Professional Documents
Culture Documents
by
J.C. Wachel
President
and
J.D. Tison
Senior Project Engineer
Engineering Dynamics Incorporated
San Antonio, Texas
24 3
244 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM
the piping mechanical natural frequencies are well above the ll = Weight per unit length of beam (including fluid and
frequencies of significant pulsation induced forces. This is insulation), lbs/in (Equal to pA if the weight of fluid and
opposite to the approach that is commonly taken in the design of insulation is negligible).
centrifugal machinery piping where the dynamic shaking forces p = Density, lbs/in3
are low, the excitation forces are at high frequencies, and one of
A = Pipe cross-sectional area, in2
the major concerns is the equipment flange loading due to the
thermal growth. Piping in reciprocating plants should have a By substituting in material properies for steel, E = 30 x 10 6
minimum number of bends, and should be rigidly supported with lb/in2,p = 0.283 lb/in3, and g = 386 infsec2, equation 1 can be
optimized span lengths. Pipe hangers, weight supports, and simplified to:
guides are practically useless in the prevention of vibration
when high pulsations are present in the piping.
The shaking force at every elbow in a piping span is propor k
f = 2231..- (2)
tional to the dynamic pressure and the inside area of the pipe. In L2
0
I
67.6 !
The piping span natural frequencies can be approximated using
! j 9690
:
LBend Out 116.5 1889 : 241 301
distributed uniform beam vibration theory. Configurations that !
exist in typical plant piping have boundary conditions that differ
i
I L-Bend In
Ij 59.4 75.5 ; i798
I
9575
j
276 266 .
from ideal values; however, the deviation is generally not large. I
The natural frequency of any piping span can be calculated if
I i 35.6 :
I
4628
nc I
UBend Out 18.7 2794 314 2T3
i
the frequency factor, span length, diameter, wall thickness and ,
i
the weight per length are known. For a straight uniform piping
span, the natural frequency can be calculated using the following .. UBend In 1 23.7 95.8 1 3751 8722 : 332 191
'
I
1
A+S+C L.
,. .. a-c
I I
relationship:
' j 3522 I
I I
Z-Bend Out 23.4 34.2 4133 317 254 :
. I
I
'
(1) I A+S+C ..c
...... a-c
l
-
Z-Bend In
1
22.4 96.8 1I 3524 8933
I
1 331
I
194 :
I
T
where:
) 3-D Bend 20.6 27.8 3987 4752 1 407 359
I -e -c
I
fo Span natural frequency, Hz A+8+C ., L
I
Formula
g Gravitation constant, 386 infsec2
f f;;/':f!-1!
=
I -
-- -------
/- ----
-
Fixed - Fixed
1 fp = (3)
where:
Pipe span natural frequency with concentrated weight, Hz
Pipe span natural frequency without concentrated weight,
Cantilever
Simply Supported
Hz
P Concentrated weight, lb
W = Weight of beam span, lb
a = Weight correction factor, dimensionless
'
Plpiq
Cantilever L 3.9
3L/4 1.7
J
3-0imensional
Simply L/2 2.0
Bend SuppGrted L/< 1.1
[2]. The frequency factors were published for a range of aspect A/2 1.24 0.63
A 2.69 3.25
ratios to develop sufficient information so that the natural B/2 0.39 0.63
frequency of piping spans could be approximated for most U-Bend First Mode
common configurations. The frequency factors for the first two "'
B/A= 1.0
Out
A /2
modes of vibration of a L-bend as a function of the aspect ratio
A
0.26 0.33
of the leg lengths and the total length of the span are given in B/2
2.24
2.31
1.79
2.00
Figure 3. Frequency factors for the U-bend, Z- bend, and three
Z..Bmd FU.stMode
dimensional bends can be found in Wachel, et a!. [2).
"'
B/A= 1.0
Out
To calculate the first natural frequency of a piping span with
A/2 0.(0 0.29
a concentrated weight, the following equation can be used. ..
A+-I+CL
.o.-a c
A 2.76 1.77
B/2 2.21 2.09
J
30-Bcd FlntMode
60
!
B/A = 1.0
A I I I I I .... -
ht 2
I I I I /(
/ I
q
A/2 0.31 0.58
I I I I ..
A 2.35 1.58
I I I
B
,.(
2.06 2.77
I
.4+1+C L. B/2
I
...
50
I ..: I
rTT7
I I I
I
I'
Figure 4. We ight Correction Factors for Uniform Piping
I I I _/I I
I I ' I
I I
Configurations.
! I /1..: '
/
d I
0 I I I I
E-< 40 I
u ..:"
I I I I I
I I 'I I I I Theoretical beam natural frequency calculations can be cor
><
u I
1st Mode Cut-of-?!one
z
rected to make them agree more closely with measured field data
/
-"I
/
Ol
I I
;:>
G--+-
- I I I
i
I I
I
I a-e' I '$-o..-1_ I I I I
vibration problems, this accuracy should be sufficient. The
'*"' I I
20
I I I I procedures for calculating the natural frequency of piping spans
I
a...__
I I I I $_ __ I I I
I I ..g,..---"$----4.----
can be used to select clamp spacings, which ensure that the
I I
s..
2
to C h a r a c terize
Nominal Pipe S-ize/Outside Diameter (in)
Vibr a t ion Type
7
Natural
t>.zs I I tsgoo " I
4 8 10 12 14
5 43.7
Freq. (Hz) 2.375 4.500 8.625 10.750 12.750 14.000 16 00 20.000
Figure
I I
18.9 26.0 31.5 35.9 40.1 45.8 48.9 51.9 54.7
I
10 13.3 18.4 22.J 25.4 28.4 30.9 32.4 34.6 36.7 38.7
5.7
1 10.9 15.0 18.2 20.7 23.2 25.2 26.4 28.3 30.0 31.6
" J(i.l
20 9.4 13.0 1 18.0 20.1 21.8 22.9 24.5 26.0 21A
6.4 11.6 14.1 17.9 19.5 20.5 2U 23.2 24.5
30
35
7.7
7.1
10.6
9.8
12.9
11.9
14.7
13.6
16.4
15.2
17.8
16.5
18.7
17.3
20.0
18.-5
2L2
19.6
22.3
20.7 1
" 17.3
40 6.7 9.2 11.1 12.7 14.2 15.4 15.2 17.3 18.4 19.3
IIA
6.3 12.0
S t e a dy S t a te S teady S t a te Transient
8.7 10.5 13.4 14.6 15.3 16.3 18.2
55
Low Frequency High Frequency V ibr a t i ons
5.2
8
60 5.4 7.5 9.1 10.4 11.6 12.6 13.2 14.1 15.0 15.8
D. I LU I
65 7.2 8.7 10.0 11.1 12.1 12.': 13.6 l-4.4 15.2
75 8.1
70 5.0 6.9 8.4 9.6 10.7 11.7 12.2 14.6
F igure Figure 11
I
I
!
4.9 6.7 9.3 10.4 11.3 ll.S 12.6 13.4 14.1
65
I ;:: 1
80 4.7 6.5 7.9 9.0 10.0 10.9 11.4 12.:? 13.0 13.7
I ILS
4.6 6.3 "1".6 8 7 9.7 10.6 11.9 12.6 13.3
95 11.2
I
90 4.4 6.1 7.4 8.5 9.5 10.3 12.2 12.9
4.3 6.0 7.2 8.2 9.2 10.0 10.5 11.9 12.6
100 4.2 5.8 7.0 8.0 9.0 9.8 10.2 10.9 11.6 12.2
Sources of Sources of
Figure 5. Table of Natural Frequencies Vs Pip e Span (ft). Mec h a n i c a l Acoustical
Resonances Resonance
Figure 9 Figure 10
er or not the high vibrations represent a problem. The evaluation
is based primarily on the vibratory stresses introduced into the
piping. In some cases, seemingly high vibrations may not cause
excessive stresses in the piping, but may require correction
because of the adverse psychological effect it can have on Mech anical Acoustical Hydraulic
Resonances Resonances Surge Transient
personnel. Solu t i on Solu tion Vibra tions
The vibrations are obviously too high if there has been a Techniques Techniques
I Acoustical
Resonance
I
! Identify Response
Frequenc1es
I
Simple Beam Modes
J
Calculate D}'Oamic Stross
Saeeninq O'ltoria
I I
IOOJU 1
01Gplocement- L2 0 mils p-p
-
Velocity- 2 ips
Strain
I I I I I I
Single Frequency Multiple Harmonic Bcoodbond Rondom
Response Response with Isolated
Resonances
Frequency Source
1 X - nX Reciprocating Machinery
1X - nPX Reciprocating Pump
1 X - nX Rotating Machinery
VPF, 2VPF Rotating Machinery
BPF, 2BPF Rotating Machinery
t--
f(O) Flow Related
Broadband Cavitation, Flashing
Frequency Source
1 X, 2X, 3X, .. Half-Wove Length Resonance
1 X, 3X, SX .... Quarter-Wave Length Resonance
Low Frequency Filter Resonance (Helmholtz)
High Frequency Piping Radial Modes
Analysis of Modes
Simple Modes - Hand Calculations
Complex Modes - Detailed Simulation
I I
Steady State
Mechanical
Resonance High Frequency
> 300 Hz
Vibrations
I
I I
Identify Response
Frequenc1es
I
I I Possible Acoustical Sources
)I
1 1 Frequency Source
I I
1X - nX Reciprocating Machinery
Fcequency Other Frequency Broadband 1X - nPX Reciprocating Pump
1 X or 2X Not 1X or 2X Random 1X - nX Centrifugal Machinery
(Lower Harmonics) VPF, 2VPF Centrifugal Machinery
(RPM) 2
I
Function of No Pulsation Function of
Induced Media Flow
l
Pressure Drop
I
Possible Mechanical Sources Fluid Flow
Across Restrictions Excitation Sources
1 X - Machinery Unbalance ( N2 Relation)
I 1
MechanicO!Iy 2X - Reciprocating Machinery Unbalance Choked Flow
Induced - Equipment Misalignment AP Across Valves
nX - Structure Borne Vibrations Cavitation Flashing
' Possible Sources Excitation at Mechanical Natural Frequency Strouhol (Vortex)
tJ. P Across Vol ves
Acoustic Piping Shell Wall
'
1
Possible Mechanical Solutions Possible Acoustical Solutions
Possible Pulsation Sources
Add Clamps and Supports Add Orifice Plate
Frequency Source Remove Clamps and Supports Add Acoustic Filter
lX - nX Reciprocating Machinery 1 X One Times Running Speed Add Damping Change Piping (Length, Oia.)
1 X - nPX Reciprocating Pump 2X Two Times Running Speed
t--
* Add Constrained Loyer Damping Add Accumulators
1 X - nX Centrifugal Machinery VPF - Vane Passing Frequency Increase Wall Thickness Simulate to Develop Solution
VPF, 2VPF Centrifugal Machinery BPF - Blade Passing Frequency Modify Piping Layout Toke 4P in Steps
BPF, 2BPF Centrifugal Machinery P - Number of Plungers
Anti-noise Trim Valves
f(O) Flow Related * Change Operating Conditions
Broadband Cavitation, Flashing
Figure 9. Flowchart for Determination of Excitation Source of Figure 1 1 . Flowchart for Investigating High Frequency Vibra
Mechanical Resonances. tion Problems.
248 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM
WalkdownjSurvey the System In liquid piping systems, low frequency movements of the
pipe may indicate waterhammer. This can be caused by sudden
The first step in the determination of the severity of the opening or closing of a valve, which may produce a pressure
vibration problem is to make an initial survey or walkdown of wave that moves down the pipe. As it reaches elbows or other
the piping system. The purpose of the walkdown is to determine changes in direction or cross section, a large low frequency force
if the reported high vibrations are a real problem or not. During can shock the pipe and cause large motion.
the walkdown, watch for the following common symptoms of Careful attention should be paid to determine if the vibrations
piping vibrations which indicate potential problems. are steady state or transient in nature. Also, note whether the
Fai led Pip ing with Fatigue Cracks. If a pipe fails and the vibrations may have a varying amplitude or "beating," which is
failure surface has classical fatigue markings, an obvious vibra typical of a piping vibration in which excitation is occurring
tion problem exists. Fatigue failures occur most often at points from two sources at slightly different frequencies.
of high stress concentration, such as at branch connections and Damaged or Ineffective Supports and Restraints. During the
welded joints. Other likely points would be near supports or initial survey, careful attention should be paid to the condition
restraints. of supports and restraints, and particularly the bolts. Loose
If failures occur repeatedly near the same location in the restraints, supports, clamps, or bolts that have been bent or
piping system, this is normally an indication that there is a broken can lower the resonant frequencies of piping and cause
mechanical or acoustical resonance, or both. If there are no the mechanical natural frequency to occur at a frequency of high
resonances present, there must be an excessive excitation force amplitude excitation. Loose or broken supports/restraints can be
in the system. The fatigue failure surface should be carefully a result of resonant vibrations, high dynamic shaking forces,
examined since the direction of the crack can give clues to the inadequate design, or excessive thermal loads. If the support
mode shape of the vibrations. The location and orientation of the does not have sufficient stiffness to control the static and dynam
failure should be fully documented with photographs or sketch ic loads, it may bend due to the large forces and movements. For
es, so that if it is necessary to perform tests, strain gages can be example, U-bolt clamps have very little stiffness and are ineffec
placed in the appropriate locations. tive restraints and, in piping systems with large shaking forces,
For example, if the fatigue failure occurred as a circumferen they will often fail or lose their preload. Thermal pipe guides
tial crack, the failure was probably caused by a bending mode. should be investigated since they are designed to keep the pipe
If the fatigue crack occurred on a 45 degree spiral, the failure in position in a particular direction, but still may not provide
may have been caused by a torsional mode, such as the low mode adequate vibration control. Long unsupported spans with low
of vibration of the compressor manifold system. Cracks in the support stiffness could result in low mechanical natural frequen
longitudinal direction could be a result of a high frequency shell cies. Piping spans with unsupported block valves or other heavy
wall resonance. masses can also have low response frequencies.
If the failure occurred at the piping reinforcement weld, the Note where the maximum vibrations occur and determine the
quality of the weld may be at fault. The location of a fatigue nearest effective support location. The lowest lateral natural
crack along the weld line usually indicates a high stress concen frequency of a span between supports is an inverse function of
tration factor. The stress concentration factor for a good weld the square of the span length. The stiffness of a piping span is a
can be as low as 1.6; however, for a poor weld, the stress function of the span length between supports cubed. Moving the
concentration factor can be five or greater. Other locations of supports closer together will shift the natural frequency and
high stress concentration include all weld joints, restraints, increase the stiffness and may significantly reduce the vibra
hangers, and other geometrical discontinuities, such as changes tions for those systems with low frequencies of less than 300Hz.
in piping wall thicknesses. Determine possible locations for restraints that could be added
Since the function of the piping system is to contain the fluid, to detune the resonant frequency.
bolt failures which cause a leak in flanges, or at valves, etc., are In systems that experience transient vibrations, the supports
considered to constitute a failure of the piping system. There or snubbers may have to be checked to ensure that they are
fore, check the bolted joints in the piping system to ensure that behaving in the proper manner. This is particularly important if
they are not loose and have no failures. This is very critical on large displacements at the snubbers and supports have been
high pressure letdown valves that may have sonic flow. Often experienced.
the high level turbulence will excite the lateral and axial modes High Vibration ofAppurtenances. Many failures that occur in
of the piping and cause bolt failures. piping systems are of the smaller diameter piping connected to
Visual Vibrations/Line Movements. During the initial survey, the larger piping. Vents, drains, pressure guage lines, instrument
look for parts of the piping system that are obviously vibrating lines, thermowells, etc., are most sensitive to this kind of fail
excessively. Tests have shown that, with training, a person can ures. The vibrations of the appurtenance can be caused by a base
judge the approximate amplitude and can distinguish low fre excitation, whereby direct mechanical coupling between the
quency from high frequency vibrations, usually those less than vibrating pipe or machinery causes the side branch to vibrate at
50Hz. This judgement is enhanced when the sense of feeling is its mechanical natural frequency. Therefore, all appurtenances
used, such as feeling the vibrations with a coin held in the near points of high vibrations should be examined. The large
fingers. (Use the coin to touch the pipe, since the pipe may be pipe can be excited by pulsations or by machinery unbalance
hot!) If the piping is experiencing high vibrations or movements, Examples of the mechanical coupling between a pump and its
then the approximate location of the maximum vibrations should piping which caused vent and drain valve failures are discussed
be noted, so that vibration measurements can be made at that by Olson [7].
location when detailed testing is performed. Many times indi Failures of appurtenances can also occur in high energy fluid
vidual components, such as guage lines, pressure guages, ther flow systems near valves with high pressure drops, especially if
mowells, instrument lines, etc., will vibrate and result in failures. the flow is sonic. The high turbulent energy can excite the low
Particular attention should; therefore, be paid to these small frequency natural frequencies, and can also excite the shell wall
connections and other appurtenances during this initial survey. resonances in the axial and circumferential directions of the
It is best to combine physical senses with a handheld vibration larger diameter piping. These shell wall resonances can cause
data collector, if it is available. excessive stresses at points of high stress concentration.
TUTORIAL ON VIBRATIONS IN RECIPROCATING MACHINERY AND PIPING SYSTEMS 249
If high vibrations occur at a particular location, note where the engineer have some simple criteria or "rules of thumb" that can
closest point of coupling occurs. Points of acoustic coupling be used to judge the severity of the vibrations.
include the closed end of headers, pulsation bottles, restrictions A fact that helps in the development of a screening criteria is
in the piping such as partially closed valves, orifices, piping that an endurance limit stress does exist for piping materials. If
elbows, and any changes in piping cross section. A branch pipe the dynamic stress can be kept below a certain stress level, the
from the suction and discharge lines to a closed bypass valve piping can withstand infinite cycles of the stress without failure.
may be the point of coupling for machinery piping systems. This stress level is called the endurance stress level.
Blind ends of headers, tees, and manifolds most often serve as The dynamic stress introduced into a piping span by vibration
points of acoustic coupling. is a function of the diameter and the inverse of the square of the
High Impact or Flow Excited Noise. During the initial walk piping span length. The natural frequency is also a function of
down survey, listen for impact noises that may be created by the the diameter, divided by the span length squared. Based on this,
piping vibrating and impacting loose clamps and supports. The screening criteria have been developed to eliminate the necessi
type of noise created due to the vibration will give clues as to the ty to make a comprehensive analysis of every piping span in the
nature of the vibrations. If the noise is a pure tone with a constant piping system.
amplitude, the vibrations will most likely be steady state and For transient events, the evaluation of the acceptability of the
caused by a constant amplitude shaking force at or near a vibrations has to be determined by the application of cumulative
mechanical natural frequency. If the noise is broadband and fatigue theory.
varies in amplitude, or is intermittent, the vibrations may be There are basically four methods [2, 3] for evaluating accept
caused by high flow excitation or a result of some process able vibration levels in piping systems, as listed below.
transient. Allowable Vibration Amplitude Vs Frequency
In piping systems with high flow velocities, such as systems
with pressure letdown valves, bypass lines, flare lines or fluid Vibration Displacement Amplitude-Stress Relationship
transfer lines, the major indication of a potential vibration Vibration Velocity Amplitude-Stress Relationship
problem is the presence of high noise levels. The high energy
Measured Dynamic Strains
broadband noise created by a large pressure drop across a
letdown valve may be amplified by mechanical shell wall reso The step-by-step procedures used to investigating the safety
nances. If acoustical resonant natural frequencies are present in and reliability of piping spans is documented in Figure 8.
the range of the broadband energy, they will be excited and the A llowable Vibration A mplitude Versus Frequency Criteria.
noise spectra will be influenced by these resonances. Acceptable vibration levels versus frequency for both lateral
In addition to the broadband energy created by the flow, the piping bending modes and compressor manifold modes can be
high velocity flow past a closed branch can generate turbulence obtained by using the chart given in Figure 12 [2]. This chart can
and vortices which excite an acoustical resonance frequency in be used as a screening criteria for low frequency vibrations of a
the side branch. In centrifugal equipment piping systems, the piping system (frequency less than 300Hz).
noise may be caused by an acoustical resonance in the compres To use this chart, the measured vibration amplitudes at specif
sor case or internals or be amplified by an acoustical resonance ic frequencies are compared to the design level amplitudes. If the
of the piping system. vibrations are at the design level or lower, the system should be
It is especially important to determine whether the noise is acceptable. If the levels are at the danger level, the chances of a
predominantly a pure tone or broad band frequency. Pure tones fatigue failure are high and the vibrations must be reduced.
are usually associated with acoustical or mechanical resonances, These criteria are very conservative for long flexible piping
whereas broad band noise is generally indicative of high energy spans, such as those used in centrifugal equipment plant piping.
flow velocity excitation. They are not applicable to shell wall vibrations.
After it is decided that the vibrations are high and additional There are no readily acceptable charts for transient vibration
analysis is needed to determine the characteristics, cause, and amplitudes excited by surge or waterhammer; however, if the
solution to the problem, it is necessary to develop a test plan for vibrations are higher than the danger level on Figure 12, the
measuring the vibrations. To ensure that the test includes the number of transient events should be limited.
conditions that were present during the high vibration event, it Vibration Displacement A mplitude as a Function of Stress.
is necessary to study the operating conditions and the past data. The severity of piping span lateral vibration displacement am
plitudes can be assessed by comparing the maximum resonant
Measure Vibration and Determ ine A llowables vibration-induced dynamic stresses to an allowable endurance
limit stress. The vibration-induced stress in a piping span vibrat
In cases where high vibration is noted, the analyst/engineer
ing at resonance has been shown to be related to the maximum
should make measurements to quantify the vibration. The fol
vibration amplitude (deflection) in the span [2, 3, 4, 8]. The
lowing observations regarding the character of the vibrations
relationship is given in the equation below:
should be made using a spectrum analysis.
Frequency of vibration (low frequency less than 300 Hz or (4)
high frequency)
Amplitude of vibration where:
Location of highest vibration
S Dynamic stress, psi
Mode shape or vibration pattern
Kd Deflection stress factor
Steady state, transient or random vibrations y Maximum vibration amplitude (deflection) measured
between nodes (normally at supports), mils
Once measurements have been made, it must be determined
whether the vibrations are excessive and whether the unit must D Outside pipe diameter, inches
be shut down immediately to ensure the safety of the installation. L Span length, ft
With the high cost of downtime, it is imperative that the analyst/ SCF = Stress concentration factor
250 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM
200 taaee I I
A
100
I I I
qB
-1
60
60
....... Da0 aeee
1777
I I I
I/
A
40 -
I I /1
30
20
-.....,
-...... , :J
oi
0
-<
0
6BBB I /I
)-/
I
....... "
.:
0
"' l// I I
10 !';.;--- "' /(
.,
o,.91"ot =:
I
i.
"E ...... 91?
z
0 4BBB
,->--' J I I I
f:<
0
! ........__
.,S"'e,..o.. '
'-
......
.,
"'
"'
I .._
t
,... :!:e-e-a-e-1
'
-- -.1 I I
., ...... I
T I -- rI ---
J.,,.SJ.,Ofr:t'-::-:.. A
zeea
-----e--.
<(
I I I I
2--
<;
>
t<o,.,
I
c-----El 1st Hode Oul-of-Pione
I I I I I
"-.. e
a.e 8.2 0.4 0.6 0.8 I.B
!"-...,
B/A LEG LENGTH RATIO
( )
amplitude, and equally difficult to accurately measure the vibra
tions. The sound pressure criteria discussed by Wachel, et al. [ 2],
s, u can be used as a screening criteria in many cases.
y. (5)
Kp Vibration Velocity A mplitude as a Functio n of Stress. A
=
(SCF) (SF)
screening criteria of 2.0 ips was developed by Wachel, et al. [ 2],
where: for a piping span with a maximum concentrated weight to span
s. Allowable stress, psi
weight of 2.0. For a piping span that does not have a weight in
the span, the allowable is 4.0 ips. The stress concentration factor
SCF Stress concentration factor
was assumed to be 4.33, the safety factor was 2.0, and the
SF Safety factor concentrated weight correction factor was 2.5. The vibration
Kd Deflection stress factor velocity must be measured :at the point of the maximum vibration
between the vibration nodes. As in the case of stress vs the
If the API 6 18 [ 6] allowable of 26000 psi peak-to-peak (single vibration amplitude, extreme care should be taken to ensure that
amplitude of 13,000 psi) is used as the endurance limit combined the frequency matches the natural frequency of the span between
with a stress concentration factor of 4.33, a safety factor of 2.0, the vibration nodes. This is accomplished by using the methods
and a stress deflection factor of 3000 (applicable for a fixed presented by Wachel, et al. [ 2], to calculate the lowest mechan
fixed pipe), the allowable vibration in peak-to-peak mils can be ical frequency. Some velocity stress factors are given in Figure
calculated. 1 for the classical types of straight spans and piping bends with
Equation 5 becomes: equal legs.
y a
= - u
D
(Rule of Thumb) (6)
The velocity measurements must be made at the point of the
maximum vibration between two vibration nodes. If the vibra
tions are at a higher mode between two supports, the allowable
can be applied if the span between the nodes is vibrating at its
This can be used (conservatively) as a screening criteria for mechanical natural frequency. Again, it should be noted that
straight runs of piping or for piping with bends. The span length these criteria are for identifying those piping spans that are
TUTORIAL ON VIBRATIONS IN RECIPROCATING MACHINERY AND PIPING SYSTEMS 251
Stiffness added at the location of maximum vibration will be develop simple or more complex finite element models of the
the most effective. Temporary stiffening using hydraulic j acks, system to evaluate potential solutions.
comealongs, etc . , may be used to determine the sensitivity of the If the high vibrations are caused by high pulsations, acoustical
resonance. Pipe clamps can add damping along with stiffness, control techniques should be used to reduce the vibrations.
particularly if a viscoelastic material is used between the pipe These acoustical control techniques will be discussed in a later
and the clamp. In addition to reducing the vibration amplitude, section. One of the test procedures that is used to determine if
the viscoelastic material will minimize pipe wear, and provide vibrations are caused by pulsation-induced shaking forces is to
extra resiliency for thermal movement. It should be noted that remove the compressor suction valves. If the suction valves are
the bracing and structural supports added to improve the system removed the pulsations are eliminated; therefore, the only re
can also add weight, which tends to lower the natural frequency maining forces are those caused by the mechanical forces and
and can offset the stiffening added. moments. Results from a field test in which the suction valves
Many times, in reciprocating machinery piping, the addition were removed are shown in Figure 1 6 .
of supports will reduce the vibrations in the piping spans near the
location of the added supports; however, high vibrations will be
noticed at other locations. The movement of the high vibrations
is most often caused by the excitation energy causing a shaking
force at each elbow, change in pipe diameter, at closed ends of
vessels, etc. The installation of the support changes the mechan
ical natural frequency near the support and can change the
response frequencies of the other parts of the piping. This does
not mean that the method is "moving or chasing the vibrations to
other parts of the piping," it j ust means that the piping is poorly
supported for the level of excitation energy. Sometimes it is
impossible to add enough supports to control the pulsation
induced shaking forces and, in those cases, pulsation control
must be used to make the vibrations acceptable.
Weights can be added to the piping spans to detune piping
mechanical resonances; however, extreme caution should be
exercised when this method is used. First, the changes in the
'
natural frequency are a square root function of the added weight.
This means that considerable weight has to be used in many J IJ ", . 1 I Fi '' I , I I I i .J
! .I
cases. Second, the added weight lowers the natural frequency,
.1.
I i
I ,,, ;
U ! I
' I H :
. . . ! ",.: ' I . : . . . /
I I I 1 I I
! _ M i l s Per '-.
I :':
which moves it nearer to lower harmonics that most often have
/
'',
the highest energy level in reciprocating compressors and pumps. : i' c lr iJ: : I :: , ! : I' k l ! I I
1:
Third, changes in the speed of sound which lowers the excitation "' 1/ I i'
lw;,:,-
, , ,_ ,
piping would be clamped to the piping and would typically have
a flat bar for the spring and a movable mass that can slide in and J r. I !!:
' oc:I:Lfl ' ' : _, I',
out from the pipe to tune its mechanical natural frequency to the . I - I IT/i
' I.. : " ! ' "'"" ' ' '
span mechanical natural frequency. In using a dynamic absorb > :/ i' ,r v ' , !j
er, the dynamic absorber vibrates at the piping span natural
frequency and the amplitudes of the pipe span would be reduced . Figure 1 6. Comparison of Suction Bottle Vibration with and
The dynamic absorber actually creates two additional mechan without Suction Valves Rem oved.
ical resonances, one below and one above the original natural
frequency. The location of these natural frequencies is deter
mined by the weight ratio of the absorber weight to the effective
COMPRESSOR MANIFOLD RESPONSES
modal weight of the piping span that was vibrating at resonance.
If the new resonances were near other excitation harmonics, Vibration problems in reciprocating compressor installations
high vibrations at other harmonics can occur. It is usually are often associated with the compressor manifold system [3,
preferable to change the support spacing or add support stiffness 1 1 ] . A typical two-cylinder compressor manifold system is
to the system to solve the problem. shown in Figure 1 7. Two compressor cylinders are connected to
The vibration amplitudes are a function of the total stiffness the compressor frame by the crosshead guide and distance piece.
of the piping supports. For example, if the piping system is Common suction and discharge bottles are shown in this case.
nonresonant, the vibration amplitude is proportional to the Secondary pulsation bottles are often used and can be oriented
shaking force divided by stiffness of the system. Whenever a horizontally near the grade elevation, vertically to minimize
resonance is incurred, the amplitudes are the amplification unsupported riser dimensions, or may even be fabricated as part
factor times the nonresonant amplitude. If stiffness is added to of the primary filter bottle.
a piping system, piping vibrations should be reduced unless the Eva luation of Vibrations in Compressor Manifold Systems
mechanical resonance is moved to a frequency where there is
greater energy. Compressor manifold system vibrations can be evaluated by
If a mechanical resonance is the cause and practical temporary using the screening criteria given in Figure 1 2 . It is desirable for
modifications can not be evaluated, the analyst may need to the vibration levels to be at or below the design line. If vibrations
TUTORIAL ON VIBRATIONS IN RECIPROCATING MACHINERY AND PIPING SYSTEMS 25 3
PRIMARY COMPONENTS
Of COMPI'!ESSOR
M A N I FOLD SYSTfM
Q cROSSHEAO GUIQ(
@ DISiANCt: PI(Cf
G) cYUNO:R
Q sucnON NOZZU:
0 SUCTION BOrtL
0 OISCHA! NOZZII
0 DISCHARC( QQTTLE:
Figure 2 1 . Discharge Bottle Cantilever Mode of Compressor Figure 23. Rota ry Mode of Compressor Manifold System.
Manifo ld System.
be a bending failure of the nozzle near the cylinder flange on
either the front or back side.
Rotary Mode
The "rotary mode" illustrated in Figure 23 involves the suc
tion and discharge bottles moving out-of-phase, but in the plane
of the manifold bottles. If this mode were excited, the highest
stress points would be on the sides of the nozzles at the bottle
nozzle junction or at the cylinder flanges.
COMPRES S OR/ENGINE
FRAME DYNAMIC VIBRATION
Top o f
o l Frome
Grout
Too o l fouo<lotlon
is possible, which can eventually cause cracking of the grout and Figure 2 7. Typical Measurement Locations For Determining
decrease the effectiveness of the interface. This is why some Dynamic D ifferential Vibrations.
older units begin to have crankshaft and bearing problems after
many years of successful operation without failures .
The resisting force between the frame and the foundation 10
depends upon the frictional component of the frame to grout/sole 9
a: Centerline U nloaded
plate interface. The friction force is a function of the bolt preload 8
E,
.!Q
and the coefficient of friction between the two surfaces . Several
7
factors determine the coefficient of friction. For dry surfaces, E
6
0
the coefficient can be as high as 0.3; however, if the surface has c:
Structural Responses
There are other problems encountered in plants with recipro
Figure 3 0. Fou ndation Rocking Mode Measu red Using Moda l
cating machinery that are caused by structural resonances. Note
Analysis Techniques.
worthy of these are large scrubbers, cooling towers, structures
that have equipment attached, and piping racks . The high vibra
Fou ndation/Soil Vibrations tions can sometimes be significantly reduced if the natural
frequencies can be detuned . Similar testing methods to those
Reciprocating machines can generate excitation forces near used to investigate the pipe vibration can be used.
one of the foundation-soil mechanical natural frequencies. Foun
dations have six rigid body natural frequencies (X, Y, Z, e . , 6 , PULSATION IN RECIPROCATING
e ), which are a function of the weight and moments of inertia J'f MACHINERY PIPING
the foundation and machinery and soil stiffnesses. The unbal
Pulsations are the major cause of high piping vibrations and
anced forces and moments from the machinery act above the
reduced reliability in reciprocating compressor and pump piping
center of rotation (which is normally below the foundation mat)
systems [2, 3, 11]. Therefore, it is important to understand how
and for systems with weak soil, the vibrations can become
pulsations are generated and how they can be controlled, so that
excessive. It is difficult to define the acceptable levels of vibra
proper design decisions can be made .
tion; however, the manufactures of the drivers and the compres
Pressure pulsations are a result of oscillatory flow (pulsative
sor generally have specifications for the frame.
flow) induced by the fluid (gas or liquid) transmission equip
When high vibrations are measured on a system, it is neces
ment. In addition to causing vibration, excessive pulsation in
sary to make detailed measurements to ascertain whether the
compressors can also significantly distort the pressure-volume
foundation system natural frequency is being excited or if the
card, reduce compressor capacity and efficiency, and reduce
forces and moments are excessive. In order to define the foun
valve life. Excessive pressure variations in pumps can result in
dation natural frequencies, it is desirable to measure the vibra
overload of pump working components and cavitation. Excessive
tions over a speed range. If the unit is motor-driven, a mechanical
pulsations can also cause significant errors in flow measurement.
shaker may be required. The results of a test which showed that
In order to reduce the potential for piping and vibration
the compressor/foundation system had a natural frequency at the
problems in the design stage or to solve problems with existing
compressor second harmonic are shown in Figure 30. Most often
reciprocating machinery systems, several concepts should be
the natural frequency that is excited is a rocking mode about a
understood:
point below the mat. Modal analysis techniques that can define
the mode shapes of the foundation and the compressor piping are Acoustical excitation mechanisms
often used since the separation of the effects of the rigid body Piping acoustical response
foundation rotation from the compressor vibrations caused by
Acoustical-mechanical coupling
mechanical or acoustical shaking forces is difficult to determine.
To control vibrations caused by foundation related problems, Techniques for control of pulsations and resulting shaking
it may be necessary to extend the mat, r etrofit piles that go down forces
to bedrock, or reduce the forces and moment that are causing the
vibrations. A c o ustical Excitation Mechanisms
The intermittent flow of a fluid through compressor or pump
OTHER STRUCTURAL RESPONSES
cylinder valves generates fluid pulsations that are related to a
There are other types of vibration problems with the piping number of parameters, including operating pressures and tem
systems that can occur; however, they are not as predominant as peratures, clearance volumes, cylinder phasing, fluid thermody
the problems with the piping spans and the compressor manifold namic properties, etc . Pulsations are generated at discrete
258 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM
250
frequency components corresponding to the multiples of operat
ing speed.
The flow modulations shown in Figure 31 are produced by a 200
20
<OO
IS
200
j 10
j
j .!
zaa
-400
0 1 00 200 300 <00 Horm.or'l l c.
0RlJr U O s o f Rotot t on Figure 32. Flow Vs Time Wave ( Top) and Flow Frequency
1 25
Spectrum (Bottom) of Idea l Triplex Pump.
1 00
j 75
j
50
25
Hor mon o c
the cross sectional area i s the basis o f the concepts presented where:
here. . lb-sec2
p = mass density,
m4
The wave travels with the speed of sound in the fluid. The
-.-
typically range from 800 to 3000 ft/sec; for liquids, the speed of sec
sound is usually 3000 to 5500 ft/sec.
X piston displacement amplitude, in
The flexibility of the pipe wall produces an effect that lowers
the speed of sound and should be accounted for in liquid sys . rad
tems, but is normally insignificant in gas systems with steel ro circu
" Iar frequency of piston,--
sec
piping (since the bulk modulus of liquid is much higher than that
of a gas). in
u
= xro = piston ve 1ocity
amp 1ltude, --
The computer model shown in Figure 34 is of a simple infinite sec
length line with a sinusoidally varying mass-flow excitation at
one end. This excitation is equivalent to a piston being displaced The amplitude of the pressure wave pcu is proportional to the
back and forth, with a constant amplitude at angular frequency velocity of the piston u . This concept is fundamental to under
in a steady-oscillatory fashion, with the piston motion described standing the source of pulsations in reciprocating equipment.
by: Also note that the pressure pulsation amplitude is proportional
to the density and speed of sound.
The mode shape information of Figure 34 may be displayed in
x = X sin (rot)
time and is useful for visualizing mode shapes.' The animated
mode shape display uses the following logic in demonstrating
the mode shape: at the location of the maximum positive pulsa
tion amplitude, the amplitude is represented by a large diameter
circle. At the minimum negative pulsation peak, the pulsation
amplitude is represented by a dot. Thus, the largest diameter
Xw=consta.nt circle and the dot at a given test point have the same amplitude,
but are 180 degrees out-of-phase. For the zero pulsation ampli
tude, the circle is approximately one-half the diameter of the
maximum positive peak. Note that at a pulsation node, the
Dynamic. Flow
amplitude of the circle does not change.
Excitation Boundary - Left End
A coustical Wave Reflections
When an acoustic wave propagating down a pipe reaches an
impedance discontinuity, a reflection takes place. The imped
ance value in a piping system changes at:
Closed ends.
Open ends.
Piping diameter changes .
Branches.
I nfinite Length Boundary
Condition (Zc) - Right End Tees .
Restrictions.
Change in density or acoustic velocity.
Figure 34. Animation of Traveling Wave in Infinite-Length,
Constant Diameter Pipe. Changes in impedance in the piping are necessary for acoustic
waves to reinforce and result in resonance. While full reflections
will occur at zero or infinite impedances in a pipe, intermediate
Since the pipe is infinitely long, no acoustic reflection occurs
changes in cross sectional area will have an intermediate effect.
and the system is nonresonant. A continuous train of compres
The ratios of reflected pressure P j P ; and the ratio of transmitted
sions and rarefactions travels along the infinitely long tube, with
pressure P / P ; are a function of the area ratios of the pipes.
each point undergoing a full cycle of dynamic pressure. In the
absence of damping, the amplitude at each point would be A coustic Standing Waves
identical. The wavelength of the pressure wave is related to the
acoustic velocity, c, and the frequency, /, by the relationship: Two waves traveling in opposite directions will result in the
classical standing wave if the frequency of the two waves are
where: equal to a characteristic frequency of the pipe length and if they
c = speed of sound, fps have a certain phase relationship. One of the waves may be
thought of as the incident wave, the other as the reflected wave.
ro
f = 2;" = frequency, Hz The superposition of these two waves produces fixed locations
of maxima and minima, i.e., a standing wave. These concepts
can be applied to describe some of the classical length resonanc
Assuming an infinitely long tube (i.e. no reflections from the
es and mode shapes in terms of standing waves. Resonances
end of the tube), Newton 's law may be applied to show that the
associated with distributed systems of constant pipe diameter
amplitude of the pressure wave will be:
have mode shapes described by portions of sinusoidal waves
P = pc (xro) sin rot = pcu sin rot (half waves, quarter waves, etc.), as shown in Figure 35.
260 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM
1X X I < X >
= ...
1
2 Q1M
1
3 1X X XI < X X >
Ougrter Wgve Resonances
Dynamic Flow
Excitation Boundary - Left End
Is ( X XI
Half Wave: f = :;.z Quuter Waveo
f
=
4 1)
(2N a
N 1 . 2. 3. . .
=
Boundary (Q=O) - Right End
I frequenty ( H z )
=
L = 30 ----1
z = 0
(Open noi
U n i t y F'low
E x c i t a t io n
Poin l C
f 2 00 tt/s. In = 1 0, 30 , 5 0 . . . . Hz
Secondary B o tt i e :
A Point A
!
0
0 20
)\. A A 40 60 80
_A_
100
I'Rf:QIJENCY { H : )
4" 1.0.
I n fi n i t e L e n g t h
Line
Dynamic Flow
Excitation Boundary - Left End
0 - Choke Tube 1 / 4 Pt
\1\ (\
0
"'--
50 lOO
lJ \. l50
0
Figure 3 7. Frequency Response (Middle) and A n imation of FREQUENCY (Hz )
Fundamental Mode of Closed-Open (Constant Diameter) Pipe.
Figure 3 9. Volume-Choke - Volume Filter ( Top) and Frequency
Response to Unity Flow Excitation (Bottom ) (FH 1 0. 5 Hz, FP =
= 1 1 2. 5 Hz).
= 00
FH = 10.5 H z 4. 0"3
Point A
I
Point 8
, s----j
A - PQint A
0 I I I .
20 40 60 80 100
FREQtJEN.CY (Hz}
!I Polnt B
50
0 I I I .
0 20 40 60 00 100
FRtQUENCY {H:t)
C Point e
50
Fp = 1 12.5 H z
0 I .
20 40 60 80 100
FREQUENCY (H:f)
!,. = 1 0. 30, 50 . . . . Hz
Oln
100
r---r-..:
', :::.
"':: ".:..
:: ' ,----r---r
harmonics. In Figure 4 1 , the 2nd, 4th and 6th orders are greater 1 00
than the 1 st, 3rd, and 5th orders, respectively. In Figure 42, the
highest amplitude now occurs at the odd multiples of running
speed, and the amplitudes are dependent upon the test point
location along the pipe.
The resonant frequencies of this system occur at 1 0, 30, 50, . . .
Hz. Therefore, since these resonance frequencies correspond to o ,,oo--
FREQUEHCY (Hz)
the excitation frequencies I x, 3x, 5x, . . . , of the compressor flow
excitation, the pulsation amplitudes at these frequencies are Figure 42. Pulsation Spe ctra - Cylinder Discharge Excitation
amplified. For example, at 1 x running speed ( 10 Hz = 600 rpm), into Finite Length, Open End (Resonant) Pipe- 600 RPM.
the pulsation is increased from three to 80 psi p-p (an amplifica
tion factor of approximately 25). Changing the operating speed pulsations. Other parameters that affect the acoustic response
changes the excitation frequency and the amplitude of the are the density of the fluid, the velocity of sound, and the
TUTORIAL ON VIBRATIONS IN RECIPROCATING MACHINERY AND PIPING SYSTEMS 263
PA
3rd H a r m on i c F=2(PA)
+P
! IXXX XI
Fou r t h Mode
PA
4 t h Harmonic F=O
-P
/
particularly important in surge volumes. The net force acting on
a bottle or surge volume is determined by summing the forces
acting on each end of a bottle (Figure 45). For the fundamental
P P s t a tic
?Dynamic
closed-closed resonance mode discussed earlier, the shaking
force acting on the bottle of area A is 2AP where P is the dynamic
pressure. Therefore, if excitation frequencies occur near the
A = P r o je c t e d Area fundamental acoustic resonance mode of a bottle, high shaking
force levels can occur since the dynamic pressures are amplified
and the instantaneous pressures at the ends are 1 80 degrees out
FDynamic ?Dynami c A Fx Fy
= =
of phase.
FR = 2 ?D ynamic A c os(li'i/2) Note that acoustical resonances can occur at the even num
bered modes; however, a shaking force is not created, since the
Figure 43. Dynamic Force at Elbow. phase relationship causes the dynamic forces to cancel.
A similar condition occurs when a volume-choke-volume
Reducers (A rea Changes) . The equation for force is shown in system is excited at resonance (Figure 46) . The dynamic pres
Figure 44 acting on the differential area occurring at a reducer. sures in the two chambers are 180 degrees apart in time. There
The force, F, is along the axis of the reducer. Note that since the fore, a force acting along the axis is produced, which is
instantaneous pressure at the reducer varies with time, the force, proportional to the area of the choke. The frequency of this
F, varies with time. resonance may be controlled by adjusting the bottle and choke
Capped Ends (Bottles) . The extreme case of area change is sizes (diameters and lengths). This concept is a fundamental tool
that of a capped end. This condition occurs in all vessels, and is for the control of pulsation bottle shaking forces.
264 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM
Vol u m e Choke Vol u m e it may reduce the pulsations in a piping system over wide
frequency ranges, resonance frequencies of the surge volume
F length can act as passbands, and excessive shaking forces of the
bottle itself can result if the surge volume is not designed
properly (Figure 45).
Surge Volumes
S urge volumes are often used to attenuate the pulsations
produced by compressors. A surge volume is a relatively large,
(empty) bottle attached to the suction or the discharge of the
compressor. The volume acts as an acoustic compliance (the
equivalent of a mechanical flexibility), which can effectively
isolate the piping fluid from the flow modulations induced by the Volume-Choke-\"olume Helmholtz Frequency
compressor . The attenuation characteristics of the surge volume
are a function of the volume enclosed by the bottle as well as the
expansion ratio of the attached pipe and bottle diameters. For
reciprocating compressors, API 618 defines the minimum suc
where f = frequency ( H z )
c
tion and discharge surge volumes required for pulsation control .
= speed of sound (s\1\:)
A., =
The formula for calculation of these minimum volumes is con
area o f choke t u b e ( ft2)
tained in paragraph 3.9.2. 2.2 of API 618 (Third Edition, Febru L, = length of choke tube ( ft )
ary 19 86) [6]. It basically uses 20 times the combined swept L; = L , + .6d ( ft )
volume of the head and crank end of the compressor cylinder, d, = choke diameter ( ft )
V1 = volume of primary bottle ( ft 3 )
V2 =
corrected by a square root function for the speed of sound
volume of secondary b ottle { ft 3 )
difference between a typical natural gas with a speed of sound of
1400 ft/sec. For example, if the speed of sound were 2 800 ft/sec, Figure 4 7. Equation for (Nonsymmetrical) Volume- Choke
the recommended volume bottle would be 2 8 . 2 8 times the swept Volume Helmholtz Frequency.
volume.
Economic and mechanical considerations limit the size of
surge bottles, and therefore impose practical limits on the degree Normal design procedure for low pass filters is to design the
of overall acoustic attenuation, which can be achieved. Since a Helmholtz frequency below the lowest pulsation frequency to be
surge volume is basically an acoustic "flexibility," it can be attenuated. Effective pulsation reduction can be achieved for
sized to reduce pulsations over certain frequency ranges. While frequencies above approximately twice the Helmholtz frequen-
TUTORIAL ON VIBRATIONS IN RECIPROCATING MACHINERY AND PIPING SYSTEMS 265
I I I I
with a 6.0 in stroke and an operating speed range of 700 to 1 000
d
rpm. The suction pressure is 267 psia, and the discharge pressure
l l
is 567 psia. To eliminate the effect of piping acoustic resonance,
with the attached piping , and therefore compares only the rela
tive effects of the various bottles themselves.
The pulsation control devices considered are listed below,
with the results of the analyses shown in Figures 49, 50, and 5 1 .
Symmetrical Volume-Choke- Volume Helmholtz Frequency
50
where f = frequency ( Hz )
c = speed of sound ( sc )
d
I
D
= choke diameter ( ft )
= diameter o f each b o ttle ( ft )
L = acoustic length o f b o t tles and choke ( ft )
pulsation devices, several devices were analyzed using the (below l x running speed).
digital acoustical simulation program. The discharge piping of a Frequency spectra of the pulsation in the discharge pipe
typical compressor cylinder was assumed in conjunction with (downstream of the pulsation suppression device) are presented
various size surge volumes and acoustic filters. A case assuming in a graphical data format for each case.
no pulsation control device in the piping system was also Each of the frequency spectra plots contain multiple curves
analyzed. The compressor cylinder simulated has a 9 . 25 in bore representing frequency response at each individual harmonic of
266 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM
P)
( 0 . 2 3%
0 so 100
pressure drop through the choke tube is approximately 2.5 psi
(0 .44 percent). The pulsation spectra for Case 5 looks almost
identical to that of Case 4. The effect of the choke tube is to
attenuate pulsations above the Helmholtz frequency (60 Hz).
The nozzle resonance near 110 Hz (See Case 3) is attenuated
with the filter; however, the pulsation at 2x running speed is
unaffected. In comparing Case 4 to Case 5, essentially the same
Vol u m e - C h o k e - V o l u m e (
f< 1 x )
V o l . E a c h B o t t l e > 1 x A P I S u r g e Vol u m e pulsation control can be obtained using an orifice plate having a
(s-o" /5-!g:: o2;J. D_oa;-zs"
x 1 0 )
. . o o\----t-so--,;,1.,;-.....i pressure drop of 0 .125 percent of line pressure as can be obtained
(0.42% P ) "'""""' (Hl
by adding a choke tube with 2.5 psi pressure drop.
Figure 5 1 . Comparison of Pulsation Control Devicesfor (Single Case 6 represents a volume-choke-volume filter (using a total
Cylinder) Compressor Discharge Piping System-Effect ofHelm volume equal to the API 618 recommended volume) with a
holtz Filter Frequency. Helmholtz frequency which has been set to approximately 22 Hz
(between 1x and 2x running speed). This is accomplished by
using a longer choke tube with a slightly larger diameter . The
compressor speed. The amplitude of pulsation in psi p-p of each resulting pressure drop through this choke tube is 2.4 psi (0 .42
harmonic is plotted vs frequency in Hertz for the full speed range degree), which is approximately the same as in Case 5. Note that
of the simulation. For example, for a compressor speed range of the maximum predicted response at 2 x running speed actually
700 to 1000 rpm, the first harmonic would sweep the 11.67 to increases in this case to approximately 11 psi p-p (compared to
16 .67 Hz range, the second harmonic would sweep the 23.34 to Cases 3, 4, and 5). Note also that the shape of the harmonic curve
33.33 Hz range, etc . These data formats are important for has changed, with the maximum amplitude occurring at the
evaluating the actual predicted pulsation amplitudes and fre lowest frequency (approximately 23.3 Hz, corresponding to 700
quencies of individual harmonic components. A knowledge of rpm compressor speed). This increase in predicted pulsation at
both amplitude and frequency is important in evaluating the 2x running speed is caused by its proximity to the Helmholtz
acceptability of piping designs from a vibration standpoint. frequency of the filter. Pulsations greater than this frequency are
For Case 1, in which no pulsation control is assumed, a high generally attenuated, but pulsations near this frequency can be
response is predicted at the second harmonic of running speed amplified. Note, however, that the predicted pulsation at 2x is
(referred to as 2x running speed-from 23.3 to 33.3 Hz). The still less than that predicted in Case 1, with no pulsation control.
TUTORIAL ON VIBRATIONS IN RECIPROCATING MACHINERY AND PIPING SYSTEMS 267
Case 7 shows a volume-choke-volume filter where the Helm Disch arge L i n e Pulsa tion
Surge volumes, acoustic filters, and orifice plates are all effec ' I
'
tive pulsation control devices when utilized properly. The me I ""
Fil ter
0
8 Cos F'le!ble
I.W.
Charged 9todder
Bot tle
t t . ...... _ ,_ ,
A. W l l h eo 8 1 o n k e l I C, I l ....... C- 11
C &.I L I C..,.p A
P Se l U o C- 1
17" I . D .
E R , .,.. rop Co..., l
B ottle
F R .... - c- e
6 iluOo .. P l l
H Ko<O<Io,. P l l
(TYP.)
I R ; .., lop C-p A
J "- - c-
( Heocioor P I )
L HuOo.. P t
N PI S
N Sc,.oJto.,. Ou l l o l
O Zc r .... ,.,., , ..,
'P..
'
:
Co pressor
"A"
Compressor
C . Go!O C h o r q e d w l h Diophrtgm
with
"B"
Cr Litf{id
-- - - - - - - - - - - --)-l-;m 6" Header
6"
Figure 54. Common Types ofPulsation A ccumulators (Dampen Ooh J..... 2 3 , 1 993
l ) l ts' , 1 3 1 115 ' ,
EOt S- Anl ... t o ,
1 3 7 115"
lua-
e rs) Used in Liquid Systems.
V volume (ft3)
v equivalent liquid volume
The upper graph in Figure 56 gives the pulsation spectrum at
Unfortunately, the performance of these devices is degraded the cylinder flange test point of compressor A for single acting
by: operation of the compressor cylinders . Since the compressors
run at 450 rpm, the fundamental excitation frequency is 7 .5 Hz,
Neck inertance (restriction) effects which reduce compli
and high pulsation levels ( 1 20 psi p-p) occur at both compressors
ance effects
near this frequency. The simulation considers a speed range
Bladder stiffness effects ( 10 percent), so that response peaks can be identified. Note that
Absorption of gas in nonbladder devices the shape of the response curve indicates a peak response or
resonance just above 7 .5 Hz.
Nonlinear effects, such as bladder restriction caused by
The passive frequency response (middle graph-Figure 56)
physical dimensions of device (cases, mandrels)
shows various resonant frequencies, with a dominant response at
Complete failure of bladder as well as permeability to 8 . 1 5 Hz. Animation showing the relative amplitude and phase
certain liquids relationships of the 8 . 1 5 Hz resonance (Figure 57), indicates that
the pulsation amplitudes are ( 1 80 degrees) out of phase at the
Sensitivity to pressure (volume and bulk modulus change)
bottles of the two compressors, with a pressure node near the
These characteristics make their performance more difficult header midway point between the compressors. These mode
to predict than the all-liquid type devices. shape data give insight into effective locations for orifice place
Gas charged devices are also used to control "water-hammer" ment, since orifice plates are most effective when located at
for transient flow problems in liquid systems . velocity maximums .
Based on the simulation results, it can be determined that
Acoustic Simu lation of Comp ressor and Pump Systems
orifice plates would be most effective when placed in the suction
An understanding of the overall characteristics of the acoustic lead lines or in the header of the two compressors as opposed to
resonant frequencies is important in order to make effective and locating one at the scrubber vessel outlet flange. The lower
efficient design decisions regarding the control of pulsation in graph of Figure 56 shows simulation results with orifice plates
the piping. One of the most important tools available to this end installed at the suction bottle inlet flange of each compressor.
is the ability to display pulsation spectra and acoustic mode Pulsation levels at 1 x running speed were reduced by a factor of
shapes of actual systems. Examples of simulation .of actual approximately 1 0 . (Note the y-axes are auto-scaled, so that the
systems are presented here. scales of the upper and lower graphs are different.)
Hydrogen Comp ressor Suction Piping System Suction Piping of Fou r Natura l Gas Compressors
The simulation of this system serves as an example of the type The computer generated piping model diagram of the suction
of data generated during an acoustic simulation, as well as the piping is shown in Figure 58 of four six-cylinder, single-stage
effectiveness of orifice plates in certain systems. compressors in a common header [ 1 1 ] . The passive frequency
TUTORIAL ON VIBRATIONS IN RECIPROCATING MACHINERY AND PIPING SYSTEMS 269
A
500
- Cylinder Ccnp A
K7
0
0
)'_ 10 20 30 40 50
FREQUENCY (Hz)
A Cyl i nder - C A
0
0
A 10
J\_ 20 30 50 Compres:sor " K 7" Piping
Bottom - "Zoom" of
FREQUEHCY (Hz)
40
r---r---r---+---+-__,
r---r---r---+---+-__,
0 oow-----so'
FREQUENCY (H.t)
A K7 Cy1 1 F lg
I I
A _/
AIEQUEHCV (Hd
0
0 10 15
6" Header
acteristic acoustical mode shape which can be demonstrated in of using the 5.0 gallon device are shown in Figure 62. It can be
a similar manner. The second mode near 1.9 Hz involves oscil seen that the larger bladder volume actually caused the pulsa
latory flow of the header portion between the two compressors tions at the cylinder to increase from approximately 30 psi p-p
on the far left. The third modes near 3.5 Hz and 5.4 Hz are at the plunger frequency to 140 psi p-p, and at the lateral from 16
associated with the primary and secondary bottles, and the mode psi to 90 psi. The general rule of thumb would be that the
near 20 Hz is associated with the frequencies of the primary pulsations should be reduced when the large gas volume is used.
bottle itself. The passive analysis (Figure 63) for the two bladder devices
Discharge Piping of a Triplex Pump System demonstrates the reason why the smaller device achieved lower
pulsations in the pump system. The larger gas volume actually
The piping model diagram for the discharge system is shown caused a resonance to shift to the plunger frequency, which
in Figure 60 of four triplex oil pumps [3]. Each pump has a gas amplified the pulsations.
charged bladder type device installed near its discharge flange.
The four pumps are tied to a common header, with one end 2.5 Gallon Bladder Device
l l.ateral
capped, and the other terminated with a characteristics imped
A """ ' 8
J ,\ (' / (1 vfl
O o I p....,p $
5 C.Il i i "" EI I add4r D<I v o c o
I I
"""""' WI. ...,.
A P.,..., I
0 -
50
- - ! ' J-
IIlli ISO
0
--
50 1 00
_! J ISO
8 ""P I lloral
... Q I
C J>v.op l tt.I&- Jo..roo FREQUENCY (H) FREQJENCY (Hz)
D P.,..p
P..
H P L o l .,. a l
I "-9 H ill- -'-"
J op
: r:-o.":..f.
I P.,.o 4 L G I ..- o l A """ '
5011 100
" Hdr O l od lo
I I \ I'
0 .)'-- 0
JI' ../'
SO IIlli !50 0 so 100 !50
FREQUENCY (Hz) FREQUEHCY {Hz)
-
Tr o p l & Puii!P<J w l t h &uCharg1> c......, l o l or fl
1\
O o I Pl.ftPm D o <>h.,rg< S v l " "
S G a l l o n B l oddr D" ' " AI\
\
... '----- -------
./
Iu.L <lU
A P p l
a f\ooo 1 t o l ... l
FRtQUEHC'I' {)
t Puop l lldr J<.n 0 -
D l'.,oop 2 10 15 20 25
[ P..op 2 l L ..,. a l
f . P...,p l l d r """"
S l'..op l
N : :':'- 1 1
l l'uop i h l .,. o l
4
lldr 8 1 1nfl1
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/I
I
'-.. "---
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o
v 15 ro
F'flEQUEHCY (H)
In designing pulsation control devices for reciprocating 15. Blevins, R. A., Flow-Induced Vibration, New York, New
pumps, a volume-choke acoustical filter system is usually effec York: Van Nostrand Reinhold (1977).
tive in controlling the pulsations in the piping and should be 16. Wachel, J. C., Szenasi, F. R., and Denison, S. C., "Analysis
placed as close as possible to the pump flange. of Vibration and Failure Problems in Reciprocating Triplex
Pumps for Oil Pipelines," ASME Paper 85-PET-10 (1985).
Pulsation control devices which use a gall-filled bladder
must be properly charged. Small changes in the charge pressure 17. Wachel, J. C., Szenasi, F. R., and Denison, S. C., "Acousti
can affect the acoustical pulsations, shaking forces, NPSHA, cal Analyses Solve Vibration, Failures in Recip Pumps, " Oil
cavitation, etc. & Gas Journal, pp. 60-72 (August 11, 1986).
Orifice plates can be very effective in attenuating specific 1 8. Wachel, J. C. and Price, S. M., " Understanding How Pulsa
acoustical natural frequencies if they are located near the point tion Accumulators Work," Pipeline Engineering Sympo
maximum acoustical velocity. sium, PD-Vol. 14, Book No. 100256 (1988).
272 PROCEEDINGS OF THE TWENTY-THIRD TURBOMACHINERY SYMPOSIUM