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Design and Testing of a Unique Compressor Test Facility Jörgen Olsson

Design and Testing of a Unique Compressor Test Facility Jörgen Olsson. Outline of the presentation. Introduction Specifications Design Hardware Test Compressors Testing Summary. What type of compressors are tested?. Low Pressure Compressor. RM 12 (GE F404). Why are compressors tested?.

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Design and Testing of a Unique Compressor Test Facility Jörgen Olsson

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  1. Design and Testing of a Unique Compressor Test FacilityJörgen Olsson STARCS Proprietary

  2. Outline of the presentation • Introduction • Specifications • Design • Hardware • Test Compressors • Testing • Summary STARCS Proprietary

  3. What type of compressors are tested? Low Pressure Compressor RM 12 (GE F404) STARCS Proprietary

  4. Why are compressors tested? • Measure the performance of a new design • Map the operational envelope • Establish the operational limits to avoid stall, surge and flutter • Verification of design models STARCS Proprietary

  5. Main design criteria for the Compressor Research Facility • Drive power 4.3 MW • Rotation speed ranges: 0-5500 rpm and 0-25000 rpm, continuously variable • Variable inlet pressure • Variable outlet pressure • Air flow through the test facility without a test compressor installed • Efficient sound proofing of the control room and to the external environment. • Control system with safety monitoring and logging STARCS Proprietary

  6. Envelope of the Compressor Test Facility STARCS Proprietary

  7. STAL-LAVAL (Siemens Turbomachinery Finspång Sweden)Compressor Test Facility In service fall 1973 6 MW STARCS Proprietary

  8. First sketch STARCS Proprietary

  9. Compressor Test Facility Overview STARCS Proprietary

  10. Side view of the Compressor Test Facility Asynchronous motor 4.3 MW Inlet valve Test object (rig) Outlet valve (2) Counter weight Control valve for ejector primary flow STARCS Proprietary

  11. The Compressor Test Facility seen from the motor Inlet valve Outlet valve Outlet valve To acoustic baffles and exhaust tower Floor level Control valve for ejector primary flow Ejector STARCS Proprietary

  12. Inlet flow manipulators Perforated plate Net Net Net STARCS Proprietary

  13. Modified ejector Insert STARCS Proprietary

  14. Gearboxes Sketch of the gear box for 25000 rpm Cut away sketch of the gearbox for 5500 rpm STARCS Proprietary

  15. Torque meters 0-10 kNm 0-8000 rpm 0-1400 Nm 0-30000 rpm STARCS Proprietary

  16. Situation plan STARCS Proprietary

  17. External view of the building STARCS Proprietary

  18. Motor and 25000 rpm gear box STARCS Proprietary

  19. Gear box and exhaust annular collector STARCS Proprietary

  20. Air inlet with inlet valve and stagnation chamber STARCS Proprietary

  21. Hardware needed to adapt a test compressor STARCS Proprietary

  22. Inlet pipe STARCS Proprietary

  23. Diffuser STARCS Proprietary

  24. Vital booster and instrumentation rack STARCS Proprietary

  25. Overview of the control and measurement system Zephyr Recording of fast response data Bandwidth: 30 kHz On-line monitoring Data to customer Strain gauges FFA 1260 Signal conditioning Instationary Pressures FFA 1220 Signal conditioning Alarm System Compilation of data and presentation online of data, RMS, FFT etc. Alarm can invoke emergency stop IDA Recording of data Bandwidth:10 Hz On-line monitoring. Facility fixed transducers Temperatures Electronic Pressure Scanners (ESP) Recording of ”slow” pressures. (10 Hz) On-line monitoring. MAESTRO Test sequence control Bearing temperature and vibration Stationary Pressures ABB 800 Control system for motor and valves On-line monitoring. Emergency stop Motor control sensors STARCS Proprietary

  26. Control Room STARCS Proprietary

  27. Control System Display STARCS Proprietary

  28. On-Line Compressor Performance Map STARCS Proprietary

  29. Hulda low pressure compressor STARCS Proprietary

  30. Vital LPC STARCS Proprietary

  31. AIDA Aggressive Duct With Hulda Compressor STARCS Proprietary

  32. Test compressor for max 5500 rpm Front view of Siemens Industrial Turbo-machinery test compressor with first stage guide vanes. (inlet hub not present) STARCS Proprietary

  33. What is measured? • Inlet and outlet pressures and temperatures • Mass flow, rotational speed and drive shaft torque • Vibration and loads on the rotor blades using strain gauges or tip-timing • Vibration and loads on the stator vanes and the inlet guide vanes using strain gauges • Stall detection using temperature sensors and unsteady pressure transducers • Static pressures in the flow channel • For monitoring: Rotor tip clearance, shaft position, temperature and vibration of the compressor bearings, lubrication oil pressure, temperature and mass flow • Flow properties in the channel using traversing probes: pressure, temperature and flow angles

  34. Summary • STARCS in-house designed and built Compressor Test Research Facility • Today a well proven concept • Drive power and mass flow capabilities in parity with customer demands • Unique capabilities with sub atmospheric outlet STARCS Proprietary

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