ANSYS Advantage — Best of Turbomachinery
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Excellence in Engineering Simulation SPECIAL ISSUE 2016 Best of Turbomachinery Pushing the Envelope Shaking All Over Pumped Table of Contents Best of Turbomachinery THERMAL TURBO 37 HYDRAULIC MACHINERY 2 Weaving In and Out As Equipment Rotates, So Goes the World 17 Force of Nature 41 Powered by Innovation COMPRESSION AND GAS MOVING 21 47 3 Shaking All Over Breaking the Code Pushing the Envelope 25 Pumped 51 8 Passing the Test Blown Away AND MORE 30 12 Rising Tide 55 1,2,3 Turbocharged Fast, Accurate Simulation for Efficiency Fuel Combustion Simulations 33 Generating Innovation 58 Heart to Heart Realize Your Product Promise® Join the simulation If you’ve ever seen a rocket launch, flown on an airplane, driven a car, used a computer, conversation touched a mobile device, crossed a bridge, or put on wearable technology, chances are ansys.com/Social@ANSYS you’ve used a product where ANSYS software played a critical role in its creation. 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ANSYS ADVANTAGE 1 EDITORIAL AS EQUIPMENT ROTATES, SO GOES THE WORLD Turbomachinery applications play a significant role in Strong vibration and pressure pulsation most industries: power generation, oil and gas, in hydraulic turbomachinery may be aeronautics, HVAC, chemical processing, healthcare harmful to machine performance, longev- and automotive. Efficiency gains can result in global ity and safety. Voith Hydro observed strong improvements, particularly in the carbon footprint. vibrations that can cause fatigue cracking While stringent emissions standards drive industrial in the guide vanes of a large Francis water equipment design, other factors play important roles. turbine. It leveraged multiphysics simula- Fuel prices are volatile. Emerging OEMs create pockets tion to solve a very difficult field problem. of increased competition with resulting shortened time Grundfos, which develops circulator frames. Offshore, deep-water and shale gas reservoirs pumps for HVAC, uses simulation optimi- call for dramatic technology advances. Equipment is zation to investigate hundreds of designs pushed to new operational boundaries, yet durability without manual intervention. The process demands remain constant. Turbomachinery design has reduced overall design time for a new pump become a series of trade-offs. by 30 percent and saved approximately By Brad Hutchinson, Not surprisingly, rotating equipment companies $400,000 in physical prototyping. Global Industry Director, increasingly leverage engineering simulation to build in Industrial Equipment efficiency as they reduce emissions, fuel burn and time THERMAL TURBO & Rotating Machinery, ANSYS to market. To achieve targets, developers look at improv- Turbines must run at very high tempera- ing all aspects of machine performance. Industry lead- tures to reduce fuel burn, but they require ers develop and use high-temperature tolerant and lightweight materials to enable higher internal cooling to maintain structural firing temperatures and reduce weight, while maintaining or improving machine reliabil- integrity and meet service-life require- ity. Virtual design is especially valuable in incorporating smart capabilities that control fuel ments. Engineers used simulation to burn, automate load switching, monitor remote equipment and gather data. Advanced ther- evaluate state-of-the-art turbine-blade mal simulation is particularly important as temperatures increase and parts are subjected cooling-channel geometries and developed to increased cycling as a result of more varied operational requirements. High-performance an innovative geometry that outperforms computing now enables simulation with greater fidelity and realism, and provides engineers existing designs. with rapid turnaround and increased throughput required for digital optimization. Engineers Simulation delivers robust design can refine designs significantly before physical tests are performed, accelerating the process with a high degree of confidence that a and reducing risk. product will operate as expected. Pratt & Whitney leverages simulation from the This “best of turbomachinery” issue of be substantial if even one compressor was earliest stages of aircraft engine design to ANSYS Advantage includes many examples adopted by each of the 20,000 U.S. munici- improve both development speed and that validate the value of engineering simu- pal wasterwater treatment plants. product fidelity. lation in building better products. In the automotive sector, turbochargers Turbomeca used embedded software are used to get more power out of smaller simulation on its helicopter engine control COMPRESSION AND engines with the additional objective of system, decreasing development time by GAS MOVING not affecting a driver’s perception of han- 30 percent. The process also reduced Large centrifugal compressors used in the dling and performance. The ideal compres- coding errors. oil and gas industry must meet several sor (the heart of a turbocharger) is Turbomachinery design presents many stringent requirements, including high efficient over a broad operating range and challenges for R&D teams. Analyzing flow efficiency, high pressure, high reliability and has low inertia while complying with pack- requires high-fidelity simulation tools, and small footprint. Recent emphasis on wide age size limitations, robustness and cost virtual analysis is dependent on compute operating ranges increases the challenge. constraints. PCA Engineers easily meets power. As technology advances into the Dresser-Rand leveraged simulation these complex requirements by using a future, expect to realize more high- in designing compressor stages to operate highly automated simulation process that fidelity solutions, and more detailed design at higher flow coefficients and inlet- provides high-fidelity aerodynamic, struc- of experiments (with thousands of fast relative Mach numbers. The result was tural and thermal information, reducing runs) to optimize components. Nano- and nearly a 10 percent improvement in the engineering effort and time to market. mega-scaled grids will together provide surge margin. accurate resolution for even the most chal- Efficient equipment reduces power HYDRAULIC TURBINES lenging problems. Multiple physics analy- consumption as well as operating costs. Today’s hydraulic equipment must cover sis — including aero, mechanical, thermal Rotating machinery company Continental an increased operating range and cycle and vibration — will be part of every design Industrie designed a centrifugal compressor more frequently. In the hydropower indus- handbook, used in parallel, interactively with a potential for up to 5 percent energy try, plants experience enormous demand and simultaneously. Engineers then will be savings during wastewater treatment oper- swings. Engineers at ANDRITZ HYDRO able to develop turbomachinery that ations — an annual savings of $6,000 to analyze turbine performance over time, incorporates the right blend of trade-offs. $20,000 per compressor. Using simulation, under conditions that are constantly the company completed the design with a changing. To quickly retrofit aging plants three-person team in a reduced time frame, and troubleshoot performance, they and still the first prototype met performance successfully apply virtual analysis to repli- requirements. The aggregate savings would cate the incredible level of product detail. © 2016 ANSYS, INC. ANSYS ADVANTAGE 2 CENTRIFUGAL COMPRESSORS Pushing the Envelope CFD simulation contributes to increasing the operating envelope of a centrifugal compressor stage. By James M. Sorokes, Principal Engineer; Jorge E. Pacheco, Manager, Aero/Thermo Design Engineering; and Kalyan C. Malnedi, Manager, Solid Mechanics Group, Dresser-Rand Company, Olean, U.S.A. entrifugal compressors, also In recent years, the industry has Two factors limit the overall operating called radial compressors, play placed greater emphasis on achieving a range of a compressor: surge or stall mar- Ca critical role in many process wide operating range so that, for exam- gin, and overload capacity. Surge or stall industries, including oil and gas, petro- ple, compressors can handle a wider margin limits the compressor’s ability to chemical, and gas transmission. These range of flow rates at different stages of operate at flow rates lower than design, machines are used to compress a gas a well’s lifecycle. Engineering simulation while