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Copyright OD 1998 by ASME All Rights Reserved Primed in U.S.A.
C Rodgers
ABSTRACT. Q Compressible flow function
W4T/ AP
The function of the centrifugal compressor Qcrit Compressible flow function ,sonic
inducer is to provide wide flow margins from conditions
the design flow to the stall and choke flow q Work factor, or dynamic head
limits, together with high static pressure RMS Root mean square
recovery. At transonic conditions the inducer Blade pitch
becomes the critical to impeller performance T Total temperature
in that shock losses and blockage growth U Blade speed
diminish stable flow range and may trigger W Massflow or relative velocity
near vertical stage characteristics.
The paper covers the various types of inlet
configurations upstream of the inducer, a Air angle
followed by a review of the state-of-art Blade angle
inducer design for centrifugal compressors, A Difference
culminating with some research developments c Diameter ratio
in transonic inducer blading characteristics. ri Efficiency
Flow factor
p Density
NOMENCLATURE co Angular velocity
A Area Subscripts
At Inducer throat area
C Velocity 1 Inducer inlet
Cp Specific heat 2 Impeller exit
CFS Volume Flow ad Adiabatic
D Diameter c Compressor
ETAC Compressor Efficiency e Stage exit
g Gravity h Hub
H Head s Shroud
k Ratio of specific heats t Throat
L/E Leading Edge
M Mach number Note : All angles are with respect to the
Mu Delaval Number = U2 /(gIcRT)" axial or radial direction.
N Rotational speed
Ns Specific speed
= o I CFS / ( g Had ) 0.75
o Throat opening
P Stagnation or total pressure
Presented at the International Gas Turbine & Aeroengine Congress & Exhibition
Stockholm, Sweden — June 2—June 5, 1998
Downloaded From: http://journals.asmedigitalcollection.asme.org/pdfaccess.ashx?url=/data/conferences/asmep/82028/ on 03/02/2017 Terms of Use: http://www.asme.org/about-a
1. INTRODUCTION. geometric features. Maximum performance is
The centrifugal impeller stage characteristic normally obtained with an axial bellmouth type
is basically determined by its entry and exit inlet. In some cases the radial inlet with
blade shapes. The entry or inducer section circumferentially accelerating flow around a 90
throat contols the stall and choke flows, and deg bend towards the inducer eye is often
the exit or exducer essentially governs the selected, such as gas turbine engine and
momentum exchange. multistage centrifugal compressor
The demand for more efficient compressor configurations. This is not to be confused with
operation at higher Mach numbers and the so called "radial inlet" from a suction pipe.
extended suction specific speeds of pumps Several types of centrifugal compressor inlet
during the early 1950's, focused extensive configurations are shown on Figla through f.
research on separate axial inducers ahead of Ref 1 describes the results of tests concerning
the radial section of the radial impeller. In radial inlet geometric features, and in
particular these inducers were shown to particular the influence of axial length
provide improved centrifugal compressor extension upstream of the inducer leading
efficiencies at the higher pressure ratios edge. The test results shown on Fig 2 indicates
necessitated by gas turbine cycle performance that relatively short axial extensions can be
requirements. used at De Laval Mach numbers up to 1.15,
The past restrictions to successfully analyze without significant performance penalties
the impeller internal flow prompted providing;
modeling the inducer section as its axial
compressor stage counterpart, a practice . The ratio of the hub axial extension to the
which is still current, for at least meanline hub diameter L/ D1 5 >0.4
stage performance predictions. . The mean streamline velocity maintains a
Later performance improvements in positive acceleration gradient, especially in
centrifugal compressor technology emerging the last third of the flow path up to the
in the last two decades have been realized by: inducer leading edge.
. A meanline axial velocity ratio of 2.0
. Adoption of diffusion controlled three- (exit/entry) is maintained.
dimensional backswept impellers.
. Applied transonic axial compressor The use of these simplistic guidelines for
technology. preliminary design layouts provides a quick
. Numerically controlled machining for three- design aid, but it is not recommended as a
dimensional arbitrary blade surfaces. detail design tool, especially when inlet
. Refinement of meanline performance distortion may be present at the radial entry,
prediction codes together with application of and or, higher inducer tip relative Mach
computational fluid dynamic codes. numbers are incurred. Under such conditions
This paper covers the various types of inlet higher meanline acceleration rates are
configurations upstream of the inducer preferred to prevent excessive shroud
followed by a review of the state-of art boundary layer growth, and a complete inlet
inducer design, culminating with recent throughflow analysis is warranted.
research developments in transonic inducer The effects of inlet flow distortion on
blading characteristics. centrifugal compressor performance are
addressed in Ref 2. Radial flow distortion was
2. INLET CONDITIONS. found to have a more pronounced effect on
surge margin and efficiency than
Maximum performance of the inducer is circumferential distortion. It is generally
achieved with unspoiled inlet flow. accepted, however, that the centrifugal
Centrifugal compressor inlets are typically of compressor is less sensitive to flow distortion
either the axial or radial single entry type. In that its axial flowcounterpart.
some instances the installation may require In most compressor applications it is required
dual, or bifurcated inlets which may impose to provide an inlet plenum or muff to direct
flow distribution problems, and or, additional the airflow from an exterior source to the
pressure losses dependent upon specific compressor eye, the radial type of inlet is
L J
Fig 1 Centrifugal Compressor Inlet Types
I dl
(----- Mu=1 .3
Fan Interstage Separate Inducer 3D Mixed Flow
Fig 3 Impeller Types
tp
fri ckness
& therefore a maximum negative incidence is set
1.2 v ng types in these cases.
4 In many instances alternate inducer blade
cutbacks are preferred to maximize the
1.0 throat area for a given blade angle and tip
Rel
Mach no diameter, or simply for ease of manufacture,
Theo etical
M 1w especially small turbocharger type impellers.
0.8 Alternate blade cutbacks , or splittered
Test
inducers provide a larger throat area for a
given blade angle and therefore tend to
0.6
exhibit a wider flow range between impeller
Thro t Op • c to Pitch Ratio °is cos 0:1 stall and choke, sometimes at the expense of
0. .-- slightly lower impeller efficiency (of the order
0.4 0.6 0 8 1 0 1.2 14 1% point), as compared to fully bladed
inducers.
Fig 4 Typical Choke Flow Correlation
Equal circumferentially spaced splittered
inducers result in unequal channel flows as a
1 .4
result of the velocity gradient from suction to
pressure surfaces, and have been postulated
1 .2
to cause additional mixing losses at the
Ri Based on 1D impeller tip. Some compressors have splitters
Ma h No Analysis spaced for equal channel flows and claim to
1 n m iws have improved performance.Tandem cascade
type inducers have also been developed, Ref
5, in an attempt to improve compressor flow
08 range with indifferent results.
A potential disadvantage of splittered
inducers is increased noise generation if
06 reduced blade number drives the blade
passing frequency into the susceptible audible
Tip Incidence deg range.
0 .4 As mentioned previously, compressor
0 5 10 15 21 operation towards shut-off results in impeller
Fig 5 Typical Inducer Stalling Incidences flow recirculation back to the inlet causing
the inlet temperature to increase rapidly.
701
u
% \'
,/ \ "..1-'°-..\-S. \)C".-. ''' 1
70 I
\ \
Test Map Research
Test Map Research S 1------■
Compressor
Compressor —
— -----, g. o_ 6.5 inch Tip dia
in_ 6.5 inch lip dia
Zero Bleed
Zero Bleed - 7 ----.. --.,
_ Bleed Dumped '\ 1.64
- - - Bleed Recirculated \ 1.64
30
Pressure 1.56
3 0 Pressure ~ 1 1.56 1.4f
)N, 1.4f Ratio
Ratio t-s
Mu 1.31
_ t-s 1.31 2.0 - ---,....,
Z.0
0.98 QfOcrit
0.98 QJQcrit 10 _ _
10 04 1.0
04 0.6 0 8 .0
Fig 7 Effect of Recirculated Bleed Fig 8 Effect of Dumped Bleed
70
.8 1.0
Flow 0/Qcrit
Fig 11 Effect of Bleed on Impeller Efficiency
88
0 •°
accumulation up to the throat, both from ,o
Impeller 0 o 0 0 0 e
reduced turning and thinner blading. Efficiency o
Thinner blading is however a detriment to %.t-t o o
0 0 0
cost, durability and vibrational concerns,
which may dominate in some applications. An o
r 0
interesting solution is the partial thinning of 86 o
1D Uniform Axial
the inducer blading from leading edge to Velocity
o 0
throat above the diameter where the relative o Test Data
8 . Several Transom:
Mach number exceeds unity. This has been c
Inducers
demonstrated to improve efficiency by up to
1% point with little change in the inducer Inducer Tlp Relmive Mach Number
8 I
first flap bending frequency. 1 2 1 3 1 4 15
The effects of blade thickness on the Fig 12 Effect of Tip Mach Number on Impeller Efficiency
performance of the NASA 10.0 pps high
pressure ratio stage are described in Ref 12,
in which discrete attention was made to
preserve both inducer and diffuser throat
areas. Stage peak efficiencies are shown on
Fig 15 versus shroud inlet relative Mach
number, indicating some two percentage
60
40
Eawn onic
_■e
points higher efficiency with inducer tip (8.34
inch diameter) blade thickness decreased
from .027 to .016 inch. 20
13 deg
Blade
Angle N I
Since typical minimum machinable inducer
tip blade thicknesses are close to .015 inch,
blade thickness effects become significant on
0 100
small compressors of 4.0 inch (100mm) tip 20 40 60 80
diameter or less. % Chord
Fig 13 Impeller Blade Angle Distributions
As mentioned previously, the radial variation
of incidence at the inducer leading edge may
be small, whereas it may be desirable to tailor
an incidence variation to the local Mach lnflexed Turning Thin Blades
1.4
number, or even select to open the throat
towards the hub to provide increased throat
area. The optimization of a high Mach
number inducer design using a CFD code is 12
briefly discussed in Ref 13. Such codes allow Rel
Mach n
individual tailoring of the inducer and
1.0
impeller blading to suit the specific
application needs rather than correlation M1s
with appropriate airfoil cascade
characteristics.
1.4
Fig 14 Effect of Blading Types
Since research on axial turbofan stages had An appraisal of design rationale for moderate
shown leading edge sweepback effective as a to high pressure ratio centrifugal
means of reducing shock losses , increasing compressors inducers has been described
blade stiffness ,and deterring buzz-saw noise based upon lessons learned in the design,
generation, the inducer blading of the test and development of small aviation gas
research compressor Fig 7, was redesigned as turbines and industrial gas compressors
shown on Fig 16 ,while maintaining the same during the latter half of the 20 th century.
throat area. Comparative performance Compressor performance improvements have
calibrations showed less than a 1% point made with the introduction of transonic
impeller efficiency improvement with sweep inducer blading featuring minimal turning up
at a relative inducer tip Mach number (one to the throat, and low thickness to pitch
dimensional) of 1.45. The effect of shroud ratios, at some expense to manufacturing cost
bleed position on this impeller is shown on and durability.
Fig 17 indicating that bleed at 30% chord Turbomachinery aerodynamic and structural
exhibited the highest performance. design of centrifugal compressors has
transitioned from the traditional meanline
performance characterization,streamline
curvature internal flow analysis, and drawing
board geometry definition, to a fully
integrated computerized procedure, from
customer specification to the finished out-the-
door product. By the year 2000 this may be
accomplished within one month.
The key to such a rapid turnover will not be
entirely in the drawing creation or machined
part, but the capability of computational fluid
dynamic codes to rapidly predict the entire
compressor map, with an assurance
commitment requiring only an acceptance
delivery performance test.
This indeed is the challenge, as todays most
Fig 16 Swept Leading Edge Impeller. expensive and time consuming compressor
development task is performance
development to satisfy design requirements.
Having been exposed to the design and
development of a wide diversity of specific
10
11