The paper describes experimental and computational fluid dynamics analyses of the non-uniform static pressure distortion caused by the discharge volute in a high pressure, centrifugal compressor. The experiments described in this paper were done using a heavily instrumented gas re-injection compressor operating at over 6000 psia discharge. Instrumentation was installed to measure static, total, and dynamic pressure as well as impeller strain and mechanical vibrations. A brief description of the compressor and instrumentation are provided. Concurrent with the experimental work, CFD runs were completed to study the reasons for the pressure non-uniformity. The CFD pressure profile trends agreed well with the experimental results and provided analytical corroboration for the conclusions drawn from the test data. Conclusions are drawn regarding: a) the response of the non-uniformity to changing flow rates; b) the extent to which the non-uniformity can be detected upstream of the impeller; and c) the mechanical influences of the non-uniformity on the impellers.

The performance of a centrifugal compressor stage can be seriously affected by inlet flow distortions due to an unsatisfactory inlet configuration and the resulting flow structure. In this study, two radial inlets were designed for a centrifugal compressor stage and investigated numerically using a commercially available 3D viscous Navier-Stokes code. The intent of the design was to minimize the total pressure loss across the inlet while distributing the flow as equally and uniformly as possible to the impeller inlet. For each inlet model, the aerodynamic performance was calculated from the simulation results and then the results from both models were evaluated and compared. The second radial inlet design outperformed the initial design in terms of total pressure loss, flow distortion and uniformity at the impeller inlet. Furthermore, the aerodynamic performance of the second radial inlet was insensitive to a wide range of mass flow rates compared to the initial design due to the distinctive geometric features implemented for the second inlet design.

Flow field measurements and flow visualization for a quarter scale model of a radial compressor inlet are presented for varying flow rates and inlet profiles. Non-uniform inlet profiles are created using a 90° bend directly upstream of the inlet. Experimental results are compared with the CFD analysis from a commercial 3-D Navier Stokes code. The experimental and computational results show good agreement, even in regions of reverse flow. The results from this study show CFD analysis can be used with confidence to predict the performance of radial compressor inlets.

The paper is a sequel to an earlier work by Sorokes et al. 1998, “Investigation of the Circumferential Static Pressure Non-Uniformity Caused by a Centrifugal Compressor Discharge Volute.” The earlier work described experimental and computational fluid dynamics analyses of the non-uniform static pressure distortion caused by the discharge volute in a high pressure, centrifugal compressor with vaneless diffusers. This paper describes additional testing and analytical work done using low solidity vaned diffusers (LSD’s) in place of select vaneless diffusers to determine the alternate diffuser’s effectiveness in eliminating or reducing the magnitude of the non-uniform pressure field. As in the earlier studies, the experiments described in this paper were done using a heavily instrumented gas re-injection compressor operating at over 6000 psia discharge pressure. Instrumentation was installed to measure static, total, and dynamic pressure as well as impeller strain and mechanical vibrations. A brief description of the compressor and instrumentation are provided. Concurrent with the experimental work, CFD runs were completed to study the effect of the alternate vaned diffusers. The CFD pressure profile trends agreed well with the experimental results and provided analytical corroboration for the conclusions drawn from the test data. Conclusions are drawn regarding: a) the effectiveness of the LSD’s on the pressure non-uniformity; b) the associated effects on the measured dynamic strains in the impellers; and c) the usefulness of computational fluid dynamics (CFD) in assessing the aerodynamic forces associated with the non-uniformity.

The past decade has seen considerable growth in the application of CFD to centrifugal compressors. As computational methods applicable to compressors have improved, and computing power has increased dramatically, so has the scope of application. Impellers, diffusers, return channels, inlets, volutes and other components are now routinely analyzed, sometimes simultaneously. With the expansion of CFD, the user is now faced with many choices in establishing the most effective and efficient way to perform a given analysis. Advice, guidance and reports as to the experiences of other practitioners are of considerable value. This paper aims to investigate and compare relevant computational factors such as mesh type and density, and CFD solver discretization scheme as applied to the impeller, vaneless diffuser and volute of a centrifugal compressor.