An extensive investigation surrounding a performance shortfall of a pipeline compressor is presented. Regions of high aerodynamic loss are identified from an extensive flange-to-flange numerical investigation. Special attention is placed on understanding the impact of the interface model between the rotating and stationary components on the performance of each individual component and the whole machine. This process lead to the redesign of the radial inlet, the diffuser region, and the volute. Upon numerical validation of the proposed design changes, the components were manufactured and installed into the compressor that was already operating in the field. “Field” testing showed the new design to have a peak efficiency improvement of 4 points surpassing the contract guarantee.

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