Abstract: Solid particle erosion has been identified as a critical wear phenomenon which takes place during operation of aeroengines in dusty environment. The present work discusses the erosion behavior of Ti-44.5Al-6.25Nb-0.8Mo-0.1B alloy (TNB-V4) which finds its application in low pressure gas turbines and can be used for high pressure compressors too. Prior to the erosion tests, the alloy was heat treated to improve the mechanical properties. Afterwards, specimens were eroded at impact angles of 30° and 90° at room and high temperatures (100 °C-400 °C). Volume loss and erosion behavior are studied through gravimetric analysis, whereas erosion mechanisms are characterized through scanning electron microscopy. The results indicate a clear difference in the erosion mechanism for different impact angles. The influence of the test temperature on the erosion behavior of the alloy is also discussed in the present contribution.
Abstract: The subject of this paper is the investigation of the
best efficiency design of a compressor diffuser applied in new
lightweight, ultra efficient micro-gas turbine engines for vehicles. The
Computational Fluid Dynamics (CFD) results are obtained utilizing
steady state simulations for a wedge and an ”oval” type pipe diffuser
in an effort to identify the beneficial effects of the pipe diffuser
design. The basic flow features are presented with particular focus
on the optimization of the pipe diffuser leading to higher efficiencies
for the compressor stage. The optimised pipe diffuser is designed to
exploit the 3D freedom enabled by Selective Laser Melting, hence
purposely involves an investigation of geometric characteristics that
do not follow the traditional diffuser concept.
Abstract: Digital signal processor, image signal processor and FIR filters have multipliers as an important part of their design. On the basis of Vedic mathematics, Vedic multipliers have come out to be very fast multipliers. One of the image processing applications is edge detection. This research presents a small area and high speed 8 bit Vedic multiplier system comprising of compressor based adders. This results in faster edge detection. This architecture is tested on Xilinx vertex 4 FPGA board and simulations were carried out using the Xilinx synthesis tool. Comparisons are made and this system is found to be smaller in area with high speed (the lesser propagation delay). This compressor based Vedic multiplier is 1.1 times speedier than a typical Vedic multiplier. Also, this Vedic Multiplier is 2 times speedier than a ‘simple’ multiplier.
Abstract: At present, vibrations of rotors of gas transmittal unit evade sustainable forecasting. This paper describes elastic oscillation modes in resilient supports and rotor impellers modeled during computational experiments with regard to interference in the system of gas-dynamic flow and compressor rotor. Verification of aeroelastic approach was done on model problem of interaction between supersonic jet in shock tube with deformed plate. ANSYS 15.0 engineering analysis system was used as a modeling tool of numerical simulation in this paper. Finite volume method for gas dynamics and finite elements method for assessment of the strain stress state (SSS) components were used as research methods. Rotation speed and material’s elasticity modulus varied during calculations, and SSS components and gas-dynamic parameters in the dynamic system of gas-dynamic flow and compressor rotor were evaluated. The analysis of time dependence demonstrated that gas-dynamic parameters near the rotor blades oscillate at 200 Hz, and SSS parameters at the upper blade edge oscillate four times higher, i.e. with blade frequency. It has been detected that vibration amplitudes correction in the test points at magnetic bearings by aeroelasticity may correspond up to 50%, and about -π/4 for phases.
Abstract: Parallel Compressor Model (PCM) is a simplified approach to predict compressor performance with inlet distortions. In PCM calculation, it is assumed that the sub-compressors’ outlet static pressure is uniform and therefore simplifies PCM calculation procedure. However, if the compressor’s outlet duct is not long and straight, such assumption frequently induces error ranging from 10% to 15%. This paper provides a revised calculation method of PCM that can correct the error. The revised method employs energy equation, momentum equation and continuity equation to acquire needed parameters and replace the equal static pressure assumption. Based on the revised method, PCM is applied on two compression system with different blades types. The predictions of their performance in non-uniform inlet conditions are yielded through the revised calculation method and are employed to evaluate the method’s efficiency. Validating the results by experimental data, it is found that although little deviation occurs, calculated result agrees well with experiment data whose error ranges from 0.1% to 3%. Therefore, this proves the revised calculation method of PCM possesses great advantages in predicting the performance of the distorted compressor with limited exhaust duct.
Abstract: Compressor fans in modern aircraft engines are of considerate importance, as they provide majority of thrust required by the aircraft. Their challenging environment is frequently subjected to non-uniform inflow conditions. These conditions could be either due to the flight operating requirements such as take-off and landing, wake interference from aircraft fuselage or cross-flow wind conditions. So, in highly maneuverable flights regimes of fighter aircrafts affects the overall performance of an engine. Since the flow in compressor of an aircraft application is highly sensitive because of adverse pressure gradient due to different flow orientations of the aircraft. Therefore, it is prone to unstable operations. This paper presents the study that focuses on axial compressor response to inlet flow orientations for the range of angles as 0 to 15 degrees. For this purpose, NASA Rotor-37 was taken and CFD mesh was developed. The compressor characteristics map was generated for the design conditions of pressure ratio of 2.106 with the rotor operating at rotational velocity of 17188.7 rpm using CFD simulating environment of ANSYS-CFX®. The grid study was done to see the effects of mesh upon computational solution. Then, the mesh giving the best results, (when validated with the available experimental NASA’s results); was used for further distortion analysis. The flow in the inlet nozzle was given angle orientations ranging from 0 to 15 degrees. The CFD results are analyzed and discussed with respect to stall margin and flow separations due to induced distortions.
Abstract: Power Regeneration in Refrigeration Plant concept
has been analyzed and has been shown to be capable of saving about
25% power in Cryogenic Plants with the Power Regeneration System
(PRS) running under nominal conditions. The innovative component
Compressor Expander Group (CEG) based on turbomachinery has
been designed and built modifying CETT compressor and expander,
both selected for optimum plant performance. Experiments have
shown the good response of the turbomachines to run with R404a as
working fluid. Power saving up to 12% under PRS derated conditions
(50% loading) has been demonstrated. Such experiments allowed
predicting a power saving up to 25% under CEG full load.
Abstract: The turbocharger and turbocharging have been the
inherent component of diesel engines, so that critical parameters of
such engines, as BSFC (Brake Specific Fuel Consumption) or
thermal efficiency, fuel consumption, BMEP (Brake Mean Effective
Pressure), the power density output and emission level have been
improved extensively. In general, the turbocharger can be considered
as the most complex component of diesel engines, because it has
closely interrelated turbomachinery concepts of the turbines and the
compressors to thermodynamic fundamentals of internal combustion
engines and stress analysis of all components.
In this paper, a waste gate for a conventional single stage radial
turbine is investigated by consideration of turbochargers operation
constrains and engine operation conditions, without any detail
designs in the turbine and the compressor. Amount of opening waste
gate which extended between the ranges of full opened and closed
valve, is demonstrated by limiting compressor boost pressure ratio.
Obtaining of an optimum point by regard above mentioned items is
surveyed by three linked meanline modeling programs together
which consist of Turbomatch®, Compal®, Rital® madules in concepts
NREC® respectively.
Abstract: Stator elements «Vane diffuser + crossover + return
channel» of stages with different specific speed were investigated by
CFD calculations. The regime parameter was introduced to present
efficiency and loss coefficient performance of all elements together.
Flow structure demonstrated advantages and disadvantages of design.
Flow separation in crossovers was eliminated by its shape
modification. Efficiency increased visibly. Calculated CFD
performances are in acceptable correlation with predicted ones by
engineering design method. The information obtained is useful for
design method better calibration.
Abstract: The 6th version of Universal modeling method for
centrifugal compressor stage calculation is described. Identification
of the new mathematical model was made. As a result of
identification the uniform set of empirical coefficients is received.
The efficiency definition error is 0,86 % at a design point. The
efficiency definition error at five flow rate points (except a point of
the maximum flow rate) is 1,22 %. Several variants of the stage with
3D impellers designed by 6th version program and quasi threedimensional
calculation programs were compared by their gas
dynamic performances CFD (NUMECA FINE TURBO).
Performance comparison demonstrated general principles of design
validity and leads to some design recommendations.
Abstract: Parameters of flow are calculated in vaneless diffusers
with relative width 0,014–0,10. Inlet angles of flow and similarity
criteria were varied. There is information on flow separation,
boundary layer development, configuration of streamlines.
Polytrophic efficiency, loss coefficient and recovery coefficient are
used to compare effectiveness of diffusers. The sample of
optimization of narrow diffuser with conical walls is presented. Three
wide diffusers with narrowing walls are compared. The work is made
in the R&D laboratory “Gas dynamics of turbo machines” of the TU
SPb.
Abstract: Universal modeling method well proven for industrial
compressors was applied for design of the high flow rate supersonic
stage. Results were checked by ANSYS CFX and NUMECA Fine
Turbo calculations. The impeller appeared to be very effective at
transonic flow velocities. Stator elements efficiency is acceptable at
design Mach numbers too. Their loss coefficient versus inlet flow
angle performances correlates well with Universal modeling
prediction. The impeller demonstrates ability of satisfactory operation
at design flow rate. Supersonic flow behavior in the impeller inducer
at the shroud blade to blade surface Φ des deserves additional study.
Abstract: There is an evident trend to elevate pressure ratio of a
single stage of a turbo compressors - axial compressors in particular.
Whilst there was an opinion recently that a pressure ratio 1,9 was a
reasonable limit, later appeared information on successful modeling
tested of stages with pressure ratio up to 2,8. The authors recon that
lack of information on high pressure stages makes actual a study of
rational choice of design parameters before high supersonic flow
problems solving. The computer program of an engineering type was
developed. Below is presented a sample of its application to study
possible parameters of the impeller of the stage with pressure ratio
3,0. Influence of two main design parameters on expected efficiency,
periphery blade speed and flow structure is demonstrated. The results
had lead to choose a variant for further analysis and improvement by
CFD methods.
Abstract: Solenoid operated electromagnetic control valve
(ECV) playing an important role for car’s air conditioning control
system. ECV is used in external variable displacement swash plate
type compressor and controls the entire air conditioning system by
means of a pulse width modulation (PWM) input signal supplying
from an external source (controller). Complete form of ECV contains
number of internal features like valve body, core, valve guide,
plunger, guide pin, plunger spring, bellows etc. While designing the
ECV; dimensions of different internal items must meet the standard
requirements as it is quite challenging. In this research paper,
especially the dimensioning of ECV body and its three pressure ports
through which the air/refrigerant passes are considered. Here internal
leakage test analysis of ECV body is being carried out from its
discharge port (Pd) to crankcase port (Pc) when the guide valve is
placed inside it. The experiments have made both in ordinary and
digital system using different assumptions and thereafter compare the
results.
Abstract: Stress Corrosion Crack (SCC) in pipeline is a type of
environmentally assisted cracking (EAC), since its discovery in 1965
as a possible cause of failure in pipeline, SCC has caused, on
average, one of two failures per year in the U.S, According to the
NACE SCC DA a pipe line segment is considered susceptible to SCC
if all of the following factors are met: The operating stress exceeds
60% of specified minimum yield strength (SMYS), the operating
temperature exceeds 38°C, the segment is less than 32 km
downstream from a compressor station, the age of the pipeline is
greater than 10 years and the coating type is other than Fusion
Bonded Epoxy(FBE). In this paper as a practical experience in
NISOC, Direct Assessment (DA) Method is used for identification
SCC defect in unpiggable pipeline located downstream of
compressor station.
Abstract: Vibration analysis of most critical equipment is considered as one of the most challenging activities in preventive maintenance. Utilities are heart of the process in big industrial plants like petrochemical zones. Vibration analysis methods and condition monitoring systems of these kinds of equipments are developed too much in recent years. On the other hand, there are too much operation factors like inlet and outlet pressures and temperatures that should be monitored. In this paper, some of the most effective concepts and techniques related to gas turbine vibration analysis are discussed. In addition, a gas turbine SIEMENS 162MW - V94.2 vibration case history related to Iran power industry in Fars province is explained. Vibration monitoring system and machinery technical specification are introduced. Besides, absolute and relative vibration trends, turbine and compressor orbits, Fast Fourier transform (FFT) in absolute vibrations, vibration modal analysis, turbine and compressor start up and shut down conditions, bode diagrams for relative vibrations, Nyquist diagrams and waterfall or three-dimensional FFT diagrams in startup and trip conditions are discussed with relative graphs. Furthermore, Split Resonance in gas turbines is discussed in details. Moreover, some updated vibration monitoring system, blade manufacturing technique and modern damping mechanism are discussed in this paper.
Abstract: The miniaturization of gas turbines promises many advantages. Miniature gas turbines can be used for local power generation or the propulsion of small aircraft, such as UAV and MAV. However, experience shows that the miniaturization of conventional gas turbines, which are optimized at their current large size, leads to a substantial loss of efficiency and performance at smaller scales. This may be due to a number of factors, such as the Reynolds-number effect, the increased heat transfer, and manufacturing tolerances. In the present work, we focus on computational investigations of the Reynolds number effect and the wall heat transfer on the performance of axial compressor during its size change. The NASA stage 35 compressor is selected as the configuration in this study and computational fluid dynamics (CFD) is used to carry out the miniaturization process and simulations. We perform parameter studies on the effect of Reynolds number and wall thermal conditions. Our results indicate a decrease of efficiency, if the compressor is miniaturized based on its original geometry due to the increase of viscous effects. The increased heat transfer through wall has only a small effect and will actually benefit compressor performance based on our study.
Abstract: Vibration monitoring methods of most critical equipment like main turbine and compressors always plays important role in preventive maintenance and management consideration in big industrial plants. There are a number of traditional methods like monitoring the overall vibration data from Bently Nevada panel and the time wave form (TWF) or fast Fourier transform (FFT) monitoring. Besides, Shaft centerline monitoring method developed too much in recent years. There are a number of arguments both in favor of and against this method between people who work in preventive maintenance and condition monitoring systems (vibration analysts). In this paper basic principal of Turbine compressor vibration analysis and rotor movement evaluation by shaft centerline method discussed in details through a case history. This case history is related to main turbine compressor of an olefin plant in Iran oil industry. In addition, some common mistakes that may occur by vibration analyst during the process discussed in details. It is worthy to know that, these mistakes may one of the reasons that sometimes this method seems to be not effective. Furthermore, recent patent and innovation in shaft position and movement evaluation are discussed in this paper.
Abstract: Cascade refrigeration systems employ series of single stage vapor compression units which are thermally coupled with evaporator/condenser cascades. Different refrigerants are used in each of the circuit depending on the optimum characteristics shown by the refrigerant for a particular application. In the present research study, a steady state thermodynamic model is developed which simulates the working of an actual cascade system. The model provides COP and all other system parameters e.g. total compressor work, temperature, pressure, enthalpy and entropy at different state points. The working fluid in low temperature circuit (LTC) is CO2 (R744) while Ammonia (R717), Propane (R290), Propylene (R1270), R404A and R12 are the refrigerants in high temperature circuit (HTC). The performance curves of Ammonia, Propane, Propylene, and R404A are compared with R12 to find its nearest substitute. Results show that Ammonia is the best substitute of R12.
Abstract: Vibration analysis of screw compressors is one of the most challenging cases in preventive maintenance. This kind of equipment considered as vibration bad actor facilities in industrial plants. On line condition monitoring systems developed too much in recent years. The high frequency vibration of ball bearings, gears, male and female caused complex fast Fourier transform (FFT) and time wave form (TWF) in screw compressors. The male and female randomly are sent to balance shop for balancing operation. This kind of operation usually caused some bending in rotors during the process that could cause further machining in such equipment. This kind of machining operation increased the vibration analysis complexity beside some process characteristic abnormality like inlet and out let pressure and temperature. In this paper mechanical principal and different type of screw compressors explained. Besides, some new condition monitoring systems and techniques for screw compressors discussed. Finally, one of the common behavior of oil injected twin rotary screw compressors called hydraulic unbalance that usually occurred after machining operation of male or female and have some specific characteristics in FFT and TWF discussed in details through a case history related to Iran oil industries.