Comparison of CFD-calculations of centrifugal compressor stages by NUMECA Fine Turbo and ANSYS CFX programs

Computational Fluid Dynamics (CFD) methods are widely used for centrifugal compressors design and flow analysis. The calculation results are dependent on the chosen software, turbulence models and solver settings. Two of the most widely applicable programs are NUMECA Fine Turbo and ANSYS CFX. The objects of the study were two different stages. CFD-calculations were made for a single blade channel and for full 360-degree flow paths. Stage 1 with 3D impeller and vaneless diffuser was tested experimentally. Its flow coefficient is 0.08 and loading factor is 0.74. For stage 1 calculations were performed with different grid quality, a different number of cells and different models of turbulence. The best results have demonstrated the Spalart-Allmaras model and mesh with 1.854 million cells. Stage 2 with return channel, vaneless diffuser and 3D impeller with flow coefficient 0.15 and loading factor 0.5 was designed by the known Universal Modeling Method. Its performances were calculated by the well identified Math model. Stage 2 performances by CFD calculations shift to higher flow rate in comparison with design performances. The same result was obtained for stage 1 in comparison with measured performances. Calculated loading factor is higher in both cases for a single blade channel. Loading factor performance calculated for full flow path ("360 degrees") by ANSYS CFX is in satisfactory agreement with the stage 2 design performance. Maximum efficiency is predicted accurately by the ANSYS CFX "360 degrees" calculation. "Sector" calculation is less accurate. Further research is needed to solve the problem of performances mismatch.