The accurate prediction of mean flow fields with high degrees of curvature, adverse pressure gradients, and three-dimensional turbulent boundary layers typically present in centrifugal compressor stages is a significant challenge when applying Reynolds averaged Navier–Stokes turbulence modeling techniques. The current study compares the steady-state mixing plane predictions using four turbulence models for a centrifugal compressor stage with a tandem impeller and a “fish-tail” style discrete passage diffuser. The models analyzed are the k-ε model (an industry standard for many years), the shear stress transport (SST) model, a proposed modification to the SST model denoted as the SST-reattachment modification (RM), and the Speziale, Sarkar, and Gatski Reynolds stress model (RSM-SSG). Comparisons with measured performance parameters—the stage total-to-static pressure and total-to-total temperature ratios—indicate more accurate performance predictions from the RSM-SSG and SST models as compared to the k-ε and SST-RM models. Details of the different predicted flow fields are presented. Estimates of blockage, aerodynamic slip factor, and impeller exit velocity profiles indicate significant physical differences in the predictions at the impeller-diffuser interface. Topological flow field differences are observed: the separated tip clearance flow is found to reattach with the SST, SST-RM, and RSM-SSG models, while it does not with the k-ε model, a larger shroud separation at the impeller exit seen with the SST and SST-RM models, and core flow differences are in the complex curved diffuser geometry. The results are discussed in terms of the production and dissipation of k predicted by the various models due to their intrinsic modeling assumptions. These comparisons will assist aerodynamic designers in choosing appropriate turbulence models, and may benefit future modeling research.
The tandem-bladed impeller centrifugal compressor, which may offer potential aerodynamic benefits over conventional designs, is rarely employed in production gas turbine applications. Conventional impeller designs are often favored because of concerns for both significant performance losses and increased manufacturing costs associated with tandem configurations. In addition, much of the available literature concerning the characteristics of tandem-impellers is inconclusive, and at times contradictory. Because of the scarcity of tandem-impellers, rules for their design are nearly nonexistent. Also, the effects of inducer/exducer clocking upon tandem-impeller performance and exit flow characteristics are not fully understood. In the present study, a numerical investigation was performed to investigate the aerodynamic characteristics of a tandem-impeller design for the rear stage of a gas turbine compressor (target impeller PRt−t≈3.0). A parametric study of tandem-impeller inducer/exducer clocking was performed in order to explore its effect upon performance and exit flow quality. Because the tandem impeller was designed to be retrofittable for an existing conventional impeller, it was also compared to predictions for the baseline conventional design. Results of the study indicated that the tandem-impeller was less efficient than the conventional design for all clocking configurations studied. Tandem-impeller blade clocking was found to have a significant effect upon predicted pressure ratio, temperature ratio, efficiency, and slip factor; the maximum values for these parameters were predicted for the in-line tandem configuration. The minimum predicted tandem-impeller isentropic efficiency occurred at a clocking fraction of 50 percent, falling 3.8 points below that of the in-line case. Although the tandem-impeller performance was predicted to diminish as blade clocking was increased, significant improvements in the uniformity of impeller exit velocity profiles were observed. Profiles of both total pressure and swirl at impeller exit indicated that the tandem-impeller design may offer both improved diffuser recovery and stalling margin over the conventional design.
The complex flow field in turbomachinery poses numerous challenges for turbulence modeling. Herein, results of Laser Doppler Velocimetry (LDV) measurements of a full-scale aeroengine centrifugal compresser are used to validate typical design simulation results using a mixing plane and the k-ε, SST, or RSM-SSG turbulence closure models. Generally good agreement between simulation results and LDV measurements was found. The largest discrepancies were found in the near-wall regions: the predicted boundary layers were thicker and the flow more diffusive than measured. Important differences between the simulation results using different closures are discussed.
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