Centrifugal Compressor Impeller
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Transcript of Centrifugal Compressor Impeller
Buffalo State College
Mechanical Engineering Technology
Senior Design Project Proposal
Spring 2015
Centrifugal Compressor Impeller
Tip-to-Shroud Measurement System
Sponsor: FS-Elliott Co. LLC
Date Presented: March 10, 2015
Design Team:
Morgan Allis _________________________
Chuck Mantell _________________________
Bradley Brooks _________________________
Jeff Villont _________________________
FS-Elliot Design Proposal Buffalo State College
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ABSTRACT
This project will introduce sensor technology to measure impeller-tip-to-shroud clearance
into FS-Elliotts Polaris+ centrifugal air compressor model P300. FS-Elliott Co., LLC, is a
leading centrifugal air compressor manufacturer with manufacturing locations around the world.
FS-Elliott is seeking solutions to maximize efficiency of their compressors by controlling and
monitoring distances between impeller blade tip and compressor shroud; the first step to this is
installing a sensor to measure impeller tip clearance. This project will explore different sensing
options to measure blade tip to shroud clearance. FS-Elliott will receive a package including
optimal sensing recommendations, product installation into their P300 compressor, and cost
analysis.
FS-Elliot Design Proposal Buffalo State College
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TABLE OF CONTENTS
Section Title Page Number
LIST OF FIGURES 1.0 4
LIST OF TABLES 2.0 5
INTRODUCTION 3.0 6
P300 COMPRESSOR 4.0 8
GUIDELINES 5.0 12
SENSOR TECHNOLOGY 6.0 13
CAPACITIVE 6.1 13
INDUCTIVE 6.2 15
LASER DOPPLER 6.3 16
EDDY-CURRENT 6.4 18
FIBER OPTICAL 6.5 20
VARIABLE RELUCTANCE SENSOR (VR) AND HALL EFFECT 6.6 22
Variable Reluctance 22
Hall Effect 23
PHOTOELECTRIC SENSOR 6.7 25
MICROWAVE DISTANCE SENSOR 6.8 27
RESTRICTIONS 7.0 28
CHOSEN DESIGN 8.0 28
CAUSE AND EFFECT MATRIX 8.1 29
PROJECT MANAGEMENT 9.0 30
APPENDIX 10.0 31
REFERENCES 11.0 32
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LIST OF FIGURES 1.0
FIGURE 3.1. A CENTRIFUGAL COMPRESSOR IN THE MANUFACTURING PROCESS 6
FIGURE 3.2. AN INTERNAL VIEW OF A COMPRESSOR BEING ASSEMBLED AT FS-ELLIOTTS MANUFACTURING
FACILITY 7
FIGURE 4.1. FS-ELLIOLTTS P300 COMPRESSOR SHOWING OUTBOARD (A.) AND INBOARD (B.) VIEWS 8
FIGURE 4.2. A LOOK AT INTERNAL COMPONENTS OF FS-ELLIOTTS P300 COMPRESSOR 9
FIGURE 4.3. TYPICAL OPERATION FLOW-DIAGRAM OF FSES P300 COMPRESSOR 10
FIGURE 5.1. SENSOR PROBE INSTALLATION ANGLE 12
FIGURE 6.1.1. POSSIBLE CAPACITIVE SENSOR PROBES 14
FIGURE 6.2.1. INDUCTIVE SENSOR PROBE 15
FIGURE 6.3.1. FIBER OPTIC LASER DOPPLER SYSTEM 17
FIGURE 6.4.1. TWO BODY STYLE EDDY-CURRENT PROBES 19
FIGURE 6.5.1. PHOTO OF MONARCH OPTICAL SENSOR 21
FIGURE 6.6.1. IN A VR SENSOR, THE RESULTING ANALOG SIGNAL MUST BE FILTERED AND
THRESHOLDED TO YIELD A USEFUL PULSE OUTPUT 22
FIGURE 6.6.2. IN A HALL-EFFECT SENSOR, ALL LOW-LEVEL SIGNAL PROCESSING IS PERFORMED ON
THE SILICON CHIP HOLDING THE TRANSDUCER 23
FIGURE 6.6.3. WAYS THAT SENSORS TAKE THEIR READING FROM ROTATING OBJECT 24
FIGURE 6.7.1 PHOTO OF PHOTOELECTRIC SENSOR 26
FIGURE 6.8.1 MICROWAVE SENSOR DIAGRAM 27
FIGURE 8.1. SIMPLIFIED SCHEMATIC OF HB-01 30
FS-Elliot Design Proposal Buffalo State College
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LIST OF TABLES 2.0
Table 8.1 Cause and Effect Matrix 29
Table 9.1. Gantt chart for project management section of our design 31
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INTRODUCTION 3.0
FS-Elliott Co., LLC is a leading manufacturer of oil-free centrifugal air and gas
compressors with sales, service, and manufacturing locations around the world. They
manufacture a variety of air compressors that range from 450 HP (335 kW) to 2500 HP (1864
kW) and 2090 CFM (987 l/sec) to 11500 CFM (5430 l/sec), As shown in FS-Elliott Co., LLC
Polaris+ (2014). Markets and industries they serve include air separation,
chemical/petrochemical, electronics, general industry, medical, mining, oil and gas,
pharmaceutical, and refining.
Turbo machinery is widely used with countless applications. Efficient aerodynamics
makes centrifugal compression ideal for many industrial applications. Centrifugal compressors
produce pressure by transferring energy from a rotating impeller to the air. Centrifugal
compressors are efficient, low maintenance with minimum wearing parts, low vibration, and
have excellent reliability over extended periods of time. FS-Elliott Co., LLC Polaris+ (2014).
Figure 3.1. A centrifugal compressor in the manufacturing
process
at FS-Elliotts manufacturing facility in Export,
PA
This project will specifically deal with FS-
Elliotts Polaris+ P300 centrifugal compressor. This
compressor is a medium to small multi stage compressor with three stages of compression. P300
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compressors range from 250-450 hp (186-335 kW) and flow rates of 900-2090 CFM (424-986
l/sec), and a discharge pressure of 45-150 psi (310-1034 kPa). FS-Elliott Co., LLC Polaris+
(2014).
This project involves introduction of a sensor that will measure impeller tip-to-shroud
clearance on FS-Elliotts P300 centrifugal compressor. Numerous sensing technologies will be
analyzed based on characteristics including cost, size, resolution, temperature rating, surface
area, installation, electronics, durability, life expectancy, sensitivity to contamination, and need
for calibration. FS-Elliott will receive design recommendations based on six-sigma matrix, 3D
model of design, and project management analysis for the project. Successful introduction of
sensor technology into FS-Elliotts centrifugal compressors could lead to further control of
impeller tip-to-shroud distances by means of actuation.
Figure 3.2. An Internal view of a compressor being assembled at FS-
Elliotts manufacturing facility
1. Driving bull gear for centrifugal
compressor
2. Driven pinion gear in which compressor impeller will be mounted
P300 COMPRESSOR 4.0
FS-Elliot Design Proposal Buffalo State College
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FS-Elliotts P300 compressor is a medium to small size, oil free, multi stage compressor,
with three stages of compression. The P300 is the smallest centrifugal compressor that FS-Elliott
manufactures and also has the highest rotational impeller speed as shown in FS-Elliott Co., LLC
P-300 (2008).
Rotational impeller speeds range from 51,310 rpm at low speed and 68,414 rpm at high
speed. The P300 compressor has 15 full and 15 splitter blades in its 1st stage of compression, and
17 blades in its 2nd and 3rd stages of compression. It operates at or below a temperature of 350F
(177C). FS-Elliott Co., LLC P-300 (2008).
Figure 4.1. FS-Ellioltts P300 compressor showing Outboard (a.) and Inboard (b.) views, as shown by Smith, D.,
Tursky, M., Wellek, R. (2013).
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Figure 4.2. A look at internal components of FS-Elliotts P300 compressor, as shown, in Smith, D., Tursky, M.,
Wellek, R. (2013).
1. Pinion (driven gear), attached to the impeller.
2. Bull gear (driving gear), connected to engine output, and drives impeller pinion.
3. Impeller, consisting of 15 or 17 blades, moves air in a rotational direction to
diffuser plates.
4. Diffuser plates, causing a decrease in velocity allowing for pressure to increase.
5. Shroud of compressor, component concerned with impeller tip clearance.
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Operation of the P300 compressor consists of ambient air entering an inlet control into its
first stage of compression. A centrifugal impeller accelerates air and then velocity is slowed and
pressure in increased, by means of a diffuser. Air then enters a bundle tube heat exchanger for
cooling. The following diagram shown in (FSE P300 brochure), demonstrates the typical
operation of FS-Elliotts P300.
Figure 4.3. Typical operation
flow-diagram of FSEs P300 compressor,
as shown in FS-Elliott Co., LLC P-300
(2008).
1. Ambient air entering inlet control
2. Air accelerated by first impeller. Temperature and velocity rise, before a radial
diffuser plate slows velocity and creates pressure.
3. Hot air enters first stage of intercooling. Air passes over water filled tubes with fins.
4. Air makes two 90-degree turns begins to flow upward, allowing separation of
condensed moisture from cooled air.
5. Air exiting heat exchanger and flowing through second inlet control device for
second stage of compression.
FS-Elliot Design Propo
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