Up to present, there have been no studies concerning the application of fluid-structure interaction（FSI） analysis to the lifetime estimation of multi-stage centrifugal compressors under dangerous unsteady aerodynami...Up to present, there have been no studies concerning the application of fluid-structure interaction（FSI） analysis to the lifetime estimation of multi-stage centrifugal compressors under dangerous unsteady aerodynamic excitations. In this paper, computational fluid dynamics（CFD） simulations of a three-stage natural gas pipeline centrifugal compressor are performed under near-choke and near-surge conditions, and the unsteady aerodynamic pressure acting on impeller blades are obtained. Then computational structural dynamics（CSD） analysis is conducted through a one-way coupling FSI model to predict alternating stresses in impeller blades. Finally, the compressor lifetime is estimated using the nominal stress approach. The FSI results show that the impellers of latter stages suffer larger fluctuation stresses but smaller mean stresses than those at preceding stages under near-choke and near-surge conditions. The most dangerous position in the compressor is found to be located near the leading edge of the last-stage impeller blade. Compressor lifetime estimation shows that the investigated compressor can run up to 102.7 h under the near-choke condition and 200.2 h under the near-surge condition. This study is expected to provide a scientific guidance for the operation safety of natural gas pipeline centrifugal compressors.展开更多
Blade fouling has been proved to be a great threat to compressor performance in operating stage. The current researches on fouling-induced performance degradations of centrifugal compressors are based mainly on simpli...Blade fouling has been proved to be a great threat to compressor performance in operating stage. The current researches on fouling-induced performance degradations of centrifugal compressors are based mainly on simplified roughness models without taking into account the realistic factors such as spatial non-uniformity and randomness of the fouling-induced surface roughness. Moreover, little attention has been paid to the robust design optimization of centrifugal compressor impellers with considerations of blade fouling. In this paper, a multi-objective robust design optimization method is developed for centrifugal impellers under surface roughness uncertainties due to blade fouling. A three-dimensional surface roughness map is proposed to describe the nonuniformity and randomness of realistic fouling accumulations on blades. To lower computational cost in robust design optimization, the support vector regression（SVR） metamodel is combined with the Monte Carlo simulation（MCS） method to conduct the uncertainty analysis of fouled impeller performance. The analyzed results show that the critical fouled region associated with impeller performance degradations lies at the leading edge of blade tip. The SVR metamodel has been proved to be an efficient and accurate means in the detection of impeller performance variations caused by roughness uncertainties. After design optimization, the robust optimal design is found to be more efficient and less sensitive to fouling uncertainties while maintaining good impeller performance in the clean condition. This research proposes a systematic design optimization method for centrifugal compressors with considerations of blade fouling, providing a practical guidance to the design of advanced centrifugal compressors.展开更多
Existing aerodynamic design systems for multi-stage axial-flow compressor suffer from several limitations,such as experience dependent models and time costly simulations.Few attempts,however,have been devoted to the r...Existing aerodynamic design systems for multi-stage axial-flow compressor suffer from several limitations,such as experience dependent models and time costly simulations.Few attempts,however,have been devoted to the rapid and automatic optimization of aerodynamic performance at the preliminary design phase,which plays a crucial role in the final aerodynamic performance.In this work,a rapid and automatic aerodynamic optimal design method is developed for the multi-stage axial-flow compressor based on one-dimensional meanline design method,radial-equilibrium equation and genetic algorithm.The one-dimensional performance prediction model includes some popular empirical correlations to calculate the flow loss,incidence angle,deviation angle and flow blockage.The radial-equilibrium equation is solved to obtain the spanwise distribution of aerodynamic and thermodynamic parameters at the inlet and outlet of each blade row.The genetic algorithm is used for an automatic search of the global optimal compressor configuration aiming at maximizing the design efficiency.The developed method is illustrated with the aerodynamic optimal design of a 6-stage axial-flow industry compressor and verified by computational fluid dynamics simulations.The results show that the developed method is capable of improving effectively the design efficiency and predicting accurately the aerodynamic performance of the 6-stage axial-flow industry compressor in a few minutes.This work is of scientific significance to improve the axial-flow compressor design system and of engineering importance to release the designers from the heavy experience dependence especially at the preliminary design phase.展开更多
基金Supported by National Natural Science Foundation of China(Grant No51406148)National Science Technology Support Program of China(Grant No.2012BAA08B06)Postdoctoral Science Foundation o China(Grant No.2014M552444)
文摘Up to present, there have been no studies concerning the application of fluid-structure interaction（FSI） analysis to the lifetime estimation of multi-stage centrifugal compressors under dangerous unsteady aerodynamic excitations. In this paper, computational fluid dynamics（CFD） simulations of a three-stage natural gas pipeline centrifugal compressor are performed under near-choke and near-surge conditions, and the unsteady aerodynamic pressure acting on impeller blades are obtained. Then computational structural dynamics（CSD） analysis is conducted through a one-way coupling FSI model to predict alternating stresses in impeller blades. Finally, the compressor lifetime is estimated using the nominal stress approach. The FSI results show that the impellers of latter stages suffer larger fluctuation stresses but smaller mean stresses than those at preceding stages under near-choke and near-surge conditions. The most dangerous position in the compressor is found to be located near the leading edge of the last-stage impeller blade. Compressor lifetime estimation shows that the investigated compressor can run up to 102.7 h under the near-choke condition and 200.2 h under the near-surge condition. This study is expected to provide a scientific guidance for the operation safety of natural gas pipeline centrifugal compressors.
基金Supported by National Natural Science Foundation of China(Grant No.51406148)National Science Technology Support Program of China(Grant No.2012BAA08B06)Postdoctoral Scientific Foundation of China(Grant No.2014M552444)
文摘Blade fouling has been proved to be a great threat to compressor performance in operating stage. The current researches on fouling-induced performance degradations of centrifugal compressors are based mainly on simplified roughness models without taking into account the realistic factors such as spatial non-uniformity and randomness of the fouling-induced surface roughness. Moreover, little attention has been paid to the robust design optimization of centrifugal compressor impellers with considerations of blade fouling. In this paper, a multi-objective robust design optimization method is developed for centrifugal impellers under surface roughness uncertainties due to blade fouling. A three-dimensional surface roughness map is proposed to describe the nonuniformity and randomness of realistic fouling accumulations on blades. To lower computational cost in robust design optimization, the support vector regression（SVR） metamodel is combined with the Monte Carlo simulation（MCS） method to conduct the uncertainty analysis of fouled impeller performance. The analyzed results show that the critical fouled region associated with impeller performance degradations lies at the leading edge of blade tip. The SVR metamodel has been proved to be an efficient and accurate means in the detection of impeller performance variations caused by roughness uncertainties. After design optimization, the robust optimal design is found to be more efficient and less sensitive to fouling uncertainties while maintaining good impeller performance in the clean condition. This research proposes a systematic design optimization method for centrifugal compressors with considerations of blade fouling, providing a practical guidance to the design of advanced centrifugal compressors.
基金This work is financially supported by the National Key Research and Development Project of China(Grant No.2016YFB0200901)National Natural Science Foundation of China(Grant No.51776154)+1 种基金National Science and Technology Major Project of China(Grant No.2017-II-0006-0020)Shaanxi Key Research and Development Project(Grant No.2018KWZ-01).
文摘Existing aerodynamic design systems for multi-stage axial-flow compressor suffer from several limitations,such as experience dependent models and time costly simulations.Few attempts,however,have been devoted to the rapid and automatic optimization of aerodynamic performance at the preliminary design phase,which plays a crucial role in the final aerodynamic performance.In this work,a rapid and automatic aerodynamic optimal design method is developed for the multi-stage axial-flow compressor based on one-dimensional meanline design method,radial-equilibrium equation and genetic algorithm.The one-dimensional performance prediction model includes some popular empirical correlations to calculate the flow loss,incidence angle,deviation angle and flow blockage.The radial-equilibrium equation is solved to obtain the spanwise distribution of aerodynamic and thermodynamic parameters at the inlet and outlet of each blade row.The genetic algorithm is used for an automatic search of the global optimal compressor configuration aiming at maximizing the design efficiency.The developed method is illustrated with the aerodynamic optimal design of a 6-stage axial-flow industry compressor and verified by computational fluid dynamics simulations.The results show that the developed method is capable of improving effectively the design efficiency and predicting accurately the aerodynamic performance of the 6-stage axial-flow industry compressor in a few minutes.This work is of scientific significance to improve the axial-flow compressor design system and of engineering importance to release the designers from the heavy experience dependence especially at the preliminary design phase.
