This research is designed to address the future of rotating compression technologies by developing methods to reduce energy consumption and reliability in order to respond to the short, medium and long-term development strategy of the industrial sponsor, Howden Compressors, a UK-based world-leader in fluid handling technologies.
20% of world energy is used for compression in refrigeration, air-conditioning, process gas and air handling systems. The limit to improve efficiency of these systems greatly depends on leakage losses through the gaps between rotating and stationary elements. Conventional approaches to minimize leakage gaps often lead to reliability issues due to thermal expansion of elements – thus alternative solutions are required to minimize losses and reduce costs. The core of this research is to fully understand the flow-heat-solid interaction in the leakage gaps and to develop novel rotating elements of larger capacities, self-regulating leakages and easy manufacturing to meet targets for reduction of compressors energy consumption. The key innovation of this research lies in the development of experimental and numerical methods to fully understand complex relationship of flow-heat-solid in gaps and the design of compressor elements with integrated mechanisms and sensor systems to remotely monitor and maximize efficiency without compromising on reliability.
The major expected outcomes are three demonstrator systems:
1. Test facility and validated numerical methods of heat-flow-solid interactions in clearances;
2. Scaled-down compressor prototype with novel rotor profiles and smart clearance management system;
3. Industrial prototype with integrated remote monitoring and self-regulating systems for minimization of energy consumption and increased reliability.
Apart of Howden and City, University of London, all industrial and academic sectors which deal with oil-free rotating machines, such as power recovery systems, food and pharmaceutical industries, vacuum pump applications and others will benefit from the knowledge, developed methods and devices built by this project. The UK public at large will benefit from the lower carbon footprint of these smart energy efficient fluid handling systems leading toward the net zero emission initiative and the wealth-creation with new jobs stimulated by this innovation.
Phase 1: Conjugate heat transfer in leakage gaps
WP1: Development of the roots blower test rig with the test equipment suitable for temperature/ flow measurements at high temperatures and pressures.
Deliverable 1: Operational optical test rig
WP2: Extensive experimental investigation of the leakage flow velocities and temperatures in the clearance gaps of the roots blower.
Deliverable 2: Test results for understanding physics of CHT in leakage gaps and CFD validation
WP3: High fidelity calculation of conjugate heat transfer and solid-fluid interaction in leakage flows using existing in-house grid generation methods.
Deliverable 3: CFD predictions.
WP4: Full validation of results based on WP3 results, with development of a new modelling software for performance and reliability analysis.
Deliverable 4: Full understanding of flow-heat-solid interaction in clearance gaps.
WP5: Establishment of a unique information platform using DDS, integrating data from WP2 tests and algorithms from WP3 validated in WP4 and creating instructions for data collection for control of efficiency/reliability.
Deliverable 5: DDA monitoring system.
Phase 2: Efficient and reliable rotating prototype machine with clearance control
WP6: PhD study on development of a measurement system for monitoring of clearances in rotating machinery.
Deliverable 6: PhD and the measurement system for monitoring of clearances
WP7: Create up to 3 novel concepts of leakage flow control in rotating machines, including new profile shapes, materials, surface quality and secondary flows. Based on the outputs from WP4 and WP6.
Deliverable 7: Concepts for control of efficiency and reliability
WP8: Specify, design and develop the hardware prototype machine able to integrate all three developed concepts of leakage flow control methods and installation of the rig at City. Based on WP6;
Deliverable 8: Prototype test rig
WP9: Integration of the DDA system into the prototype with the novel sensor system for monitoring gaps based on WP5 and WP6;
Deliverable 9: Fully operational smart prototype machine in the test rig
WP10: Extensive and rigorous testing of the three concepts with special attention to efficiency and reliability of each. Implementation of any required changes.
Deliverable 10a: Tested and selected optimal concept of a smart efficient machine.
Deliverable 10b: Extensive report on the most efficient leakage/reliability control option.
Phase 3: Smart efficient commercial screw machine
WP11: City and HOWDEN define specifications for the commercial smart efficient screw machine to be prototyped and tested by Howden based on reports from WP10.
Deliverable 11: Specification for the commercial machine
WP12: Design and development of a smart efficient screw compressor with Howden and Holroyd, integrated with DDA system for monitoring and control, aiming to meet both the efficiency requirements and the reliability targets.
Deliverable 12: Design of a commercial machine
WP13: Manufacture all elements of the smart efficient screw machine package and Install it in Howden. This includes; rotor manufacturing, commercial prototype manufacturing, DDA system manufacturing, test rig manufacturing and installation;
Deliverable 13: Fully equipped test rig with a commercial machine prototype
WP14: Extensive and rigorous performance testing of the commercial prototype developed in WP12 and WP13 including testing of control strategies and extreme operation conditions.
Deliverable 14: Fully tested and validated commercial prototype
WP15: Extensive feasibility study on the application and benefits of this novel smart efficient and reliable screw machine.
Deliverable 15: Final guidelines for future of new smart efficient and reliable rotating machines
WP16: Project management and administration including:
- Contracting
- Recruitments
- Financial management and administration
- Reporting
- Dissemination
Contents
Professor Ahmed Kovacevic
Howden/Royal Academy of Engineering Chair in Compressor Technology (City, University of London)
Describe your involvement in SECRET project?
I initiated and I now lead the project SECRET which is the acronym for “Smart Efficient Compression: Reliability and Energy Targets”. My main objective with this project is to extend the knowledge on the flow and heat transfer in leakage gaps of rotating machines. Lack of fully understanding physics of this phenomena is currently the major obstacle for radical improvements in rotating positive displacement machines. This will allow improvements in design of these machines and lead to reducing environmental impact and increasing reliability of these machines. This in turn will allow Howden to commercialise new technologies and reinforce their position of a leading provider of rotating machines.
What interests you about the SECRET project?
Scientifically, I am looking forward to a breakthrough in understanding internal leakage flows and their influence on the overall performance and reliability. With a great team we built I am sure this will lead to exciting and innovative concepts to deliver more efficient and reliable oil free machines than ever. It is very important for universities to make a positive impact on science, technology and general wellbeing. I hope that with this project we will make remarkable positive impact on environment and living standards.
What excites you most about working on a unique project like this?
Project SECRET is funded by Royal Academy of Engineering and Howden with the aim to extend knowledge and move technology of rotating positive machines forward. This will reduce environmental impact. Being the Director of renowned Centre for Compressor Technology, I am excited that this unique project will contribute to already very extensive portfolio of projects with industry which the Centre had in 25 years of its existence. We are already seeing large interest from industry for this exciting topic of project SECRET and we will be showing the first results at our 12th International Conference on Compressors and their Systems in September 2021.
Aleksander Krupa
Research Assistant (City, University of London)
Describe your involvement in the SECRET project?
I am working on experimental arrangement alongside with integration of the DDA monitoring system into the City’s tests rigs.
What interests you about the SECRET project?
I am most interesting part is designing and working on things that are later produced and used globally every day as well as introducing technology to pure mechanics for automation, monitoring and self-regulation.
What excites you most about working on a unique project like this?
To be a part of the team having a worldwide impact on compression technology and its sustainability.
Dr. Billy Milligan
Solutions Development Lead (Howden, a Chart Industries Company)
Describe your involvement in SECRET project?
I’ve been involved from the beginning when discussing topics such as instrumentation deployed on rotating equipment and control system connectivity, both locally and to the cloud.
What interests you about the SECRET project?
To deliver connected next generation air and gas handling assets that can measure, analyse and then optimise to provide the most efficient output possible.
What excites you most about working on a unique project like this?
The designing of a complete technology stack, from the measurement tip to the cloud that delivers leading edge analysis back to the actual asset to optimise performance.
Donald Lawson
Head of Product Engineering & Technology (Howden, a Chart Industries Company)
Describe your involvement in SECRET project?
Guiding the work of the programme to ensure that the research is focussed on areas which have relevance to industry and making sure that City University and Howden are working together as effectively as possible.
What interests you about the SECRET project?
Being able to collaborate with a team with varied background and interests is fascinating as every meeting generates new ideas and possibilities as the different development threads interact. The potential for revolutionary changes in how we approach machine design and operation is huge.
What excites you most about working on a unique project like this?
Close cooperation between the research team and our product development engineers at such an early stage of the project gives me a huge amount of confidence in our ability to rapidly commercialise the research outcomes. When it comes to reducing energy consumption to help fight climate change every day counts.
Dr. James Ure
Lead Design Analysis Engineer (Howden, a Chart Industries Company)
Describe your involvement in SECRET project?
My role is primarily to take the newly developed physics and novel clearance management technologies and incorporate them into a new Howden compressor design.
What interests you about the SECRET project?
Being involved in novel research to gain a deeper understanding of the physics of screw compressors.
What excites you most about working on a unique project like this?
The opportunity to create and develop novel technologies which will have a direct practical application to every new oil-free Howden compressor.
Dr Sham Rane
Research Fellow (City, University of London)
Describe your involvement in SECRET project?
I am involved in numerical analysis of leakage flows in twin screw compressors under Work Package – 3 and 4. An influence of Conjugate Heat Transfer on the flow physics is being studied to provide better CFD and lower order computational modelling procedures. By developing validated and reliable computational models, it will be possible to investigate further about flow control strategies and leakage gap management to improve the performance of these machines.
What interests you about the SECRET project?
SECRET is focused on the integrating traditional machines and its working to a modern computer assisted infrastructure with real time data monitoring and control. These facilitates a broad platform for innovation and development. In the field of computational analysis, the project aims to develop new models, validate them using experimental data and extend the scope to other flow machines where leakage gap plays an important role.
What excites you most about working on a unique project like this?
Working as a part of an excellent team with wide technical skills and possibility to innovate.
Thibaud Plantegenet
Howden/RAEng Postdoctoral Research Fellow (City, University of London)
Describe your involvement in SECRET project?
I am mainly working on phase 2 of the SECRET project that consist of improving performance and reliability of oil-free screw compressors by designing and testing a prototype. Especially, I am involved in the definition and realisation of the new design concepts of the oil-free screw compressor in order to reduce or control leakage flows by the use of various methods (new rotor profiles, coatings…). I am also responsible for the installation of the new test rig and the experiments conduct on it.
What interests you about the SECRET project?
I am interested by the SECRET project because his goal is to reduce the power consumption while improving the reliability and efficiency of the oil-free screw compressor and so making this technology much affordable for industry in an equal place with the oil injected screw compressors.
What excites you most about working on a unique project like this?
To be in close collaboration with an industrial partner and working together toward innovative technologies that will reduced our impact on the environment.
Neeraj Bikramaditya
PhD Candidate (City, University of London)
Describe your involvement in SECRET project?
I am responsible for the WP4. The part of the package is aimed to develop a modelling software for more reliable solutions. The full understanding of the physics in the leakage is desired to be resolved using Fluid-Structure interactions and Conjugate heat transfers.
What interests you about the SECRET project?
SECRET project is focused on innovations and developments of the product using the Numerical modelling and experiments. It gives confidence when the computational results are fully validated with state-of art testing, and finally being developed.
What excites you most about working on a unique project like this?
As a CFD enthusiast, I always like to hone my skills by solving complex and challenging problems. This projects gives me the opportunity to work with pioneers of this field, and use my previously gained skills to obtain better results in an efficient manner.
Craig Anderson
Lead Development & Design Engineer (Howden, a Chart Industries Company)
Describe your involvement in SECRET project?
My role within project SECRET is to provide technical support regarding Howden screw compressors, and to assess the objectives and progress.
What interests you about the SECRET project?
The prospect of improving screw compressor efficiency and performance using improved clearance management technique based on the data obtained on leakage.
What excites you most about working on a unique project like this?
The opportunity to work with such a highly regarded team to develop my knowledge and skills, and the ability to be able to take the findings from the project to help optimise Howden oil-free screw compressors.
Anurag Kishan
E,C&I Engineer at Howden, a Chart Industries Company and PhD Student at City, University of London
Describe your involvement in SECRET project?
My involvement is in WP6. The tasks involves to Investigate experimentally the variation of operational clearances in a positive displacement machine during operation and compare to mathematical and numerical models. The operational radial clearances will be measured through various measurement techniques involving FBG sensors to eddy current probes. The other part of the work packages involves in Investigate concepts and strategies for reducing leakage flows and clearance gap size.
What interests you about the SECRET project?
By training and profession I am mostly involved Measurement and control system of rotating machines and equipment’s. Even though there are multiple engineering tasks involved in WP6, the measurement part will be most challenging and interesting. This motivates me to explore on the WP6 in detail. Also I am very interested to see how my contributions ,finding and solutions will help to validate mathematical modelling examples.
What excites you most about working on a unique project like this?
Since my work is in WP6. The topic is also my part of PhD Study. I am excited to know and explore how academia and industry collaboration can define and solve lot of challenging tasks involved with Rotating positive displacement machines. Also I am very glad that my contribution to this studies might help in developing efficient machines that can contribute to effective goal of net zero targets.
Emma Fogg
Sales & Marketing Administrator (Howden, a Chart Industries Company)
Describe your involvement in SECRET project?
My involvement in project SECRET is to work closely with the project team to identify and implement strategic marketing initiatives. By working closely with the team I can ensure that the marketing aligns with the overall project goals.
What interests you about the SECRET project?
Working with the team on novel research and the potential for revolutionary change and understanding of screw compresssors.
What excites you most about working on a unique project like this?
Having the opportunity to work with an excellent team and in the end having a brand new product to bring to market
Anderson Leao
PhD Candidate
Describe your involvement in SECRET project?
I am primarily involved in the WP2 SECRET project, where my primary responsibility is investigating the Roots Blower's clearance gap. This consists of conducting measurements using PIV and PLIF techniques, which is also the focus of my PhD research. Specifically, I will utilise PLIF and PIV to measure and analyse the clearance gaps in the positive displacement machines within the Roots Blower.
What interests you about the SECRET project?
Through the SECRET project, I had the chance to delve into various areas, including Particle image velocimetry (PIV) and Planar laser-induced fluorescence PLIF. Out of the two, PLIF was particularly captivating and held my interest.
What excites you most about working on a unique project like this?
The successful collaboration between academic and industry teams enables the PhD Student to perform the signed projects by giving assurance and allowing them to explore new techniques.
Dr. Manoj Heiyantuduwa
Lead Design & Development Engineer
Describe your involvement in SECRET project?
My involvement in SECRET project includes working within the project team to review the objectives and progress, and also to provide the necessary technical assistance when required.
What interests you about the SECRET project?
SECRET project is aiming to investigate the fundamental physical characteristics of leakage gaps and leakage behaviour of oil free screw compressors. This will enable us to improve the performance of oil free screw compressors without compromising the compressor reliability.
What excites you most about working on a unique project like this?
The opportunity to work within a team which has a wide range of expertise in screw compressor technology. This will help me to enhance my knowledge and expertise and to keep me up-to-date with the latest technological advancements in the screw compressor field.
Thibault Tam
PhD Candidate
Describe your involvement in SECRET project?
I will primarily be working on WP6 as the main topic of my PhD thesis. Specifically, I will be developing a measurement system for monitoring radial clearances in dry-running screw compressors and collecting experimental data at the Centre for Compressor Technology. I hope that measuring the variation in radial clearances of a compressor in operation will allow us to further underline the close relationship between the efficiency and reliability of these machines. We expect this dimension to vary differently depending on its location in the compressor, so it will be very interesting to propose a system that can quantify this. As the project team explores concepts for controlling and minimising leakage flows on the prototype compressor, the measurement system of WP6 has the potential to collect one of the key parameters of interest during these tests. Moreover, it has the potential to be further developed as an instrument that can be integrated into an industrial compressor package.
What interests you about the SECRET project?
What interest me most about the SECRET project are the technical challenges that can only be addressed by drawing from multiple engineering disciplines. These challenges are not only extremely stimulating to engineers who share these interests, but more importantly they are relevant to today’s industry and research. The findings of this project will open new research opportunities, and will result in industrial solutions that can reduce energy usage while extending the operating life of assets.
What excites you most about working on a unique project like this?
In a first instance, the chance to complete a technical body of work that will be directly relevant to an industrial application is very important to me. But perhaps what excites me most about this unique project is the chance to learn from the most engaging researchers and engineers in this field, and working alongside them towards a common goal. This wouldn’t be possible without the strong partnerships in this project.
Brijeshkumar Patel
PHD Candidate
Describe your involvement in SECRET project?
Responsible for WP1 and WP2 of secret project, which involves development of Roots blower test rig and Experimental investigation of the leakage flows in the optical test rig.
What interests you about the SECRET project?
SECRET project allows me the opportunity to explore and implement the new measurement techniques which is the most interesting part for me.
What excites you most about working on a unique project like this?
Working on the project like this allow us to work with team members from academia as well as Industry, which provide chance to learn from vast range of experience of others. In addition, at the end we will be able to provide excellent new product to the market.
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