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Originally Posted by lillberg

Try something smaller than 90 deg feature angle since it represents the maximum angle between two neighboring surface normals on a surface without corners. That is, the mesh will consider your surface shape a corner if the angel is larger than this value. I typically use something between 45 and 80 depending on the tet mesh resolution on highly curved surfaces. This might be the root of your problem. Looking at my picture the curved surface in the middle would (wrongly) be treated as a corner if

Originally Posted by chegdan

Nick,

There are some strategies that I would try to get these residuals down to something you would like.

1. Lower your pressure relTol by an order of magnitude compared to U i.e. relTol = 0.001 for P and relTol = 0.01 for U.
2. Without knowing the mesh you are using you may need to increase the nonorthogonal corrector by 1 or 2. if you are using a tet mesh...then there are many things you can do.
3. Use first order schemes to start with (you will move to higher order ones