Modular multi-stage axial compressor design: A conceptual study with an example

Increasingly, companies are becoming more interested in reducing cost. Initially, cost reduction efforts were focused on the manufacturing and service side since the majority of the budget was consumed during that phase. However, recent studies indicate that up to 80% of the life cycle costs (LCC) has been embedded in the engine's DNA at the end of the development and design phase. This fact is motivating many companies to consider cost cutting initiatives much earlier in the development cycle than before. One concept to aid in such cost reduction is the modular design of expensive and development-intensive components, such as multi-stage axial compressors. With sufficient planning, any potentially negative impact on performance can be addressed and almost entirely eliminated. Conceptually, the compressor is divided into five (5) functional modules. In the successful modular design, the core module size is maximized, while all other modules are held to a minimum. It is the objective of this approach to utilize the core module in all the compressors, thus, maximizing commonality and minimizing all relevant development, design, manufacture, procurement, and service costs. This paper introduces the modular concept with an example; a multi-stage high pressure compressor (HPC) design is carried out to the preliminary meanline phase. The compressor is consequently divided up into its five (5) modules, and a modular upgrade is then developed for a different application using the same core. Discussion is presented as to the advantages and potential limitations.