• Investigating possibilities for anomaly detection and condition-based maintenance using vibration and acoustic measurement data
• maximum pressure ratio: 2,2
• maximum mass-flow rate: 2 kg/s
• maximum specific head: 70 kJ/kg
• Rotor speeds up to 22000 rpm
• IGV positions: -20° to +70°

Measurement Equipment

• Accelerometers with frequency range up to 20 kHz
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• Acoustic free field microphones with frequency range up to 20 kHz​
• Measuerments of process data: inlet/outlet Temperature, inlet/outlet Pressure, Shaft Vibration, Rotor Speed, Bearing and Oil temperature

Universal data acquisition system:

•     HBM QuantumX 410B (≤ 100 kS/s, 12-channels)
•     HBM QuantumX 840B (≤ 50 kS/s, 8-channels)

• single-stage radial compressor
• investigating the impact of wet compression on the compressor map
• nominal pressure ratio: 2
• nominal mass flow rate: 2,5 kg/s
• nominal power required: 440 kW
• adjustable air temperature at compressor inlet 20-90 °C
• water injection via pneumatic atomizing nozzles

Measurement Equipment

• probe calibrator:
  • modified and automated TSI 1127 (Ma ≤ 0.95)
    
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• rapid manufacturing / selective laser sintering (SLS)
  • stator geometries for different flow coefficients (≤ 𝝋 = 0.12)
  • low cost and time efficient testing
• Mach numbers up to Ma ≤ 0.8 at diffusor inlet
• Reynolds numbers up to Re ≈ 5.5∙10⁵
• separate generation of steady and unsteady inlet flow characteristics
• five hole probes with thermocouple
• steady state and time-resolved wall-bounded pressure measurements
• hot wire probes for measuring turbulent statistics (< 200 kHz)

Measurement Equipment

Hot Wire Anemometry​

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• measurement systems:
  • Dantec Dynamics – StreamlinePro
  • TSI – IFA 300
• data acquisition system:
  • HBM QuantumX 410B (≤ 200 kS/s)
• probe calibrator:
  • modified and automated TSI 1127 (Ma ≤ 0.95)
    
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Probe Traversing Device

• translational and rotational motion
• variable translation travel
• step control with micro switches
• step resolution
  • minimal translation step size:   5 µm
  • minimal rotational step size:     0.07 °
• electrical isolation through FDM* manufactured clamping fixture
  
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Rotating disk in cylindrical cavity for aerodynamics and acoustics measurements

• different working fluids, pre-mix vessel
• different disks with different shapes and surface roughness
• non-dimensional axial gap width down to G = 0.0125
• circumferential Reynolds numbers up to Re =1.2∙10⁸ (CO2)
• circumferential Mach numbers up to Ma = 0.75 (CO2)

Investigation of acoustic modes and disk vibration as means of studying rotor-stator interaction in a simplified radial compressor model

• two loudspeakers as excitation source capable to excite acoustic and structural modes of the gas and disk, respectively

Measurement Equipment

• pressure and temperature sensors in front and back cavity
• strain gauges and pressure sensors on disk
• rotatable pressure sensor (for mode identification)
• hot wire anemometry

• design operating condition: 18,000 rpm, 100 bar
• overhung configuration with rigid couplings
  • reduced turnaround time
  • direct access to test seals and sensors
• film thickness (0 – 50 µm)  and static pressure (≤ 110 bar) measurements in the running gap

Measurement Equipment

• high frequency pressure measurements with ultraminiature pressure probes (≤ 100 kHz)
• proximity sensors for measuring the film thickness and the displacement of the parts
• fast response surface thermocouples for the ring temperature

Experimental Multi-phase Measurement Application

• maximum steam massflow = 55 kg/h
• connection for external steam generator for possible steam massflow increase
• maximum absolute steam pressure = 5 bar
• maximum superheated steam temperature = 300 °C
• cooling capacity of 10kW for wallsubcooling to induce condensation
• 8-zone controllable heating system for wallsuperheating to induce evaporation
• preheated liquid water injection for wet steam generation
• modular measurement section for variation of wall geometries
• optical access to the measurement section
• resolvable liquid film thickness range = 1 µm – 3000 µm

Measurement Equipment

• ​heat transfer coefficient (HTC) measurement systems for condensation and evaporation
• infrared-interferometric filmthickness measurement system
• chromatic-confocal filmthickness measurement system
• extinction measurement system for determination of wet steam density

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evaporative cooling Multiphase Axial Compressor

• Four-stage axial compressor
• investigation of wet compression and interstage injection
• pressure ratio: 1.9
• mass flow: 15 kg/s
• power at shaft: 980 kW (Driven by two DC-engines and tandem gear box)
• injection of highly pressurized water (up to 200 bar)
  • in front of the compressor
  • behind stator 1 (SLM manufactured stator, containing internal conduits to supply twin jet nozzles with water)
• adjustable IGV and stator blades
• droplet measurements via nonintrusive LDA/PDPA-system

To get an insight into the compressor, watch our VR video.

Measurement Equipment

• torque and rotational speed at shaft
• inlet mass flow rate
• steady state pressures in front/behind every stage
• thermocouples in front/behind every stage
• bearing oscillations (proximity sensors)
• five hole probe with thermocouple in between stator and rotor
   
• non-intrusive PDPA (Phase doppler particle analysis)
  spray characterization in superposed flows via light scattering mechanism
  measurement of droplet diameters and velocities
  • Argon-Ionen-Laser
  • transceiver-probe: TSI-TR260 (2D-LDA)
    • wavelenghts: 488 nm and 514.4 nm
    • focal lenghts: 512, 350 mm
  • receiver-probe: TSI-RV2100 Receiver (2D-PDPA)
    • focal length: 500 mm
    • backward and front scattering (e.g. off-angle: 150, 30 degree)
  • traversing in x,y,z,φ-coordinates

Steam Turbine Experimental Valve Enhancement

• investigation of fluid-structure-interaction in a single control valve
• modular design
  • interchangeable diffusor-geometry
  • complete interchangeable inner geometry
• mach similarity to full scale ensured
• pressure ratios
• first test rig with full vibrational similarity due to
  • material selection
  • operating conditions

Measurement Equipment

• highly dynamic universal data acquisition system:
  • HBM QuantumX 410B (≤ 200 kS/s), 20-channels
• high frequency displacement measurements with Eddy current proximity sensors (≤ 125 kHz)
• high frequency pressure measurements with ultra-miniature pressure sensors (17 bar, nat. frequency 550 kHz)
• high frequency piezo electric force measurements (1 kN, 10 kHz)

cooperation with Siemens location in Görlitz

• investigating of fluid-structure-interaction
• investigating interaction between two control valves
• modular design
  • interchangeable diffusor-geometry
  • complete interchangeable inner geometry
• mach similarity to full scale ensured
• full vibrational similarity due to
  • material selection
  • operating conditions

Measurement equipment

• highly dynamic universal data acquisition system:
  • HBM QuantumX 410B (≤ 200 kS/s, 20-channels)
  • HBM QuantumX 840B (≤ 40 kS/s, 8-channels)
• high frequency strain measurements on valve plug with miniature strain gauges
• high frequency pressure measurements with ultra-miniature pressure sensors (17 bar, nat. frequency 550 kHz)
• high frequency piezo electric force measurements (1 kN, 10 kHz)
• high frequency displacement measurements with Laser proximity sensors (110-190 mm, 392 kHz)

• experimental investigation of water injection for compressor applications
  • interstage injection in a vaned cascade with curved flow path (shown here)
  • cylindrical nozzles in a straight glass pipe
• data
  • superimposed air flow:
    • Ma_air ≤ 0.6
    • T_max = 450 °C
    • p_max = 10 bar @ 1.5 kg/s
    • ṁ_max = 2 kg/s @ 2 bar
  • injected water
    • T_max = 200 °C
    • p_max = 250 bar @ 1.35 kg/s

Measurement Equipment

non-intrusive PDPA (Phase doppler particle analysis)
spray characterization in superposed flows via light scattering mechanism
measurement of droplet diameters and velocities

• Argon-Ionen-Laser
• transceiver-probe: TSI-TR260 (2D-LDA)
  • wavelenghts: 488 nm and 514.4 nm
  • focal lenghts: 512, 350 mm
• receiver-probe: TSI-RV2100 Receiver (2D-PDPA)
  • focal length: 500 mm
  • backward and front scattering (e.g. off-angle: 150, 30 degree)
• traversing in x,y,z,φ-coordinates