Centrifugal compressors
Aerodynamic robustness optimization of centrifugal compressor impeller under multiple uncertainties is an involving task, due to high dimension, beyond modelling workload and trial and error optimization, and an automatic optimization process is often treated as a black box, the underlying mechanism are often not well understood and explored
PRODUCT RANGE FOR TURBO / CENTRIFUGAL COMPRESSORS
ESG approach to provide an efficient robustness optimization procedure and explore the underlying physical mechanism for centrifugal compressor impeller under operational and geometric uncertainties.
- Axial compressors
- Radial compressors – Splitline and Barrel type
- Screw compressors
- Bull gear type compressors / integrally geared compressors
MAN TURBO – ATLAS COPCO – BORSIG – DRESSER RAND – YORK – DEMAG – ELLIOTT – HITACHI – MITSUBISHI – NUOVO PIGNONE – SIEMENS – STORK DELAVAL – SULZER – THOMASSES
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Aerodynamic robustness optimization
The approach is proposed for the multi-objective aerodynamic robustness optimization and design exploration of a centrifugal compressor impeller. Models are constructed and integrated into the aerodynamic robustness optimization. The correlation between the design variables and performance parameters are explored from optimization and directly visualized by self-organizing mapping.
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Optimized impeller
Compared to the initial impeller, the average pressure ratio of the optimized impeller increases by 9.3%, the average isentropic efficiency increases by 6.7%, the standard deviations of pressure ratio and efficiency decrease by 7.5% and 15.4% respectively, and the acoustic power level decreases by 11dB.
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Optimization - re-stage
With the Kriging model, exhibits preferable accuracy for uncertain approximation modeling. The data visualization and interpretation facilitate designers to perform efficient design optimizations. The proposed approach supports design explorations for different applications of turbomachinery
get in touch with us
Contact us for reference lists and technical documents of typical solution concepts.
Please send your request (RFQ) to
Compressoraaplication@esg-systems.com
Engineering services for Turbomachinery
Our Services
Design exploration and optimization of turbomachinery
Apply state of the art CAE methods for fast, effective development projects.
Flow simulation – CFD
Use of commercial solvers such as Ansys-CFX or StarCCM+ to simulate complex flows patterns including heat transfer, multiphase, moving geometries, and more.
Structural analysis – FEA
Statics and dynamics, vibrations, rotor dynamics, life cycle fatigue, fracture mechanics, thermal analysis, fluid-structure coupling, and more.
Product development
Conceptual designs, design exploration, mechanical design evaluation.
Prototyping and testing
Rapid prototyping, Additive Manufacturing to validate simulation results. Testing is also in collaboration with partners in academia with Purdue University.
Consulting & Field Service
Consulting on turbomachinery, Problem solving, Increase reliability. All the service work can be also provided by our Field Service Engineers.
All our work is Backed up with 3 years Warranty.
IMPELLER DESIGN AND RE-MANUFACTURING
ESG manufactures open and closed impellers (2D & 3D) as replacement components for centrifugal compressors, High Pressure, Overhung, Barrel Casing. Our state-of-the-art facilities and engineering capabilities enable us to carry out the entire process internally (from 3D scanning, redesigning and modeling to manufacturing and Simulations Ansys CFX). We can supply single impellers as spare parts, but also completely assembled rotors.
Process:
Inspection
After reception and dismantling of the compressor rotor in our facilities, a comprehensive NDT inspection is carried out. Incoming inspections can include material analysis and dye penetrant-, ultrasonic- or magnetic particle testing. ESG Goal is to find the root cause of the problem and not just replace parts.
After NDT, a report and a repair proposal are made.
When impellers are irreparable, a proposal is made to supply new impellers based on redesigning and modeling.
Engineering
Once technical specifications have been defined, preliminary designs and feasibility studies can begin to determine the viability of a project, idea or system.
Based on the initial project requirements, our engineers will help determine the most relevant machine configuration, parameters, arrangement, operating conditions, and design constraints.
In many cases the conceptual and preliminary designs are performed from scratch on the basis of the customer’s specifications only and do not require any initial prototype. However, sometimes a customer may want to examine an existing machine for benchmarking or as a starting point. ESG has excellent tools to simplify this task.
At this stage the most value can be added in terms of improving efficiency from existing designs.
ESG Turbomachinery Retrofitting & Upgrades
While it is important to provide support for new and modern machinery, ESG also offers engineering services for retrofitting and upgrading of existing rotating equipment. Our engineering team has extensive expertise in this field as ex Siemens and MAN Turbomachinery Design Engineers, we provide outstanding results by providing design, optimization and analytical capabilities that exceed expectations.
ESG is capable of performing optimization and redesign of existing turbines, pumps, cycles, and compressors taking into consideration both client specification requirements and the limitations of the old geometry (shafts, casings, etc.).
Efficiency recovery upgrade options and considerations:
- Partial replacement of blading on existing stationary and rotating parts
- Replacement of complete inner blocks (steam path, rotor, inner casing)
- Replacement of complete turbine sections
- Introduction of advanced steam path technology
- Improved gland seal arrangements
- Centrifugal compressor rerate may include conversion of compressor to new process, fluid, and mass flow. There are a number of possible options to consider, including replacement of blading, development of new schedules of nozzle rotation, etc.
ESG spare parts are manufactured according to the most stringent standards and are 100% compatible. We combine the highest standards of turbo machinery knowledge with an in-depth understanding of material specifications, manufacturing standards and tolerances:
- Fast delivery
- Inhouse engineering
- Inhouse manufacturing
- Inhouse high speed balancing
- Onsite installation & commissioning
Analysis of Existing Machines
ESG strive on analytical expertise with a goal of evaluating performance, carrying out machine benchmarking, simulating design, and various off-design operational modes. To obtain the geometry of existing machines we can work with different sources of input information, such as; 2D drawings, 3D CAD solid models, and laser scanned data.
A number of performance maps can be generated for different operating conditions. This allows us to clearly achieve performance evaluations. In some cases (compressor characteristics analysis for example) we will help you find the limits of stable operation and uncover potentially weak elements. Our analysis includes:
- Different types of working fluids (ideal and real gases, gas mixtures, and steam) are available for analysis as well as for the transition to other speeds and/or other flow rates.
- Existing machine analysis can be performed for different cycles to calculate the most effective configuration.
- Different loading conditions – startup and shut down – can also be simulated to evaluate effect of transients on turbine operation.
Within the framework of analysis, it is also reasonable to check the impact of sealing types and clearances, etc. on machine performance and effectiveness. Simulation analysis does not require time-consuming and costly experiments on real machines, and reliability of the results is very high.
ESG objective is to first assist you in developing your strategy to identify and maintain optimal machine characteristics and then help you execute the most appropriate design. All these with conscious of economics and outstanding reliability.
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