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NASA NTRS2015

Exprimental Results of the First Two Stages of an Advanced Transonic Core Compressor Under Isolated and Multi-Stage Conditions.

NASA's Environmentally Responsible Aviation (ERA) Program calls for investigation of the technology barriers associated with improved fuel efficiency for large gas turbine engines. Under ERA, the highly loaded core compressor technology program attempts to realize the fuel burn reduction goal by increasing overall pressure ratio of the compressor to increase thermal efficiency of the engine. Study engines with overall pressure ratio of 60 to 70 are now being investigated. This means that the high pressure compressor would have to almost double in pressure ratio while keeping a high level of efficiency. NASA and GE teamed to address this challenge by testing the first two stages of an advanced GE compressor designed to meet the requirements of a very high pressure ratio core compressor. Previous test experience of a compressor which included these front two stages indicated a performance deficit relative to design intent. Therefore, the current rig was designed to run in 1-stage and 2-stage configurations in two separate tests to assess whether the bow shock of the second rotor interacting with the upstream stage contributed to the unpredicted performance deficit, or if the culprit was due to interaction of rotor 1 and stator 1. Thus, the goal was to fully understand the stage 1 performance under isolated and multi-stage conditions, and additionally to provide a detailed aerodynamic data set for CFD validation. Full use was made of steady and unsteady measurement methods to understand fluid dynamics loss source mechanisms due to rotor shock interaction and endwall losses. This paper will present the description of the compressor test article and its measured performance and operability, for both the single stage and two stage configurations. We focus the paper on measurements at 97% corrected speed with design intent vane setting angles.

transonic compressors↗

DOE OSTI2026

Cold compressor performance and energy consumption improvements at Jefferson Lab’s Central Helium Liquefiers

Abstract Jefferson Lab operates two central helium liquefiers (CHLs) which both utilize full cold compression from the saturation pressure at operating temperature (approximately 2.1 K) to just over atmospheric pressure. The original plant, CHL1, was recently outfitted with a replacement subatmospheric cold box (SC1R) containing state-of-the-art cold compressor technology, while the newer plant, CHL2, uses an older cold compressor system. In both cases, the heat of compression is absorbed at low temperature at the expense of electrical power consumed by the warm compressors. Due to the superior efficiency and turndown capabilities of SC1R, a new operating mode has been identified for CHL1 in which the required number of operating warm compressors is reduced by one. A cost-based method for optimizing cold compressor stability and efficiency has been developed and applied to CHL2, improving its turndown and lowering the warm compressor discharge pressure. As a result of these efforts, power consumption of the combined CHLs during normal operations has been reduced by nearly 10%, or a total of 650 kW. The observed performance of CHL1 with SC1R, as well as the cold compressor optimization method, leading to this improved energy consumption rate will be discussed in detail.

Mastracci, B [Thomas Jefferson National Accelerato↗

DOE OSTI2024

Liquid Piston with Spray Cooling Near-Isothermal Compressor

The goal of this project was to prototype and characterize the performance of a liquid-piston spray-cooled gas compressor. The working principle of the compressor enables optimized high-efficiency operation over a very wide range of operating conditions, unlike conventional compressors that are optimized for a narrow range of operating conditions. The compressor technology is suitable for many applications, such as gas pipeline transport, gas storage, and commercial and residential heat pumps. Both physical testing and computational fluid dynamics (CFD) modeling of the processes using the Oak Ridge National Laboratory high-performance computing center were completed. The experimental and CFD studies focused on a near-isothermal liquid-piston compressor (LPC) that uses propylene glycol to compress CO 2 . The first prototype demonstrated isothermal operation during several sequentially executed cycles of CO 2 compression and raised the temperature of the compressed CO 2 by only 2 K, compared with approximately 6 K when the gas was compressed non-isothermally. Isothermal operation was demonstrated at CO 2 flow rates of up to 2 L/min. The second prototype was designed with two compression chambers to allow continuous flow of high-pressure CO 2 . However, the design of the valve train to direct flow between the compression chambers was not sufficient to allow demonstration of CO 2 compression. Numerical simulations of the LPC in which the compression chamber was filled with propylene glycol injected from the bottom inlet were performed using large eddy simulation (LES) with the wall-adapting local eddy-viscosity subgrid-scale model coupled with the multiphase volume of fluid (VOF) model to simulate the transient interface between gas and liquid and to capture the heat and mass transfers within the compression chamber. In this effort, the effects of boundary conditions applied to the LES-VOF calculations (i.e., no wall, an adiabatic wall, and a wall with a heat flux subscribed) on the overall pressure and temperature of the CO 2 gas as well as the transient evolution of flow and heat transfer within the compression chamber were investigated and are discussed in this report. The LES calculation with no wall showed no dynamical flow patterns, and the volume-averaged temperature of CO 2 increased from 305 to 392.7 K, whereas LES calculations with a constant wall temperature or a wall heat flux had similar increases of CO 2 temperatures. The results of the LES simulation using a wall heat flux showed different stages in the compression process and revealed dynamical formation and interaction of CO 2 gas layers and circulation flow patterns within the chamber that contributed to the overall heat transfer between the solid wall, gas, and liquid surface in the compressor. Though an industrial partnership for commercializing the compressor was not secured, the technology was attractive for an industrial partner to use in two research proposals in response to US Department of Energy funding opportunity announcements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1979

Core compressor exit stage study. 1: Aerodynamic and mechanical design

The effect of aspect ratio on the performance of core compressor exit stages was demonstrated using two three stage, highly loaded, core compressors. Aspect ratio was identified as having a strong influence on compressors endwall loss. Both compressors simulated the last three stages of an advanced eight stage core compressor and were designed with the same 0.915 hub/tip ratio, 4.30 kg/sec (9.47 1bm/sec) inlet corrected flow, and 167 m/sec (547 ft/sec) corrected mean wheel speed. The first compressor had an aspect ratio of 0.81 and an overall pressure ratio of 1.357 at a design adiabatic efficiency of 88.3% with an average diffusion factor or 0.529. The aspect ratio of the second compressor was 1.22 with an overall pressure ratio of 1.324 at a design adiabatic efficiency of 88.7% with an average diffusion factor of 0.491.

Burdsall, E. A.↗

NASA NTRS1980

Review - Axial compressor stall phenomena

Stall in compressors can be associated with the initiation of several types of fluid dynamic instabilities. These instabilities and the different phenomena, surge and rotating stall, which result from them, are discussed in this paper. Assessment is made of the various methods of predicting the onset of compressor and/or compression system instability, such as empirical correlations, linearized stability analyses, and numerical unsteady flow calculation procedures. Factors which affect the compressor stall point, in particular inlet flow distortion, are reviewed, and the techniques which are used to predict the loss in stall margin due to these factors are described. The influence of rotor casing treatment (grooves) on increasing compressor flow range is examined. Compressor and compression system behavior subsequent to the onset of stall is surveyed, with particular reference to the problem of engine recovery from a stalled condition. The distinction between surge and rotating stall is emphasized because of the very different consequences on recoverability. The structure of the compressor flow field during rotating stall is examined, and the prediction of compressor performance in rotating stall, including stall/unstall hysteresis, is described.

Greitzer, E. M.↗

NASA NTRS1984

Determination of compressor in-stall characteristics from engine surge transients

A technique for extracting the in-stall pumping characteristics for an axial flow compressor operating in an engine system environment is developed. The technique utilizes a Hybrid computer simulation of the compressor momentum equation into which actual transient data are used to provide all terms but the desired compressor characteristic. The compressor force characteristic as a function of corrected flow and speed result from the computation. The critical problem of data filtering is addressed. Results for a compressor operating in a turbofan engine are presented and comparison is made with the conventional compressor map. The relationship of the compressor surge characteristic with its rotating stall characteristic is explored. Initial interpretation of the measured results is presented.

Lorenzo, C. F.↗

NASA NTRS1984

Determination of compressor in-stall characteristics from engine surge transients

A technique for extracting the in-stall pumping characteristics for an axial flow compressor operating in an engine system environment is developed. The technique utilzes a Hybrid computer simulation of the compressor momentum equation in which actual transient data are used to provide all terms but the desired compressor characteristic. The compressor force characteristic as a function of corrected flow and speed results from the computation. The critical problem of data filtering is addressed. Results for a compressor operating in a turbofan engine are presented and comparison is made with the conventional compressor map. The relationship of the compressor surge charcteristic with its rotating stall characteristic is explored. Initial interpretation of the measured results is presented. Previously announced in STAR as N84-22566

Lorenzo, C. F.↗

NASA NTRS1989

Small Displacement, Long Life On-Orbit Compressor Design and Fabrication

The focus is the generation of technology and fabrication of prototype hardware applicable to seven Space Station compressor system applications. The compressors are of the single acting reciprocating piston type and, in general, may be termed miniature in size compared with normal commercially available equipment. The initial technology development is focused on improved valve designs, and the control of pulsations and heating effects in order to increase compressor efficiency and reduce cycle temperatures, thus permitting significantly increased stage pressure ratios. The initial test compressor was successfully operated at pressure ratios of up to 50:1, and this significant extension of allowable pressure ratio will result in a reduction of the number of required stages and, hence, total hardware thereby reducing system weight and volume. These experiments have also identified the need to employ low shaft speeds, on the order of 250 to 500 rpm, to enhance heat transfer and increase life. The prototype compressor currently being designed, is to be driven by a low-speed brushless dc motor sealed in a case common to the compressor drive mechanism case. The compressor and motor case will communicate with stage suction pressure so that any minor gas leakage past the piston rings will be returned to the suction. Emphasis in this prototype design is being placed on simplicity, durability, commonality of components, and high efficiency.

Gerlach, C. R.↗

NASA NTRS2004

Experimental Investigation of Diffuser Hub Injection to Improve Centrifugal Compressor Stability

Results from a series of experiments to investigate whether centrifugal compressor stability could be improved by injecting air through the diffuser hub surface are reported. The research was conducted in a 4:1 pressure ratio centrifugal compressor configured with a vane-island diffuser. Injector nozzles were located just upstream of the leading edge of the diffuser vanes. Nozzle orientations were set to produce injected streams angled at 8, 0 and +8 degrees relative to the vane mean camber line. Several injection flow rates were tested using both an external air supply and recirculation from the diffuser exit. Compressor flow range did not improve at any injection flow rate that was tested. Compressor flow range did improve slightly at zero injection due to the flow resistance created by injector openings on the hub surface. Leading edge loading and semi-vaneless space diffusion showed trends similar to those reported earlier from shroud surface experiments that did improve compressor flow range. Opposite trends are seen for hub injection cases where compressor flow range decreased. The hub injection data further explain the range improvement provided by shroud-side injection and suggest that different hub-side techniques may produce range improvement in centrifugal compressors.

Skoch, Gary J.↗

NASA NTRS1948

Effect of Inlet Air Distortion on the Steady-State and Surge Characteristics of an Axial-Flow Turbojet Compressor

An investigation was conducted in an altitude test chamber to determine the effects of inlet airflow distortion on the compressor steady-state and surge characteristics of a high-pressure ratio, axial-flow turbojet engine. Circumferential-type inlet flow distortions were investigated, which covered a range of distortion sector angles from 20 deg to 168 deg and distortion levels up to 22 percent. The presence of inlet airflow distortions at the compressor face resulted in a substantial increase in the local pressure ratio in the distorted region, primarily for the inlet stages. The local pressure ratio in the distorted region for the inlet stages increased as either the distortion sector angle decreased or the percent distortion increased. The average compressor-surge pressure ratio was much more sensitive to inlet airflow distortions at lower engine speeds than at engine speeds near rated. Hence, compressor-surge margin reduction due to inlet airflow distortion was quite severe at the lower engine speeds. Although the average compressor-surge pressure ratio was generally reduced with inlet flow distortion, local pressure ratios across the distorted sector of the compressor were obtained during surge and were significantly greater than the normal compressor-surge pressure ratio. This was a result of increased loading of the inlet stages in the distorted region.

Ciepluch, Carl C.↗

NASA NTRS2002

Centrifugal Compressor Surge Margin Improved With Diffuser Hub Surface Air Injection

Aerodynamic stability is an important parameter in the design of compressors for aircraft gas turbine engines. Compression system instabilities can cause compressor surge, which may lead to the loss of an aircraft. As a result, engine designers include a margin of safety between the operating line of the engine and the stability limit line of the compressor. The margin of safety is typically referred to as "surge margin." Achieving the highest possible level of surge margin while meeting design point performance objectives is the goal of the compressor designer. However, performance goals often must be compromised in order to achieve adequate levels of surge margin. Techniques to improve surge margin will permit more aggressive compressor designs. Centrifugal compressor surge margin improvement was demonstrated at the NASA Glenn Research Center by injecting air into the vaned diffuser of a 4:1-pressure-ratio centrifugal compressor. Tests were performed using injector nozzles located on the diffuser hub surface of a vane-island diffuser in the vaneless region between the impeller trailing edge and the diffuser-vane leading edge. The nozzle flow path and discharge shape were designed to produce an air stream that remained tangent to the hub surface as it traveled into the diffuser passage. Injector nozzles were located near the leading edge of 23 of the 24 diffuser vanes. One passage did not contain an injector so that instrumentation located in that passage would be preserved. Several orientations of the injected stream relative to the diffuser vane leading edge were tested over a range of injected flow rates. Only steady flow (nonpulsed) air injection was tested. At 100 percent of the design speed, a 15-percent improvement in the baseline surge margin was achieved with a nozzle orientation that produced a jet that was bisected by the diffuser vane leading edge. Other orientations also improved the baseline surge margin. Tests were conducted at speeds below the design speed, and similar results were obtained. In most cases, the greatest improvement in surge margin occurred at fairly low levels of injected flow rate. Externally supplied injection air was used in these experiments. However, the injected flow rates that provided the greatest benefit could be produced using injection air that is recirculating between the diffuser discharge and nozzles located in the diffuser vaneless region. Future experiments will evaluate the effectiveness of recirculating air injection.

Skoch, Gary J.↗

NASA NTRS1955

Preliminary Results of the Determination of Inlet-Pressure Distortion Effects on Compressor Stall and Altitude Operating Limits of the J57-P-1 Turbojet Engine

During an investigation of the J57-P-1 turbojet engine in the Lewis altitude wind tunnel, effects of inlet-flow distortion on engine stall characteristics and operating limits were determined. In addition to a uniform inlet-flow profile, the inlet-pressure distortions imposed included two radial, two circumferential, and one combined radial-circumferential profile. Data were obtained over a range of compressor speeds at an altitude of 50,000 and a flight Mach number of 0.8; in addition, the high- and low-speed engine operating limits were investigated up to the maximum operable altitude. The effect of changing the compressor bleed position on the stall and operating limits was determined for one of the inlet distortions. The circumferential distortions lowered the compressor stall pressure ratios; this resulted in less fuel-flow margin between steady-state operation and compressor stall. Consequently, the altitude operating Limits with circumferential distortions were reduced compared with the uniform inlet profile. Radial inlet-pressure distortions increased the pressure ratio required for compressor stall over that obtained with uniform inlet flow; this resulted in higher altitude operating limits. Likewise, the stall-limit fuel flows required with the radial inlet-pressure distortions were considerably higher than those obtained with the uniform inlet-pressure profile. A combined radial-circumferential inlet distortion had effects on the engine similar to the circumferential distortion. Bleeding air between the two compressors eliminated the low-speed stall limit and thus permitted higher altitude operation than was possible without compressor bleed.

Wallner, L. E.↗

DOE OSTI2022

Initial Design and Experimental Results of a Novel Near-Isothermal Compressor for Heat Pump Applications

In efforts to increase the efficiency of residential and commercial air conditioners and heat pumps, it is found that the compressor has the highest electrical energy usage of the system. Therefore, it is appropriate to try to increase the efficiency of this component to reduce its energy usage. Another challenge with heat pump design is that some compressor types have drawbacks that make modulation difficult. To answer these challenges, we are developing an isothermal liquid compressor. The compressor uses propylene glycol to compress carbon dioxide. In the compression chamber the propylene glycol can enter either from the bottom to create a liquid piston for compression or it can enter through a spray nozzle at the top of the chamber. In the latter case, heat transfer from the gas to be compressed to the liquid droplets is high. This allows near isothermal operation of the compressor, which increases the efficiency by 17% to 30%, compared to adiabatic compression. In addition, the isothermal liquid compressor enables very efficient and simple part load modulation.Experimental results demonstrating the operation of the liquid compressor are presented. Initial data demonstrated a temperature rise of 7 K at pressure ratios of almost 4. For comparison at the same initial pressure, temperature, and pressure ratio, adiabatic compression would result in a temperature increase of approximately 70 K. Plotting data on a P-h diagram demonstrates that the compression started at superheated state and ended in supercritical state. Testing was later performed with repeated compressions in the superheated region of the P-h diagram at liquid flow rates of 2 x 10-3 m3/min and 2 x 10-3 m3/min to understand the limitations of the prototype for use with an actual heat pump system. This work demonstrated a novel cycle on a T-s diagram. Results from this work will be used to develop a second-generation prototype where more rapid cycling is possible.

Kowalski, Steve↗

NASA NTRS2015

Stage-by-Stage and Parallel Flow Path Compressor Modeling for a Variable Cycle Engine

Parallel Flow Path modeling↗

NASA NTRS2015

Stage-by-Stage and Parallel Flow Path Compressor Modeling for a Variable Cycle Engine, NASA Advanced Air Vehicles Program - Commercial Supersonic Technology Project - AeroServoElasticity

This paper covers the development of stage-by-stage and parallel flow path compressor modeling approaches for a Variable Cycle Engine. The stage-by-stage compressor modeling approach is an extension of a technique for lumped volume dynamics and performance characteristic modeling. It was developed to improve the accuracy of axial compressor dynamics over lumped volume dynamics modeling. The stage-by-stage compressor model presented here is formulated into a parallel flow path model that includes both axial and rotational dynamics. This is done to enable the study of compressor and propulsion system dynamic performance under flow distortion conditions. The approaches utilized here are generic and should be applicable for the modeling of any axial flow compressor design accurate time domain simulations. The objective of this work is as follows. Given the parameters describing the conditions of atmospheric disturbances, and utilizing the derived formulations, directly compute the transfer function poles and zeros describing these disturbances for acoustic velocity, temperature, pressure, and density. Time domain simulations of representative atmospheric turbulence can then be developed by utilizing these computed transfer functions together with the disturbance frequencies of interest.

Compressor Modeling Modeling↗

NASA NTRS2014

ERA Advanced Core Compressor Technology Program

As part of the NASA Integrated Systems Research Program, Environmentally Responsible Aviation Project, NASA GRC and GE Aviation have partnered to investigate the technology barriers associated with improved fuel economy of large gas turbine engines. Crucial to improving fuel economy is the increase in Pressure Ratio (PR) of the core compressor. General Electric is in the process of defining new advanced technology engine concepts and related engine architectures for both commercial and military subsonic and supersonic flight applications. These new concepts and architectures offer the potential of providing substantial improvements in mission fuel burn, emissions, and noise levels relative to SOTA engines and support the needs and goals of future Air force, Navy, and NASA aircraft systems. A key aspect of many of these new engine concepts is an ultra high pressure ratio core compressor. Current SOTA engines such as the GENx utilize a 23:1 class pressure ratio core compressor to achieve an overall pressure ratio in the 50:1 class. Future engines with overall pressure ratios in the 70– 80:1 class will need core compressors with pressure ratios in the 30:1 class. These single spool, ultra high pressure ratio compressors will have inherent challenges. The goal of this work is to provide a dedicated component test vehicle to study the very challenging compressor front stage performance and operability issues that arise in these aggressive machines. With a view to providing highly detailed aerodynamic data that will provide, subject to the rights restrictions for test data afforded under NASA Contract NNC10BA06B/NNC10TA64T, an industry standard data set for CFD validation.

Axial Compressors↗

NASA NTRS1974

Frequency response of an axial-flow compressor exposed to inlet pressure perturbations

Experimental results of a series of engine tests designed to obtain the stage dynamics of an eight-stage axial-flow compressor over the frequency range of 0.5 to 200 hertz are presented. The total pressure at the compressor face was varied by means of a secondary air jet system installed in the engine inlet and positioned to oppose the primary airflow. Total-pressure probes located at each compressor stage were used to obtain the frequency response of each compressor-stage total pressure to the average compressor-inlet total pressure. The engine operating conditions were chosen to illustrate the effects of changing the rotor speed, changing the exhaust nozzle area, and isolating the compressor discharge pressure perturbations from the fuel control and hence, the fuel flow.

Milner, E. J.↗

NASA NTRS1976

A method to account for variation of average compressor inlet pressure during instantaneous distortion analyses

Instantaneous distortion analyses compare a time-varying value of an index (or 'surge margin used up') with a critical level (or 'available surge margin' of the compressor) to determine inlet-engine compatibility. Unless freestream conditions or propulsion system controls are changing, it is generally assumed that the available surge margin of the compressor is accurately determined from the steady-state operating point. Results are presented which show that variations of average compressor inlet pressure may occur without changes in freestream conditions or propulsion system controls. The volume dynamics of the compressor will cause these pressure variations to be attenuated and delayed by the time they reach the exit. This will cause the compressor pressure ratio (and available surge margin) to vary with time. A method is presented to calculate the available surge margin as a function of time and incorporate it into an instantaneous distortion analysis. Results show that inlet pressure variations which cause only a small change at the compressor exit can cause a significant variation in the available surge margin.

Burstadt, P. L.↗