The Application of Mathematical Models for Industrial Centrifugal Compressor Optimal Design

The authors present the design approach aiming to reach maximum possible efficiency of an industrial centrifugal compressor. To reach the goal the flow coefficient of stages must lie within the range where velocity at an impeller inlet are not more than 0,7 of blade speed. Flow path channels must not be less than 0,05 of an impeller diameter. A loading factor must vary between 0,4 and 0,5. Design limitations are important too. The Universal Modeling Method of effective design and reliable calculation is shortly described. The original two-zone model is being processed by implemented in PC programs to optimize basic dimensions of a flow path and to calculate gas dynamic performances. Q3D calculations are applied to optimize 2D and 3D blade cascades. CFD calculations are used as a finishing operation. Two samples of high effective compressors developed in cooperation with PAO SMPO (Sumy city, Ukraine) are presented. 16 MW booster compressor demonstrated efficiency close to 88% due to proper choice of number of stages'. 32 MW single-stage compressor design was based on most effective scheme and parameters offered by PAO SMPO. The Industrial partner designed, manufactured and tested 1:2 scale model. The tests have verified the project gas dynamic performances with high accuracy. Polytropic efficiency of 90% was reached for the first time in the Authors' design practice.