压缩机首级旋转失速的计算分析
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摘要
离心压缩机在我国国民经济建设中数量多,应用广,在石油化工、冶金业等领域发挥着极其重要的作用。在大多数情况下,离心压缩机在整个运行系统的工作过程中扮演着核心角色,压缩机的平稳运行是整个生产线安全生产的重要保障。离心压缩机在实际运行中经常会在非设计工况下运转而伴随着旋转失速等非稳态流的发生,旋转失速等现象的存在对离心压缩机的稳定运行构成极大的威胁,很多时候它们的存在给机组的安全运行带来严重的危害甚至导致灾难性的后果。所以,对压缩机旋转失速机理的认识和研究,进而实现对其进行控制,对于提高其性能和可靠性具有重要意义。
本文针对实际运行过程中某压缩机首级叶轮叶片断裂的问题,以该机组低压缸首级部分内部流场为研究对象,利用CFD软件NUMECA搭建一个基于完整真实的三维几何结构的离心压缩机内部流场数值分析平台,选用实际运行工况进行计算,使用三维造型软件Pro/E建立整个首级流场的物理模型,计算分析了包括进气室、进气导叶和首级叶轮及无叶扩压器在内的完整流场,发现由于进气室和进口导叶的设计可能存在一定的问题,叶轮进口的来流是不均匀的,导致首级叶轮前的流场畸变,从而诱发压缩机首级叶轮失速,引起叶轮内部的压力场在较大范围内变化,进一步的力学分析结果表明这种压力脉动可能是造成叶轮叶片振动、疲劳断裂的原因,通过进行非定常流动计算,动态模拟了旋转失速的发展传播过程,得到了比较真实的旋转失速的压力脉动情况,以此更加直观地证明了旋转失速是导致叶轮叶片疲劳破坏的直接原因,为工厂实际问题的解决提供了有利的科学依据。
Centrifugal compressors play an important role in national economy construction for its broad usage in many important industries, such as the petrochemical industry, metallurgy, etc. In many cases, centrifugal compressors are the key equipments in the whole cooperation. The smooth operations of the centrifugal compressors are vital to the production lines. One particular phenomenon that threatens the safe running of the compressor is the rotating stall in the compressor. In many cases, rotating stall had caused great damages with serious consequence. The study of the rotating stall is of great importance for the prevention of the rotating stall in the design stage or the control of the rotating stall during the operation.
The fracture problem of the first stage impeller blades in one centrifugal compressor was studied in this thesis by analysis the flow field in the inlet camber and the first stage. The numerical analytic platform was based on the CFD commercial software NUMECA and the real 3-D geometry model of the compressor. The boundary condition was specified by the actual operating parameters. Simulation results indicate that the flow distortion at the impeller inlet is induced by the poor design of the inlet camber and the inlet guide vane. The flow distortion upstream of the impeller inlet excitateds the rotating stall so that the pressure field oscillated violently. Based on the simulation results of the pressure field, further mechanic analysis proved that the vibration and fracture failure of the impeller blades is most likely caused by this pressure fluctuation. Unsteady flow simulation was carried out and the propagation and development of the rotating stall cell was observed clearly. The actual pressure fluctuation on the blade surface was obtained for accurate mechanic analysis. The study may provide a guideline in solving the fracture problem of the impeller blades.
本文针对实际运行过程中某压缩机首级叶轮叶片断裂的问题,以该机组低压缸首级部分内部流场为研究对象,利用CFD软件NUMECA搭建一个基于完整真实的三维几何结构的离心压缩机内部流场数值分析平台,选用实际运行工况进行计算,使用三维造型软件Pro/E建立整个首级流场的物理模型,计算分析了包括进气室、进气导叶和首级叶轮及无叶扩压器在内的完整流场,发现由于进气室和进口导叶的设计可能存在一定的问题,叶轮进口的来流是不均匀的,导致首级叶轮前的流场畸变,从而诱发压缩机首级叶轮失速,引起叶轮内部的压力场在较大范围内变化,进一步的力学分析结果表明这种压力脉动可能是造成叶轮叶片振动、疲劳断裂的原因,通过进行非定常流动计算,动态模拟了旋转失速的发展传播过程,得到了比较真实的旋转失速的压力脉动情况,以此更加直观地证明了旋转失速是导致叶轮叶片疲劳破坏的直接原因,为工厂实际问题的解决提供了有利的科学依据。
Centrifugal compressors play an important role in national economy construction for its broad usage in many important industries, such as the petrochemical industry, metallurgy, etc. In many cases, centrifugal compressors are the key equipments in the whole cooperation. The smooth operations of the centrifugal compressors are vital to the production lines. One particular phenomenon that threatens the safe running of the compressor is the rotating stall in the compressor. In many cases, rotating stall had caused great damages with serious consequence. The study of the rotating stall is of great importance for the prevention of the rotating stall in the design stage or the control of the rotating stall during the operation.
The fracture problem of the first stage impeller blades in one centrifugal compressor was studied in this thesis by analysis the flow field in the inlet camber and the first stage. The numerical analytic platform was based on the CFD commercial software NUMECA and the real 3-D geometry model of the compressor. The boundary condition was specified by the actual operating parameters. Simulation results indicate that the flow distortion at the impeller inlet is induced by the poor design of the inlet camber and the inlet guide vane. The flow distortion upstream of the impeller inlet excitateds the rotating stall so that the pressure field oscillated violently. Based on the simulation results of the pressure field, further mechanic analysis proved that the vibration and fracture failure of the impeller blades is most likely caused by this pressure fluctuation. Unsteady flow simulation was carried out and the propagation and development of the rotating stall cell was observed clearly. The actual pressure fluctuation on the blade surface was obtained for accurate mechanic analysis. The study may provide a guideline in solving the fracture problem of the impeller blades.
引文
[1]黄钟岳,王晓放.透平式压缩机.北京:化学工业出版社,2004.
[2]侯安平,熊劲松.轴流压气机尾流撞击效应机理的数值模拟.北京航空航天大学报,2005,31(9).
[3]蒋康涛,徐刚,黄伟光.低速轴流压气机旋转失速的二维数值模拟[J].工程热物理学报,2004,24(6):935-938.
[4]唐狄毅.叶轮机非定常流.国防工业出版社,1992.
[5]邹正平,徐力平.叶轮机三维非定常流动数值模拟的研究.北京:北京航空航天大学,2001,22(1):1-5.
[6]Emmons H W,Pearson C E,Grant H P.Compressor Surge and Stall Propagation Trans.ASME,Vol.77,1955.
[7]Oreitzer E M,Moore F K.A theory of post-stall transients in axial compressor:part 2:Application[J]1 Journal of engineering for gas turbines and Dower,1986.
[8]蒋康涛.低速轴流压气机旋转失速的数值模拟研究:(博士学位论文).北京:中国科学院工程热物理研究所,2004.
[9]Takata R,Naganon S.Nonlinear Analysis of Rotating Stall.Journal of ASME Engineering for Power,OCt.1972:PP.279-293.
[10]Burwell A E,Patterson G T,Dynamic Engine Behavior During Post Surge Operation Of a Turbine Engine,AIAA:85-143.
[11]朱俊强等.斜沟槽型机匣处理的实验研究.航空动力学报,Vol.13,No.1998.
[12]L.He,J.Denton,Three-Dimension Time-marching Inviscid and Solutions for Unsteady Flows Around Vibrating Blades.Whittle Laboratory,Cambridge,England.ASME Journal of Turbine machinery,1994.
[13]He h.Computational study of rotating stall inception in axial compressor[J].Journal of Propulsion and Power,1997,13(1):31-38.
[14]张燕东,王光华,陆亚钧.用小波变换对机匣处理抑制旋转失速的机理研究.航空动力学报,1998(2).
[15]周盛,唐智明.轴流压气机叶片赌塞颤振之数值预测.AIAA Paper 83(0006),1983.
[16]蒋滋康,张卫伟.振动叶栅非定常流场的时间推进计算方法.工程热物理学报.Vol.6,No.3,1985:232-237.
[17]井有浩,陈佐一,胡志刚.叶轮机械失速颤振的全三维数值分析方法.航空动力学报,1995.
[18]林强.计算流体力学在压缩机设计中的应用.压缩机技术,1999.1.
[19]鲁嘉华.计算流体力学与求解方法在叶轮机械中的应用.上海工程技术大学学报,2003.3.
[20]谷现量,赵加宁,高军等.CFD商业软件与制冷空调.制冷学报,2003年第4期:pp.45-49.
[21]邓向阳.压气机叶顶间隙流的数值模拟研究:(博士学位论文).北京:中国科学院工程热物理研究所,2006.
[22]江宏俊.流体力学.高等教育出版社,1985.
[23]FINE User Manual.FINE Version 5.2.2001.
[24]Hirsh C,etc.An Integrated CFD System for 3D Turbomachinary Applications[R],ADARD-CP-510,1992.
[25]姚征,陈康民.CFD通用软件综述.上海理工大学学报,2002,24(2):137-144.
[26]刘超群.多重网格及其在计算流体力学中的应用.北京:清华大学出版社,1995.1-64.
[27]Autogrid~(TM) v5 User Manual.Autogrid~(TM) v5.3.2006.1.
[28]Outa E,Kato D,Chiba K.An N-S simulation of stall cell behavior in a compressor rotor-stator system.
[29]袁新.三维非定常粘性流动的数值方法及其应用[J].清华大学学报(自然科学版),1997,37(2):39-42.
[30]项春等.离心式压缩机旋转失速的故障机理研究.振动、测试与诊断[J],2002.3:54-60.
[31]吴艳辉.轴流压缩系统过失速性能和失速可恢复性的研究:(硕士学位论文).陕西:西北工业大学,2001.
[32]程晓斌,聂超群,陈静宜.轴流压气机旋转失速先兆过程中的频率阶跃现象.工程热物理学报,1999,20(6).
[33]杜朝辉.水平轴风力涡轮设计与性能预估方法的三维失速延迟模型.太阳能学报,2000,21(1)。
[34]Leishman J G,Beddoes T S.A Generalized Model for Unsteady Air foil Behavior and Dynamic stall using the Indicial Method,Proceedings of 42.Annual Form of the American Helicopter Society,Washington D.C.Jun.1986.
[35]Wang T.Unsteady aerodynamic modeling of horizontal axis wind turbine Performance PHD Thesis.University of Glasgow,1999.
[36]Nie Xu G,Cheng X,et all.Micro air injection and its unsteady response in a low-speed axial compressor[J]Journal of Turbomachinery,2002,124(4):572-579.
[37]么立新.小流量模型级内部流动数值实验与实验研究:(硕士学位论文).大连:大连理工大学,2006.
[38]余舂华,李秋实,袁巍,周盛.进口畸变下非定常数值模拟进口边界数学模型.北京:航空动力学报,2008(9).
[39]Padano J D,Epstin A H,Valavnai L,et al.Active Control of Roaring Stall in a Low-speed Axial Compressor,ASME J.Turbomachinery Vol.115,1993.
[40]Saxer H M,Saxer A P,Inderbitzin A,et al.Prediction and measurement of rotating stall in an axial compressor[R].ASME 982GT267,1998.
[41]Stein A.Computational analysis of stall and separation control in centrifugal compressor[D].Doctor Thesis,USA:Georgia Institute of Technology,2000.
[2]侯安平,熊劲松.轴流压气机尾流撞击效应机理的数值模拟.北京航空航天大学报,2005,31(9).
[3]蒋康涛,徐刚,黄伟光.低速轴流压气机旋转失速的二维数值模拟[J].工程热物理学报,2004,24(6):935-938.
[4]唐狄毅.叶轮机非定常流.国防工业出版社,1992.
[5]邹正平,徐力平.叶轮机三维非定常流动数值模拟的研究.北京:北京航空航天大学,2001,22(1):1-5.
[6]Emmons H W,Pearson C E,Grant H P.Compressor Surge and Stall Propagation Trans.ASME,Vol.77,1955.
[7]Oreitzer E M,Moore F K.A theory of post-stall transients in axial compressor:part 2:Application[J]1 Journal of engineering for gas turbines and Dower,1986.
[8]蒋康涛.低速轴流压气机旋转失速的数值模拟研究:(博士学位论文).北京:中国科学院工程热物理研究所,2004.
[9]Takata R,Naganon S.Nonlinear Analysis of Rotating Stall.Journal of ASME Engineering for Power,OCt.1972:PP.279-293.
[10]Burwell A E,Patterson G T,Dynamic Engine Behavior During Post Surge Operation Of a Turbine Engine,AIAA:85-143.
[11]朱俊强等.斜沟槽型机匣处理的实验研究.航空动力学报,Vol.13,No.1998.
[12]L.He,J.Denton,Three-Dimension Time-marching Inviscid and Solutions for Unsteady Flows Around Vibrating Blades.Whittle Laboratory,Cambridge,England.ASME Journal of Turbine machinery,1994.
[13]He h.Computational study of rotating stall inception in axial compressor[J].Journal of Propulsion and Power,1997,13(1):31-38.
[14]张燕东,王光华,陆亚钧.用小波变换对机匣处理抑制旋转失速的机理研究.航空动力学报,1998(2).
[15]周盛,唐智明.轴流压气机叶片赌塞颤振之数值预测.AIAA Paper 83(0006),1983.
[16]蒋滋康,张卫伟.振动叶栅非定常流场的时间推进计算方法.工程热物理学报.Vol.6,No.3,1985:232-237.
[17]井有浩,陈佐一,胡志刚.叶轮机械失速颤振的全三维数值分析方法.航空动力学报,1995.
[18]林强.计算流体力学在压缩机设计中的应用.压缩机技术,1999.1.
[19]鲁嘉华.计算流体力学与求解方法在叶轮机械中的应用.上海工程技术大学学报,2003.3.
[20]谷现量,赵加宁,高军等.CFD商业软件与制冷空调.制冷学报,2003年第4期:pp.45-49.
[21]邓向阳.压气机叶顶间隙流的数值模拟研究:(博士学位论文).北京:中国科学院工程热物理研究所,2006.
[22]江宏俊.流体力学.高等教育出版社,1985.
[23]FINE User Manual.FINE Version 5.2.2001.
[24]Hirsh C,etc.An Integrated CFD System for 3D Turbomachinary Applications[R],ADARD-CP-510,1992.
[25]姚征,陈康民.CFD通用软件综述.上海理工大学学报,2002,24(2):137-144.
[26]刘超群.多重网格及其在计算流体力学中的应用.北京:清华大学出版社,1995.1-64.
[27]Autogrid~(TM) v5 User Manual.Autogrid~(TM) v5.3.2006.1.
[28]Outa E,Kato D,Chiba K.An N-S simulation of stall cell behavior in a compressor rotor-stator system.
[29]袁新.三维非定常粘性流动的数值方法及其应用[J].清华大学学报(自然科学版),1997,37(2):39-42.
[30]项春等.离心式压缩机旋转失速的故障机理研究.振动、测试与诊断[J],2002.3:54-60.
[31]吴艳辉.轴流压缩系统过失速性能和失速可恢复性的研究:(硕士学位论文).陕西:西北工业大学,2001.
[32]程晓斌,聂超群,陈静宜.轴流压气机旋转失速先兆过程中的频率阶跃现象.工程热物理学报,1999,20(6).
[33]杜朝辉.水平轴风力涡轮设计与性能预估方法的三维失速延迟模型.太阳能学报,2000,21(1)。
[34]Leishman J G,Beddoes T S.A Generalized Model for Unsteady Air foil Behavior and Dynamic stall using the Indicial Method,Proceedings of 42.Annual Form of the American Helicopter Society,Washington D.C.Jun.1986.
[35]Wang T.Unsteady aerodynamic modeling of horizontal axis wind turbine Performance PHD Thesis.University of Glasgow,1999.
[36]Nie Xu G,Cheng X,et all.Micro air injection and its unsteady response in a low-speed axial compressor[J]Journal of Turbomachinery,2002,124(4):572-579.
[37]么立新.小流量模型级内部流动数值实验与实验研究:(硕士学位论文).大连:大连理工大学,2006.
[38]余舂华,李秋实,袁巍,周盛.进口畸变下非定常数值模拟进口边界数学模型.北京:航空动力学报,2008(9).
[39]Padano J D,Epstin A H,Valavnai L,et al.Active Control of Roaring Stall in a Low-speed Axial Compressor,ASME J.Turbomachinery Vol.115,1993.
[40]Saxer H M,Saxer A P,Inderbitzin A,et al.Prediction and measurement of rotating stall in an axial compressor[R].ASME 982GT267,1998.
[41]Stein A.Computational analysis of stall and separation control in centrifugal compressor[D].Doctor Thesis,USA:Georgia Institute of Technology,2000.