Abstract:Siemens Energy has commissioned an extensive multiyear experimental and numerical (computational fluid dynamics (CFD)) project to improve its ability to design for and predict compressor stall. The experimental test rig is a half scale six stage axial compressor. The goal of this work is to provide insight into how best to predict the compressor performance map and in particular the stall point by applying state-of-the-art multiple blade row CFD simulation tools. A preliminary CFD analysis quantified numerical… Show more
“…The stall limit is detected by the numerical divergence of the solving process of steady calculations, and this approach for determining the stall limit of compressor has been adopted and demonstrated by many investigations, such as ref. 27,28 The minimum step of increasing the exit pressure before the stall condition achieves 5 Pa.Figure 2.Mesh of NASA Stage 35.…”
The gas–liquid two-phase flow in a transonic compressor stage, Stage 35, under wet compression was numerically simulated by Computational Fluid Dynamics (CFD) technique along with Euler–Lagrange approach. The evaporation and cooling effect of water droplets on compressor performance and stable flow range was investigated by changing the inlet spraying conditions (droplet sizes and injected water flow rates). Further, the influencing mechanism was explained by the changes of rotor velocity triangle, rotor specific work, blade loading, and tip leakage flow before and after spraying. The results indicate that wet compression can improve the pressure ratio and efficiency of the compressor, but, under different comparison conditions before and after spraying, the influence on compressor power consumption has different trends. Wet compression improves the compressor specific power consumption under constant flow rate conditions, while it reduces compressor specific power consumption under equal pressure ratio conditions. Additionally, the stalling flow rate of compressor increases by wet compression effect, and the increasing degree of stalling flow rate is positively correlated with the increasing level of pressure ratio. The evaporative and cooling effect of droplets reduces the airflow temperature at rotor outlet, leading to the increase of airflow density, the decrease of axial velocity, which results in the promotion of rotor specific work—this is the main reason for the improvement of pressure ratio under constant flow rate conditions. Under wet compression condition, the enhanced blade loading near tip strengthens the tip leakage flow, making the compressor achieve stall criteria at larger flow rate, which is the cause for wet compression influencing the compressor stall boundary.
“…The stall limit is detected by the numerical divergence of the solving process of steady calculations, and this approach for determining the stall limit of compressor has been adopted and demonstrated by many investigations, such as ref. 27,28 The minimum step of increasing the exit pressure before the stall condition achieves 5 Pa.Figure 2.Mesh of NASA Stage 35.…”
The gas–liquid two-phase flow in a transonic compressor stage, Stage 35, under wet compression was numerically simulated by Computational Fluid Dynamics (CFD) technique along with Euler–Lagrange approach. The evaporation and cooling effect of water droplets on compressor performance and stable flow range was investigated by changing the inlet spraying conditions (droplet sizes and injected water flow rates). Further, the influencing mechanism was explained by the changes of rotor velocity triangle, rotor specific work, blade loading, and tip leakage flow before and after spraying. The results indicate that wet compression can improve the pressure ratio and efficiency of the compressor, but, under different comparison conditions before and after spraying, the influence on compressor power consumption has different trends. Wet compression improves the compressor specific power consumption under constant flow rate conditions, while it reduces compressor specific power consumption under equal pressure ratio conditions. Additionally, the stalling flow rate of compressor increases by wet compression effect, and the increasing degree of stalling flow rate is positively correlated with the increasing level of pressure ratio. The evaporative and cooling effect of droplets reduces the airflow temperature at rotor outlet, leading to the increase of airflow density, the decrease of axial velocity, which results in the promotion of rotor specific work—this is the main reason for the improvement of pressure ratio under constant flow rate conditions. Under wet compression condition, the enhanced blade loading near tip strengthens the tip leakage flow, making the compressor achieve stall criteria at larger flow rate, which is the cause for wet compression influencing the compressor stall boundary.
“…It is important to state that the evaluation of multi-stage axial compressor working limits with CFD, using limited experimental data, is not straightforward. Simulations using a limited number of blade passages [22] with the RANS method often overestimate the compressor stability [23][24][25]. To estimate the critical flow characterisation responsible for operational limitations, advanced URANS or LES simulations are more appropriate to precisely determine the onset of stall [26,27].…”
Improved operational flexibility of gas turbines can play a major role in stabilising the electric power grid, by backing up intermittent renewable power. Gas turbines offer on-demand power and fast dispatch of power that is vital when renewable power reduces. This has brought about increasing demand to improve the ramp-up rate of gas turbines. One approach is through the injection of compressed air from energy storage or an auxiliary compressor. This method is the focus of the present work, which shows for the first time, the implications and limits of compressor air injection in a high-fidelity Computational Fluid Dynamics model (CFD). The 3D multi-stage model of the compressor was developed in ANSYS CFX v19.2, while the boundary conditions related to the injection cases have been obtained from a corresponding 0D engine model. The upper limits to air injection determine how much air can be injected into the engine, providing indicative values of power augmentation and ramp-up rate capabilities. These have been previously addressed by the authors using 0D models that do not consider the compressor aerodynamics in great detail. The CFD study has shown that for power augmentation, 16% of compressed air (based on compressor exit) is allowed based on the onset of stall. It also shows that increasing air injection amplifies losses, blockage factor and absolute velocity angle. Also, about 30% of the blade span from the hub is dominated by a rise in the total pressure loss coefficient, except the outlet guide vane for which separation occurs at the tip. For the ramp-up rate analysis, up to 10% air injection is shown to be sustainable. The work shows that the improvements in the 0D analytical engine model are plausible, in addition to demonstrating similar limits at different ambient temperatures.
“…Commercial CFD ANSYS codes have been used to compare RANS/URANS transition and scale resolving simulation (SRS) turbulence methods. Studies showed that CFD simulation applications are computationally practicable and suitable for most of the turbo machinery design analysis [25][26][27]. Moreover, flow field simulations for predicting the action of turbine performance on freesurface flow situations have appeared due to the complex nature of this physic spectacle [10].…”
In recent years, advances in using computational fluid dynamics (CFD) software have greatly increased due to its great potential to save time in the design process compared to experimental testing for data acquisition. Additionally, in real-life tests, a limited number of quantities are measured at a time, while in a CFD analysis all desired quantities can be measured at once, and with a high resolution in space and time. This article reviews the advances made regarding CFD modeling and simulation for the design and optimization of crossflow hydro turbines (CFTs). The performance of these turbines depends on various parameters like the number of blades, tip speed ratio, type of airfoil, blade pitch, chord length and twist, and its distribution along the blade span. Technical aspects of the model design, which include boundary conditions, solution of the governing equations of the water flow through CFTS, and the assumptions made during the simulations are thoroughly described. From the review, a clear idea on the suitability of the accuracy CFD applications in the design and optimization of crossflow hydro turbines has been provided. Therefore, this gives an insight that CFD is a useful and effective tool suitable for the design and optimization of CFTs.
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