Anti-surge systems
We have developed a working prototype of the anti surge system. Our solution is cheap, reliable and extends the machine working range.
We have developed an industrial prototype of the anti-surge system. The surge is a well-known instability appearing at low mass flow rates close to the optimal point of operation. Entering surge, even for a short time, can cause irreversible damage to the machine and display its crew health at serious risk. Classic solutions are based on a theoretical calculation of the surge limit. Due to possible inaccuracy of theoretical prediction, there is an additional 10%-15% cut of machine working range called “surge margin”. Our solution allows for rapid reaction on the presence of local flow instabilities preceding the surge. The solution allows to decrease the surge margin and introduce real-time preview into machine working condition. The algorithm is based on a single pressure monitoring point – it is cheap and reliable. It could be easily implemented on existing machines without much investment. The system can also support classic anti-surge system to extend the machine working range and safety. The system development was funded by the National Centre for Research and Development in Poland in the grant framework LIDER.
Machine Monitoring
We implement various non-linear signal analysis techniques. Our algorithms allow to detect local flow instabilities and prevent machine from energy losses.
We are developing a real-time detections system that allows us to detect machine operating conditions and capture the presence of instabilities in centrifugal compressors. We focus on the pressure signal as the instabilities and flow conditions will be best reflected in the pressure characteristics. Our work is also connected with acceleration and acoustic characteristics of the compressor operation. We are working with advanced data analysis and decomposition techniques, including Discrete Wavelet Transform, Empirical Mode Decomposition, Singular Spectrum Analysis, Spectral maps method. Our work lead to the creation of a patented instabilities detection solution called Rate of Derivative Fluctuation (RDF). The potential of the method was well proven by experimental and numerical research. Two next innovative systems are patent pending. Due to an advanced testing facility with three different industrial-size machines we test our systems in a real-life environment.
Compressor design
Our team delivers custom design of the centrifugal compressor. We can design the compressor from scratch or optimize existing designs.
Our team has wide experience in turbomachinery design. As a part of the Institute of Turbomachinery, Łódź University of Technology we have been involved in various design projects of centrifugal compressors, blowers, and other flow machinery. Our R&D experience includes also the design of novel, non-conventional designs for special purposes. We combine classic analytical design methods with CFD analyses and optimization techniques. Our experience in machine monitoring allows us to deliver a compressor together with a dedicated monitoring system. We are also open to deliver updates and improvements to the existing flow systems.
Digital Twin
We are working on algorithms to the digital twin technology. The system will deliver flexible predictive maintenance technique that could be used on any compressor.
This is an ongoing project for which we are open to new partnerships. Our mission is to design a multi-purpose digital twin of a centrifugal compressor. The system includes a predictive maintenance unit that informs about possible a malfunction at a very early stage. In most cases, the part replacement would be scheduled in advance. In immediate cases the system assures critical safety cut-off. In the course of regular machine operation, the algorithm is also able to provide automatic detection of off-design operation with the estimation of financial losses compared to possible optimal working conditions. This element is important for machines in continuous operation. The main advantage of our solution lies in minimized investment. A mixture of non-linear signal processing methods, numerical simulations, and analytical computations allows us to identify the machine working conditions with a minimized number of real-time measurements.
Design Optimization
We are developing and applying state of the art design optimization techniques and numerical models for turbomachinery components.
We are working on the development of innovative aerodynamic geometry optimization techniques. Our scope is concentrated on their application to turbomachinery problems. Our current research focuses on adjoint-based optimization methods and the application of isogeometric analysis to compressible flow problems. We also develop and enhance robust one-dimensional models of turbomachinery components as well as mathematical models of unstable phenomena in compressors.