Analysis of the Flow-Field Distortions Induced by Pneumatic Pressure Probes in Test Bench Experiments on Centrifugal Compressors: Are We Testing Right?

Abstract

Experimental testing at the test rig still plays a key role in the development of new centrifugal compressor designs for industrial applications. Although a wide set of different probes is used as per common practice, the overall impact of the probes' dimensions on the stage performance and rangeability is often assumed to be negligible. In this study, we aimed at quantifying the intrusiveness effects of pneumatic pressure probes on the flow-field inside a vaned diffuser using a model stage of an industrial centrifugal compressor, for which different experimental setups were tested at the University of Florence test rig. Performance and rangeability were initially assessed using a conventional set of pneumatic probes inserted in the flow path. Then, comparative analyses were realized through dedicated tests by either removing all probes at the diffuser inlet or introducing only a single pressure probe in the upstream section and varying its angular position in the measuring section. Experiments revealed an impact of upstream probes much higher than expected, with a decrease in efficiency and a substantial reduction of stall margin. Moving from this experimental evidence, accurate three-dimensional computational fluid dynamics (CFD) simulations of the entire stage were carried out including the actual geometry of the probes for two probes configurations and three operating points (OPs). Simulations highlighted the effect probes' wakes on downstream vanes and the induced blockage effect, which both appear in line with experimental evidence. As a handout, a recommendation on the optimal probe positioning is suggested.