Work done and pressure rise, Velocity diagrams, Diffuser vane design considerations, Concept of pre-whirl, Elementary theory of axial flow compressor, Velocity triangles, degree of reaction, Three dimensional, Air angle distributions for free vortex and constant reaction designs, Rotation stall, Compressor blade design, Centrifugal and Axial compressor performance characteristics.
Introduction: Rotating machines are usually called turbomachines. These machines work on the principle of work addition or extraction. When a fluid passes through a rotating machine two things happen, viz., energy transfer and energy transformation. The energy transfer means transfer of available energy from one part (rotor) to the medium (fluid) or vice versa. Energy transformation means change of one form of energy into another form, for example, change of kinetic energy to pressure energy in a compressor. The energy transfer can occur only in its moving or rotating elements whereas the energy transformation can occur in both stationary and rotating elements.
As both the compressors and turbines are concerned with energy transfer, we will consider their basic performance together. In compressors the energy is transferred from the rotor to the fluid while in turbines it is from fluid to the rotor. The effectiveness of this transfer of energy in a fluid machine is governed mainly by the fluid dynamics of the system.
Principle of operation of centrifugal compressor: The centrifugal compressor consists essentially of a stationary casing containing a rotating impeller which imparts a high velocity to the air, and a number of fixed diverging passages in which the air is decelerated with a consequent rise in static pressure. The latter process is one of diffusion, and consequently the part of the compressor containing the diverging passages is known as the diffuser. Figure (a) is a diagrammatic sketch of a centrifugal compressor. The impeller may be single- or double-sided as in l(b) or l(c), but the fundamental theory is the same for both. The double-sided impeller was required in early aero-engines because of the relatively small flow capacity of the centrifugal compressor for a given overall diameter. Air is sucked into the impeller eye and whirled round at high speed by the vanes on the
impeller disc. 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 the air leaving the impeller tip is reduced to somewhere in the region of the velocity with which the air enters the impeller eye; it should be appreciated that friction in the diffuser will cause some loss in stagnation pressure. The normal practice is to design the compressor so that about half the pressure rise occurs in the impeller and half in the diffuser. It will be appreciated that owing to the action of the vanes in carrying the air around with the impeller, there will be a slightly higher static pressure on the forward face of a vane than on the trailing face. The air will thus tend to flow round the edges of the vanes in the clearance space between the impeller and the casing. This naturally results in a loss of efficiency, and the clearance must be kept as small as possible.
A shroud attached to the vanes, Fig. (d), would eliminate such a loss, but the manufacturing difficulties are vastly increased and there would be a disc friction or 'windage' loss associated with the shroud. Although shrouds have been used on superchargers and process compressors, they are not used on impellers for gas turbines. The impellers of modern centrifugal compressors operate with very high tip speeds resulting in very high stress levels. It will be shown in the next section that backswept curved vanes are desirable for compressors of high pressure ratio, but for many years designers were forced to use radial vanes because of the tendency for curved vanes to straighten out under the action of the considerable centrifugal force involved, setting up undesirable bending stresses in the vanes. Modern methods of stress analysis combined with stronger materials, however, now permit backswept vanes to be used in high-performance compressors. Work done and pressure rise: Since no work is done on the air in the diffuser, the energy absorbed by the compressor will be determined by the conditions of the air at the inlet and outlet of the impeller. Figure shows the nomenclature employed, in the first instance it will be assumed that the air enters the impeller eye in the axial direction, so that the initial angular momentum of the air is zero. The axial portion of the vanes must be curved so that the air can pass smoothly into the eye. The angle which the leading edge of a vane makes with the tangential direction a will be given the direction of the relative velocity of the air at inlet, V1, as shown in Fig. If the air leaves the impeller tip with an absolute velocity C2, it will have a tangential or whirl component Cw2, and a comparatively small radial component Cr2• Under ideal conditions
C2 would be such that the whirl component is equal to the impeller tip speed U, as shown by the velocity triangle at the top of Fig. Due to its inertia, the air trapped between the impeller vanes is reluctant to move round with the impeller, and we have already noted that this results in a higher static pressure on the leading face of a vane than on the trailing face. Centrifugal Compressor: A centrifugal compressor is one of its class of machines in producing pressure rise and is known as turbo-compressors. In this type, energy is transferred by dynamic means from a rotating member (or impeller) to the continuously flowing working fluid. The main feature of the centrifugal compressor is that, the angular momentum of the fluid flowing through the impeller is increased partly by virtue of the impeller’s outlet diameter being significantly larger than its inlet diameter. The centrifugal compressor may be known as a fan, blower, supercharger, booster, exhauster or compressor; the distinction between these types being very vague. Broadly speaking, fans are classified as low-pressure compressors and blowers as medium pressure compressors. Boosters, exhausters and superchargers are named from their point of view of applications. Although the centrifugal compressor is unlikely to be used in gas turbine power plants where specific fuel consumption is the main criterion, it still has certain advantages for some applications. 1) It occupies a smaller length than the equivalent axial flow compressor. 2) It is not so liable to loss of performance by build up of deposits on the surfaces of the air channels. 3) It can work reasonably well in a contaminated atmosphere compared to axial flow machine. 4) It is able to operate efficiently over a wider range of mass flow rate at any particular rotational speed.