1. Design and Testing of a Unique Compressor Test Facility Jörgen Olsson
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2. Outline of the presentation
Introduction
Specifications
Design
Hardware
Test Compressors
Testing
Summary
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3. What type of compressors are tested?
Low Pressure Compressor
RM 12 (GE F404)
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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
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5. Main design criteria for the Compressor Research Facility
Drive power 4.3 MW
Rotation speed ranges: rpm and 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
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6. Envelope of the Compressor Test Facility
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7. STAL-LAVAL (Siemens Turbomachinery Finspång Sweden) Compressor Test Facility
In service fall 1973
6 MW
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8. First sketch
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9. Compressor Test Facility Overview
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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
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11. The Compressor Test Facility seen from the motor
Inlet valve
Outlet valve
Outlet valve
To acoustic baffles and exhaust tower
Floor level
Ejector
Control valve for ejector primary flow
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12. Inlet flow manipulators
Perforated plate
Net
Net
Net
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13. Cross section at the ejector
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14. Modified ejector
Insert
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15. 16 MPa pipe for the ejector drive air
Compressor building for wind tunnel T1500
Connection to pressure vessel
Compressor Research Facility
Shut off valve
Pipe
Pipe support
Control valve
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16. Gearboxes Sketch of the gear box for 25000 rpm
Cut away sketch of the gearbox for 5500 rpm
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17. Drive shafts between gear box and test compressor
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18. Torque meters 0-10 kNm 0-8000 rpm 0-1400 Nm 0-30000 rpm
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19. Situation plan
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20. External view of the building
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21. Motor and rpm gear box
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22. Gear box and exhaust annular collector
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23. Air inlet with inlet valve and stagnation chamber
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24. Hardware needed to adapt a test compressor
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25. Inlet pipe
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26. Diffuser
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27. Vital booster and instrumentation rack
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28. Overview of the control and measurement system
Zephyr
Recording of fast response data
Bandwidth: 30 kHz
On-line monitoring
IDA
Recording of data
Bandwidth:10 Hz
On-line monitoring.
Electronic Pressure Scanners (ESP)
Recording of ”slow” pressures. (10 Hz)
ABB 800
Control system for motor and valves
FFA 1260
Signal conditioning
Alarm System
Compilation of data and presentation online of data, RMS, FFT etc. Alarm can invoke emergency stop
FFA 1220
Strain gauges
Temperatures
Instationary Pressures
Facility fixed transducers
Stationary Pressures
Data to customer
Bearing temperature and vibration
Emergency stop
Motor control sensors
MAESTRO
Test sequence control
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29. Control Room
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30. Control System Display
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31. On-Line Compressor Performance Map
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32. Hulda low pressure compressor
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33. Vital LPC
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34. AIDA Aggressive Duct With Hulda Compressor
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35. Test compressor for max 5500 rpm
Front view of Siemens
Industrial Turbo-machinery test compressor with first stage guide vanes.
(inlet hub not present)
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36. 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

37. STARCS in-house designed and built Compressor Test Research Facility
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
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