Axial-Flow Compressor Performance Prediction in Design and Off-Design Conditions Through 1-D and 3-D Modeling and Experimental Study
Axial-Flow Compressor Performance Prediction in Design and Off-Design Conditions Through 1-D and 3-D Modeling and Experimental Study
Axial-Flow Compressor Performance Prediction in Design and Off-Design Conditions Through 1-D and 3-D Modeling and Experimental Study
ABSTRACT
In this study, the main objective is to develop a one dimensional model to predict design and off design
performance of an operational axial flow compressor by considering the whole gas turbine assembly. The
design and off-design performance of a single stage axial compressor are predicted through 1D and 3D
modeling. In one dimensional model the mass, momentum and energy conservation equations and ideal gas
equation of state are solved in mean line at three axial stations including rotor inlet, rotor outlet and stator
outlet. The total to total efficiency and pressure ratio are forecasted using the compressor geometry, inlet
stagnation temperature and stagnation pressure, the mass flow rate and the rotational speed of the rotor, and
the available empirical correlation predicting the losses. By changing the mass flow rate while the rotational
speed is fixed, characteristic curves of the compressor are obtained. The 3D modeling is accomplished with
CFD method to verify one dimensional code at non-running line conditions. By defining the three-
dimensional geometry of the compressor and the boundary conditions coinciding with one dimensional model
for the numerical solver, axial compressor behavior is predicted for various mass flow rates in different
rotational speeds. Experimental data are obtained from tests of the axial compressor of a gas turbine engine in
Sharif University gas turbine laboratory and consequently the running line is attained. As a result, the two
important extremities of compressor performance including surge and choking conditions are obtained
through 1D and 3D modeling. Moreover, by comparing the results of one-dimensional and three-dimensional
models with experimental results, good agreement is observed. The maximum differences of pressure ratio
and isentropic efficiency of one dimensional modeling with experimental results are 2.1 and 3.4 percent,
respectively.
Keywords: Axial compressor; One dimensional modeling; Three dimensional modeling; Characteristic curve.
NOMENCLATURE
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gas turbine performance which uses compressor and radial and circumferential directions.
turbine performance maps obtained by using
generalized stage performance curves matched by 2. Constant pressure specific heat coefficient
means of the “stage–stacking” procedure. The change is neglected.
overall multistage compressor performance is 3. In design condition, inlet flow collides the
predicted using generalized relationships between blade at design incidence angle.
stage efficiency, pressure coefficient and flow
coefficient. 4. Flow viscosity doesn’t change due to small
variations of temperature.
Here, because the tests are performed on an axial
compressor within a gas turbine engine, only the 2.2 Inputs
running line could be obtained because it is Two types of inputs must be defined for one-
impossible to change the mass flow rate while the dimensional modeling: flow properties and
rotational speed of the engine is fixed. Therefore, compressor geometry. The entry requirements for
for each rotational speed there is only a single point design and off-design conditions are not the same.
to compare and validate the one-dimensional Not only mass flow rate isn’t defined as an input for
modeling results. To compare and verify the design condition but also with regard to inlet flow
modeling results for non-running line conditions, a angle, which is calculated with design condition
CFD modeling is applied using a verified correlation, design mass flow rate is calculated. On
commercial code. the other hand, for off-design, inlet mass flow is
Three-dimensional modeling is performed using defined as an input. Information required as input
computational fluid dynamics. Having three- for design and off-design conditions are presented
dimensional geometry of the compressor, it is in Table 1 and Table 2, respectively.
meshed. Overall number of grid for rotor and stator
domain is about 500,000. Then the boundary
Table 1 Flow inputs for 1D modeling
conditions are defined. In this process, turbulence
design Off-design
model and flow are considered to be k-epsilon and
Rotor inlet total Rotor inlet total
compressible, respectively. Total pressure and total
temperature temperature
temperature are specified as rotor inlet boundary
conditions and mass flow rate is specified for stator Rotor inlet total
Rotor inlet total pressure
outlet. In each rotational speeds, by solving the flow pressure
field with different mass flow rates, the Absolute velocity angle Absolute velocity
characteristic curves of the compressor are at rotor inlet angle at rotor inlet
obtained. Rotor rotational speed Rotor rotational speed
Mass flow rate
The experiments have been done for an axial
compressor embedded in a gas turbine in Gas
Turbine laboratory of Sharif University. There are Table 2 Geometric inputs for 1D modeling
several measuring stations on gas turbine engine Rotor and stator
and only the first four of them are used for this Inlet hub radius
study including bell mouth throat, axial compressor Inlet shroud radius
rotor inlet and outlet and finally axial compressor Outlet hub radius
stator outlet. At these stations, the stagnation and Outlet shroud radius
static pressures and temperatures as well as the Inlet camber angle of blade
engine speed and mass flow rate are measured. All Outlet camber angle of blade
measuring devices are calibrated prior to tests and Stagger angle
actual values are calculated using calibration Blade number
curves. Chord length
Maximum thickness to chord ratio
2. ONE-DIMENSIONAL MODELING Maximum thickness distance to chord ratio
Tip clearance
One dimensional modeling is performed to predict Blade roughness
design and off-design performance of the axial Axial gap between rotor and stator
compressor.
For one dimensional modeling, equations of To predict the performance of the compressor and
conservation of mass, momentum, and energy, as obtain its characteristic curves, it is necessary to
well as equations of ideal gas, second law of calculate compressor performances at design and
thermodynamics, the energy losses and predicted off-design points.
deviation angles in design and off-design conditions
are solved together on mean radius of compressor 2.3 Design Condition
blades in order to determine the air flow unknowns.
Figure 1 shows schematic of the axial compressor
2.1 Assumptions and some geometric parameters. Stations 1, 2 and 3
represent rotor inlet, rotor outlet and stator outlet
Main assumptions of 1D modeling are as below:
respectively.
1. Air flow properties changes are ignored in First with knowing geometric specifications of the
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compressor such as inlet and outlet angle of camber stagnation temperature and pressure at stator inlet
line and maximum thickness to chord ratio, it is are considered the same as calculated at rotor exit.
possible to compute design incidence and deviation With these assumptions it is possible to compute all
angles using Eqs. (1) and (2). parameters at stator inlet. The next step is obtaining
unknowns at stator exit by algorithm in Fig. 3.
i * K shK t ,i (i 0* )10 m (1)
The outcome of design condition computations is to
calculate profile loss coefficients in design
K shK t ,
*
*
0 10
m (2) condition for rotor and stator rows.
Given the inlet stagnation pressure and temperature, 2.4 Off-design Condition
the rotor rotational speed and angles of velocity
After determination of design profile loss
triangle at rotor inlet, design parameters can be
coefficients, it is affordable to obtain profile loss
calculated according to Eqs. (3) to (14) “Peyvan
coefficients in off design condition. The coefficient
(2013).
can be obtain through Eqs. (15) and (16). Mass flow
u1 rm 1N / 30 (3) rate is the code input for off-design condition.
Consequently, for one stage of axial compressor, all
Ca1 u1 /(tan(1 ) tan( 1 )) (4) the unknown quantities for off design condition in
the rotor inlet, rotor exit and stator exit are
C 1 Ca1 / cos(1 ) (5) calculated.
To obtain the off-design loss coefficients a
W1 Ca1 / cos( 1 ) (6)
dimensionless parameter for incidence angle is
defined as follow “Aungier (2003):
T1 T01 C 12 /2C p (7)
(i i * )/(i ps i * ) i i * (15)
T01rel T1 W /2C p
1
2
(8)
(i i * )/(i * i ns ) i i* (16)
M 1 C 1 / RT1 (9)
i ps and i ns are related to incidence angle of positive
M 1rel W1 / RT1 (10)
and negative stall and i is the design incidence
angle that is used in correlations represented by
P1 P01 /(1 0.5( 1)M 12 ) / 1 (11)
Herig Aungier (2003). Herig presented approximate
relationships to calculate positive and negative stall
1 P1 / RT 1 (12) incidence angle for NACA 65 series.
P01rel P1(T01rel /T1 ) / 1 (13) 30
0.48
(17)
i * i ns 9 1
1ns 4.176
m 1 A1Ca1 (14)
1 ps (18)
i ps i * 10.3 2.92
15.6 8.2
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P01rel P1(T01rel /T1 ) / 1 stator exit stations with a slight change using
(27) Johnson and Bullak (1965) model to calculate
The algorithm used for calculating design condition outflow relative angle. Incidence angle and axial
is also applied for off design condition at rotor and velocity ratio of the stage are the most significant
parameters for calculation of deviation angle
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Aungier (2003). Johnson and Bullak (1965) performance of a compressor with a specific
presented a model to calculate variation of deviation geometry.
angle at design point. After a lot of experiments and
corrections they succeeded to obtain a correlation
which predicts linear variation of deviation angle
based on incidence angle, Eq. (28). According to
linear variation of deviation angle with incidence
angle and the correction that was made by Pullard
and Gastello, considering the effect of axial velocity
variation, the deviation angle for off design
condition is calculated with Eq. (29).
*
1 ( 0.25 )( 1 /53) / exp(3.1 ) (28)
4 2.5
i
*
* (i i ) 10(1 Wa 2 /Wa 1 )
*
(29)
i
P02rel P2
W RE (30)
P01rel P1
eq max
/ c / 0.25 10t max / c momentum and energy coupled with ideal gas
WRE (32) equation and k-epsilon turbulence model are solved
0.65
1 0.4 / 2sin( / 2)cos
simultaneously to achieve flow field solution Nili-
Ahmadabadi et al. (2014).
Eq. (32) is valid if relation (33) is satisfied.
(33)
4.2 Grid Construction
/ 2sin( /2)cos 1.1
Because of symmetry of flow field it is sufficient to
just take a rotor blade and a stator blade into
4. THREE DIMENSIONAL MODELING account with definition of proper boundary
condition which results in dramatically reducing
Application of numerical methods for solving time. Fig. 5 shows the flow field around a
turbomachinery simulation has started since 1940. rotor blade with boundary conditions.
In fact, these methods have been formulated before Flow fields in the rotor and stator are meshed using
digital computers advent. First, streamline curvature structured grid (Figs. 6 to 8). The topology of mesh
was presented by Wu which can be considered as a is H/J/C/L. The ratio of number of nodes of rotor
primary numerical method for turbomachinery and domain to stator domain is 60 to 40. The grid
its concept has been used wildly till 1980 when independency was performed based on the results
CFD methods were practically applicable Denton which resulted in 500,000 nodes are enough for
and Dawes (1998). rotor and stator domains overall in order to obtain
an acceptable result.
Full three dimensional CFD method considers
geometric details such as sweep angle, lean angle 4.3 Problem Setup
and wall profile of axial compressor which
results in detailed investigation of flow field. In Flow field includes various zones such as hub,
this study CFD method was used to predict the shroud, and blade walls, flow inlet boundary, flow
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A. Pressures: all static pressures are measured using enthalpy of the compressor increases which causes
four static pressure taps equally spaced around the more pressure augmentation. In Fig. 12, the
circumference of the duct, and joined together and compressor isentropic efficiency is plotted versus
connected to a strain gauge pressure transducer, to the mass parameter.
give an average static pressure. The total pressures
are measured using Pitot tubes connected to the
strain gauge pressure transducers.
B. Temperatures: Temperatures are measured using
J type thermocouples. The maximum error of the
temperature measurement system is about 0.25 0C
Pourfarzaneh (2010). All thermocouples are
connected to the computer data acquisition system
by Adams cards Asgarshamsi et al. (2014).
C. Air mass flow rate: The compressor air mass
flow rate is measured using a bell mouth entry flow
meter. The mass flow calculation is based on Fig. 10. Stagnation Pressure ratio versus mass
pressure drop measurement across the bell mouth
parameter Mp m (kg / s ) T0 (k ) / P0 (bar )
throat and ambient temperature and pressure
measurements. (experimental results).
D. Rotational speed: The compressor rotational
speed is measured using a magnetic pick-up, which
counts shaft revolution per second.
5.1.2 Calibration
For calibration of the pressure gauges 2 meters long
manometer filled with mercury is used. It is
accomplished by measuring different values of
pressures by data acquisition system as well as
manometers. Thereafter, by a curve fitting the test
points with minimum error, the calibration curve is
obtained Pourfarzaneh (2010).
In order to calibrate J type thermocouples, some
equilibrium temperatures such as ice-water mixture Fig. 11. Stagnation Pressure ratio versus speed
temperature are used. An accurate RTD parameter N N (rpm) / T0 (k ) (experimental
thermometer is used as well.
results).
5.2 Test Method
The compressed air is blown into the turbine blades
and consequently engine speed rises to ignition
speed. Then the fuel is injected and the ignition
system ignites the mixture of air-fuel and finally.
Gradually engine accelerates to higher speeds,
which at several steady state conditions, the
Automated Data acquisition system records all data
every second. All the data obtained from the sensors
are calibrated with calibration curves achieved from
regression of calibration data points.
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the combined effects of different variables can be a given rotational speed the curve of pressure ratio
written as: versus mass parameter has a negative slope. The
curve to the left side and right side is limiting to
1/2
n y 2 choking and surge conditions respectively. With a
2
I xi (35) slight increase in mass parameter near choking
i 1 x i condition, pressure drop increases sharply resulting
the declination of pressure ratio. It is observed that
The term I is general uncertainty for y parameter the compressor maximum pressure ratio near surge
condition for design rotational speed is 1.432. Surge
and the term xi is uncertainty relating to measured line is ascending which is the same as those are in
quantity x i . the literature.
In order to investigate flow angles, the compressor
For example, the stagnation pressure ratio blade characteristics are briefly presented in Table
uncertainty is obtained by Eq. (36). 5.
P02
P P
2 2
Pr Pr Pr / P02 / P01 (36)
P01 02 01 Table 5 Compressor blade angles
Inlet Outlet Stagger
Experimental results which are extracted from the camber camber angle
data that is captured from three measuring stations angle angle
of gas turbine engine are used for comparison with Rotor 51.28o 23.49o 39.9o
theoretical results and uncertainty analysis is Stator 38.28o 0o 12.06o
performed on the data captured at these stations.
The values of uncertainties for mass parameter, There are several performance points which were
total pressure ratio and isentropic efficiency are modeled through 1D modeling so that it is
shown in Table 3. According to the obtained values impossible to investigate their velocity triangles.
of the uncertainty it can be concluded that the However, the velocity triangles are delineated for
sensors are suitable to be used in the test. As an three mass flow rate amount at design speed which
example for mass parameter of 104.37, are shown in Fig. 16.
uncertainties of mass parameter, pressure ratio, and
isentropic efficiency are 0.4, 0.15 and 3 percent
respectively.
Axial compressor maps are shown in Figs 13 and According to Fig. 14 at a specific mass parameter,
14. In these diagrams stagnation pressure ratio and isentropic efficiency increases with rotational
efficiency changes versus mass parameter are speed. Similar to pressure ratio graph, efficiency
plotted in four different rotational speeds. Also curves are limiting to choking condition with
surge line of the compressor is plotted. Stall minimum magnitude at right side and surge
condition is defined according to Eqs. (31) and (32) condition at left side.
for rotor and stator rows. If parameter WRE for rotor Fig. 15 shows the ratio of required power to design
row or stator row is less than the value defined by point power of compressor versus mass parameter
Eq. (32), stall condition occurs. As the rotational for different rotational speeds. Maximum required
speed increases, more pressure ratio is obtained. For power is related to design point rotational speed at
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mass parameter near the surge condition. residuals are changed oscillatory and the
convergence rate becomes lower. Away from the
surge condition and at midpoints, convergence rate
increases and residuals do not oscillate. Near
choking condition, if mass flow rate wouldn’t be
chosen in the proper range, then solution diverges.
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residuals when they become oscillating. Moreover, with 1D modeling is that the compressor works near
similarly the maximum mass flow which is possible its surge as the engine reaches its nominal speed.
to pass through the compressor for a specific speed
is obtainable through 1D modeling with high slop Comparison between one-dimensional modeling
of efficiency and pressure ratio curves. results with experimental results shows good
Furthermore, with estimated value of choking mass agreements for different rotational speeds.
flow rate by 1D modeling the mass flow capacity of Maximum performance prediction difference for
the compressor is determined by 3D modeling so pressure ratio and isentropic efficiency are 2.1 and
that mass flow rate for a particular speed can be 3.4 percent respectively. Due to the fact that the
increased to the point above of which the solution experimental results are obtained for a compressor,
diverges. which is effected by other components of the
engine, working inside a gas turbine engine, it can
be concluded that the 1D modeling sufficiently
predict the performance of a compressor while
working in an assembly.
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