December 2009 Vibration

Dynaflow Lectures Reciprocating compressors
Acoustics and Mechanical Response

Rotterdam, December 10
th
2009
2
EXAMPLE
Compressor piping vibration analysis
Two parts:
1. Acoustical/pulsation study
2. Mechanical response analysis
Labor intensive modeling
Large number of load cases.
Copyright 2009 Dynaflow Research Group BV
3
Sequence of dependence
Acoustics is about propagation of
pressure pulsations in piping systems
Source of Pressure pulsations:
Reciprocating compressors and pumps
Pressure waves are propagated thru the
piping system.
Pressure waves are reflected (partly) and
transmitted (partly) at geometrical
discontinuities
Pressure pulsations generate unbalanced
forces that are the source of piping
vibration
Sustained vibration may result in fatigue
failures
4
Elements of Acoustics
Aspects of Mechanical Response
Examples of Mechanical Response
Agenda
Reciprocating compressors and pumps inherently
produce pulsations in the suction and discharge piping
5
Double acting cylinder:
Piston displacement opens and closes
suction and discharge valves
Actual Piston movement (not purely sinusoidal) due to
finite rod length
7
Valve openings result in a Sawtooth type of gas flow
Due the sequence of piston movement and valve opening and closing
8
The shape of the sawtooth is determined by the rotational speed of the
compressor, the geometry of the cylinder and the pressure ratio.
Flow time history for a single acting cylinder
With ideal instantaneous reacting valves
9
Resulting Flow Frequency Spectrum (discrete) for single
acting cylinder
10
Double acting cylinder (slightly unsymmetrical)
Head end cranck end because of the piston rod volume
12
Uneven frequency components finite but
small due to imperfect symmetry
Flow Frequency Spectrum (discrete) for double acting
unsymmetrical cylinder
13
Flow pulsations result in pressure pulsations
Pressure pulsations propagate thru the piping system at the speed of sound
Speed of sound depends on:
Gas composition
Gas Temperature
Gas Density
Pressure/Flow pulsations reflect at geometrical discontinuities
Wave length of propagating wave depending on speed of sound and pulsation frequency
Wave reflection and wave interaction results in system acoustical natural frequencies.
e.g. for wave length/frequency that match a geometrical length scale standing waves may
occur
Presence of Acoustical natural frequencies may result in Acoustical resonance
System will show an acoustical response to an acoustical excitation
f
c
=
14
Example of acoustical natural frequency result
15
Limited accuracy of acoustical model
Accuracy of prediction of acoustical natural frequencies relatively large
Error margin relatively small: +/- 5%
Errors controlled by limited number of parameters:
Geometry
Speed of sound
Compressor RPM
16
Guidelines for acoustical pulsation levels according API618
Guidelines for acceptable pulsation levels.
Acceptable levels are related to (inversely proportional to) frequency, pipe
diameter and (proportional to) average pressure level
Measures to control pulsation levels:
Geometry changes (controlling acoustical natural frequencies)
Changing pipe diameters to reduce pulsation level
Introduction of damping (orifice plates at location of max oscillating flow)
Introduction of additional volumes with or without internals (creating filters)
Increasing size of bottles (windkessel function).
17
Pulsation Bottles are a way to reduce pulsations
Bottles serve two effects: (1) Surge volume and (2) Filter function
1. SURGE VOLUME 2. FILTER FUNCTION
Maximum filter function for pulsations
with a wave length that matches the
bottle length
Minimum filter function (attenuation)
for pulsation with a half wave length
that matches the bottle length
Pulsation reduction is proportional to
surge volume size
18
19
EXAMPLE
Pulsation Bottles located near the compressor
Two bottles per
compressor
Multiple pistons per
compressor
Inlet scrubbers
COMPRESSORS
Guidelines for Pulsation Bottle sizing
1. SINGLE CYLINDER BOTTLE 2. MULTICYLINDER BOTTLE
20
Acoustical filters
Volumes connected by choke tubes
Filter frequency f
h
:
Filter frequency response
21
22
Elements of Acoustics
Mechanical Response
Example of Mechanical Response
Agenda
Mechanical response calculation fifth edition of API 618
Guidelines for pulsation levels.
If pulsation levels exceed guidelines system may be qualified by means of
mechanical response analysis.
Vibration control by mechanical means is a possible option
Large uncertainty margin in mechanics during design (minimum 10-20%)
Acoustic is more accurate (typically +/- 5%)
Preference for reduction of pulsations and thereby shaking forces by
means of acoustical measures e.g. filtering (e.g. Helmholtz resonator)
23
Accuracy of prediction of mechanical natural frequencies
Error margin: 10-20% or many time even larger
Modeling of Boundary conditions
Modeling of rack structures
Support clearance
Support lift off (thermal), support settling
Support stiffness i.e. stiffness of clamps and restraints
Influence of friction
Nonlinear supports (supports with gaps or single acting supports)
Uncertainties in masses
Differences between as built and design
Interaction between parallel pipes in pipe racks
Stiffness of concrete sleepers and pedestals
24
Many vibration problems related to attached components
Examples:
Valve Actuators
Small bore branch connections
Instrument connections
Level indicators
Stairs & Ladders
25
Mechanical properties and pulsations
Rule of thumb: minimum mechanical natural frequency 20% above
second compressor harmonic. Question: is this feasible???
26
Mechanical properties and pulsations (2)
Mechanical resonance difficult to avoid due to uncertainty in mechanical nat. freq..
Variable speed compressor makes separation virtually impossible.
At resonance condition amplitude limited by damping only (typical damping factors
of 2%-3% of critical)
High stiffness results in lower amplitudes.
27
Application of filters in combination with high
mechanical natural frequencies looks ideal
28
29
Acoustics
Mechanical Response
Example of Mechanical Response analysis in design
Agenda
EXAMPLE
30
Example: Mechanical Response of NAM Oude Pekela
Compressor plant
Air cooler A-174
Focal area
EXAMPLE
Acoustical results of suction piping
31
Nodal correspondence:
3360-3430 = C2 node 1085
3350-3360 = C2 node 1070
3000-3350 = C2 node 1033
EXAMPLE
32
Unbalanced shaking forces in [kN peak to peak] per
pipe section and per compressor harmonic
Focal area
EXAMPLE
Acoustical results of interstage piping
33
Nodal correspondence:
3330-3340 = C2 node 5060
3340-3350 = C2 node 5076
3380-3350 = C2 node 5097
EXAMPLE
Unbalanced shaking forces in [kN peak to peak] per
pipe section and per compressor harmonic
34
Summary of shaking forces
Conservative selection: maximum value of all harmonics
Acoustic pipe
section
Caesar II node number Force [N.] [peak-peak] Force [N.] [0-peak]
3330-3340 5060 131 65.5
3340-3350 5076 355 177.5
3350-3380 5097 815 407.5
3360-3430 1085 535 267.5
3350-3360 1070 240 120
3000-3350 1033 81 40.5
EXAMPLE
35
EXAMPLE
36
Two-stage compression combined model
Suction (partly), Interstage (upto cooler), Discharge (complete)
Aircooler E-174
nozzles
Suction Line
Discharge Line
Additional discharge volumes
to reduce pulsation levels in
remaining piping
Compressor discharge bottles
Interstage Line
Additional discharge volumes
EXAMPLE
37
EXAMPLE
Harmonic frequency assessment in CAESAR II
Sweep from 4 -56 Hz with 1 Hz steps
38
Harmonic forces are inserted in the model
Conservative Shaking force set taken from acoustic pulsation report
EXAMPLE
39
EXAMPLE
Maximum dynamic stress amplitude calculation
Max amplitude 6 MPa
40
Carbon Steel Fatigue Curve in the high cycle range
EXAMPLE
At a stress amplitude level of 6 MPa the number of
cycles is > 10
11
41
6 MPa
42
Acoustics
Mechanical Response
Example of Mechanical Response analysis as built
Agenda
43
1. Vibration Measurements: identification of main contributions in frequency
domain
2. Acoustical Resonance: verification of acoustical natural frequencies
3. Mechanical Resonance: verification of mechanical natural frequencies
4. Identification of source of vibration problem
5. Modification proposal
EXAMPLE
Issue: Unacceptably high vibration level in compressor
suction piping
In 5 steps to solution
Compressor plant
44
Structure and support details around the compressor (I)
45
Structure and support details around the compressor (II)
46
Details of the compressor location
47
48
0.00
20.00
40.00
60.00
80.00
100.00
120.00
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0
Frequency (Hz)
A
m
p
l
i
t
u
d
e

(
d
B
)
66 Hz
49 Hz
33 Hz
16 Hz
99 Hz
83 Hz
EXAMPLE
Step 1. Vibration Measurements
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)
49
1
2
3
50
0
50
100
150
200
250
10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00
Frequency (Hz)
A
m
p
l
i
t
u
d
e
16 Hz
EXAMPLE
Step 2. Acoustical natural frequencies & Compressor
Harmonics
51
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
or
problem)
EXAMPLE
Intermediate conclusion from step 2
1
2
52
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0
Frequency (Hz)
A
m
p
l
i
t
u
d
e

(
d
B
)
66 Hz
33 Hz
83 Hz
EXAMPLE
Step 3. Vibration Measurements & Calculated Mechanical
Natural Frequencies (Search for Mechanical Resonance)
Purple vertical lines represent pipe system natural frequencies
Conclusion from step 3 & Identification of 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)
53
54
The high vibration level at 16.5 Hz most probably is an acoustical
resonance problem.
Apparently there is mechanical resonance at 33 Hz and 66 Hz and near
mechanical resonance at 83 Hz.
The high vibration levels 33 Hz, 66 Hz and 83 Hz are of mechanical nature
No mechanical resonance condition at the first compressor harmonic (16.5
Hz.) and at 49 Hz. and 99 Hz.
The high vibration level at 49 Hz and 99 Hz. must be the result of:
problem)
EXAMPLE
Step 4. Identification of cause of vibration problem
55
Large amplitude movement
in suction manifold
EXAMPLE
Examination of mechanical behavior
Example of 66 Hz. mode shape
56
1. 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
2. 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
3. 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.
EXAMPLE
Step 5. Modifications
57
EXAMPLE
Modified structure implemented and connected to
attached piping
AS BUILT SITUATION IMPROVED AND IMPLEMENTED SITUATION
58
Compressor vibration problems many cases 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.
EXAMPLE
Conclusion from example
END
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Dynaflow Lectures Reciprocating compressors

Acoustics and Mechanical Response

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