near the impeller outlet are the largest. Through the noise calculation by using broadband noise source model under different inlet shapes and blade shapes, we find that the noise level of the inlet of cylindrical and cone types are smaller. Compared with the current widespread used backward skewed or radial blades, there is little difference of the noise value of the inlet of the forward skewed blades.     

基于有限体积法的G4-73型离心风机三维流场数值模拟

基于有限体积法,利用Fluent软件对G4-73型离心风机内部流场进行了全三维数值模拟。结果表明:蜗壳内的低能流体区沿轴向朝流动方向推进;叶轮内的静压和动压在叶片吸力面靠近叶轮进口处最低,叶轮流道中动压等值线呈"凸"型分布,在叶片压力面靠近叶轮出口处静压和动压达到最大值,且叶轮出口相对总压损失集中在吸力面和前盘侧。     

利用轴向力预测离心压缩机的级密封状态

根据离心压缩机转子所承受的、可实时监测的轴向力与级密封间隙的关系,提出了基于轴向力的离心压缩机级密封状态的预测方法.在分析叶轮两侧缝隙内泄漏气体流动的基础上,采用计算流体动力学方法对其进行仿真,得到轮盘及轮盖上的压力分布,由此计算出轴向力.把不同级密封间隙值及对应的轴向力作为输出、输入向量,对BP神经网络进行训练,以获得在线状态预测模型.测试结果表明,该模型对离心压缩机级密封的状态预测是有效的.     

长短叶片半开式离心叶轮内部流动的数值模拟

为了分析分流叶片对于半开式离心叶轮内部流动的影响，对轴向间隙为1.1 mm的4长叶片和4长4短叶片的两种半开式低比转速高速离心叶轮进行了研究.采用S A湍流模型和雷诺时均N-S方程，对叶轮内部的流动进行了三维紊流数值计算和分析；并对离心泵进行了试验研究.数值计算结果表明，分流短叶片可以改善叶轮内部的流动；两个叶轮内部的静压力都由叶片进口到出口逐渐升高，等静压曲线几乎是沿圆周方向的；具有分流叶片的叶轮出口的压力系数较高.实验结果表明，具有分流叶片的叶轮离心泵的扬程和效率较高，说明分流叶片可以提高离心泵的性能.