Vishnu Sishtla

In the current energy scenario, it is necessary to reduce fossil fuel consumption to achieve the far-sighted and stringent decarbonization goals. To date, heat is mainly produced through fossil fuels. Alternatively, electrically driven heat pumps can exploit renewable power to recover environmental and waste heat, offering energy efficient and environmentally friendly heating and cooling for applications ranging from domestic and commercial buildings to process industries. For this reason, they are expected to play a primary role in complementing or displacing natural gas boilers in the residential and industrial sectors in the near future. Centrifugal compressors are already used as prime movers of the working fluid in heat pumps, thanks to their industrial replicability, compact size, affordable costs, and good performance in terms of efficiency and low noise. However, they are subject to instabilities such as surge and stall like any other dynamic compressor and these phenomena develop quite differently than in classic open-loop systems such as gas turbines. In fact, such peculiarity is mainly due to the closed-loop configuration with real gases in two-phase conditions, occurring in typical heat pump cycles. In addition, heat exchangers also contribute to make these phenomena different from what is commonly studied. Compressor surge in closed-loop heat pump systems has received lower attention than other applications by the engineering community, lacking dedicated experimental characterization, and clear exposition of the phenomenon. The aim of this paper is to experimentally investigate the behavior of a centrifugal compressor installed into an innovative close loop heat pump system under stable and unstable conditions from both vibrational and fluid-dynamic points of view. The impact of the main process parameters on the evolution of the instability is shown, highlighting how surge cycles change by varying system operating conditions. The energy contents of surge cycles and pressure fluctuations are highlighted, using data postprocessing techniques such as fast Fourier transform and phase locked average. The vibro-acoustic analysis enrich the comprehension of the phenomena. The experimental results shown in this paper can be a basis for the future development of validated mathematical models of closed-loop heat pumps systems equipped with dynamic compressors operating under stable and unstable operating conditions.

Modern radial compressors are designed to operate with high performance and a wide range of applications while minimizing their environmental impact. It is necessary to study the machine near the stability limit and gain a comprehensive understanding of the fluid dynamic mechanisms that trigger the instability in the system to extend the operating range at high efficiency. Machine learning aids in developing pattern identification models for detecting compressor instability. In a prior study, a two-stage radial compressor for refrigerant gas underwent extensive simulation, capturing unsteady RANS conditions and generating a substantial dataset of pressure signals from multiple probes. Selected signals, coupled with detailed computational fluid dynamics (CFD) post-processing, revealed fluid dynamic structures near surge conditions. This study utilizes all pressure signals to assess the stage's operational state (stable, transient, or unstable/surge). An additional goal is to develop an algorithm predicting flow patterns in different stage sections with minimal pressure signals at the rotor inlet. This is a preliminary step toward the development of a smart monitoring and diagnostic model for the compressor installed in a plant. The developed model consists of three submodels, trained with CFD results obtained from unsteady Reynolds averaged Navier–Stokes (URANS) simulations. The three submodels are a regression submodule, a classification submodule, and a forecasting algorithm. The regression submodule predicts diffuser static pressure fields, the classification submodule categorizes whether the compressor is in a critical condition or not, and the forecasting algorithm predicts the inducer pressure signals in the future impeller rotations according to the actual operation history. These sub-modules work together to forecast whether the compressor, according to the operation strategy, is going into instability conditions.

In the present energy scenario, heat pumps (HPs) are assuming an important role to improve energy efficiency in reversible cooling systems. In particular, in case of industrial size plants, centrifugal compressors are preferred with respect to other solutions; nonetheless, they are often subjected to variable operation and therefore they must withstand off-design conditions. For studying unstable operation of refrigerant closed-loop systems, Carrier provided the University of Genoa with a small size chiller rig equipped with an innovative high speed centrifugal compressor driven by a variable speed motor. This paper presents the vibro-acoustic signature analysis of such a closed-loop rig from a system perspective, mainly focusing on mechanical response of compressor casing. First, its vibro-acoustic characterization is conducted at on-design and stable operation. Afterwards, some surge transients are obtained by progressively closing some valves in plant feeding lines, and meanwhile vibro-acoustic signals are acquired at relevant plant locations to characterize system response just before instability onset. In this way, suitable surge precursors can be defined in incipient surge conditions for early surge detection in this kind of complex plants. Indeed, system dynamics is significantly affected by interposed volumes, and therefore the effect of heat exchangers in system response may be relevant. To this aim, system dynamics is analyzed in detail both in subsynchronous frequency range and in high frequency region to assess how its vibro-acoustic response varies when moving from stable conditions toward surge. Surge precursors are obtained by relying only on vibro-acoustic signals both in low and high frequency ranges in order to perform early surge detection in such chiller pilot system. The main advantage of the proposed approach is to exploit nonintrusive probes, which allow to define diagnostic indicators without interacting directly with the working fluid, therefore preserving system integrity and reliability.

Modern compressor design targets require high performance and a wide operating range in order to reduce the environmental impact. To understand the fluid dynamics mechanisms that trigger instability, studying the system at the stability limit is required. In this work, a two-stage back-to-back centrifugal compressor for refrigerant applications has been simulated with computational fluid dynamics (CFD) techniques using unsteady calculations in different operating points close to surge. These models have been validated by comparing numerical performance with experimental data. An in-depth fluid dynamics analysis combined with the monitoring of several pressure signals, postprocessed with FFT, identified different flow phenomena in the two stages toward the surge limit. The key role of the volute that induces a stronger upstream counterpressure in the first stage has been highlighted. This effect causes the formation of high entropy (low momentum) rotating cells in the diffuser that involve a higher channel portion with respect to the flow structure in the second diffuser. This phenomenon affects the upstream flow conditions at the impeller. In addition, the interaction between the inlet guide vane (IGV) and the inducer has been analyzed, observing that in the second stage, due to the flow nonuniformity after the intermediate compressor pipe, non-negligible separations occur. Starting from the peaks detected in the FFT analysis of the pressure signals, all the above flow mechanisms have been detected and discussed.