Unit 4
Unit 4
2 Principles of Turbomachines
4.1 INTRODUCTION
It is a turbomachine which employs centrifugal effects to increase the pressure of the fluid
(Pressure Ratio 4 : 1).
A Centrifugal Compressor is a radial flow rotodynamic fluid machine that uses mostly air as the
working fluid and utilizes the mechanical energy imparted to the machine from outside to increase
the total internal energy of the fluid mainly in the form of increased static pressure head.
During the second world war most of the gas turbine units used centrifugal compressors. Attention
was focused on the simple turbojet units where low power-plant weight was of great importance.
Since the war, however, the axial compressors have been developed to the point where it has an
appreciably higher isentropic efficiency. Though centrifugal compressors are not that popular today,
there is renewed interest in the centrifugal stage, used in conjunction with one or more axial stages,
for small turbofan and turboprop aircraft engines.
Mechanical Energy converted into Fluid Kinetic Energy and further kinetic energy converted
into Pressure Energy
Mechanical Energy Fluid Kinetic Energy
Pressure Energy
An impeller has :
(i) Vanes—It is used to transfer the energy from impeller to the fluid.
(ii) Hub—Inner periphery of the impeller.
(iii) Inducer— It is used to increase the angular momentum of the fluid without increasing its
Radius of Rotation.
(iv) Shroud
(3) Diffuser :
Whose function is to transform the high Kinetic Energy of the fluid (at the impeller outlet) into
Static Pressure.
Impeller partially converts kinetic energy into pressure energy (increasing in velocity).
Diffuser converts this remaining kinetic energy into the pressure energy (pressure rise).
For Radial Blade Impeller, the diffuser does compress and increase the pressure upto 50% of
overall static pressure.
(i) Volute (Scroll) Collector :
Vw >> V f so C Vw
1
C C or V = Absolute velocity
r
4.6 Principles of Turbomachines
After leaving the impeller, the air moves in logarithmic spiral motion across a short vaneless
space before entering the diffuser vanes.
Outlet Casing consists of an accelerating nozzle with or without inlet guide vanes.
Function — Minimum loss and to provide uniform velocity profile at the eye.
The losses in a centrifugal compressor are almost of the same types as those in a centrifugal
pump. However, the following features are to be noted :
Centrifugal Compressors and Fans 4.7
Frictional losses : A major portion of the losses is due to fluid friction in stationary and rotating
blade passages. The flow in impeller and diffuser is decelerating in nature. Therefore the frictional
losses are due to both skin friction and boundary layer separation. The losses depend on the friction
factor, length of the flow passage and square of the fluid velocity. The variation of frictional losses
with mass flow is shown in Figure. 4.9.
Incidence losses : During the off-design conditions, the direction of relative velocity of fluid at
inlet does not match with the inlet blade angle and therefore fluid cannot enter the blade passage
smoothly by gliding along the blade surface. The loss in energy that takes place because of this is
known as incidence loss. This is sometimes referred to as shock losses. However, the word shock in
this context should not be confused with the aerodynamic sense of shock which is a sudden discon-
tinuity in fluid properties and flow parameters that arises when a supersonic flow decelerates to a
subsonic one.
Clearance and leakage losses : Certain minimum clearances are necessary between the
impeller shaft and the casing and between the outlet periphery of the impeller eye and the casing.
The leakage of gas through the shaft clearance is minimized by employing glands. The clearance
losses depend upon the impeller diameter and the static pressure at the impeller tip. A larger diameter
of impeller is necessary for a higher peripheral speed (U2) and it is very difficult in the situation to
provide sealing between the casing and the impeller eye tip.
The variations of frictional losses, incidence losses and the total losses with mass flow rate are
shown in Figure
Fig. 4.9 : Dependence of Various Losses with Mass Flow in a Centrifugal Compressor
The leakage losses comprise a small fraction of the total loss. The incidence losses attain the mini-
mum value at the designed mass flow rate. The shock losses are, in fact zero at the designed flow
rate. However, the incidence losses, as shown in Fig. 4.9, comprises both shock losses and impeller
entry loss due to a change in the direction of fluid flow from axial to radial direction in the vaneless
space before entering the impeller blades. The impeller entry loss is similar to that in a pipe bend and
is very small compared to other losses. This is why the incidence losses show a non zero minimum
value (Figure. 4.9) at the designed flow rate.
4.8 Principles of Turbomachines
Vr2
Vf2
C2 or V2
Tip
Hub
C1
R1
or
Vr1 R2
1V
Vf1
Vw1
u1
Vw1 = u1
Air is sucked into the impeller eye and whirled outwards at high speed by the impeller disk. At
any point in the flow of air through the impeller the centripetal acceleration is obtained by a pressure
head so that the static pressure of the air increases from the eye to the tip of the impeller. The
remainder of the static pressure rise is obtained in the diffuser, where the very high velocity of air
leaving the impeller tip is reduced to almost the velocity with which the air enters the impeller eye.
Usually, about half of the total pressure rise occurs in the impeller and the other half in the
diffuser. Owing to the action of the vanes in carrying the air around with the impeller, there is a
slightly higher static pressure on the forward side of the vane than on the trailing face. The air will
thus tend to flow around the edge of the vanes in the clearing space between the impeller and the
casing. This results in a loss of efficiency and the clearance must be kept as small as possible.
Sometimes, a shroud attached to the blades as shown in figure 4.1 may eliminate such a loss, but it is
avoided because of increased disc friction loss and of manufacturing difficulties.
The straight and radial blades are usually employed to avoid any undesirable bending stress to be
set up in the blades. The choice of radial blades also determines that the total pressure rise is divided
equally between impeller and diffuser.
Before further discussions, following points are worth mentioning for a centrifugal compresssor:
(i) The pressure rise per stage is high and the volume flow rate tends to be low. The pressure
rise per stage is generally limited to 4 : 1 for smooth operations.
(ii) Blade geometry is relatively simple and small foreign material does not affect much on
operational characteristics.
(iii) Centrifugal impellers have lower efficiency compared to axial impellers and when used in
aircraft engine it increases frontal area and thus drag. Multistaging is also difficult to achieve
in case of centrifugal machines.
Centrifugal Compressors and Fans 4.21
2 1 cot 2
2
= 1 2 1 cot
2
2 1 2 cot 2 2 cot 2 2
= 1
2 1 cot 2
2 1 cot 2 2 1 2 cot 2
= 1 2 1 cot 2
2 1 cot 2 2 1 cot 2 2 1 2 cot 2
=
2 1 cot 2
1 2 1 cot 2 2 1 1 cot
2 2
2
R =
2 1 cot 2 2 p
For Radical Vanes, 2 = 90°
1 2
R = and p 1 2 cot 2 or p 1
2
P 01
m T
03
Curve between Pressure Ratio P and Mass Flow Parameter P and Constant
01 01
Speed interval N / T01 is as follows :
2 Pressure Ratio
(max)
3 Design state
(Loading) (c)max
1
4
P03/P01
Shutoff (valve closed) Choking point
5 5
M T01
P01
Fig. 4.13 : Characteristics Curve of Centrifugal Compressor
4.22 Principles of Turbomachines
The opening and closing of the discharge valve can be treated on the external load on the
compressor at point B (OB curve) after a lapse of time.
The fluid from the delivery pipe would leave and the back pressure would fall. The compressor
would again start delivering fluid and cycle would be repeated with in stability.
Due to low mass flow, P2 P2' P2' P2 or P2' P1 P2 P1 or p' P
Result :
(i) Mechanical failure – Due to ulternating stress, it may damage the compressor bearings,
rotor blading and seals them.
(ii) Bend the rotor shaft.
If the air angle of incidence on blade A is excessive, (purhaps due to partial blockage the blade)
because of this, Mass flow will decrease which in turn increases the angle of incidence to
the left of blade A and angle of incidence decreases to the right of blade A.
Thus blade B will be the next to stall while blade A will be unstalled.
Due to Mass flow rate decrease, pressure ratio will increase and density will increase so by
4.24 Principles of Turbomachines
m
Vf axial velocity will decreased and due to this incidence angle will increase and stalling
A
'
will occur 1 1 .
4.13.3 Choking (Due to Excess Mass Flow)
Due to flow, velocity reaches sound velocity and flow will choke or fixed mass flow rate regardless
of pressure ratio is called Choking.
2 Pressure Ratio
(max)
3 Design state
(Loading) ()cmax
1
4
P/P
0301
Choking point
5 5
M T01
P01
Fig. 4.16 : Chocking of Centrifugal Compressor
When the mass flow rate is increased to the right of point 3 on the negative slope of the
characteristics curve, a point 5 reached, where further increase in mass flow is not possible.
This indicates that the flow velocity in the passage reaches the speed of sound at some point in
the Compressor V f C and the flow chokes.
Choking means fixed mass flow rate regardless of pressure ratio.
It will occur in the inlet of stationary guide vanes which are fitted at inlet of compressor.
Stationary Passage is called Nozzle.
Relative velocity Vr that is choked velocity.
Centrifugal Compressors and Fans 4.25
M T0 1
h01 = P0 1
C12
h01 = h1
2
h01 = h1
V 2
r1 u12
2
where C12 u12 Vr12 (by inlet velocity triangle for Radial entry 1 = 90°)
C1 = Absolute velocity at inlet
When choke occurs,
Relative Velocity = Acoustic Velocity (Choked velocity) Vr Vs
RT1 u12
T01 = T1 1
2T1C p
1 1 u12
= 1 1
2 2 RT1
1 u12
= 1
2 2C pT1
T1 2 u12
= 1
T01 1 2C pT01
4.26 Principles of Turbomachines
PROBLEM 1
A centrifugal compressor has to deliver 35 kg of air per sec. The impeller is 76 cm
diameter revolving at 11,500 rpm with an adiabatic efficiency of 80%. If the pressure
ratio is 4.2:1, estimate the probable axial width of the impeller at the impeller tip if the
radial velocity is 120 m/s. The inlet conditions are 1 bar and 47°C.
T02' T01
T02 = T01 c
02
02
T
01
s
482.4 320
= 320 523K
0.8
Ignoring the effects of velocity of flow
p02 4.2 10 5
2 = 2.8 kg / m3
RT02 287 523
35
Atip = 0.1042 m 2
2.8 120
0.1042
Axial width = 0.0436 4.36 cm Ans.
0.76
Centrifugal Compressors and Fans 4.27
PROBLEM 2
Air enters the inducer blades of a centrifugal compressor at p01 = 1.02 bar, T01 = 335K.
The hub and tip diameters of the impeller eye are 0.1 m and 0.25 m respectively. If the
compressor runs at 7200 rpm and delivers 5.0 kg/s of air, determine the air angle at the
inducer blade entry and the relative Mach number. If IGVs are used to obtain a straight
inducer section, determine the air angle at the IGVs exit and the new value of the
relative Mach number.
2
Solution : A =
4
dt d h2 0.25 2 0.10 2 0.0412 m 2
4
Both the density and the axial velocity component at the entry of the inducer are unknown.
Therefore, these are determined by trial and error.
p01 1.02 10 5
I. Let 1 = 1.0609 kg / m 3
RT01 287 335
In the absence of IGVs,
m 5
C1 = V f 1 A 1.0609 0.0412 114.39 m / s
1 1
C12 114.39 2
= 6.51 K
2C p 2 1005
C12
T1 = 01 2C 335 6.51 328.49 K
T
p
3.5
T 1 328.49
p1 = p01 1 1.02 0.952 bar
T01 335
0.952 10 5
1 = 1.01 kg / m 3
287 328.49
The assumed value of Vf1 can now be checked.
Vf1 = 5/(1.01 × 0.0412) = 120.16 m/s
Since the difference is large, another trial has to done
II. Let C 1 = Vf1 = 123 m/s
C12 1232
= 7.527 K
2C p 2 1005
4.28 Principles of Turbomachines
Vf 1 121
tan 1 = 1.834
u1 65.97
1 = 61.4° Ans.
Vf 1 121
Vr1 = 137.8 m / s
sin 1 sin 65.97
Vr1 137.8
M r1 = 0.38 Ans.
a1 362.737
The axial entry of the air into the inducer can be obtained by employing IGVs. In this case
1
Vf 1
1 = tan 61.4° Ans.
u1
1 = 90°
V f 1 = Vr1 121 m / s
The new value of the relative Mach number is different on account of the changed value of Vr1
and a1.
Centrifugal Compressors and Fans 4.29
Vf 1 121
C1 = 137.8 m / s
sin 1 sin 61.4
C12 137.8 2
= 9.447 K
2C p 2 1005
121
M r1 = 0.334 Ans.
361.67
PROBLEM 3
A centrifugal compressor compresses 30 kg of air per second and a rotational speed of
15000 rpm. The air enters the compressor axially, and the conditions at the exit sections
are radius = 0.3 m, relative velocity of air at the tip = 1000 m/s at an angle of 80°C with
respect to plane of rotation. Take p01 = 1 bar and T01 = 300 K.
Find the torque and power required to drive the compressor and also the ideal head
developed.
Solution :
C2
Vr2
Vf2
vw2 Vx2
u2
D2 N 15000
u2 = 0.6 471.24 m / s
60 60
Vw2 = u2 Vr 2 cos 1 471.24 100 cos 80
= 453.88 m / s
Torque = Fr mVw2 r 30 453.88 0.3
4.30 Principles of Turbomachines
= 4084.92 Nm Ans.
15000
Power = T 4084.92 2
60
= 6.417 10 6 W
= 6.417 103 kW
= 213886.41
1
p
= C p T03 T01 C pT01 p 1
02
W
01
1
p02
213886.41 = 1005 300 p 1
01
p02
p01 = 6.531
PROBLEM 4
A centrifugal blower with a radial impeller produces a pressure equivalent to 100 cm
column of water. The pressure and temperature at its entry are 0.98 bar and 310K. The
electric motor driving the blower runs at 3000 rpm. The efficiencies of the fan and drive
are 82% and 88% respectively. The radial velocity remains constant and has a value of
0.2u2. The velocity at the inlet eye is 0.4u2.
If the blower handles 200 m3/min of air at the entry conditions, determine :
(a) power required by the electric motor,
(b) impeller diameter,
(c) inner diameter of the blade ring,
(d) air angle at entry,
(e) impeller widths at entry and exit,
(f) number of impeller blades, and
(g) the specific speed.
Centrifugal Compressors and Fans 4.31
p 0.98 10 5
= 1.10 kg / m3
RT 287 310
(b) For a radial impeller,
p0
f = u22
9.81
u22 = 1000 0.82 10875.83
1.10
u2 = 104.28 m / s
D2 N
= u2
60
104.28 60
d2 = 0.664 m
3000
d2 = 66.4 cm Ans.
2
di ci = Q 3.333 m3 / s
4
di = 0.319 m 31.9 cm
di = 31.9 cm Ans.
4.32 Principles of Turbomachines
d1 104.28 31.9
(d) u1 = u2 d 66.4
50.1 m / s
2
Vf 1 20.856
tan 1 = 0.416
u1 50.1
1 = 22.6° Ans.
(e) V f 1 d 1b1 = Q
Q
b1 = V d
f1 1
3.333 100
b1 = 20.856 0.319 15.95 cm Ans.
15.95 31.9
b2 = b1 d1 / d 2 7.66 cm Ans.
66.4
8.5 sin 2 8.5
(f) z = 1 d / d 1 31.9 / 66.4 16.35
1 2
z = 17 Ans.
gH = u22 10875.83 m2 / s 2
2 N 2 3000
= 314.16 rad / s
60 60
The specific speed is
Q
Ns =
gH 3 / 4
314.16 3.333
Ns = 3/ 4
0.538 Ans.
10875.83
Centrifugal Compressors and Fans 4.33
PROBLEM 5
A centrifugal compressor takes in gas at 0°C and 0.7 bar and delivers at 1.05 bar. The
efficiency of the process compared with the adiabatic compression is 83%. The specific
heat of the gas at constant pressure and constant volume are 1.005 and 0.717
respectively. Calculate the final temperature of the gas and work done per kg of gas.
If the gas were further compressed by passing through a second compressor having the
same pressure ratio and efficiency and with no cooling between the two compressors,
what would be the overall efficiency of the complete process?
Solution :
03
03
T
02 02
01
s
1
0.286
p02
1.05
T02' = T01 273
p01 0.7
= 306.6 K
02' T01
T02 = T01 c
306.6 273
= 273 313.5 K Ans.
0.83
Wc = 1.005 313.5 273 40.7 kJ/kg Ans.
T03' T02
T03 = T02 c
352.0 313.5
= 313.5 359.9 K
0.83
0.286 T03 T01
T03' = 273 1.5 1.5 344.3 K overall
T03 T01
344.3 273
overall = 359.9 273 100 82% Ans.
PROBLEM 6
Calculate the pressure ratio developed and the power required to drive a centrifugal
air compressor (impeller diameter = 45 cm) running at 7200 rpm. Take zero swirl at
the entry and T01 = 288 K. Assume isentropic flow with no shock, and radially tipped
impeller blades.
2 169.65 2
W = u2 28.78 kJ / kg
1000
at m 1 kg / s P = 28.78 kW(kg/s) Ans.
PROBLEM 7
A centrifugal compressor runs at 10,000 rpm and delivers 600 m3/min of free air at a
pressure ratio of 4:1. The isentropic efficiency of compressor is 82%. The outer radius
of impeller (which has radial blades) is twice the inner one and neglect the slip coefficient.
Assume that the ambient air conditions are 1 bar and 293K. The axial velocity of flow is
60 m/s and is constant throughout. Determine :
(i) Power input to the compressor
(ii) Impeller diameters at inlet and outlet and width at inlet
(iii) Impeller and diffuser blade angles at inlet
Centrifugal Compressors and Fans 4.35
Solution :
03
03
C1
Vr1 = Vf1
T
01
root
01
u1
s
1
T03' = T01 4 293 4 0.286 435.56 K
T03' T01 435.56 293
T03 = T01 c
293
0.82
= 293 173.85 466.85 K
u22 = C p T 1005 173.85
= 174719.25 m2 / s 2
u2 = 418 m / s
Wc = u22 174.719kW/kg/s Ans.
418 60
D2 = 10000 0.8 m
D2
D1 = 0.4 m Ans.
2
V f2 60 2
T1 = T01 293 291.2 K
2C p 2 1005
3.5
T 1 291.2
p1 = p01 1 0.9787 bar
T01 293
p1 0.9787 10 5
1 =
RT1 287 291.2
= 1.171 kg/m3 Ans.