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Advances in Modelling of Screw Machines - Keynote at ICSC2018

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Presentation · September 2018

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 International Conference on Screw
Machines
Technische Universität Dortmund
18th-19th September 2018
KEYNOTE

Academic excellence for

business and the professions

Advances in Modelling of Screw Machines

Professor Ahmed Kovacevic

Howden Chair in Engineering Design and Compressor Technology

Centre for Compressor Technology

Department of Engineering, City, University of London, UK
 'Essentially,

all models are wrong,

but some are useful‘

George Edward Pelham Box FRS (1919-2013)

25/09/2018 2
 Agenda

Introduction
■ 3D CFD modelling of screw machines

■ Grid generation for 3D CFD

■ Test cases

Future

Thanks to:
EPSRC, Howden, Trane, UTRC, Goodrich, Kobelco,
PDM Analysis Ltd, Simerics, Star-CCM+, CFX Berlin, VertRotors,
for support in developing CFD in PD screw machines and software SCORG.
25/09/2018 3
 Kosaka lab

Flowserve Bornemann

Vert Rotor

Howden
Vilter
 Screw Compressors Today
83% Oil injected ; 17% Oil free
• Applications:
Industrial and commercial
Air compression, Refrigeration,
Process gasses Oil & Gas,
Expanders, multiphase
• Dia (35) 50 – 1000 mm
• 0.3 – >1000 m3/min
• 0.5 kW – 5 MW
• High Efficiency, Reliable

~ 11 million screw compressors

produced to date

Bear shaft screw compressors

commissioned in 2016 (est.):
Refrigeration/AC: 166,000
Oil and Gas: 24,000
Petrochemical: 25,000
Air (est.) >500,000

80% of new industrial compressors are screw compressors Large Packages ~800
17% energy produced in developed countries used for compression
25% energy in USA during summer is used for refrigeration and air-conditioning
Trends

25/09/2018 6
Global screw compressor sales $7.99 billion in 2016

$3.15 b
$2.53 8.05%
7.65
%

$1.76b
6.07%
$2.25 b
4.82%

$1.32 b
3.21%

Forecast CAGR 2017 to 2021 = 6.62% (>$11Billion USD)

7
The oil-free segment is expected to grow at the highest CAGR from 2016 to 2021
Compressors and energy
■ Compressors consume more than 17% energy produced in developed
countries. This pollutes the environment with more than 3000 MtCO2
per year, while energy costs exceed €275 billion per year*.
■ The global CO2 emission will increase by up 28% from 2015 to 2030,
■ The latest EU targets for 2020 are to reduce the CO2 emissions by 20%
from the levels recorded in 1990. This requires:
• 20% of energy produced by renewable sources
• increase energy efficiency by 20% from the levels recorded in 2007.
currently these targets may not be achieved despite efforts by both
industry and academia.
■ Oil injected compressors and other multiphase fluid handling machines
have great potential for improvements in efficiency and contributing to
reduction in CO2 emission.
*Source: http://www.iea.org/publications/freepublications/publication/EE_for_ElectricSystems.pdf
 3rd Short Course/Forum on
CFD in Positive displacement rotary machines
9th – 10th September 2017

Previous events:
2007;
2013; 2015, 2017
Next event
2019

25/09/2018
25/09/2018 10
Test cases used in this presentation:
Oil free Screw Compressor - XK18 3/5 ‘N’ Profile, CD 93
– Main Rotor OD, 127.446mm
– Gate Rotor OD, 120.380mm
– L/D Ratio, 1.6
– Wrap Angle, 280º
– Built in Vi, 1.8
– Clearances: • Interlobe 170 µm
• Radial 160µm
• End Axial 160µm

Oil Injected twin Screw Compressor - JYC 4/5 ‘N’ Profile, CD 93

– Main Rotor OD, 105.28 mm

– L/D Ratio, 1.55
– Wrap Angle, 306.6º
– Built in Vi, 4.6
– Clearances: • Interlobe 50 µm
• Radial 50 µm
• End Axial 50µm

25/09/2018 11
 Agenda

Introduction
■ 3D CFD modelling of screw machines

■ Grid generation for 3D CFD

■ Test cases

Future

25/09/2018 12
Mathematical models for calculation of
positive displacement screw machines
Differential methods based on continuum principles (macroscopic)
A. Thermodynamic chamber model:
Simple(r), many assumptions made, fast, limited accuracy
B. 3D Computational Fluid Dynamics (CFD) model
Complex, fewer assumptions, slow(er), gives more detail
C. Integrated models:
Not as complex as 3D but more accurate than Chamber model

Differential methods based on kinetic theory (microscopic)

D. 3D Lattice Boltzman method
Solves discrete Boltzman equation on grid lattice, suitable for
parallel computing, multiphase flows and moving meshes
25/09/2018 13
General conservation equation – continuum

d
∫
dt V
ρφ dV + ∫ ρφ ( v − v b ) ⋅ ds =Γ
S
∫
S
φ grad φ ⋅ ds + ∫ qφ S ⋅ ds + ∫ qφV ⋅ dV
S V
Thermodynamic Multi Chamber Modelling
Numerical solution: Conservation of mass and energy dm
• Any working fluid - Ideal or real, ω = m in − m out
• Includes fluid to solid heat transfer dθ
 dU  dV
• Independent on a machine geometry ω  =  m in hin − m out hout + Q − ω p
• Liquid injection modelled (multiphase)  d θ  dθ
Limitations: Same
• Fluid flow is assumed “quasi” one-dimensional principle
• Kinetic energy is neglected for energy
• Assumed isentropic flow through inlet and outlet ports
• Assumed adiabatic flow through clearances pV = zmRT
• Tuning required for specific machines

Dilute Oil Flow

25/09/2018 15
 3D CFD modelling based on continuity principles
d
∫
dt V
ρφ dV + ∫ ρφ ( v − v b ) ⋅ ds =Γ
S
∫
S
φ grad φ ⋅ ds + ∫ qφ S ⋅ ds + ∫ qφV ⋅ dV
S V
Navier-Stokes
φ Γφ qfS qfV
Continuity 1 0 0 0

Fluid momentum µeff  2  

 µ eff ( grad v ) −  3 µ eff div v +
vi T
p  I  ⋅ ii f b,i
   
Solid momentum ∂ui η
η ( grad u )T + ( λ div u - 3Kα∆T ) I  ⋅ i i f b,i
∂t  
k µ k ∂e
Energy e + t − ⋅ gradp
T: grad v + h
∂e ∂T σ T ∂e ∂T ∂p
ρ Di ,eff
Concentration ci 0
sci
Space 1 0 0 0
ρ
Turbulent kinetic µt
µ+
K 0
energy P − ρε
σk
Dissipation ε µ 0 ε ε2
µ+ t C1 P − C2 ρ − C3 ρε div v
σε k k
ρ ρ=
( p, T ), e e( p, T ) Constitutive relations, equation of state and turbulence model.
Solution algorithm
Prediction parameters
– Pressure field,
– Temperature field,
– Velocity field,
– Mass flow rates,
– Leakage volume and Efficiency,
– Power,
– Dynamic losses,
– Design Improvements.

Key Elements
• 3D Transient,
• Turbulence,
• Grid Generation,
• Moving / Deforming Boundaries,
• Compressible Fluids,
• Multiphase / Oil Injection

25/09/2018 17
Solution domain and grid generation

25/09/2018 18
Grid generation approaches

• Grid systems
- structured
body fitted,
cut Cartesian
- unstructured
- mixed

• Block structured
- overlapping
- discontinuous
- continuous
- conformal

• Grid generation methods

- Algebraic - interpolation or some special functions
- Differential - based on the solution of partial differential equations
- Variational - based on optimization of the grid quality properties.
25/09/2018 19
Grid generation - grid quality

• Expansion factor fe < 2

• Aspect ratio fa < 10
• Angle of non-orthogonality θno < 50o
• Warp angle θw < 50o

Skewness factor gives more information about grid than other quality measures
25/09/2018 20
 Agenda

Introduction
■ 3D CFD modelling of screw machines - Issues

■ Grid generation for 3D CFD

■ Test cases

Future

25/09/2018 21
Issues - Requirements
Phenomenological

• Volumetric machine (thermo)

• Flow through clearances (flow)

• Multi-Phase fluids

• Fluid-Solid Interaction

• Speed and accuracy

of solution

25/09/2018 22
Numerical

Mass, Momentum, Energy and Space

conservation in 3D CFD

Issue 1
Conservativeness

Mesh topology

from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, Short Course, London, Sep 2015
Case Study Piston-Cylinder Analysis
■ Reversible Adiabatic Compression-Expansion Process
■ Mesh Smoothing and Key-Frame re-meshing methods compared with
the theoretical results

Mesh Smoothing Key Frame Remeshing

25/09/2018 24
Numerical

Piston-Cylinder Analysis
𝛾𝛾
𝑝𝑝2 𝑉𝑉1 𝛾𝛾 𝑇𝑇2 (𝛾𝛾−1)
� � =� � =� �
𝑝𝑝1 𝑉𝑉2 𝑇𝑇1

Issue 1
Conservativeness

Mesh topology

Diffusion Equation Mesh Smoothing is more accurate then Key Frame Remeshing

25/09/2018 25
Numerical

Discretisation and solution methods

Time discretisation:
• Explicit forward Euler - 1st Order
• Implicit backward Euler - 1st Order Issue 2
• Implicit 2nd order backward - 2nd order Discretisation and
• Explicit Multi-stage (Runge Kutta) – higher order solution method

Speed and
Space discretisation: accuracy of a
• 1st order forward differencing solver
• 1st order backward differencing
• 2nd order central differencing
• 2nd order backward differencing

Pressure, density, velocity balancing

• There is no governing equation for pressure (it is not a math. field)
• Pressure is obtained by balancing continuity and momentum equations
• SIMPLE (Semi implicit Method for Pressure Linked Equations), SIMPLEC, PISO

25/09/2018 26
Numerical - practical

Discretisation and solution methods

CFX Simerics MP
Fluent Coupled Fluent Segregated
CCM+ Coupled CCM+ Segregated

25/09/2018 27
Numerical - practical
Representing the mesh in the solver
CFX

Element based approach

Other solvers

Cell centred approach

25/09/2018 28
 Performance comparison - Oil free compressor

Criteria CFX Fluent Simerics MP

Solver type Coupled Segregated Segregated
Co-located layout, Rhie and SIMPLE (first order Staggered layout,
Pressure-Velocity Coupling
Chow’s interpolation upwind formulation) SIMPLE – S
Total Pressure, Inlet pressure, Total Pressure,
Inlet Boundary Condition
Temperature temperature Temperature
Outlet Boundary Condition Static Pressure Pressure outlet Static Pressure

Advection Scheme High Resolution Upwind 2nd Order Upwind 2nd Order Upwind

Transient Scheme Second Order First order implicit First Order

Turbulence Model SST – k Omega k-epsilon k-epsilon RNG

Turbulence Scheme First Order Upwind First order upwind First Order Upwind

Transient Inner Loop Iterations Up to 6 10 Up to 25

Convergence Criteria 1e-03 1e-03 1e-03

Rotor mesh size male/female 292320/290000 Total=582320 rotor cells (medium coarse mesh)
25/09/2018 29
 Numerical - practical

Comparison of CFX, Fluent and Simerics MP

Mass Flow Rate vs Speed

14.0
13.0
Mass Flow Rate (kg/min)

12.0
11.0
10.0
9.0
8.0
7.0
6.0
5500 6000 6500 7000 7500 8000 8500

2.0 bar Expt Rotor Speed

2.0 bar(rpm)
CFX 2.0 bar Simerics 2.0 bar Fluent

Total number of Calculation time Coefficient Error in cycle averaged

Solver
time steps per time step / total Loops mass flow
CFX 1000 7.30 mins / total = 5 days 6 1.01
FLUENT 1000 2.40 mins / total= 1.7 days 10 0.99
SIMERICS MP
25/09/2018 1000 1.5 min / total = 1 day 10 1 30
Difference in flow predictions → 2D CFD leakage study

25/09/2018 31
Solvers Formulation Turbulence Model

Solver - 1 ANSYS CFX Coupled Laminar, k-epsilon and SST k-Omega

Issue 2
For all solvers:
Solver - 2 Simerics-PD Segregated Laminar and k-epsilon Discretisation
Density – Air Ideal Gas Law and
Total Pressure Inlet = 201325
solution method Pa
Solver - 3 ANSYS FLUENT Segregated Laminar, k-epsilon and SST k-Omega
Total Temperature at Inlet = 300K
Solver - 4 ANSYS FLUENT Coupled Laminar, k-epsilon and SST k-Omega Static Pressure Outlet = 101325 Pa
Speed
Conservation target and
= 1e-04,
Solver - 5 Star CCM+ Segregated Laminar, k-epsilon and SST k-Omega accuracy
Transient solution of=a5e-05 sec
with Δt
Solver - 6 Star CCM+ Coupled Laminar, k-epsilon and SST k-Omega solver

Analytical Mass Flow Rate: Solver–1 gives ~ 7% higher leakage Product of average Velocity
• Steady, 1D isentropic flow through flow under same operating conditions. and Density at the throat area
a Converging-Diverging Nozzle
v_avg ρ_avg vρ % Diff
• choked flow
• Mass flow rate depends only Solver-1 270.57 1.636 442.7 Reference
on the upstream density Solver-2 291.51 1.386 403.9 8.77
Solver-3 244.83 1.641 401.7 9.26
Solver-4 244.83 1.641 401.7 9.26
Solver-5 308.21 1.305 402.2 9.16
Solver-6 293.33 1.425 418.0 5.58

25/09/2018 32
Results plotted for k-epsilon turbulence model
Numerical

Alignment of the grid to the flow

Issue 3
Mesh Orientation

Numerical
Diffusion

25/09/2018 33
from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, 3rd Short Course, London, Sep 2017
25/09/2018 34
from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, 3rd Short Course, London, Sep 2017
 Issue 3
Alignment of the
flow and the grid

Accuracy

25/09/2018 35
from J. Vierendeels, Ghent University, Introduction to CFD in PD machines, 3rd Short Course, London, Sep 2017
Numerical - practical

Modelling of Multiphase Screw Machines

Eulerian treatment of the compressed gas and the injected oil
a) Full Euler-Euler
• Pressure field shared between the phases
• Independent u,v,w - momentum conservation equation for each phase with
interphase drag effects
• Mass conservation between phases in case of phase change.
• Independent energy conservation equation with interphase heat transfer
• Homogeneous or Phase specific turbulence model
a) Volume of Fluid suitable for dense stratified flows
• Pressure field shared between the phases
• One additional momentum conservation equation for liquid phase

b) Simplified Euler approach for fluids with no slip conditions

• Pressure field shared between the phases
• Additional concentration equation with special modelling of source terms

Definition of Solve
Definition of
Interphase Conservation
phases
Interactions PDE’s
25/09/2018 36
 Agenda

Introduction
■ 3D CFD modelling of screw machines

■ Grid generation for 3D CFD

■ Test cases

Future

25/09/2018 37
 Geometrical Inputs
Grid generation for
Boundary Distribution Inputs
Meshing Inputs reliable 3D CFD
How we do it!
Generation of Rotor Profiles and
Rack as the Parting line

Intersection with Outer Circles to

determine CUSP points and ‘O’
Grid outer boundary

Boundary Discretisation

Adaptation and Mapping of ‘O’

Grid inner and outer boundaries
Check Regularity

Transfinite Interpolation for

Interior Node Distribution

Grid Orthogonalisation and

Smoothing

Write Vertex, Cell connectivity

and Domain Boundary Data 38
 Analytical grid generation with differential smoothing
Sliding and stretching interface between rotor subdomains
25/09/2018 39
 Casing to Rotor
Conformal

Analytical grid generation with differential smoothing

Single domain of two rotors with no interface
25/09/2018 40
 Application of structured body fitted grids
analytical grid generation with differential smoothing

Rotor to Casing Casing to Rotor

Non-Conformal Conformal

• Fully conservative • Fully conservative

• Two rotor domains - interface
• Suitable for multiple gate rotors
• Easy grid refinement in clearances
• Straight and helical rotors
• Accurate mapping of a rotor profile
even with the coarser mesh
• Grid aligned to flow in clearances
• Suitable for single phase calculation
• Interface not suitable for all solvers
25/09/2018 with CFX; Fluent; Star CCM+; Simerics MP, Open Foam
• Single Domain - no interface
• Difficult local grid refinement
• Straight and helical rotors
• Higher density required to
accurately map the rotor profile
• Grid not aligned to clearance flow
• Suitable for multiphase flows using
Euler-Euler or VOF
• Suitable for any CFD solver
41
 How others do it
Similar grid generation techniques

• Fully conservative
• Grid aligned/not aligned to clearance flow
• Used exclusively with CFX solver

25/09/2018
From Dr. Andreas Spille-Kohoff, Jan Hesse, Rainer Andres, CFX Berlin Software GmbH, Germany 42
presented at 2nd Short Course on CFD in Positive Displacement Machines, London, September 2015
 Similar grid generation techniques

• Fully conservative
• Grid not aligned to clearance flow
• Used exclusively with Fluent solver / proprietary to Atlas Copco
From: Iva Papes, Joris Degroote, Jan Vierendeels, University of Gent, Belgium
“New insights in twin screw expander performance for small scale ORC systems from 3D CFD analysis”
25/09/2018 43
https://doi.org/10.1016/j.applthermaleng.2015.08.034
 Other grid generation techniques
Structured Cut-Cartesian body fitted

• Not fully conservative

• Grid not aligned to clearance flow / leakage capture is bottleneck
• Easy setup from CAD but could require long calculation time for
resolution of clearances
25/09/2018 From Dr David H. Rowinski, Convergent Science, Inc., USA, 44
rd
presented at 3 Short Course on CFD in Positive Displacement Machines, London, September 2017
 Other grid generation techniques
Unstructured 2D and 3D

• Not conservative
• Grid not aligned to clearance flow
• Attempted by many users but not suitable for screw
machines
• Computationally very expensive
25/09/2018 From Dr Mohammad Omidyeganeh, City, University of London, UK 45
nd
presented at 2 Short Course on CFD in Positive Displacement Machines, London, September 2015
 Other grid generation techniques
Overset meshes:
- No re-meshing
- Expensive interpolation
- Redundant calculation
in some regions of
overlapping meshes
- Very large grids,
impractical and slow

• Not conservative
• Grid not aligned to clearance flow
• Extensive calculation and large mesh

25/09/2018 From Dr Mohammad Omidyeganeh, City, University of London, UK 46

nd
presented at 2 Short Course on CFD in Positive Displacement Machines, London, September 2015
 Other grid generation techniques
Overset meshes – Ghost cell approach –
single mesh with solid, ghost and fluid cells

Immersed
Surface

Baseline
Grid

• Not conservative
• Grid not aligned to clearance flow
• Special solvers required

25/09/2018 From Dr Mohammad Omidyeganeh, City, University of London, UK 47

nd
presented at 2 Short Course on CFD in Positive Displacement Machines, London, September 2015
 Single screw – overset meshes

• Not conservative
• Grid not aligned to clearance flow
• Demanding grid generation and special algorithms for calculations
• But first results are available
25/09/2018 48
 Agenda

Introduction
■ 3D CFD modelling of screw machines

■ Grid generation for 3D CFD

■ Test cases – some examples

Future

25/09/2018 49
25/09/2018 50
SCORG to Star-CCM+

C# written
DLL library
SCORG to Ansys-CFX

User Fortran
Library
SCORG to Simerics MP

Direct Link
Multiphase flow
Oil - distribution
(2001)
Multiphase flows
2016

55
Oil Injected low pressure case
(includes end leakage gaps)
High Pressure
End Leakage
gap

Oil Injection Port

56
Oil Injected low pressure case
(includes end leakage gaps)

Iso Surface with oil volume fraction 10%

Water Evaporation – water injected screw compressor 11 bar

July 09-12, 2018 58

Conjugate heat transfer using SCORG post-processing
 Conjugate heat transfer (CCM) using SCORG and Comet
Pinl=1b Pout=3b n=5000 rpm tinl=20 oC tout=150oC
Pinl=1b Pout=7b n=5000 rpm tinl =20 oC tout=40 oC
Oil free
Oil injected

Pinl=30b Pout=90b n=5000 rpm tinl=0 oC tout=40 oC

High pressure oil injected

25/09/2018 60
Conjugate heat transfer using SCORG and Ansys-CFX

2016

61
Air Screw Expander
Internally geared conical screw
Helical Gate Rotor (Internal Lobes)
Suction

Outlet

Helical Main Rotor (External Lobes)

63
 Liquid Screw Pump – Cavitation
SCORG and Star CCM+

‘A’ type rotor with CD40 lubricating oil

64
0.85 MPa Discharge Pressure, 630 rpm 0.85 MPa Discharge Pressure, 2100 rpm
 Integrated model (CFD + Thermodynamic)

Integrated
Full 3D CFD
model
model (Comet)
(Star CCM+)
Flow oscillations - Noise suppression
Comparison of different calculation models
To summarise – what we learned so far
■ CFD based on continuity principle is today readily available
to be used in industry for modelling of screw machines
■ Grid generation is critical for analysis of screw machines:
■ Conservativeness
■ Alignment of the flow and numerical mesh
■ Discretisation scheme and selection of a solver
Questions still open to be answered:
■ How can we use models to further reduce leakage losses?
■ How to reduce modelling efforts and improve efficiency of
multiphase machines?
■ How is conjugate heat transfer affecting performance and
reliability and how to use it in improving screw machines?
■ How can we reduce computing time?
■ Are there any better methods than the current ones?
25/09/2018 67
Future work
Initialising solution – faster convergence

• Small benefits for oil free

compressors
• Much faster convergence
expected for multiphase
25/09/2018 machines 68
Future work
Body fitted mesh from 2D cross sections in normal planes

Transverse and normal 2D sections in transverse planes

planes are identical Hex cells are skewed

Hex cells
are orthogonal
Straight rotor Screw rotor

2D sections in normal planes

Could be suitable for: Hex cells are orthogonal
• Twin screw machines with large
helix angles (wrap angles)
• Single screw machines
• Conical and other configuration
rotors
Screw rotor

25/09/2018 69
Future work
Leakage flows, conjugate heat transfer and validation cases

25/09/2018 70
Future work - Lattice Boltzman Method
■ LBM models the fluid consisting of fictive particles, and such
particles perform consecutive propagation and collision
processes over a discrete lattice mesh.
■ Based on Kinetic theory of gases (Microscopic)
■ Uses Mesoscopic scale to solve Boltzman Equation

Lattice arrangement Lattice Boltzman process (evolution equation)

25/09/2018 71
Future work - Lattice Boltzman method

LBM in terms of discrete distribution function

discretize the differential operator and the collision operator in this form

Assuming we essentially recover the LBM evolution equation.

■ Suitable for multiphase flows; FSI; parallelization;

■ Complex boundaries are easier to deal with
■ Easy implementation of initial and boundary conditions

■ OpenLB is an object-oriented implementation of the

Lattice Boltzmann methods (LBM)

25/09/2018 72

Days 1 and 2
Research and technical papers including
keynotes, podium papers and
discussions.
Industry Day (Day 3)
Representatives from industry discuss
challenges and success in technology or
market demands, eg. due to economic,
environmental or legislative changes.
25/09/2018
The 4th Short Course on CFD in Rotary
Positive Displacement Machines
7th - 8th September 2019
• Advances in grid generation, CFD tools and new
techniques for PD machine analysis
• Modelling leakage flows and conjugate heat
transfer
• Prediction of clearance gap sizes during operation
and application of modern FSI computations
• Stability and accuracy of Multiphase flow
calculations in PD machines.
73
 Conclusions
■ CFD in screw machines is becoming increasingly popular.

■ The key element required for successful CFD of these machines is

availability a good numerical mesh.
■ SCORGTM is unique grid generator which allows fast and reliable
multiphase CFD with Pumplinx, Ansys-CFX, Star-CCM+ and Fluent

■ Results heavily depend on the selection and setup of a solver

■ Future activities: Structured grid generation from a Normal Plane;

Initial and boundary conditions; Lattice Boltzmann Method;
Modelling of leakage flows; Validation data using PIV and micro PIV.
Advances in Modelling of Screw Machines
Professor Ahmed Kovacevic
a.kovacevic@city.ac.uk , www.city.ac.uk/centre-compressor-technology
25/09/2018 74
Centre for Compressor Technology

Department of Mechanical Engineering and Aeronautics

City, University of London
Northampton Square
London
EC1V 0HB
United Kingdom

T: +44 (0)20 7040 8780

E: a.kovacevic@city.ac.uk
www.city.ac.uk/centre-compressor-technology

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