Early surge detection on a turbocharger used to pressurize a SOFC plant emulator

High-speed centrifugal compressors are commonly exploited to pressurize fuel cell-based hybrid energy systems. In such complex plants, because of significant interposed volumes due to fuel cells, dynamic compressor response can induce severe vibrations caused by low mass flow rates instability. In particular, surge strongly limits centrifugal compressors stable working region when moving towards low mass flow rate due to a change in system operating point. Consequently, a complete system identification is performed in order to adequately characterize compressor dynamic response for early surge detection. To this goal, a tailored experimental activity has been carried out at the Thermochemical Power Group of the University of Genoa on a vaneless diffuser compressor turbocharger used for the pressurization of an innovative solid oxide fuel cell (SOFC) emulator plant. Several post-processing methods have been performed on system vibro-acoustic responses to better predict and classify compressor status as stable or unstable. The obtained results provide original diagnostic insights for monitoring systems capable of preventing surge and other low mass flow unstable phenomena, such as rotating stall cells inception. Low mass flow rate fluid-dynamic instabilities prevention can extend compressor operating range, performance, and reliability to allow better integration with other plant components.