International Journal of Fluid Mechanics & Thermal Sciences

2019; 5(1): 1-9

http://www.sciencepublishinggroup.com/j/ijfmts
doi: 10.11648/j.ijfmts.20190501.11
ISSN: 2469-8105 (Print); ISSN: 2469-8113 (Online)

The Development of an Integrally Geared Centrifugal

Compressor
Cheng Xu1, 2, Hanqian Yang1, *, Yandan Jiang1, Zhongwei Yi1
1
Department of Mechanical and Electrical Engineering, Central South University of Forestry and Technology, Changsha, China
2
Department of Mechanical Engineering, University of Wisconsin, Milwaukee, USA

Email address:
*
Corresponding author

To cite this article:

Cheng Xu, Hanqian Yang, Yandan Jiang, Zhongwei Yi. The Development of an Integrally Geared Centrifugal Compressor. International
Journal of Fluid Mechanics & Thermal Sciences. Vol. 5, No. 1, 2019, pp. 1-9. doi: 10.11648/j.ijfmts.20190501.11

Received: September 26, 2018; Accepted: April 8, 2019; Published: May DD, 2019

Abstract: Integrally geared centrifugal compressors have been widely used in industry especially. Reliable design, good
performance, low noise, no resonant frequencies in the operating range and cost effective machining and casting parts are the
goals of the design. Computational Fluid Dynamics (CFD) tools have been widely used to optimize the impeller, diffuser and
volute designs. Many design considerations are useful for compressor preliminary parameter selections and compressor
package designs. In this paper, the detailed development and design of a integrally geared centrifugal compressor are discussed.
Some initial design considerations for compressor configureuration, power distribution for each stage, and possible field
application issues are discussed in details. The aerodynamic and structural optimization using CFD and Finite Element
Analysis (FEA) are performed to obtain a high efficiency and wide operating range compressor with robust operation. The new
compressor development process addressed in this paper provides the basic design guidance for future new integrally geared
compressor development.
Keywords: Centrifugal Compressor, Compressor Design Consideration, CFD

experience of the stage power distributions can help

1. Introduction designers to get reasonable stage loading in short time. This
The integrally geared centrifugal compressor is one of the paper will discuss in details of design experience.
important types of turbomachines to increase the gas pressure Recent progress being made on the development of small
[1-8]. Integrally geared centrifugal compressors have more capacity high-speed direct drive compressors [9], however,
advantages than direct drive compressor because impellers the high cost in high-speed motor only allows them to use in
can rotated in a higher tip speed. The power density of the some of the premium applications. The geared centrifugal
integrally geared centrifugal compressors is higher than compressors are very popular in industrial applications. The
direct driven compressors. The integrally geared centrifugal geared centrifugal compressor design process has been
compressors have small compressor frames and low capital discussed for years [3]. However, there is no standard process
expenditures. Its applications can be in a way of single stage can be used for modern industrial gear compressor designs.
or multi-stages for gas compression. The integrally geared The modern centrifugal compressor design process still needs
centrifugal compressors have wide applications in process to further develop.
and air separation industries. Due to the high rotating speed The air separation industrial grows rapidly recently due to
of the geared compressor, the semi-open unshrouded the industrial needs of pure Oxygen and nitrogen. In air
impellers are always used. The unshrouded impellers have separation process, air compressors draw the air and
advantages in manufacturing but bring extra tip clearance compress it to a certain pressure before it is cooled and
aerodynamic losses. The tip clearance losses are related to separated into its main constituents. The gas was separated
each impeller loading and impeller design. The design into oxygen and nitrogen and then be compressed and fed
into a pipeline. Cryogenic air separation compressors are one
2 Cheng Xu et al.: The Development of an Integrally Geared Centrifugal Compressor

of the high-energy consumption devices in air separation proportional to impeller diameter and impeller rotational
plants. The utility cost of the air compressors is the primary speed. In most of the cases, the gas leaves the impeller then
energy consumer of an air separation process. The energy- enters a vaned or vanless diffuser to decelerate the gas to
saving opportunities have been studied extensively [10]. For increase the static pressure. The compressed gas finally
the air separation plant, the system demands for compressed enters a scroll or collector and then delivers to applications or
air are not always same. Sometime the system airflow can be next stage.
less than 50% of the maximum flow capability. The The compressor design processes normally started with the
variations of the airflow demands require compressor performance and cost target optimizations. The life time cost
turndown as much as 50%. It is necessary to develop a high of the compressor includes the capital cost, i.e. the cost for
efficient and wide operating range compressor. This paper purchasing the compressor; and the annual operational cost,
authors present a detail compressor design process from i.e. the cost of the compressor energy consumption. The new
marketing requirement to final design. It will be a good compressor design needs to make sure that the end users have
reference for compressor manufacturers. a lowest lifetime cost. The optimizations and considerations
In this paper, the centrifugal compressor design process for the compressor manufacturing cost and operational cost
and development method were presented in detail through a are normally done by compressor manufacturing based on in-
geared centrifugal compressor development. The compressor house experience and database. Most of the current method
developed here is an integrally geared four stage centrifugal for new compressor design is scale and modify the previous
compressor with the total-to-static pressure ratio of 12 and design to a new design and then do the optimization in the
inlet volumetric flow of 7.3m3/s. The reliable, higher components [1, 15]. A few academic studies have been done
performance, large surge margin, low noise, no resonant to mention to combine the detail compressor design
frequencies in the operating range and economic to considerations and optimizations; there are very limited
manufacture are the goals of the design. The detail processes publications in this area. The authors have discussed the
for this integrally geared centrifugal compressor importance of some of the design considerations in the past
developments are discussed in this paper. The integral studies [1, 16]. In this paper, the detail new compressor
thinking and optimization used in this design process can development process and considerations are discussed.
serve as a guideline for future compressor developments. In this paper, a centrifugal compressor is developed for air
While CFD and FEA are widely used in the compressor separation applications. The air separation customers use
design, many detail compressor design considerations and both engines and motors to drive the compressors. For this
optimizations can accelerate the design before CFD and FEA size of machine, the customers are most likely to use an
optimizations [2-20]. The compressor stage design, analysis electric motor to drive compressors. Therefore, the choice of
and optimization are similar for all stages. The detail design different poles of the motor is important. The studies between
processes and aerodynamic analysis are presented here by two-pole and four-pole motor are conducted based on the
using first stage as an example. cost and performance trade-off studies. To effectively study
the motor selection, it is necessary to determine numbers of
2. Preliminary Design Considerations stages. Based on some of the design consideration and
manufacturing cost analysis [1], the annual operation and
capital cost vs number of compressor stages are shown in
Figure 2. It is shown that three and four stages for this
machine are good choices. Considering the applications need
10% more pressure ratio in some of the applications, four
stages are used for this compressor design.
The historical in-house manufacturing compressor cost for
both two-pole and four-pole motors for different compressor
design inlet flow are shown in Figure 3. It can be seen than
the two-pole motor drivers are used for small compressors.
For the compressor size in this study, we can use both two-
pole and four-pole motors. Figure.3 shows that the initial
aerodynamic components (impeller, impeller housing, scroll,
and diffuser) cost using four-pole motor is about 80% more
than two-pole motor. The performance penalty using two-
Figure 1. Centrifugal compressor.
pole motor is about 1.9% using in-house analysis system [3,
4]. Based on the current energy cost information, a 2500kW
A typical single stage compressor is shown in Figure 1. machine will increase operation cost about $180,000 for two
The gas enters a centrifugal compressor in axial direction. As years which is more than the total cost of aerodynamic
the gas continues to pass into centrifugal impeller, the components. Based on the hardware cost and operation cost
impeller forces the gas flow to increase the kinetic energy information, it is obvious that the customers prefer the four
and static pressure. The work input to gas by impeller is pole motor design. The compressor developed here uses four-
 International Journal of Fluid Mechanics & Thermal Sciences 2019; 5(1): 1-9 3

pole motor.
This integrally geared compressor is chosen to have two
pinions with two stages in each pinion. The stage power
distributions are critical for cost and performance. The cost
and efficiency trade off studies are conducted. The studies for
power split in two pinions are conducted. The manufacturing
cost and performance impacts for different power splits are
shown in Figure 4. It is demonstrated that a low speed pinion
load of about 52% of the overall power is good for both
compressor performance and manufacturing cost.
The selection of flow coefficient at compressor design
point is important for both compressor efficiency and
aerodynamic components’ cost. Normally, the cost of the
aerodynamic components is about 35% of the whole
compressor system cost. An in-house cost database and
Figure 4. Performance and cost Vs power split.
performance estimation program is used to predict the
performance and compressor cost impacts [3, 4]. The
manufacturing cost of the aerodynamic components is
calculated based on the size of the impeller, diffuser and
scroll for different flow coefficient as shown in Figure 5. The
cost ratio is the cost versus the cost of airend with best
aerodynamic efficiency. It is shown that flow coefficient
around 0.08 is good for both aerodynamic performance and
cost.

Figure 5. Flow coefficient Vs cost and performance.

The power distributions of each pinion are determined by

the flow coefficient requirements of each stage. With certain
flow coefficients, the pinions need to have certain speeds to
transfer designed power to gas. It is necessary to check
whether the power and speed combination in each pinion is
within the manufacturing experience and capability.
Figure 2. The number of stage selections.
Compressors developed in the past are always a good
reference for new development. The experience demonstrates
that once the pinion power is within a certain range for a
given pinion speed, no need special material or treatment are
needed for the pinion and bull-gear; otherwise the
manufacturing cost could increase significantly. The study
results are shown in Figure6. It is shown that the pinion cost
and manufacturing method are within past low cost
experience for current design.
The impeller back sweep angle is also one of the
parameters which need to be determined before starting the
detail design of the impeller. The work input of the impeller
can be expressed in term of back sweep angle as
∆h=u22-Cs u2-Cr2 u2 tanβ2 (1)

Figure 3. Motor selections. Where the slip velocity can be expressed as [21]
4 Cheng Xu et al.: The Development of an Integrally Geared Centrifugal Compressor

Cs= u2(cos β2)0.5Z0.7 (2) temperature is 308.15 oK.

Three-dimensional CFD analysis has been extensively
It can be seen from eq(1) that the large back sweep angle used in centrifugal compressor designs [12-21]. Most
reduces the work input of the impeller. For same stage turbomachinery design systems use extensive RANS three-
pressure ratio, larger back sweep angle impeller needs bigger dimensional equations for CFD. In structure analysis, FEA
diameter than the small back sweep impeller. However, the and frequency analyses are commonly used in an iterative
larger sweep angle has a beneficial on reducing the impeller manner with CFD during the design. It this study, a
discharge Mach number. A small impeller discharge Mach commercial code from Ansys CFX [22] and Ansys structure
number improves the compressor efficiency and operating [23] are used for CFD analysis and structure design
range. In this study, the back sweep angle was initially set optimization. During the impeller design, the structure and
between 40o to 50o to perform the optimization considering aerodynamic optimizations are performed to produce a
both cost and efficiency [1]. The final average blade sweep reliable design with good performance. The low solidity
angle was set about 46o to have the best combination of diffusers are used in all stages to produce the wide operating
benefits for both performance and impeller cost. range of the compressor [1, 2].

Figure 6. Design experience for pinion speed.

3. Compressor Design and Optimization

After the initial and preliminary considerations, the
detailed aerodynamic and structure optimizations are
conducted. The centrifugal compressor design normally starts
with meanline optimization [1-3], and then moves to detail Figure 7. Centrifugal compressor design process.
designs of the individual components. A turbomachinery
design system combined with a number of tools has been
successfully used in the past for centrifugal compressor
development [13]. The preliminary meanline design tool is
used to optimize the compressor one-dimensional parameters.
In this study, a similar design process has been used for this
new compressor design. Before the three-dimensional CFD
optimizations, the meanline tool is used to optimize the
design parameters of the impeller, diffuser and scroll. Based
on the primary parameters set by meanline tool, the shape of
the impeller blades and flow channels are modified until an
optimal geometry is found. The detail design process is
shown in Figure7.
The detailed aerodynamic design process for each stage is
same for all four compressor stages. This paper only presents Figure 8. Non-dimensional Head comparison between experiment and
the detail information of the first stage design. The first stage calculations.
rotational speed is about 23,000 RPM, the design total to
static pressure ratio is 2.05. The inlet pressure is 99.0 kpa and
 International Journal of Fluid Mechanics & Thermal Sciences 2019; 5(1): 1-9 5

performance within typical test tolerances [4, 5]. The CFD

verification by using the existing compressor stage were
performed. The CFD results were compared with experiment
are shown in Figure 8 and 9. It can be seen that CFD
provided a good simulations when the compressor operated
near the design point.For this design process, the past
experience of the CFD were used. A typical CFD mesh is
shown in Figure10.
The lean of the impeller has significant impacts of the
compressor performance [16]. Previous studies [16] indicated
that negative lean improves the peak efficiency and positive
lean can improve the operating range. In this study, the peak
efficiency is more critical for the application. The negative 4o
Figure 9. Non-dimensional efficiency comparison between experiment and lean design is chosen for the final design.
calculations. The final designed stage streamline from CFD is shown in
Figure 11. It can be seen that the flow inside of the
The aerodynamic optimizations for impeller, diffuser and compressor does not have any flow separation. The design
scroll are very important to provide the compressor stage target is set to have 87% stage efficiency. The CFD
with good efficiency and wide operation range [5-12]. CFD calculation results of the compressor stage are shown in
is one of the important tools to predict the performance of Figure12. It can be seen that the peak isentropic total to static
each design iteration. The mesh independence and sensitivity stage efficiency is about 87.6% which exists the design target
is critical during design iterations to make sure that analyses of 87%.
can predict the design performance without the impacts of From time to time, the impeller failures are one of the most
the mesh sizes. In this study, hexahedron meshes are used in important damage of the centrifugal compressor. Impellers
all CFD calculations. The hexahedron meshes were generated not only undergo the centrifugal force due to high speed
by using Ansys ICEM [22]. All the endwall mesh are rotating and aerodynamic forces but also get excitation from
adjusted to make sure the y+ value is less than 1 to make sure aerodynamics vibration and other vibrations. For the final
the CFD calculations converge and agree with empirical impeller design, the structure and vibration analyses are
results of past CFX analysis experience [4-7]. The mesh necessary to make sure the impeller is reliable. The impeller
count independence and sensitivity studies are conducted [14] is made by using 17-4PH stainless steel. The main
basis the five levels of impeller and vane meshes and three mechanical properties of 17-4PH stainless steel are shown in
levels of the scroll meshes. The goal of the mesh Table 1 [24]. The FEA stress calculation result is shown in
independence studies is to have less than 0.05% change in Figure 13. It can be seen that the maximum von Mises stress
efficiency and 0.1% change in mass flow of the compressor stress of the impeller at design rotating speed is below 137ksi
when the mesh size changes. Once the mesh count (944.6 Mpa). The maximum stress location is at blade filet.
independence studies are completed, the mesh temperate is And it is lower than 17-4 PH H1150 stainless steel yield
kept the same for all CFD studies to reduce the mesh cell stress of 150 ksi (1034Mpa). The stress level meets the
structure sensitivity. The number of mesh nodes in the design standard. The interference diagram for six IGV
impeller, vaned diffuser and scroll are about 1.5, 1.2 and 4.5 airfoils and thirteen diffuser vanes is shown in Figure 14. It is
million, respectively. These mesh sizes agree with past shown that it doesn't have any frequency excitation problem
experience [4, 5]. Previous CFD experience for different for both IGV and diffuser.
centrifugal compressors with a similar type of mesh
demonstrated that CFD predicts the centrifugal compressor
Table 1. Typical 17-4 PH mechanical properties [24].

Property A H900 H925 H1025 H1075 H1150 H1150-M

UTS, MPa 1103 1448 1379 1276 1207 1103 1034
0.2%YS, MPa 1000 1379 1345 1172 1148 1034 896
Elongation,%in 50.8 mm 5.0 7.0 8.0 8.0 8.0 11.0 12.0
Hardness, Rockwell C35 C45 C43 C38 C37 C35 C33

The rotor vibrations cause the impeller and other bearing clearances is shown in table 2. The pinion speed is
compressor component failure. The rotordynamicanalysis for about 23000RPM. The smallest range for 2nd and 3rd mode is
pinion with impellers are critical to avoid the rotor system at maximum bearing clearance. This range is between 11908
vibration issues. The extensive iterations for bearing and RPM and 26888 RPM. It is shown that the compressor pinion
pinion design through rotordynamic analyses were performed. is operated between 2nd mode speed and 3rd mode speed.
The final design meet the design requirements. The damped There is enough separation margin between operational speed
unbalanced response analysis with maximum and minimum and nature frequencies.
6 Cheng Xu et al.: The Development of an Integrally Geared Centrifugal Compressor

Table 2. Damped natural frequencies at design pinion speed.

Rotating Second mode Third mode Rotating

First mode LogDec Rotating speed
speed LogDec LogDec speed
Maximum bearing clearance 0.695 7677 0.474 11908 7.949 26888
Minimum bearing clearance 0.672 7090 0.513 11523 4.609 28714

reliability and good performance, but also possible field

issues must predict. It is a good practice to analyze the
potential application issues or misuse problems. In this paper,
the authors present one of the many analyses for potential
field impacts as an example to address one of the field issues
through analysis.
Due to the cost reason, some of the customers want to use
Aluminum diffuser vanes for their applications. However,
harmful vapor contaminants including sulfides and chlorides
Figure 10. Computational mesh. are often found near salt water coastal locations. The harmful
vapors can cause diffuser blade erosion and corrosion. As a
result, the compressor performance will degrade. After
finishing the compressor design, the performance impacts of
the diffuser corrosion and erosion are analyzed. The CFD
geometry for eroded diffuser shape based on the typical field
application after five years running of the compressor is
shown in Figure15. The compressor performance impacts
from the erosion and corrosion from CFD compared with
new diffuser are shown in Figure. 16 and 17. It demonstrates
from Figure16 that the peak efficiency point moves toward to
the lower flow coefficient. The stage efficiency at design
flow coefficient drops about 0.4%. The efficiency drops more
at low flow coefficients. Figure15 demonstrates that the stage
pressure also drops about 3% at design flow. The pressure
drop of one stage impacts the stage matching for the overall
compressor. The compressor power consumption of the
compressor unit will increase about 1.1% due to first stage
diffuser erosion and corrosion. Studies suggested after five
Figure 11. Streamlines from CFD. years operation, the Aluminum diffuser should be replaced
by a new diffuser to keep the good compressor unit
performance.

Figure 12. Efficiency and head coefficient.

4. Analysis of the Potential Field Issue

The new compressor development not only needs have Figure 13. Stress analysis results.
 International Journal of Fluid Mechanics & Thermal Sciences 2019; 5(1): 1-9 7

Figure 14. Interference diagram for 6 IGV airfoils and 13 diffusers.

Figure 15. Diffuser after erosion and a CFD model.

Figure 16. Adibatic efficiency impacts. Figure 17. Pressure ratio impacts.
8 Cheng Xu et al.: The Development of an Integrally Geared Centrifugal Compressor

5. Conclusions
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