Aircraft Propulsion Group Assignment
Group Members ID No
1. Furtuna G/tensae……………………………... 0243/13
2. Milkiyas Ketero……………………………….. 0199/13
3. Eyoseyas Tesera……………………………….. 0073/13
Submitted to: Capt. Yesuf Hussien
December 26 ,2024
INTRODUCTION
Centrifugal compressors are widely used in various industrial applications
due to their ability to handle large volumes of air or gas at relatively high
pressures. However, these compressors are prone to operational
challenges such as stall and surge.
What are Stall and Surge in Centrifugal Compressors?
In a centrifugal compressor, "stalling" refers to a localized disruption in airflow within
the impeller, causing a decrease in pressure rise, while "surging" is a more severe,
oscillating flow reversal where the airflow through the compressor rapidly fluctuates,
sometimes even reversing direction completely, leading to significant pressure
fluctuations and potential damage to the system.
Stall:
Stall occurs when the angle of attack on the compressor blades becomes excessively
high, causing a disruption in the airflow over the blades. This disruption leads to a
phenomenon known as flow separation, where the air no longer adheres to the surface
of the blade. This results in a loss of lift and a significant reduction in the compressor's
efficiency. Stall is typically localized and occurs in one or more stages of the compressor.
It can lead to increased vibrations, noise, and mechanical stress on the affected
components.
Surge:
Surge is a more severe condition compared to stall. It occurs when the flow through the
compressor reverses entirely due to excessive back pressure in the system. This
phenomenon is characterized by oscillations in flow and pressure, often accompanied by
loud noises and strong vibrations. Surge not only compromises the compressor's
efficiency but can also cause severe damage to its components, including impellers,
bearings, and seals. It disrupts the stable operation of the entire system, often requiring
immediate corrective action to prevent further damage.
Key Differences between stall and surge:
Flow Pattern:
Stalling usually occurs in a localized area within the impeller, while surging affects
the entire compressor flow path, causing a large-scale oscillation.
Severity:
Stalling is generally considered less severe than surging, although it can sometimes
lead to surge if not addressed.
Pressure Fluctuations:
During stalling, pressure fluctuations are relatively small compared to the dramatic
pressure swings experienced during surging.
What are the operational issues that can lead to
compressor surge or stall in a centrifugal compressor?
Aerodynamic Factors
Blade Angle: The angle at which air approaches the compressor blades is critical. An
improper blade design or deviations in the blade angle can lead to airflow separation
and stall.
Flow Disturbances: Inconsistent or turbulent airflow entering the compressor, often
caused by upstream piping configurations or obstructions, can disrupt the uniform
flow pattern. This increases the likelihood of stall by creating regions of low pressure
and flow separation.
Operational Factors
Excessive Back Pressure: When the downstream resistance in the system is too high,
it forces the compressor to operate closer to its surge line. This can lead to flow
reversal and surge.
Low Mass Flow Rate: Operating the compressor below its design flow rate creates
an imbalance between the supply and demand of air or gas, destabilizing the flow
and increasing the risk of both stall and surge.
Mechanical Factors
Wear and Tear: Over time, components such as blades, seals, and bearings can
degrade. Damaged or eroded blades lose their aerodynamic efficiency, making them
more susceptible to stall.
Misalignment: Improper alignment of the compressor shaft or other components
can lead to uneven loading, vibrations, and operational instability, all of which
contribute to stall and surge.
Control System Issues
Faulty Control Mechanisms: Ineffective or outdated control systems may fail to
adjust the operating parameters of the compressor promptly, allowing it to enter
unstable conditions.
Inadequate Surge Control: The absence or malfunction of surge control systems,
such as anti-surge valves or bypass systems, leaves the compressor vulnerable to
surging under varying load conditions.
How to mitigate these issues in real-time operations?
Design Improvements
Optimized Blade Design: Advanced computational fluid dynamics (CFD) techniques
can be used to design blades with optimized angles, profiles, and surface finishes.
These improvements help minimize flow separation and delay the onset of stall.
Variable Geometry: Incorporating adjustable inlet guide vanes (IGVs) or diffuser
vanes allows operators to control the airflow more effectively. This flexibility helps
maintain stable operation across a wider range of flow rates.
Operational Adjustments
Flow Control: Ensuring that the compressor operates within its design flow range
prevents conditions that can lead to instability. This may involve installing flow
meters and control valves to regulate the process.
Load Balancing: When multiple compressors are used in parallel, distributing the
load evenly among them ensures stable operation and reduces the likelihood of stall
or surge.
Advanced Control Systems
Anti-Surge Valves: Installing anti-surge valves that open when surge conditions are
detected helps redirect flow, maintaining stability within the compressor.
Dynamic Control Systems: Modern control systems equipped with sensors and real-
time feedback mechanisms can monitor pressure, temperature, and flow
parameters. These systems automatically adjust operating conditions to avoid stall
and surge.
Maintenance Practices
Regular Inspections: Conducting periodic inspections of blades, bearings, seals, and
other critical components can identify wear or damage early, allowing for timely
repairs.
Timely Repairs: Addressing minor issues promptly, such as replacing worn blades or
aligning misaligned shafts, prevents them from escalating into significant problems
that could trigger stall or surge.
Conclusion
Stall and surge are critical challenges in the operation of centrifugal compressors,
potentially leading to efficiency loss, mechanical damage, and system downtime. These
phenomena arise from a combination of aerodynamic, operational, mechanical, and
control system factors. Understanding these factors and their interplay is essential for
preventing instability. Through design improvements, operational adjustments,
advanced control systems, and proactive maintenance practices, the risks associated
with stall and surge can be effectively mitigated. These measures not only enhance the
reliability and efficiency of centrifugal compressors but also extend their operational
lifespan, contributing to safer and more cost-effective industrial processes.
References
1. Dixon, S. L., & Hall, C. A. (2010). Fluid Mechanics and Thermodynamics of
Turbomachinery. Elsevier.
2. Whitfield, A., & Baines, N. C. (1990). Design of Radial Turbomachines. Longman
Scientific & Technical.
3. Cumpsty, N. A. (2004). Compressor Aerodynamics. Cambridge University Press.
4. Eckardt, D. (1976). "Detailed Flow Investigations Within a High-Speed Centrifugal
Compressor Impeller." ASME Journal of Fluids Engineering.
