The article presents results of applying the methods of computational fluid dynamics for model low-flow rate stages of centrifugal compressors with flow rate coefficient F = 0.028. The computational domain of a model centrifugal compressor for CFD-simulation consists of the following elements: inlet chamber, impeller, vaneless diffuser, return channel, outlet chamber, shaft seal labyrinth, front and back shroud leakage. Full-scale experimental studies were conducted to model stage 028 in air at an inlet pressure of p* = 1 atm. Numerical research for stage 028 held with flow rate coefficient F=(0.019-0.046) for three variants trailing edge of the impeller. According to the results of numerical research are constructed performances of stages centrifugal compressor and conducted verification of results. Estimated discrepancy between the results of numerical researches on the model with shaft seal labyrinth and without shaft seal labyrinth.
The study presents the simulation results of the viscid gas flow in low flow coefficient centrifugal compressor stages. The problem is solved in a stationary formulation using the Ansys CFX software package. The numerical simulation is carried out on three ultrahigh-pressure model stages; two stages have blades of the classical type impeller and one stage is of the bodily type. The value of the conditional flow coefficient is 0.0063 to 0.015. As part of the study, block-structured design meshes are used for all gas channel elements, with their total number being equaled as 13–15 million. During the calculations a numerical characteristic was validated with the results of tests carried out at the Department of Compressor, Vacuum and Refrigeration Engineering of Peter the Great St. Petersburg Polytechnic University. With an increase of inlet pressure as a result of a numerical study, it was found that for a given mathematical model the disk friction and leakage coefficient (1 + βfr + βlk) is overestimated. The analysis of flow in labyrinth seals has shown an increase of total temperature near the discs by 30–50 °С, nevertheless this fact did not influence gas parameters in the behind-the-rotor section. The calculation data obtained with finer design mesh (the first near-wall cell was 0.001 mm) is identical to those obtained with the first near-wall cell 0.01 mm mesh.
In this paper, we review the problem of accounting for heat exchange between the flow and the flow part surfaces when creating a calculation model for modeling the workflow process of low-flow stages of a centrifugal compressor using computational fluid dynamics (CFD). The objective selected for this study was a low-flow intermediate type stage with the conditional flow coefficient Փ = 0.008 and the relative width at the impeller exit b2/D2 = 0.0133. We show that, in the case of modeling with widespread adiabatic wall simplification, the calculated temperature in the gaps between the impeller and the stator elements is significantly overestimated. Modeling of the working process in the flow part was carried out with a coupled heat exchanger, as well as with simplified accounting for heat transfer by setting the temperatures of the walls. The gas-dynamic characteristics of the stage were compared with the experimental data, the heat transfer influence on the disks friction coefficient was estimated, and the temperature distributions in the gaps between disks and in the flow part of the stage were analyzed. It is shown that the main principle when modeling the flow in low-flow stage is to ensure correct temperature distribution in the gaps.
The article deals with the problems of diagnostics of surging phenomena in centrifugal compressors. The reasons for the surge phenomenon and the method for its diagnosis to prevent emergencies are stated. The article describes the phenomenon of rotating stall, which precedes the surge. Diagnostics of the appearance of a rotating stall opens the possibility of predicting the appearance of a surge. This allows for an efficient and safe surge protection system. Solving the problem of developing new principles for constructing surge diagnostics systems. Application of biorthogonal wavelet transform for prebreak detection.
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