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Printed in U.S.A.
Copyright 1993 by ASME

AERODYNAMIC DESIGN AND ANALYSIS OF

VANELESS DIFFUSERS AND RETURN CHANNELS

Ronald H. Aungier
Product Development
Elliott Company
Jeannette, Pennsylvania

ABSTRACT L - passage length

Procedures are presented for the aerodynamic design and LC - total pressure loss coefficient (based on component
performance analysis of vaneless diffusers, crossover bends and inlet velocity pressure)
return channels. The design of the crossover bend and return m - meridional coordinate
channel is formulated to permit a computerized interactive design M o - rotational Mach number (impeller tip speed divided by the
system, which has provided dramatic improvements in both stage inlet total sound speed)
quality of designs and engineering productivity. Mean streamline n, - dimensionless specific speed (Babe, 1981)
performance models are employed to fully support the interactive P - pressure
design system. These performance models are qualified against R - mean streamline radius of curvature
experimental data from several centrifugal compressor stage tests. - radial coordinate
A recent development program which used these procedures is t - vane thickness
reviewed to demonstrate their benefits. - gas specific volume
w - mass flow
x - distance along vane chord line
NOMENCLATURE z - number of vanes
A - area a - flow angle with respect to tangent
A R - area ratio - vane inlet flow angle at minimum loss condition
a chordwise location of the point of maximum camber
- - blade angle with respect to tangent
b - passage hub-to-shroud width O" - vane deviation angle at minimum loss condition
C - velocity 0 - vane camber angle
c - vane chord length B o - equivalent divergence angle, equations (5) and (43).
cr - skin friction coefficient 0 7 - vane trailing edge angle with axial direction
C o, - meridional velocity component q5 - angle of C o, relative to the axis of rotation
C, - tangential velocity component a - vane equivalent solidity
D - passage divergence parameter, equations (5) and (7)
d - minimum metal thickness of return channel, figure 8 Subscripts
d H - hydraulic diameter av - average value or value at mid-chord
E - diffusion efficiency, equations (9) c - crossover bend parameter
h - gas enthalpy h - parameter on the hub contour
l c - curvature loss term, equation (13) m - a maximum condition
I D - diffusion loss term, equations (10) and (12) o - exit turn bend parameter
i - vane incidence angle s - parameter on the shroud contour
K - blade loading parameters t - total thermodynamic condition
K B - area blockage factor (fraction unblocked) 1 - passage entrance parameter

Presented at the International Gas Turbine and Aeroengine Congress and Exposition
Cincinnati, Ohio May 24-27, 1993

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 4 - diffuser exit parameter are modeled by a classical diffuser analogy. The data of Reneau
5 - crossover exit parameter et. al. (1967) shows the low loss regime can be identified by the
6 - return channel vane inlet parameter divergence parameter
7 - return channel vane exit parameter D = MA R - 1) 1 L = 2tane, (5)
8 - return channel passage discharge parameter
where diffusion losses are low for values of D less than
D m = 0.4(b 1 / L)35 (6)
INTRODUCTION
The aerodynamic performance of centrifugal compressor stages Equation (6) is an empirical fit of the data in figure (8b) of
is strongly influenced by the internal flow and losses in the Reneau et. al. (1967). The analogy for the vaneless annular
stationary components. The return system stands out as passage used is
undoubtedly the least understood component of the centrifugal
b dC (7)
compressor stage. The presence of the upstream 180 annular C dm
crossover bend, and the interaction of the flow through the bend
with the downstream vane row, present a formidable fluid
D,,, = 0.4(b 1 1 L)35sina (8)
dynamics problem. The literature offers little information
relative to specific design procedures or performance prediction The flow angle term in equation (8) is an empirical factor derived
models for this component. Most published experimental and from comparisons of predicted and measured loss data from over
theoretical investigations are directed toward developing a better 35 compressor stage tests. Based on this same comparison, an
understanding of these complex flows (e.g., Davis, 1976, Fister, empirical diffusion efficiency model was formulated as
et. al., 1982, Japikse and Osborne, 1982, Nykorowytsch, 1983, E=1;DO
Aungier, 1988a). Return system design has largely consisted of
applying basic engineering judgement to control diffusion rates, E = 1 - 0.2(D / D,,) 2 ; 0 DD m (9)
passage curvatures and other design parameters, based primarily
upon empirical categorization of performance from past E = 1D;D
development activity (e.g., Hohlweg, 1987).
The diffusion term is given by
The present paper presents aerodynamic performance analysis v dC
dip = -2(P, - P)(1 - E) (10)
techniques for general vaneless annular passages and return dm C dm
channels, including comparison with experimental data. Specific
aerodynamic design procedures for vaneless diffusers and return In addition to this streamwise diffusion loss term, an excessive
systems are presented. meridional gradient of the passage area can cause higher losses.
Again, a diffuser analogy is used to check for this situation at
each computing station. The maximum, stall-free, local area is
VANELESS PASSAGE PERFORMANCE estimated by
Experience gained while predicting vaneless diffuser and (rb) m = (rb) 1 [1 + 0.16m / b 1 ]
crossover bend losses with the author's three-dimensional analysis
(Aungier, 1988a) has provided insight into loss mechanisms to which is equivalent to a diffuser divergence angle, 28 c , of 9 . If
permit formulating an accurate mean-streamline performance the local area exceeds this value, a second estimate of the
analysis. The governing equations are diffusion term is generated
21crbCif / v = w (1) r s.b .
Ip = 0.65v(P, - P)(1 (12)
r )
d(rC )
bC,,, dm" - If this value exceeds the local value obtained by integrating
equation (3), it replaces that lower value. The passage curvature
loss term is given by
vdp scP
Cin dc cICC, dip
C - /c. = v(P, - P)C, 1 (13RC) (13)
dm r m dm b dm
Equation (13) was developed empirically from comparisons of
C2
predictions with test data for 35 different vaneless diffuser/return
h, = h + system combinations. This term has negligible effect on vaneless
2
diffuser performance, but is always significant (and sometimes
Except for the last two terms in equation (3), this set of equations dominant) for crossover bends. Once the accuracy of the analysis
is conventional for mean-streamline analysis (e.g., Johnston and was established for vaneless diffusers, equation (13) was
Dean, 1966). The additional terms address loss contributions due developed to extend the analysis to crossover bends. Its validity
to flow diffusion and passage curvature. Flow diffusion losses is further supported by the successful use of this same analysis in

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overall stage performance prediction for other curved passages
such as the stage inlet passage and the exit turn from return
channels.
The
tana* area blockage factor and the skin friction coefficient
= are
computed using a simple boundary layer growth model, based on
a 1/7th power law for the boundary layer velocity profiles. The
analysis requires specification of an inlet boundary layer thickness is given by
(typically supplied by an impeller performance analysis).
Boundary layer growth is estimated from the change in angular
momentum predicted by integration of the governing equations.
The
LC boundary layer thickness is used to compute the blockage
factor. Skin friction is computed from an empirical correlation
of classical fully-developed pipe flow friction factors, including
laminar, transition and turbulent flow as well as surface
roughness effects (e.g., Schlichting, 1979). Pipe flow friction
factors are also valid for boundary layers if the pipe diameter is
replaced by twice the boundary layer thickness. Hence, the
thickness of the two boundary layers is used in place of the
passage width to compute the friction factors. This leads
AC = to
higher values for cases where the boundary layers do not fill the
passage, which is quite significant for high specific speed stages.
This performance analysis is used for vaneless diffusers,
crossover bends and other vaneless annular passages. Its validity
has been established for a broad range of stage specific speeds
and operating conditions, including cases where D is far in excess
of D,. Use of velocity pressure (P, - P) rather then velocity head
as a loss coefficient base, insures applicability to a broad range
of Mach number levels. The analysis has been qualified against
test data for Mach number levels up to 0.85 with no observable
influence of Mach number level on prediction accuracy. But, it
should be noted that effects due to differences in inlet flow profile when the boundary layer separates from the blade is set to C7.
distortion and turbulence intensity levels are not specifically
modeled by this analysis.
C
angle is equal to the flow angle in the vane throat. Since the
return channel analysis does not use area blockage directly, the
minimum loss incidence angle is corrected to account for the
entrance blockage to yield
KBtan[sin 1 (A, / A 6)] -
(16)
where A, is the vane throat area. The incidence loss coefficient
LCin, = 0.8[1 - C ii6 / (C6sina")] 2 (17)
Skin friction loss is computed by
D = (4Lcf cl,)(Cm, C6) 2 (18)
where C., is the average of the discharge velocity and either the
inlet or throat velocity (whichever is larger), d H is the average of
the throat and discharge hydraulic diameters and c f is computed
from the correlation discussed previously. The average
blade-to-blade velocity difference is computed from the vane
circulation
2n(r6C.6 r7 C. 7) I (a) - (19)
and the blade loading loss coefficient is given by
LC B, = [AC / (6C6)] 2 (20)
The maximum vane surface velocity is estimated assuming it
occurs at mid-passage for a mid-loaded vane
= 0.5(C6 + C7) + AC (21)
and C m > C6 is required to include the more common case where
the return channel vane maximum surface velocity is the inlet
value. When C m > 2C 7 , it is assumed that the boundary layer
will separate at a velocity, C, = C m /2. Otherwise, the velocity
The velocity after wake mixing is estimated from
o = V(C7A 7 / A0)2 + C!7
(22)

RETURN CHANNEL PERFORMANCE
-The return channel vane passage performance shares many
common features with the author's vaned diffuser analysis
(Aungier, 1990), both of which are adaptations of a mean
streamline impeller flow analysis. A significant difference is the
treatment of incidence losses, which are strongly influenced by
flow distortion imposed by the upstream crossover bend. Two
estimates of aerodynamic area blockage factors at the vane
entrance are made, and the smaller value is used.
1 constant velocity. Our analysis also includes the choking loss of
- (14)
1 + g (12R)
KB = (r6b6) (15)
Equation (14) is a simple inviscid flow estimate using the average
radius of curvature, R, of the crossover bend. Equation (15)
estimates blockage due to stall, based upon equation (11). The
Minimum incidence loss is assumed to occur when the flow inlet
where A7 includes the vane metal blockage, while A, does not.
The wake mixing loss coefficient is given by
= [(Csp - Co) / C6] 2 (23)
The loss coefficient due to the exit turn into the eye of the next
stage is given by
LCo = / C6)2 (24)
which is derived from equation (13) for a 90 turn, assuming a
Aungier, 1990. But, since the author has never seen choke in a
return channel, it will not be repeated here. The flow discharge
angle is computed from the transformed axial flow compressor
deviation angle model reported in Aungier (1990). The position
of the point of maximum camber, the vane solidity and camber
angle are estimated using the vane camberline vane angle at
mid-chord, O.,.

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 parameter defined in equation (43) and evaluated at the crossover
a 2 (13 , - Pe)
= Li ] (25) discharge. The return systems considered represent both fairly
3 (P7 - Po) modern good design practice and obsolete designs containing very
undesirable features. The multiple integrations required, and
z(r6 / r7 - 1) their use in the ratios of small differences to define the loss
a - (26) coefficients, result in considerable data scatter. However, the
2nsink, agreement between prediction and test data is considered
satisfactory to support both design and application activity.
(27)
= P7 - P6
and the reference deviation angle is based on Howell (1947) RADIAL VANELESS DIFFUSER DESIGN
6[0.92(a / c) 2 + 0.02(90 - p 6) The radial vaneless diffuser passage construction is constant
8* (28) width, parallel wall style with a width adjustment in the first
FT - 0.026
% 15-20% of the passage to blend to the impeller tip width.
Specifications required are the inlet and discharge radii and
Off-design incidence effects on flow deviation angle are included widths and the blend radius at the start of the constant width
by an empirical correlation of figure 177 of Johnsen and Bullock, section. A second-order polynomial variation of width with
1965.
= exp[((1.5 - p, / 60) 2 - 3.3)0]
di
(29 )

da
_
0 -

a77 = P7 8 - (P4 - ar)

di
rn
The analysis is a simple iteration procedure, computing the Ho - O
losses and fluid turning while balancing mass at the discharge, I-4
O
until convergence is achieved. C.)

44
410
TABLE I: COMPRESSOR STAGE DESIGN DATA 0

0.-
STAGE n. M. b./r4 b./b4 b./R 20cs
0 a

A #1 0.776 0.70 0.081 1.448 0.922 5.20

O TEST DATA 0
A #2 0.776 0.70 0.072 1.767 1.995 15.41 0 - PREDICTION
0 10 15 20 25 30 35 40
B 0.854 0.88 0.058 1.444 1.453 8.09 DIFFUSER EXIT FLOW ANGLE - degrees
FIGURE 1: VANELESS DIFFUSER PERFORMANCE - COMPRESSOR 0 A41"
C 0.272 0.50 0.011 3.064 0.717 8.74

0 0.699 0.70 0.049 2.338 1.747 17.65

E 1.110 0.70 0.097 1.294 0.913 3.78

COMPARISON WITH EXPERIMENTAL DATA

Validation of the performance models was accomplished for

over 35 individual centrifugal compressor stage development
tests. These tests include traverse probes at the impeller tip,
vaneless diffuser exit and stage exit. These data are integrated
and mass averaged to permit calculation of the component loss
coefficients (where the crossover bend and the return channel
vane section are treated as a single component). Figures 1 to 7 0 TEST DATA
are representative of the correlation between prediction and test 0 - PREDICTION
data for vaneless diffusers and return systems. As seen from 0 15
10 20 25 30 35 40
Table I, these cover a range of stage specific speeds and DIFFUSER EXIT FLOW ANGLE - degrees
rotational Mach numbers. The last column in Table I is a design FIGURE 2: VANELESS DIFFUSER PERFORMANCE FOR COMPRESSOR "B"

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radius is used at the entrance to match the two specified widths

and the zero gradient condition at the blend radius. Normal
practice is to use a radial hub contour with all width adjustment O TEST DATA
- PREDICTION
imposed on the shroud contour. This is believed to be more
effective in improving the impeller tip flow profiles, which often
tend to deteriorate toward the shroud wall.

Design optimization involves selecting the discharge width and

the blend radius with the other specifications viewed as design
constraints. Loss curves similar to figures 1 and 2 are used to
evaluate the alternate choices of these parameters. An interactive
design program could be used for this purpose. But, direct use
of a mean streamline centrifugal compressor performance
program is more convenient, since impeller discharge flow
predictions are provided directly.
0-12.0 -8.0 -4.0 0.0 4.0 8.0 12.0
RETURN CHANNEL VANE INCIDENCE - degrees
FIGURE 5: RETURN SYSTEM PERFORMANCE FOR COMPRESSOR "B"

O TEST DATA
- PREDICTION

0
0

- PREDICTION
0 0 TEST DATA m
.::;
0 50 60 70 80 90 100 110 120 130 140 -6.0 0.0 4.0 8.0 12.0 16.0
% DESIGN FLOW RETURN CHANNEL VANE INCIDENCE - degrees
FIGURE 3: VANELESS DIFFUSER PERFORMANCE FOR COMPRESSOR "C" FIGURE 6: RETURN SYSTEM PERFORMANCE FOR COMPRESSOR "A42"

O" 0

zH 0 z o
I-1
O
U

U
ra,r L . V)
W
47O' Cal
0 0
U
0

0 0 O
O r 0v
W 0
0 0

0 TEST DATA O TEST DATA

N - PREDICTION - PREDICTION
o 0 18.0
-12.0 -6.0 -2.0 2.0 6.0 10.0 -8.0 -2.0 2.0 6.0 10.0 14.0
RETURN CHANNEL VANE INCIDENCE - degrees RETURN CHANNEL VANE INCIDENCE- degrees
FIGURE 4: RETURN SYSTEM PERFORMANCE FOR COMPRESSOR "A#1" FIGURE 7: RETURN SYSTEM PERFORMANCE FOR COMPRESSOR "D"

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 RETURN SYSTEM DESIGN A = - cotp 6 - B - 2C - 3D (37)
Figure 8 illustrates the construction of the return system gas
path geometry. The 180 crossover bend is constructed with a These equations apply to radii greater than the vane discharge
circular-arc hub contour and an elliptical-arc shroud contour. shroud radius, r7s . Below r 78 , a constant blade angle camberline
The 90 exit turn uses a similar construction, but with the arc is used. The vane thickness distribution used is given as a
types reversed for the hub and shroud contours. Straight line function of the distance, x, along the chord line between I -, and
contours are used for the return channel vane section, blended to r7s . Below r 7s , the vane thickness is held constant. The
the crossover and exit turn contours by circular arcs with arc thickness distribution is given by

radii equal to the local bend contour elliptical-arc axial semi-axis t = to + - to)y e (38)
or circular-arc radius. The vane camberline used is an adaptation

of the author's vaned diffuser camberline (Aungier, 1988b). to = rb + (t7 - t6)x / c (39)
Leading and trailing edge blade loading parameters, 1( 6 and K7,

are specified to define the vane
y = camberline by x / xm ; for x > (40)
y r r6 (30)
y = (1 - x) 1 (1 - ; forx> x1 , (41)
cote = - A - By - 2Cy 2 - 3Dy 3
e = [0.95(1 + /x1 (42)
- + 0.05]
0 = Aln(y) + B(y - 1) + C(y 2 - 1) + D(y 3

Y = r7, / r6 (33) The blade maximum thickness, t,,, and its location, x,/c, are
specified, as are t 6 and t 7 . Figure 9 shows a typical return
(cot0 6 - cot0 7 )(k6 + - 2) channel vane designed with these equations.
D- (34)
3(Y - 1) 3 With reference to figure 8, the design constraints imposed on
the return system design are r b 4 , and the diffuser exit flow
(cotp 6 - coti3 7 )(K7 - K6) 9 angle (from the vaned or vaneless diffuser design). To complete
C- + + I) (35) definition of the crossover contours, the designer must specify the
4(Y - 1) 2 4 following

B = K6 (cot13 6 - cot(3 7) / (Y - 1) - 4C - 9D (36) 1) either b 6 or the crossover exit flow angle

2) either r 4 or (A,, - A 4 )/(A 5 - A 4 )
3) either R, or the average b/R over the bend

Axial Distance
FIGURE 8: RETURN SYSTEM GEOMETRY

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 where A., is the passage area mid-way through the bend and b/R
is the ratio of passage width to mean streamline radius of
curvature. The alternate choices provide direct control over vane
incidence, the passage area distribution and the distribution of
b/R. Their availability greatly accelerates the design process.
With reference to figure 8, the designer specifies the return
channel gas path contours by supplying r 6 , r8h, rss , bs /R0 , d, and
the area ratio across the 90 exit turn. The parameter, d, is
useful since it controls the minimum metal thickness in a cast
return channel. This parameter sets the minimum axial length
achievable with the designer's other specifications. Design of the
vane requires supplying the number of vanes, the vane trailing
edge angle (0, of figure 8), t6, t7, t,,,, K6, K7, X,/e, 136 and 13 7 .
Note that the entire gas path displayed on figure 8 is defined by
only 12 parameters, which provide direct control over the key
area and curvature distributions. The vane requires 10 more
parameters which directly control the vane passage area
distribution and blade loading style. The vane and all contours
are defined analytically. This reduces the problem to a form well
suited to a computerized interactive design system. Our design
system allows the user to interactively modify the design
parameters while supplying the following support functions on
demand
1) Screen displays of gas path geometry (figures 8 & 9).
2) Screen displays of graphical and tabular summaries of
geometry and key area and curvature distributions.
3) Aerodynamic performance analysis.
4) Linearized blade-to-blade flow analysis Aungier (1988b).
Results to date from this design system have been impressive.
Return channel design activity has been reduced from several
days to a few hours. Figure 10 shows results from a recent high
specific speed stage development program. The present methods
0 TEST DATA
0 PREDICTION
44,
3
E-
Z
41ID
,
'- sr
U6.0 6:74, 14,
0
U systems show excellent agreement with experimental data. These
M':
M
opppuse
0
A design activity and can be incorporated into any mean line
Cl "
0
0 A systematic interactive design system for return system design
0 60
20 80 40
100 120 140
t DESIGN FLOW
FIGURE 10: COMPONENT PERFORMANCE FOR COMPRESSOR "E"
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were used to design the stationary components for this stage.
Return system losses achieved are about 15% lower than our
standard designs. This is equivalent to a gain in overall stage
efficiency of over 1 percentage point. Within the usual test data
scatter, both the vaneless diffuser and the return system
performance are in good agreement with prediction.
DESIGN RECOMMENDATIONS
Vaneless diffuser design optimization normally leads to diffuser
discharge flow angles in the range of 30 to 35 , where
component loss coefficients approach a minimum and a good
stable operating range can be expected (e.g., see figures 1 and 2).
But, each choice of blend radius and discharge width produces a
different loss curve. Only an investigation of alternatives can
identify the choices best suited to the design objectives. This is
very significant for low specific speed stages where loss curves
for different passage widths can be dramatically different.
Crossover bend and exit turn design should control the ratio of
passage width to mean streamline radius of curvature, b/R.
Local values of b/R should be less than 1. An average over the
bend less than 0.8 is preferred. Based on experimental loss data
for numerous return systems, the passage equivalent divergence
angles, 20,, should not exceed 9 , where
20 c = 2tan l [k(A / A 4 1) / (m m4) /2] (43)
- - -
Ideal diffusers show increased losses for 20 c greater than about
11 , so this lower value for a bend is not unexpected.
Return channel vane design should typically feature front loaded
vanes to minimize discharge flow deviation. Since inlet Mach
numbers are normally moderate, this loading style is a reasonable
choice. The vane loading parameters, K6 and K 7 , define the local
radial gradient of the cotangent of the blade angle as a fraction of
the overall (average) gradient. This provides direct control of the
blade loading style (Aungier, 19886). Values of 10 6 = 1.6 and
K, = 0.4 have been found to be reasonable choices. The vane
maximum thickness, and its location along the chord line should
be used to control the vane passage area distribution to minimize
local mean velocity gradients.
CONCLUSIONS
Mean streamline aerodynamic performance models have been
presented for vaneless annular passages and return channels.
Predicted loss coefficients for vaneless diffusers and return
performance models are well suited to interactive aerodynamic
centrifugal compressor performance analysis.
has been presented. It has dramatically reduced the engineering
time required for this design activity. Test results from a recent
return system design accomplished with this design system show
 that the improved return system performance predicted by this
aerodynamic design and performance analysis system was actually
achieved.

REFERENCES
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Vaneless Components Of Centrifugal Compressors", Flows In
Non-Rotating Turbomachinery Components, ASME FED-Vol 69,
pp 35-43.
Aungier, R.H., 1988b, "A Systematic Procedure For The
Aerodynamic Design of Vaned Diffusers", Flows In Non-Rotating
Turbomachinery Components, ASME FED-Vol 69, pp 27-34.
Aungier, R.H., 1990, "Aerodynamic Performance Analysis Of
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Davis, W.R., 1976, "Three-Dimensional Boundary Layer
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Hohlweg, W.C., 1987, "Correlation and Application of
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(Proprietary).
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Design of Axial Flow Compressors, NASA SP-36.
Johnston, J.P. and Dean, R.C., 1966, "Losses in Vaneless
Diffusers of Centrifugal Compressors and Pumps", Trans. ASME,
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Nykorowytsch, P. , editor, 1983, Return Passages of Multi-Stage
Turbomachinery, ASME FED-Vol 3.
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and Design of Straight Two-Dimensional Diffusers", Trans.
ASME, J. of Basic Eng. , pp. 141-150.
Schlichting, H., 1979, Boundary Layer Theory, Seventh
Edition, McGraw-Hill, New York, Chapter 20.

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