Turbomachinery (MEng 3202) Part II

Melesse Haile
(Asst. Professor)
Adama University
Ethiopia

Turbomachinery (MEng 3202)
Part - II

Compressors are machines used to increase the pressure of a fluid.

Note:- This chapter also includes the discussion of Chapter 7 and 8. That is, it
includes the design of rotor blades, guide vanes and spiral casings.
Classification of work absorbing machines.
Adama University Melesse Haile (Asst. Professor)

Classification of Compressors

Positive displacement compressors increase the pressure of a gas or air by
reducing the volume.
Dynamic compressors increase the air velocity by the rotational motion of impeller
or rotor, which is then converted to pressure at the outlet.


Classification of Dynamic Compressors
1. By the type of flow,
Radial flow
Axial flow

2. By the type of energy conversion,
Volute casing
Volute casing with guide vanes
3. By the method of drive,
Gear drive
Belt drive
Radial flow Axial flow

Radial (Centrifugal) Compressors

Component parts
1. Impeller
2. Inducer
3. Diffuser and Diffuser vanes
4. Collector or Casing
5. Inlet Guide Vane

Class work

1. Write the function of each component part.


A Typical Compressed air System Components and Network


Radial Compressors

Principle of operation
When the impeller is rotating at high speed (more than 20000 rpm), air is drawn in
through the eye of the impeller. The absolute velocity of the inflow air is axial. The
magnitude and direction of relative velocity at inlet depends upon the velocity of the
impeller as well as the magnitude and direction of the entering absolute velocity. The
impeller vanes at the eye are bent so as to provide shockless entry (inducer). The air
then flows radially through the impeller passages due to centrifugal force. The total
mechanical energy driving the compressor is transmitted to the fluid stream in the
impeller where it is converted into kinetic energy of air. The diffuser then converts the

kinetic energy of air into pressure.
The air leaving the diffuser is
collected in a spiral passage from
which it is discharged from the
compressor.

The pressure and velocity variation
across the compressor is as shown
in the figure.

Radial Compressors

Shapes of Radial Compressor blades

Velocity diagrams for a Radial Compressor blades
inlet outlet

Radial Compressors

Velocity diagrams for a Radial Blades

at the inlet
Figure (a) represents the velocity triangle
when the air enters the impeller in the axial
direction. In this case, C
1
= C
a1
. Figure (b)
represents the velocity triangle at the inlet to
the impeller eye and air enters through the
inlet guide vanes. Angle u is made by C
1
and
C
a1
and this angle is known as the angle of
prewhirl. The absolute velocity C
1
has a whirl
component C
w1
.

at the outlet
In ideal case, as shown in Figure (c), air
leaves the impeller tip at an angle of 90
0
.
Hence, C
w2
= U
2
. But in actual case due to slip
between the impeller and the fluid, C
w1
is
somewhat less than U
2
as shown in Figure
(d).

inlet
outlet

Radial Compressors

Slip Factor

As shown in the figure, due to slip the actual fluid does not follow the blade shape.
Slip (o) is, therefore, defined as,

For radial vane impellers, a relation for slip is given by Stanitz,

where, n is the number of vanes.

Assume, o y 0.9 for n value 19 to 21.

2
'
2
w
w
C
C
= o

Radial Compressors

Energy Transfer (P
t
)

From Eulers equation, the energy transfer per unit mass flow rate is given by,

considering velocity triangle (a)

Considering velocity triangle (c), C
w2
= U
2
and with slip the theoretical energy transfer
is given by,

=
c
t
W
m
P
inlet outlet

Radial Compressors

Energy Transfer (P
t
)

In a real fluid, some of the power supplied by the impeller is used in overcoming
losses that have a breaking effect on the air carried by the vanes. These include
windage, disk friction, and casing friction losses. To take into account these losses, a
power input factor () , which is the ratio of the actual to theoretical energy transfer, is
introduced. This factor typically takes values between 1.035 and 1.04. Thus the actual
work done on the air becomes,

From Mollier Chart, the stagnation or total
temperature equivalent of work done on
the air is given by,

( Refer:- Reference-1 page 68 - 75 )


Radial Compressors

Energy Transfer (P
t
)

The compressor isentropic efficiency (q
c
) is defined as,

T
03
= T
03ss

Hence,

And,

Note:- The tip speed ratio (U
2
) is about 460 m/s.
Class work

1. Write your own observation and conclusion on the derived relation for .


Radial Compressors

Effect of impeller blade shape on performance

There are three types of blade shapes as shown in the figure.

a) Backward-curved blades (|
2
<90
0
):-

From this equation one can observe that, as the mass flow rate increases energy
or power transfer decreases.
A g
U m
g
U
P Hence
A
m
C where
g
C U U
P and
g
C U
P equation s Euler From
t
a
a
t
w
t
|

|
2 2
2
2
2
2 2 2 2
2 2
cot
,
,
) cot (
,
, '
=
=
=
=

Radial Compressors


b) Backward-curved blades (|
2
= 90
0
):-

From this equation one can observe that, as the
energy or power transfer remains constant.

c) Forward-curved blades (|
2
> 90
0
):-

As the mass flow rate increases energy or power transfer also increases.
A g
U m
g
U
P Hence
A
m
C where
g
C U U
P and
g
C U
t
a
a
t
w
t
|

|
2 2
2
2
2
2 2 2 2
2 2
cot
,
,
) cot (
,
, '
+ =
=
=
=
t cons is
g
U
P
A g
U m
g
U
P Hence
A
m
C where
g
C U U
P and
g
C U
t
t
a
a
t
w
t
tan
0 cot
cot
,
,
) cot (
,
, '
2
2
2
2 2
2
2
2
2 2 2 2
2 2
=
= =
=
=
=
|
|

|

Radial Compressors


In the case of backward-curved blades or vanes, the maximum efficiency occurs in the
region of maximum power. If the flow rate increases beyond the design point, the
power starts to decrease. This keeps the motor to operate safely and this
characteristics is called self-limiting characteristics. Whereas in the case of radial
and forward-curved blades or vanes, as the flow rate increases the power also tend to
increase even beyond the design point. This is not only make the operation costly but
also damage the motor. But, designers may sometimes prefer these two types of
shapes to get some performance advantage as compared to backward-curved blades.

Compressibility effects

If the relative velocity of a compressible fluid reaches
the speed of sound in the fluid, separation of flow
causes excessive pressure losses and cyclic loading on
the impeller due to eddy or shock wave formation. It is,
therefore, necessary to control the Mach number at a
certain points in the flow to mitigate the problem. The
Mach number at the impeller inlet must be less than
unity. This is possible by reducing the relative velocity at
inlet by introducing a guide vane as shown in the figure.
inlet

Radial Compressors

Compressibility effects
Actually, reducing the relative velocity at inlet causes the tangential velocity of the
absolute velocity to increase. This in turn decreases the work capacity of the
compressor.

Mach number in the diffuser
The absolute velocity of the fluid becomes a maximum at the tip of the impeller.
Assuming a perfect gas, the Mach number at the impeller exit M
2
can be written as:

However, it has been found that as long as the radial velocity component (C
r2
) is
subsonic, Mach number greater than unity can be used at the impeller tip without loss
of efficiency.
High Mach number at the inlet causes high stagnation pressure. This leads to a
variation of static pressure and is transmitted upstream in a radial direction through
the vaneless space. The end result will be exerting a cyclic type of load on the
impeller. This in turn lead to early fatigue and failure on the impeller.


Radial Compressors

Characteristics of a Radial Compressor
The performance of compressible flow machines usually be described in terms of the
groups of variables derived in dimensional analysis ( Refer:- Rference-1 on Page 62).
These variables are dependent on other variables such as the condition of pressure
and temperature at the compressor inlet and physical properties of working fluid. To
study the performance of a compressor completely, it is necessary to plot
against the mass flow parameter for a fixed speed intervals of .

The figure below shows the theoretical characteristics of a Centrifugal Compressor.

Consider a valve is placed in the delivery line
of a compressor running at constant speed.
Suppose at the beginning the valve is fully
closed. The pressure ratio then will have
some value as indicated by point A. This
pressure ratio is available from vanes moving
the air about in the impeller. The pressure
head so developed is called shut off head.

Radial Compressors


Now, suppose that the valve is opened and
air flow begins. The diffuser contributes to the
pressure rise. The pressure ratio increases
and the maximum pressure occurs at point B.
But the compressor efficiency at this
pressure ratio will be below the maximum
efficiency. Point C indicates the further
increase in mass flow, but the pressure is
dropped slightly from the maximum possible
value. This is the design mass flow rate
pressure ratio as efficiency is maximum.
Further increase in mass flow will decrease the pressure ratio until point D. This
point indicates that the pressure rise is zero. At this point all the power absorbed is
used to overcome the internal friction and thus the compression efficiency is zero.
However, the actual curve is different from this ideal curve shown in the figure due
to chocking, surging and stall.


Radial Compressors


Choking:- When the velocity of fluid in a passage reaches the speed of sound at
any cross-section, then the air ceases to flow and the process is called chocking.
Choking may occur at the inlet, at the impeller or at the diffuser.

Surging:- The phenomenon of a momentary increase in the delivery pressure
resulting in unsteady, periodic and reversal flow through the compressor is called
surging. Surging may lead to failure of the compressor parts.

Stall:- The phenomenon of a reduction in mass flow rate through the blade passage
at higher angle of incidence is known as stall. This phenomenon may lead to
surging.


Radial Compressors

Energy transfer by the impeller to the fluid (air)

A radial compressor is a dynamic type compressor and it works on the principle of
forced vortex flow ( Refer:- Fluid mechanics ). When a certain mass of fluid is rotated
by an external torque, the rise in pressure head of liquid takes place. The rise in
pressure head ( H
p
) at any point of the rotating liquid is proportional to the square of
tangential velocity ( v ) of the liquid at that point.

g
r
g
v
H head pressure The
p
2 2
) (
2 2 2
=
= =
Thus at the outlet of the impeller where
radius is more, the rise in pressure is more
and the liquid will be discharged at the
outlet with a high pressure head.


Radial Compressors

In case of radial (centrifugal) compressors, work is done by the impeller on the
fluid (air). The expression for work done by the impeller on the air is obtained
by drawing velocity triangle at inlet and outlet of the impeller in a similar way as
for a centrifugal pump.
Velocity diagram

Radial Compressors

As shown in the velocity diagram, the angle between v and u is called o and
the angle between w and u is called |. The difference between the absolute
velocity v and the relative velocity w is also illustrated.
Velocity diagrams
Inlet
outlet

Radial Compressors

Ideal Head Equation
The equation which forms the basis of pump, compressor and blower design is
based on the following assumptions:
The fluid leaves the impeller passages tangentially to the vane surfaces or
there is a complete guidance of the fluid at the outlet and the fluid is
assumed to be frictionless, non-turbulent, etc.
The impeller passages are completely filled with actively flowing fluid at all
times.
The velocities of the fluid at similar points on all the flow lines are the same.

The ideal total head developed by the impeller based on these assumptions is
called Euler head and designated by H
E
and is given by,

Note:-The deviation of actual conditions from these assumptions will be
considered later.
.
.
. ,
2
1
2 1
velocity absolute in change to due dif f user the in head pressure the is H
velocity relative in change to due impeller the in head pressure the is H
f orce l centrif uga to due impeller the in head pressure the is H Where
H H H H
d
i
i
d i i E
+ + =

Radial Compressors

The Pressure Head in the impeller due to centrifugal force (H
i1
)
Consider a closed container filled with fluid (air), as shown in the figure, is
rotated at constant speed about its axis. The motion is transmitted to the fluid
by its viscosity until the angular velocity = of the fluid is the same as that of the
container.

Rotating container filled with fluid
To determine the pressure distribution
within the fluid, consider a very small fluid
element having a width b, thickness dR and
circumferential length Rd| rotating with an
angular velocity =. The centrifugal force
acting on the particle is,

The pressure increment due to this force
between R and R+dR is,

dR d R b dF Hence
dR Rd b dm Where R dm dF
| =
| =
2 2
2
,
,
=
= =
dR R
Rd b
dR d R b
dA
dF
dp
2
2 2
=
|
| =
= = =

Radial Compressors

The Pressure Head in the impeller due to centrifugal force (H
i1
)
Rotating container filled with fluid
Integrating between the radii R
1
and R
2

gives the total pressure,

g
u u
H H H
H H
g
p p
but
g
u u
g
p p
Hence
u R and
R R
p p
i p p
p p
2
,
2
,
,
2
2
1
2
2
1 1 2
1 2
1 2
2
1
2
2 1 2
2 2 2
2
1
2
2 2
1 2
= =
=

=
=
|
|
.
|
\
|
=

= =

Radial Compressors

The Pressure Head in the impeller due to change in relative velocity (H
i2
)
Consider the passage through the impeller at radius r having a cross-section da
as shown in the figure. Let the small element of area da moves a small
distance ds in time dt. Hence,

g
w w
g
p
H
w w
dw w dp p
outlet and inlet between equation the g Integratin
dw w
w
dt
ds
but dw
dt
ds
dp
da by all dividing and
dt
dw
ds da dp da dF
i
2
2
), 2 ( ) 1 (
,
2
2
2
1
2
2
2
2
2
2
1
2
1
= =
|
|
.
|
\
|
=
= =
=
= =
|
.
|
\
|
= =
} }

Radial Compressors

The Pressure Head in the diffuser due to change in absolute velocity (H
d
)
Inside the diffuser, the dynamic pressure or velocity head is converted into
static pressure head. The velocity in the discharge pipeline is almost the same
as the velocity in the suction pipe.
Consider a fluid element of area da moving through the diffuser vanes a
distance ds in time dt as shown in the figure.

g
v v
g
p
H
v v
dv v dp p
outlet and inlet dif f user between equation the g Integratin
dv v
v
dt
ds
but dw
dt
ds
dp
da by all dividing and
dt
dv
ds da dp da dF
d
2
2
), 1 ( ) 2 (
,
2
1
2
2
2
2
2
1
2
1
2
1
= =
|
|
.
|
\
|
=
= =
=
= =
|
.
|
\
|
= =
} }

Radial Compressors

The Ideal Total Head (H
E
)
( ) ( ) ( )
( )
( )
g
v u
H
inlet radial having impeller f or and
g
v u v u
H
v v and v v but
g
v u v u
H
equation above the in equations these Inserting
v u v u w
v u v u w
impeller the of outlet and inlet at diagram velocity the From
g
v v w w u u
g
v v
g
w w
g
u u
H H H H
u
E
u u
E
u u
E
d i i E
2 2
0
1
1 1 2 2
2 2 2 1 1 1
1 1 1 2 2 2
2 2 2
2
2
2
2
2
2
1 1 1
2
1
2
1
2
1
2
1
2
2
2
2
2
1
2
1
2
2
2
1
2
2
2
2
2
1
2
1
2
2
2 1
), 90 (
cos cos ,
cos cos
,
cos 2
cos 2
,
2
2 2 2
=
=
=
= =
=
+ =
+ =
+ +
=
=
+ + =
o
o o
o o
o
o

Radial Compressors

The Ideal Power (P) and Torque (T)
Nm in v R v R Q
v R v R Q
v u v u Q
P
T
HP in
v u v u Q
kW in
v u v u Q
W in
g
v u v u
g Q
gH m P
u u
u u
u u
u u
u u
u u
E
) (
) (
) (
746
) (
1000
) (
) (
1 1 2 2
1 1 2 2
1 1 2 2
1 1 2 2
1 1 2 2
1 1 2 2
=
=
=
=
=
=
=
=

Radial Compressors

Degree of Reaction ()
Degree of reaction is the ratio of the static pressure head rise in the impeller (H
i1
) to
the total head rise (H
E
).

2
2
2
1
2
2
2
2
2
1
2
2
2
2
2
2
1 2
2 1
1 1
0
2 2
2
1
2
2
1
,
,
; 90
,
2
1
,
1
u
u u r
r
r r
r
u
E d
E
d
E
d E
E
i
v v v and
v v v v v
triangle velocity outlet From
v v
v v
v v
inlet radial For
v u
v v
H and H f or ng Substituti
H
H
H
H H
H
H
=
+ = + =
=
=
= =
=
=
= =
o
|
|
.
|
\
|
+ =
=
=
=
=
2 2
2
2
2
2
2
2
2
2 2
2
2
2 2
2
2
tan
1
2
1
2
tan
1
tan
,
2
1
2
1 ,
|
u
v
u
v
u
v
u v
triangle velocity outlet the From
u
v
v u
v
Hence
r
r
r
u
u
u
u
Question:- What do you observe from
this relation ?

Radial Compressors


From this relation one can observe that,
a) For |
2
= 90
0
, the degree of reaction = , as |
2
= . This means that the
pressure generated by the impeller and diffuser will be the same.

b) For |
2
having values between 0
0
and 90
0
, the degree of reaction is more than
half. This means is that the pressure generated by the impeller is more than in
the diffuser.
c) When the degree of reaction is one.

|
|
.
|
\
|
+ =
2 2
2
tan
1
2
1
|
u
v
r
2
1
. ) ( , 1 ,
0
, tan
tan
,
tan 1
tan
2
2 2
2
2
2
2
2
2
2 2 2
2
2
2
2 2
2
zero is H head total ideal the f or Thus
v
u v
u
g
u
H
of value the ng Substituti
v
u
g
u
g
v u
H Then
u
v
or
u
v
E
r
r
E
r u
E
r r
=
=
|
|
.
|
\
|
=
|
|
.
|
\
|
= =
= =
|
|
|
|

Radial Compressors


d) When = 0, there is no static pressure change in the impeller. The energy transfer
is entirely due to the change of absolute velocity in the diffuser. In other words,
the impeller has equi-pressure blades or impulse blades. Machines having such
an impeller is known as an impulse machines. The blades of impulse impellers
are forward curved and the blades of reaction impellers are backward curved as
shown in the figure. In order to generate more pressure in the impeller, the angle
|
2
should be nearly zero. For the same discharge reaction machines have larger
outlet impeller diameter or high rotational speed than impulse machines.


Radial Compressors

Actual Head or Power developed by the impeller

It has been discussed that the ideal head or power developed by the impeller is
derived based on the listed assumptions. Some of these assumptions were if the
fluid is frictionless, non-turbulent, etc. In this section the factors which causes these
deviations will be discussed.

Factors which causes deviation of actual machines from the ideal
a) Circulatory flow:- If a closed container is filled with fluid and rotated about an
axis, the fluid tends to rotate in opposite direction relative to the container due to
its inertia. It is apparent that the fluid in contact with the side A of the container is
at a higher pressure than at B, as the container is exerting a pressure on the fluid
on that side while it is being accelerated as shown in the figure.


Radial Compressors


Factors which causes deviation of the actual machines from the ideal
This implies that the velocity at B is higher than A according to Bernoullis
equation. The amount of this circulatory flow depends on the shape of the
container. It will be less if is long and narrow. In a rotating impeller two flows take
place simultaneously; namely, the flow of fluid through the passage and the
circulatory flow as shown in the figure. The resultant effect for a given flow is to
cause the fluid to leave the wheel at an angle less than the vane angle and to
increase the guide blade angle. This effect is illustrated in the velocity diagram
where the dotted lines represent the ideal velocity diagrams.


Radial Compressors


b) Effect of Finite Number of Blades:- Taking finite number of blades of impeller,
the Ideal or Euler Head (H
E
) is changed as follows due to changes in velocity
diagram.

Where, c is the correction factor for finite number of blades. It is sometimes known as
blade efficiency q
blade.

( )
E
u
E
E
u u
E
H
g
v u
H
H
g
v u v u
H
c
o
c
= =
=
=
=
'
2 2 '
0
1
'
1 1
'
2 2 '
), 90 (

Radial Compressors


c) Shock loss:- The usual assumption made in designing such a machine is that
the fluid enters the impeller vanes radially so that o
1
= 90
0
. As the fluid
approaches the vane inlet, it comes in contact with the rotating impeller. This
tends to cause a mismatch between the blade angles and the inlet flow
directions specially at high flow rates. This causes the inlet vane angle to be
larger as shown in the figure. The net effect is to reduce the head and hence the
power to be transferred to the fluid due to the presence of v
u1
.

( )
g
v u
H
g
v u v u
H
u
E
u u
E
2 2
0
1
1 1 2 2
), 90 (
=
=
=
o

Radial Compressors


d) Fluid and Disc or Surface Friction:- This is due to the friction that exists within
the fluid and between the fluid and the surfaces of the impeller and the diffuser.

e) Turbulence:- The type of flow existing in a pump or a compressor or a blower is
turbulent as the determined from the Reynold number. The effect of turbulence is
also to reduce the machine performance.

f) Leakage:- This is due to the loss of fluid during operation. The effect of this
leakage loss is to reduce the discharge capacity.

The actual head is called the manometric head (H
m
) is, therefore, given by:

.
sin
2 2
radial is velocity f low inlet if H
g
v u
H H
g ca and impeller the in Losses head Euler H
L
u
L E
m
=
=
=
Video-5
Video-6
Video-7


Radial Compressors

Efficiencies
The actual head developed by a compressor is less than the ideal or Euler Head (H
E
)
due to various losses. In designing such machines it is usually difficult to predict
these losses. Engineers or Designers prefer to use empirical relations and/or
efficiencies to consider the effects of these losses in the performance of the
machine.
a) Circulatory flow coefficient (q
):- the ideal or Euler Head (H

E
) is derived by
considering an impeller with infinite number of vanes so as to avoid circulatory
flow. The effect of circulatory flow is to reduce v
2
as shown in the velocity diagram.

2
'
2
u
u
v
v
=
q
As v
2
reduces, v
u2
also reduces and hence
the head will reduce.

Hence, the circulatory flow coefficient (q
) is
given by,
( )
g
v u
H
g
v u v u
H
u
E
u u
E
2 2
0
1
1 1 2 2
), 90 (
=
=
=
o

Efficiencies

b) Overall Head Coefficient (|):- the head developed by a turbomachine due to
forced vortex flow has been derived as,

But, due to the shape of the vanes and the casing the ratio can not be unity.
Hence, in actual case the ratio 1 is replaced by |.

From this equation, D
2
can also be determined.

c) Hydraulic efficiency (q
H
):- the actual head or manometric head (H
m
) developed
by the machine is less than the ideal or Euler Head (H
E
) due to mainly friction and
turbulence losses. To consider this effect, a hydraulic efficiency (q
H
) is related as,

) ( ) (
1 1 2 2 1 1 2 2 u u
m
u u
m
t
out
E
m
H
v u v u
gH
v u v u m
gH m
P
P
H
H
= = =
q
. , 1
2 2
2
2
2
head off Shut the is H Where
gH
u
or
g
u
H = =
gH
u
2
2
= |
N
H
N
H
gH D
N D
gH u
gH
u
|
|
t
t
| |
5 . 84
2
60
60
2
2
2
2
2
2
=
=
= = =

Efficiencies

d) Volumetric efficiency (q
V
):- the volumetric efficiency is a measure of the amount
of leakage. It is given by,

e) Mechanical efficiency (q
m
):- It is the ratio of the power at the impeller (P
t
) to the
power of the the shaft (P
s
).

f) Overall efficiency (q
o
):- It is the ratio of the fluid power (P
out
) to the power of the
prime mover (P
in
).

. ,
. arg ,
leakage the is Q and
rate f low e disch the is Q Where
Q Q
Q
L
L
V
+
= q
=
=
q
T P and
T
v u v u m
v u v u m P Where
P
P
s
u u
u u t
s
t
m
=
=
= =
,
) (
) ( ,
1 1 2 2
1 1 2 2
m V H
in
m
m out
in
out
o
P
gH Q
gH m P Where
P
P
q q q
q
= =
= =
,

Reading Assignment
Refernce-1 ( Turbomachinery design and theory)
Page 187 273
Class work

1. 10 kg/s of air is to be compressed in centrifugal compressor of the single sided impeller
type. The ambient air conditions are 1 bar and 20
0
C. The compressor runs at 20000 rpm,
has isentropic efficiency of 80 % and compresses air from 1 bar static pressure to 4.5 bar
total pressure. The air enters the impeller eye with a velocity of 150 m/s with no prewhirl.
Assuming that the ratio of whirl speed is 0.95, determine:
a) rise in total temperature during compression,
b) the impeller tip speed and tip diameter,
c) power required to drive to drive the compressor,
d) the external diameter of the eye, for which the internal diameter is 15 cm.
Worksheet 6-1

Preliminary Design of a Centrifugal (Radial) Pump

Example:- Design a water transport system given in Assignment 5-1.

Design procedure:
Step-1:-
Determine the specific speed of the pump (N
s
).

rpm
H
Q N
N
s
14 . 13
35
017 . 0 1450
4
3
4
3
=
=
=

% 65 ~
o
q
Estimate the pump efficiency (q
o
)
from the curve for a specific speed
of 13.14 rpm and discharge of 1020
LPM (Liter Per Minute).


Step-2:-
Determine the Maximum Shaft Power (P
smax
).

This can be determined from the performance curve.

Determine shaft diameter (D
s
) using stress theory.

Q(m
3
/sec) H
p
(m) P
s
(HP) q
o
(%) H
sys
(m)
0 46.2 4.2 0 26
0.005 42.9 7 40.07 26.77
0.01 39.6 9.4 55.21 29.09
0.015 36.3 11.4 62.87 32.96
0.02 33 12.9 67.21 38.38
0.025 29.6 14 69.73 45.34
0.03 26.3 14.6 71.05 53.85
0.035 23 14.8 71.44 63.91
0.04 19.7 14.6 70.97 75.52
MPa stress
shear e permissibl the is and
N
P
T Where
T
D
s
s
s
s
s
s
30
,
30
,
16
max
3
~
= = t
t t t


Step-3:-
Determine the Hub diameter (D
H
) and the diameter of suction flange (D
su
).

a) Hub diameter (D
H
) can be assumed 1 cm larger than the shaft diameter.

b) Suction flange diameter (D
su
).

Step-4:-
Determine Impeller dimensions.

a) Impeller eye diameter (D
o
).

cm D D
s H
1 + =
s m velocity suction is V Where
V
Q
D
su
su
su
/ 3 ,
4
~ =
t

2
1
4
H
su
o
D
V
Q
D D + = ~
t


b) Impeller inlet passage width (b
1
).

c) Inlet vane angle (|
1
).

d) Impeller outside diameter (D
2
).

e) Impeller outlet passage width (b
2
).

Note:- Other variables and dimensions can be determined from the
velocity diagrams.
1
1
1
1 1
1
1 1 1
1
sin
85 . 0 ,
/ 25 . 0 ,
D
t Z
D
or f actor n contractio the is and
s m V velocity f low is V Where
V D
Q
b
su r
r
t
|
t
c c
c t
= ~
+ ~ =

o
r
D D and
N D
u Where
u
V
diagrams velocity the from inlet radial a For
~ = =
1
1
1
1
1
1
,
60
, tan
,
t
|
05 . 1 ,
5 . 84
2
~ = t coefficien head the is Where
N
H
D |
|
0 0
2
2 2 2
2
40 30 to assumed be may and
V D
Q
b
r
|
c t

=


Step-5:-
Design vanes of the impeller.
a) The radius of arc (), defining the shape between any two rings having radius r
a

and r
b
is given by,

b) The number of vanes (Z) is given by,

c) The thickness of vanes ( t ) can be determined from stress analysis. In actual
design a uniform thickness of 3 mm is adopted.

angle vane the is Where
r r
r r
a a b b
a b
| |
| |
=
= ,
) cos cos ( 2
2 2
2 2 1 1
2 1
1 2
1 2
,
2
) (
sin 5 . 6 | | | |
| |
= =
+
+
= and Where
D D
D D
Z


d) Plot or generate the curves of vanes.
Procedure:-
Divide the distance between the impeller internal radius r
1
and r
2
into a
number of equal parts (say 4 or 5) as shown in the figure.
For each division determine the values of r, r
a
, r
b
,

| and as shown in the
table.



Draw all concentric circles with O as center and radius r
1
,r
x
,r
Y
,r
Z
and r
2
.
Draw a radial line OJ = r
1
from the center of rotation O to the point J.
With J as center and angle OJK = |
1
and radius
1
, get point K .
With K as center and radius
1
, draw the arc JL .
Draw a line through points L and K of length
2
= LM.
With M as center and radius
2
, draw the arc LN.
Draw a line through points N and M of length
3
= NP.
With P as center and radius
3
, draw the arc NQ.
Draw a line through points Q and P of length
4
= QR.
With R as center and radius
4
, draw the arc QS.



Step-6:-
Compute data for determining the passage width.
Similarly, the following data can be obtained and the side view of the
impeller is drawn as shown.



Both the front and side views are as shown below.



Step-7:-
Design the volute.



The following relations are used in designing the volute.

718 . 2 log
,
,
. 60 30
sec
60 ,
tan ,
2
tan 2
,
2
,
,
360
.
.
:
2
tan
2
0 0
0
2 3
2 3
3
2 2
0
2
2
=
=
=
~
+ =
=
=
-
-

}
arithm natural of base base the is e
radian in measured angle the is
vane impeller the of angle vane guide the is Where e R R
by given is R f or relation The
or lines radial the with of angle an having
trapezoid be to assumed is volute the of shape tional cross basic The
and
R and R radius any between ce dis the is x Where x b b
by given is b width average The
b b
as assumed is b volute the of width base The
tongue the f rom measured angle the is Where
R
dR
b
Q
v R
neglected be to assumed are losses and slip of ef f ect The
f low spiral nearly have to assumed volute the in water The
s Assumption
t
R
R
u
t
|
o
u
u
u
| |
| o
|


The output of the mathematical relations for the volute is as shown in the
table.



Using the values in the table, the volute can be drawn as shown in the figure.



This is generally a preliminary design, but the results of a complete design is
similar to the design shown in the figures.

Video-7

Two important areas of application of thermodynamics are power
generation and refrigeration.

The devices or systems used to produce a net power output are often
called heat engines, and the thermodynamic cycles they operate on are
called power cycles.
Main application areas
of
Thermodynamics
Power cycles Refrigeration cycles
Vapor power
cycles
Gas
power cycles
Steam power plants
Nuclear power plants
Gasoline (Otto cycle) engines
Diesel (Diesel cycle) engines
Gas turbines (Brayton cycle)
Refrigerators
Heat pumps

What is a Steam Turbine ?

A Steam Turbine is a turbomachine which converts steam or vapor
(thermal) energy into mechanical energy. The so obtained mechanical
energy is used to drive a generator.

Steam power plants use steam or vapor as a working medium. Such
power plants are: coal plants, nuclear plants, or natural gas plants,
depending on the type of fuel used to supply heat to the water or steam.

The thermodynamic cycle on which such power plants operate is called
the vapor power cycle (Rankine cycle). In the vapor power cycle the
working fluid continuously vaporized and condensed. Vapor(steam) or
water is the most common working fluid used in vapor power cycle
because of its many desirable characteristics, such as low cost,
availability, and high enthalpy of vaporization.

(Refer:- Engineering Thermodynamics).
Steam turbine
Thermal
(Steam)
energy
Mechanical
energy

Main application areas of Vapor Power Cycles are in the design and
operation of Steam Power Plants.

Steam Power Plant

Principle of operation of a simple vapor power cycle (Rankine Cycle)

A simple ideal vapor power cycle (Rankine cycle) consists of four
processes.


Principle of operation of a Reheat-Regenerative vapor power cycle


Steam Turbine

Basic configuration of a Steam Power Plant


Steam Turbine


Steam Turbine

Basic configuration of a Steam Power Plant


Steam Turbine

In a steam turbine, high-pressure steam from the boiler expands in a set
of stationary blades (nozzles). The high-velocity steam from stationary
blades (nozzles) strikes the set of moving blades (buckets) as shown in
the figure.

The kinetic energy of the steam or vapor is
utilized to produce work on the turbine rotor.
Low-pressure steam then leaves the turbine
and enters into the condenser.

There are two types of steam-turbine stage
designs:
the impulse stage, and
the reaction stage.

Steam Turbine

Principles of Impulse stage-turbines

In the case of Impulse stage-turbine:
pressure change (drop) occurs across the
nozzles.
pressure drop does not occur across the
moving blades (buckets).


Steam Turbine

Principles of Reaction stage-turbines

In the case of Reaction stage-turbine:
pressure drop occurs across the stationary
blades as well as in the moving blades.


Steam Turbine

Velocity diagram


Steam Turbine

Velocity diagram


Steam Turbine

Maximum Efficiency

For supplementary notes, refer
Page 279 324

Main application areas of Gas Power Cycles are in the design and
operation of IC Engines and Gas Turbines.

Gas Turbines

IC Engines

In gas power cycles, the working fluid remains a gas throughout the entire cycle.
Spark-ignition engines, compression-ignition engines, and conventional gas turbines
are familiar examples of devices that operate on a gas power cycle. In all these
engines, energy is provided by burning a fuel within the system boundaries. That is,
they are internal combustion (IC) engines.

Principle of operation of a simple gas power cycle (Brayton Cycle)

Brayton cycle
The Brayton cycle, an ideal cycle for gas turbines, was first proposed by
George Brayton in 1870. This cycle can operate as an open cycle or as a
closed cycle.

The closed Brayton cycle composed of four internally reversible processes:
isentropic compression (1-2), constant-pressure heat addition (2-3), isentropic
expansion (3-4), and constant-pressure heat rejection (4-1). Such a cycle is
used in the combined Vapor-Power Cycle to generate electrical energy.

Principle of operation of a simple gas power cycle (Brayton Cycle)


Ideal Jet-Propulsion cycle
The ideal Jet-Propulsion cycle is a modified Brayton open cycle, used in the
design of jet propulsion systems. Gas-turbine engines are widely used to
power aircraft because they are light and compact and have high power-to-
weight ratio. Aircraft gas turbines operate on an open cycle called a jet-
propulsion cycle. The ideal jet-propulsion cycle differs from the ideal Brayton
cycle in that the gases are expanded to a pressure such that the power
produced by the turbine is just sufficient to drive the compressor and the
auxiliary equipment, such as a small generator and hydraulic pumps. That is
the net work output of a jet-propulsion cycle is zero. The gases that exit the
turbine at a relatively high pressure are subsequently accelerated in a nozzle
to provide the thrust to propel the aircraft.


Ideal Jet-Propulsion cycle
The thrust developed in a turbojet engine is the unbalanced force that is
caused by the difference in the momentum of the low-velocity air entering the
engine and the high-velocity exhaust gases leaving the engine, and it is
determined from Newtons second law. The pressure at the inlet and the exit
of a turbojet engine are identical (the ambient pressure); thus the net thrust
developed by the engine is,

The power developed from the thrust of the engine is called the propulsive
power, which is the propulsive force (thrust) times the aircraft velocity.


For supplementary notes, refer
Page 325 361
How Gas Turbines work ?
Video-1
Video-2
Video-3

What is a Wind Turbine ?

A Wind Turbine is a turbomachine which converts wind (fluid) energy into
mechanical energy. The so obtained mechanical energy is used to drive a
pump or a generator.

Wind energy is a renewable, pollution free and cheap energy source like
those of water and solar energies.
Wind is air in motion, caused by uneven heating of the earth by the sun.
This creates difference in densities and leads to a mass movement of air
from one location to the other.

Wind Turbines may be classified as Vertical-Axis, Horizontal-Axis, Fast-
Running, Slow-Running, etc.

Wind turbine
Wind
energy
Mechanical
energy

Component parts of a Horizontal-Axis, Fast-Running Wind Turbine

A
Detail A
Class work
1. Write the principle of operation.


Principle of operation
The figure shown below is the cross-section of the rotor blade called an
aerofoil. It is similar to the aerofoil of an aircraft.

When air is moving over the surface of
an aerofoil, a pressure difference is
created ( Refer:- Bernoullis Principle ).
This pressure difference creates a
resultant force F. If this force is
decomposed into perpendicular and
parallel to flow direction, results Lift L
and Drag D.

Determination of maximum power available from the wind

. ,
. ,
2
1
0
2
0
velocity flow air is V and
air of mass is m where mV KE =
As it is already defined, wind is
air in motion. Since air has
mass and a certain velocity,
then it has got a kinetic energy
given by:

Question:- Is it possible to get
such power in a real machine ?
I II IV III
p
p
2
0
2
1
, ) (
V m
t
KE
P
by given is P Power Wind
wind
wind
= =
3
0
0
2
1
,
.
,
,
AV P Hence
air of density is
rotor the of area swept is A Where
AV m but
a wind
a
a
=
=


The answer is No. Because,
such power can only be
obtained, if there would be
100% extraction. This means,
the moving air stops and gives
up all its energy. Since the air
has to keep on moving for the
wind turbine to work, the power
that can be obtained from the
wind should be less than this
maximum amount. This can be
related by introducing a power
coefficient (C
p
).

This implies that there is an
optimum value of the velocity
of the wind u
1
for which the
power extraction is maximum.
I II IV III
p
p
3
0
2
1
AV C P
P
P
C
a p mech
wind
mech
p
= =


The maximum mechanical
power has a direct relationship
with C
pmax
. C
pmax
is known as
the Betzs coefficient and is
obtained from the following
assumptions:
flow is compressible,
flow is non-viscous,
flow is entirely axial.

Hence,
I II IV III
p
p
) 2 . 11 ..( .......... .......... .......... .......... ) ' ( ,
1 11 . .......... ) ( ) (
: '
1 0 1 0
A p p F Also
) . ( u V Au u V m F
Motion of Law Second s Newton From
th
a th
=
= =
) 3 . 11 ( ........ .......... ..........
2 2
: ) ( ) ( '
2 2
0 0
g
u
g
p
g
V
g
p
II and I between Equation s Bernoulli Applynig
a a
+ = +

) 4 . 11 ( .......... .......... ..........
2 2
'
: ) ( ) ( '
2
1 0
2
g
u
g
p
g
u
g
p
IV and III between Equation s Bernoulli Applynig
a a
+ = +



I II IV III
p
p
) 5 . 11 ( .. .......... .......... .......... ) (
2
1
'
: ) 4 . 11 ( ) 3 . 11 (
2
1
2
0
u V p p
and Equations From
a
=
) 6 . 11 ( .. .......... .......... .......... ) (
2
1
: ) 2 . 11 ( int ) 5 . 11 (
2
1
2
0
u V A F
o Equations ng Substituti
a th
=
) 7 . 11 ........( .......... .......... .......... .......... ) (
2
1
) ( ) (
2
1
: ) 1 . 11 ( ) 6 . 11 (
1 0
1 0
2
1
2
0
u V u
u V Au u V A
and Equations Equating
a a
+ =
=
Which shows that the air
velocity u at the rotor is
equal to the mean of the
upstream and downstream
velocities V
0
and u
1
.



I II IV III
p
p

Axial Induction Factor a
The axial induction factor a
is a measure of the decrease
in axial air velocity through the
turbine .

The power extracted by the
rotor is the difference between
the power of the wind up-
steam and down-stream of the
rotor. Hence, P
mech
is given by,
) 8 . 11 ...( .......... .......... .......... .......... ..........
0
) 1 ( V a u =
) 9 . 11 ( .......... .......... .......... .......... .......... ) 2 1 (
) (
2
1
) 1 (
: ) 7 . 11 ( ) 8 . 11 (
0 1
1 0 0
V a u
u V V a
and Equations Equating
=
+ =
) 10 . 11 ( ...... .......... ) ) 1 ( 4 (
2
1
: ,
) (
2
1
2 3
0
1
2
1
2
0
a a V A P
gives u and u f or ng Substituti
u V u A P
a mech
a mech
=
=


I II IV III
p
p

Maximum power is obtained
when C
p
attains its maximum
value. Hence, Cpmax can be
obtained by differentiating the
above equation,

2
3
0
2 3
0
) 1 ( 4
2
1
) ) 1 ( 4 (
2
1
a a
AV
a a V A
P
P
C
a
a
wind
mech
p
=
=
=
3
1
0 ) 1 ( 4 (
2
= = = a a a
da
d
da
dC
p
3
))
3
1
2 ( 1 (
) 2 1 (
), 9 . 11 ( sin
max
0
0
0 1
1
V
V
V a u
equqtion g u obtained be can power
imum the to ing correspond u of value The
=
=
=


I II IV III
p
p

The maximum mechanical
power is given by,

Power Density (P
D
)
The ratio of mechanical power
(P
mech
) to swept area (A) of
the rotor.

Assignment:- Plot the curves
of P
D
versus V
0
.

27
16
)
3
1
1 )(
3
1
( 4
) 1 ( 4
2
2
max
=
=
= a a C
p
)
2
1
(
27
16
3
0 max
AV P
a mach
=
)
2
1
(
27
16
3
0
V
A
P
P
a
mech
D
= =

Fluid Couplings and Torque Converters are power transmitting systems. Power is
transmitted between the driving and driven shaft usually by mechanical means like
gear drive. In such drives the shock loads and vibration are transmitted from one side
to the other which is not desirable. Also in gear drives there is a speed fluctuation. In
certain cases where the driven machine has a large inertia, the driving prime mover
like electric motor will not be able to provide a large starting torque. Instead of the
mechanical connection if fluids can be used for such drives, high inertia can be met.
Also shock loads and vibration will not be transmitted. Smooth speed variation is also
possible.

There are two types of power transmitting devices using a fluid.
i) Fluid Coupling
ii) Torque Converter or Torque Multiplier

i) Fluid Coupling

A sectional view of a Fluid Coupling is as shown in the
figure. In this device the driving and driven shafts are not
rigidly connected. The drive shaft carries a pump with
radial vanes and the driven shaft carries a turbine runner.
Both of these are enclosed in a casing filled with oil of
suitable viscosity. The pump accelerates the oil by
imparting energy to it.

i) Fluid Coupling

The oil is then directed to hit the turbine vanes where
energy is absorbed and the oil is decelerated. The
decelerated oil now enters the pump and the cycle is
repeated. There is no flow of fluid to or from the outside.
The oil transfers energy from the drive shaft to the driven
shaft. As there is no mechanical connection between the
shafts, shock loads or vibration will not be transmitted
from one to the other. The turbine will start rotating only
after a certain level of energy is picked up by the oil from
the pump.

ii) Torque Converter
In case of Fluid Coupling the torque on the driver and
driven members are equal. The application is for direct-
drive machines. But there are cases where the torque
required at the driven member should be more than the
torque on the driver or in other words, the speed required
at the driven member should be less than the speed on
the driver. Such an application is widely used in
automobile transmission systems.

One advantage of Torque Converter is that the speed
variation is smooth as compared to mechanical
connection (Gear Drive) as shown in the figure.

A sectional view of Torque Converter is as shown in the
figure. Torque Converter consists of three elements:
Pump impeller, Turbine runner and a Guide wheel or
Stator.
The pump is connected to the drive shaft. The guide
vanes are fixed. The turbine runner is connected to the
driven shaft. All the three are enclosed in a casing filled
with a suitable transmission oil. When the engine starts to
operate, mechanical energy from the crankshaft is
transmitted to the driven shaft and then to the pump
impeller. The impeller then imparts energy to the oil.


Due to centrifugal force, the oil moves out of the impeller
to strike the turbine runner. In doing so the fluid imparts
momentum to the turbine and the turbine together with the
driving shaft starts to rotate and transmit the power to the
planetary gear box. The oil after being expended its
energy in the turbine runner made to flow back to the
pump impeller through a stator or guide vane. This
produces a reactive torque on the pump which increases
the torque to be transmitted.

Pump Impeller Turbine Runner
Automatic transmission
Video-4


Automatic transmission
Manual transmission

End
of
the Course

Final Examination !

Turbomachinery (MEng 3202) Part II

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Melesse Haile

Adama University Melesse Haile (Asst. Professor)

Adama University Melesse Haile (Asst. Professor)

Adama University Melesse Haile (Asst. Professor)

Adama University Melesse Haile (Asst. Professor)

):- the ideal or Euler Head (H

Adama University Melesse Haile (Asst. Professor)

Adama University Melesse Haile (Asst. Professor)

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