The Development of Machine Learning Models for Radial Compressor Monitoring With Instability Detection

Abstract 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.