Dynamic Module of CAESAR II PDF

DYNAMIC MODULE OF CAESAR II
Is it of any use??
30th August 2007
DYNAFLOW
lectures 2007
Copyright 2007 by Dynaflow Engineering B.V. All rights reserved
-1-
Why is dynamics not used more

Coade: < 5% of Caesar II license holders also makes use of dynamic module
Dynamical effects are overlooked

Dynamical effects are underestimated
Pipe stress engineers prefer quasi static approach
Dynamic load * 2
Pipe stress engineer feels uncomfortable with dynamics
-2-
Function of the dynamical module

Facilitate accurate assessment of the dynamical effects
Effects of unsteady loads on stress and load levels in piping

systems.
When is it used??
During design (avoid fatigue, overloading, large displacements)
Control of Vibration problems (development of mitigation

measures)
-3-
Few examples of what might go wrong!!
Piping Incidents due to dynamic loads
-4-
Collateral Damage due Dynamic Effects from

Flange Failure
-5-
Support Damage (I)
-6-
Support Damage (II)
-7-
Support Damage (II)
-8-
Support Damage (III)
-9-
More Incidents due to fluid/gas transients

(small bore piping)
-10-
Examples of incidents as a result of fluid transients
-11-
Deluge FF System on Jetty when

Tested First Time (I)
-12-
Deluge FF System on Jetty when

Tested First Time (II)
-13-
Flange Failure
-14-
Dynamic loads are classified based on time history

Sustained dynamic loads
Periodic loads of moderate amplitude and long duration (minutesdays)

- Forces due to pressure oscillations in pump/compressor
suction or discharge systems
- Imposed oscillating displacements at pump/compressor nozzle
connections.
- Oscillating forces originating from flow fluctuations/instabilities
Transient, intermittent dynamic loads
Relatively large forces of relatively short duration (seconds)

- Slug Loads
- Relief Loads
- Waterhammer, surge loads
- Earthquake
-15-
Effect of dynamic loads

Vibration with a periodicity equal to the excitation mechanism
Vibration amplitude depends on separation between excitation

frequency and natural frequency of the piping system
Failure mechanism: High cycle fatigue
Transient dynamic loads
All natural mode shapes and natural frequencies of the piping system
are affected.
Response may show large amplitude vibrations of short duration.
Failure mechanism:
Excessive support loads
Accumulation of strain, low or high cycle fatigue
-16-
Required data for dynamic analysis

Dynamic model of piping system
Good distribution of lumped masses, additional nodes
Sufficient number of DOF

-
For lumped mass (FE) type calculations typically only the

first 33% of the modes shapes are accurate.
Accurate boundary conditions
Magnitude of the excitation forces
Mechanical
Fluid mechanical
-
Slug load calculation (manual??)
Acoustical simulation (pulsation study)
Waterhammer (surge) load calculation, simulation or

manual
(Measurement results for bench marking the simulations)

-17-
Assessment of dynamic results

Material Fatigue data,
ASME B&PV section VIII div 2 appendix 5
API 579
AD Merkblatter
BS-5500
EN-13445
-18-
Vibration Assessment conform VDI 3842

Typical Vibration Level Limits conform VDI 3842, Vibrations in Piping Systems
Vibration Velocity [mm/s] RMS
1000.0
100.0
10.0
1.0
1
10
100
1000
Frequency [Hz.]
design
marginal
correction
danger
-19-
Three Options for Dynamic Response Analysis

in Caesar II
0
1
2
3
-20-
Harmonic analysis
Application
Sustained vibrations (compressors & pumps)
Periodic Loads can be applied at any node in the system
Per load case one excitation frequency
Many load cases are possible
Input
Solution method
Since response frequency equals excitation frequency solution

procedure is quasi static (fast)
Output
Stress, displacement and load amplitude per frequency
-21-
Spectrum Analysis
Application
Transient vibrations: slug, waterhammer, relief
Load time histories at many nodes in the system
Input
Calculation method
Load time histories are translated into response spectra (time

phase between different loads is lost)
Natural frequencies and mode shapes are calculated
Response for each mode shape is determined
Mode shape responses are combined into a final system

response
Output
Maximum stress, largest modal contribution
Maximum loads, largest modal contribution
Maximum displacements
-22-
Response Spectrum Generation
-23-
Response Spectrum Generation
DLF may grow > 2 if time history contains only a limited amount of consistent
periodicity
DLF Related to 4 harmonic cycles
-24-
Time History Analysis

Application
Transient vibrations: slug, waterhammer, relief
Load time histories at many nodes in the system
Input
Calculation method
Load time histories are maintained (time phase between different loads is
conserved)
Natural frequencies and mode shapes are calculated
Response of each mode shape is determined
Mode shape responses are combined into a final system response

Output
Maximum stress, actual stress at user defined times (snapshots)

Maximum loads, actual load at user defined times
Maximum displacements, actual displacement at user defined times
By combination of several runs a time history of stress, loads
displacements can be composed
-25-
Missing Mass correction

Only limited number of mode shapes are extracted and participating in
the response
Only a fraction (preferably close to 100%) of the system mass is
participating
Only a fraction of the total excitation force is participating
The missing force fraction is calculated and applied statically after
multiplication by the largest DLF value above the frequency cut-off.
Important when large axial loads are applied (axial mode shapes have
relatively high natural frequencies.
-26-
Spectrum versus Time History

Spectrum
Frequency domain
Conservative results: only maximum response per mode shape is

calculated and combined in system response
Mode making maximum contribution is identified (advantage for

vibration control)
Only maxima are calculated, time phase is lost
Number of participating modes is finite (missing mass)

Time history
Time domain
More accurate results: time history response per mode is

conserved and time phasing between model maxima is
maintained during combination.
Load, stress time histories (enables fatigue assessment by means

of cumulative damage, counting of cycles)
Graphical response is possible
Modal info is not available
Calculation is memory intensive (limits simulation duration,

number of participating modes, time step resolution)
Number of participating modes is finite (missing mass)

-27-
Quasi-Static Approach
Dynamic Load amplitude (maximum) * DLF=2 as static load
Quasi static approach is simple and fast
Quasi static approach works when there is only one dominant mode
shape that is excited
Quasi static approach focuses on loads (dynamic response is not
considered), i.e. solution by change/elimination of modes is not possible.
-28-
Best Method for Transient (Impact) Loads Analysis

Quasi static
Simple but only if there is one dominant mode shape
Spectrum
Time phase between several impacts on one system is lost (e.g.

slug hitting consecutive elbows)
Conservative but output provides clues for problem solving.

Mode with largest contribution is identified.
Time history
Exact, timing relation between impacts is maintained (slug,

waterhammer)
Clues for diagnosis are less obvious
For transient loads a combination of spectrum and time history runs

provides the best opportunities
-29-
Protective Measures
Control of mechanical natural frequencies of the piping system

in relation to the excitation frequency
Support functions and support stiffness (in general high

stiffness)
Analysis accuracy is increased if support structure is included

in the model
Transient dynamic loads
Control of support and nozzle loads
Support flexibility is sometimes useful
Elimination of damaging mode shapes
Protective measures for dynamics may be conflicting with statics
-30-
-31-
-32-
Example 1
Problem
High vibration level in compressor suction piping
Steps to solution
Vibration Measurements, identification of main contributions in

frequency domain
Verification of acoustical natural frequencies of piping system

(acoustical resonance)
Verification of mechanical natural frequencies (mechanical

resonance)
Identification of source of vibration problem
Modification proposal
-33-
Compressor Location
-34-
Steel Supporting (I)
-35-
Steel Supporting (II)
-36-
Compressor Layout
-37-
Step 1. Vibration Measurements and Compressor

Harmonics
120.00
33 Hz
66 Hz
49 Hz
100.00
16 Hz
99 Hz
83 Hz
Amplitude (dB)
80.00
60.00
40.00
20.00
0.00
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Frequency (Hz)
-38-
Intermediate Conclusion from Step 1

Vibrations are at compressor harmonics
Vibrations must be result of:
Acoustical resonance
or
Mechanical resonance
or
High pulsation forces without resonance (compressor bottle

sizing problem)
-39-
Step 2. Acoustical Natural Frequencies & Compressor

Harmonics (Search for acoustical resonance)
250
16 Hz
200
Purple vertical lines represent compressor harmonics
Amplitude
150
100
50
0
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
Frequency (Hz)
-40-
Intermediate Conclusion from Step 2

Maybe near to resonance condition at first compressor harmonic (16.5 Hz.).
No further acoustical resonance
Vibration peak at 16.5 Hz, most probably is due high shaking forces as a result
of near resonant condition.
The other vibration peaks must be the result of:
Mechanical resonance
High pulsation forces without resonance (compressor bottle sizing

problem)
or
-41-
Step 3. Vibration Measurements & Calculated Mech.

Natural Frequencies (Search for Mechanical Resonance)
100.00
90.00
66 Hz.
33 Hz
80.00
Amplitude (dB)
70.00
60.00
83 Hz
50.00
40.00
30.00
20.00
Purple vertical lines represent pipe system natural frequencies
10.00
0.00
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
Frequency (Hz)
-42-
Conclusion from Step 3 & Identification Cause of

Vibration Problem
Apparently there is mechanical resonance at 33 Hz and 66 Hz and near
mechanical resonance at 83 Hz.
No mechanical resonance condition at the first compressor harmonic (16.5 Hz.)
and at 49 Hz. and 99 Hz.
The high vibration levels 33 Hz, 66 Hz and 83 Hz are of mechanical nature.
The high vibration level at 16.5 Hz most probably is an acoustical resonance
problem.
The high vibration level at 49 Hz and 99 Hz. must be the result of:
High pulsation forces without resonance (compressor bottle sizing

problem)
-43-
Examination of Mechanical Behavior

66 Hz. Mode Shape
Large amplitude movement

in suction manifold
-44-
Step 4. Modifications
The high vibration levels 33 Hz, 66 Hz and 83 Hz are of mechanical nature
and need a mechanical solution
Better supporting
Improved support stiffness
The high vibration level at 16.5 Hz is due to acoustical resonance and

needs an acoustical solution, I.e. different bottles and/or orifice plates to
introduce more damping
The high vibration level at 49 Hz and 99 Hz. are the result of high pulsation
forces without resonance and must be resolved by compressor bottle
(re)sizing.
-45-
As Built Supporting Structure of Compressor Manifold
-46-
Modified/Improved Supporting Structure of

Compressor Manifold
-47-
Modified Structure Implemented & Connected to

Attached Piping
-48-
Conclusion from Example 1

Compressor vibration problems are of a mixed nature
Part is mechanical
Part is acoustical
Each category requires a different approach and result in different

solutions
Not all vibration problems can be solved by mechanical measures.
-49-
Example 2
Problem
Failure in cooling pump discharge line (possibly vibration induced)
Steps to solution
No vibration measurements just visual observation
Identification of excitation mechanism thru fluid simulations (pump

trips & start-up and check valve closures)
Time history mechanical simulation to verify stress levels
Identification of source of vibration problem
Modification proposal
-50-
Model of the System
Steady State Volume Flowrate [m3/s]
-51-
Time History of Pumps
Pump trips at t=1 seconds,

Pump inertia: 8 kgm2
-52-
Time History of Valve
Check valve closes in 0.5 second
-53-
Time History of Flow through Valve
Flow thru checkvalve
-54-
Maximum Transient Pressure
Maximum Transient Pressure during pump trip [Barg]
-55-
Unbalanced Load Time Histories (I)

Load in Newton * 104
-56-
Unbalanced Load Time Histories (II)

-57-
Unbalanced Load Time Histories (III)

-58-
Unbalanced Load Time Histories (IV)

-59-
Unbalanced Load Time Histories available in CAESAR
-60-
Conclusion from Example 2:
Alternating stress amplitude of 233 MPa results in stress range of 466 MPa
may be responsible for LCF
-61-
Example 3
Problem
Excessive pressure in injection line.
Steps to solution
Assumed mechanism entrapped (undrained) fluid propelled by gas at

gas velocity during start-up hits valve that is cracked open
Identification of source of problem thru simulation
-62-
Valve Damage
-63-
Model of the System
-64-
Pressure Time History at the Ball Valve in Case of

Entrapped Gas at the Valve
Pressure in Barg
Valve cracked open at t=0
-65-
Pressure Time History of Entrapped Gas

Maximum Transient Pressure in trapped gas
Slug 29 liter, 20 meter
Slug 130 liter, 90 meter
500
450
400
M a x im u m P re s s u re [B a rg ]
350
300
250
200
150
100
50
0
0
100
200
300
400
500
600
700
800
900
1000
Trapped gas volume [Liter at atmospheric pressure]

-66-
Conclusions for presentation

Dynamic analysis is an important and sometimes a critical element in
integrity analysis
Many failure modes are to be addressed
Excessive loads are to be handled
CAESAR offers several types of dynamic analyses to assist in the

demonstration of integrity:
1.
Harmonic Analysis
2.
Spectrum Analysis
3.
Time History Analysis
Solutions to possible problems are often found by introduction of the right

supporting and/or supporting steel structure
-67-
END
Thank you for your attention
-68-

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DYNAMIC MODULE OF CAESAR II

Why is dynamics not used more

Dynamical effects are overlooked

Pipe stress engineer feels uncomfortable with dynamics

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Function of the dynamical module

Effects of unsteady loads on stress and load levels in piping

During design (avoid fatigue, overloading, large displacements)

Control of Vibration problems (development of mitigation

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Few examples of what might go wrong!!

Piping Incidents due to dynamic loads

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Collateral Damage due Dynamic Effects from

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Support Damage (I)

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Support Damage (II)

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Support Damage (II)

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Support Damage (III)

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

More Incidents due to fluid/gas transients

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Examples of incidents as a result of fluid transients

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Deluge FF System on Jetty when

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Deluge FF System on Jetty when

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Dynamic loads are classified based on time history

Periodic loads of moderate amplitude and long duration (minutesdays)

Transient, intermittent dynamic loads

Relatively large forces of relatively short duration (seconds)

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Effect of dynamic loads

Vibration with a periodicity equal to the excitation mechanism

Vibration amplitude depends on separation between excitation

Failure mechanism: High cycle fatigue

Transient dynamic loads

Response may show large amplitude vibrations of short duration.

Excessive support loads

Accumulation of strain, low or high cycle fatigue

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Required data for dynamic analysis

Good distribution of lumped masses, additional nodes

Sufficient number of DOF

For lumped mass (FE) type calculations typically only the

Accurate boundary conditions

Magnitude of the excitation forces

Slug load calculation (manual??)

Acoustical simulation (pulsation study)

Waterhammer (surge) load calculation, simulation or

(Measurement results for bench marking the simulations)

Assessment of dynamic results

ASME B&PV section VIII div 2 appendix 5

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved

Vibration Assessment conform VDI 3842

Vibration Velocity [mm/s] RMS

Copyright 2007 by Dynaflow Engineering B.V. All rights reserved