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COST-EFFECTIVE AND DETAILED MODELLING OF COMPRESSOR MANIFOLD<br />

VIBRATIONS<br />

A. <strong>Eijk</strong><br />

<strong>Flow</strong> <strong>and</strong> <strong>Structural</strong> <strong>Dynamics</strong> (<strong>PULSIM</strong>)<br />

<strong>TNO</strong> <strong>Institute</strong> <strong>of</strong> Applied Physics (T PD)<br />

Delft, The Netherl<strong>and</strong>s<br />

ABSTRACT<br />

In systems with large reciprocating compressors, so-calIed compressor manif\)ld<br />

vibrations can contribute to fatigue failure <strong>of</strong> the pipe system. These vibrations are<br />

excited by pulsation-induced forces <strong>and</strong> by forces generated by the compressor.<br />

This paper describes an advanced <strong>and</strong> accurate method for predic- ting vibration levels<br />

<strong>and</strong> cyclic stresses in critical parts <strong>of</strong> the pi- ping, based on detailed modelling <strong>of</strong> the<br />

pulsations <strong>and</strong> compres- sor parts. Although detailed finite element modelling is applied.<br />

the method can compete in ease <strong>of</strong> use with analytical methods <strong>and</strong> is far more accurate.<br />

The effectiveness <strong>of</strong> this approach will be demonstrated by a case study in which a<br />

detailed compressor manifold vibration analysis has been carried out.<br />

INTRODUCTION<br />

Reciprocating compressors are used in gas transportation. gas storage <strong>and</strong> in the<br />

process industry. The compressor, including the pulsation dampers <strong>and</strong> connected pipe<br />

work. is <strong>of</strong>ten the heart <strong>of</strong> an installation <strong>and</strong> should therefore operate reliably. Pulsations<br />

<strong>and</strong> vibrations may disturb safe <strong>and</strong> reliable operation. To avoid vibration problems <strong>and</strong><br />

to optimize the dynamic behaviour, it is common practice to carry out a so-calIed<br />

pulsation <strong>and</strong> mechani- cal response study during the design <strong>of</strong> an installation. Such studies<br />

include investigation <strong>of</strong> compressor manifold vibrations. which are the vibrations <strong>of</strong><br />

compressor cylinders. di stance pieces, crosshead guides, pulsation dampers <strong>and</strong> piping<br />

near the compres- sor. Especially for larger compressors, compressor manifold vibrations<br />

are important as the mass <strong>of</strong> compressor parts <strong>and</strong> pul- sation dampers increases.<br />

which leads to low-resonance frequen- cies which may be excited by pulsation forces. by<br />

gas forces in the compressor cylinder, <strong>and</strong> by unbalanced forces <strong>and</strong> moments <strong>of</strong> the<br />

compressor (Palazzolo, Smalley <strong>and</strong> Lifshits, 1985, Lifson <strong>and</strong> Dube 1987). We have<br />

encountered several actual cases in which pulsation forces have excited compressor<br />

manifold vibrati- ons <strong>and</strong> caused fatigue failure.<br />

The importance <strong>of</strong> calculations <strong>of</strong> compressor manifold vibrations is also retlected in the<br />

fourth edition <strong>of</strong> the API St<strong>and</strong>ard 61 R<br />

J.P .M. Smeulers<br />

<strong>Flow</strong> <strong>and</strong> <strong>Structural</strong> <strong>Dynamics</strong> (<strong>PULSIM</strong>)<br />

<strong>TNO</strong> <strong>Institute</strong> <strong>of</strong> Applied Physics (T PD)<br />

Delft, The Netherl<strong>and</strong>s<br />

415<br />

PVP-Vol. 328. <strong>Flow</strong>-lnduced Vibration<br />

ASME 1996<br />

G. Egas<br />

<strong>Flow</strong><strong>and</strong> <strong>Structural</strong> <strong>Dynamics</strong> (<strong>PULSIM</strong>)<br />

<strong>TNO</strong> <strong>Institute</strong> <strong>of</strong> Applied Physics (T PD)<br />

Delft, The Netherl<strong>and</strong>s<br />

(11).<br />

In this paper, a method for the prediction <strong>of</strong> compressor manifold vibrations<br />

is discussed, which is based on rigorous finite element modelling <strong>of</strong> the<br />

compressor parts. Despite rigorous modelling, the method is efficient <strong>and</strong><br />

easy to" use <strong>and</strong> more accurate than the usual analytical methods.<br />

Before going into detail about the method, a short overview <strong>of</strong> the pulsation<br />

<strong>and</strong> mechanical response study will be given. fol- lowed by a description <strong>of</strong><br />

the kind <strong>of</strong> compressor manifold vi- brations which may occur.<br />

The paper concludes with a description <strong>of</strong> a case study, in which the accuracy<br />

<strong>of</strong> FEM roodels <strong>of</strong> compressor parts has been asses- sed by means <strong>of</strong> modal<br />

analysis measurements.<br />

PULSATION AND MECHANICAL RESPONSE STUDY<br />

Pulsation <strong>and</strong> mechanical response studies have become ac- cepted as part <strong>of</strong> the<br />

process <strong>of</strong> designing a reliable instalIation free <strong>of</strong> vibration problems. Such studies are<br />

carried out by the <strong>Flow</strong> <strong>and</strong> <strong>Structural</strong> <strong>Dynamics</strong> Department <strong>of</strong> the <strong>TNO</strong> <strong>Institute</strong> <strong>of</strong><br />

Applied Physics T PD, also known by the name <strong>PULSIM</strong>. The <strong>Flow</strong> <strong>and</strong> <strong>Structural</strong><br />

<strong>Dynamics</strong> Department is specialized in thé dynamics <strong>of</strong> pipe systems <strong>and</strong> has carried out<br />

some 600 studjes over a period <strong>of</strong> 25 years.<br />

In the study, a two-step approach is folIowed. In the first step, the pulsations, e.g.<br />

pressure <strong>and</strong> tlow velocity waves in the pipe system <strong>and</strong> tluid machinery are calculated,<br />

including pulsation- induced vibration forces. The layout <strong>of</strong> the pipe system <strong>and</strong> the<br />

design <strong>of</strong> pulsation dampers are harmonized to minimize pulsati- on levels <strong>and</strong> forces.<br />

In the pulsation study, worst-case situations are calculated, which means that aII resonant<br />

conditions in a certain range around the nominal condition are investigated. Calculated<br />

amplitudes <strong>and</strong> phases <strong>of</strong> the forces which act on the system at elbows, T -joints,<br />

reducers, pulsation dampers etc., are stored so that they can be used later in the<br />

mechanjcal response study <strong>of</strong> the pipe system.<br />

The pulsatjon study js carried out using the djgjtal sjmulation en- vironment <strong>PULSIM</strong><br />

(pJ.!L.sation SIMulatjon), whjch has been de- veloped by the <strong>Flow</strong> <strong>and</strong> <strong>Structural</strong><br />

<strong>Dynamics</strong> Department <strong>of</strong> the T PD. In general, <strong>PULSIM</strong> is a simulation envjronment for<br />

one-


dimensional non-stationary flow. Besides the functionality for pul- sation<br />

studies, other non-stationary flow phenomena, such as tran- sients, can also<br />

be modelled in the <strong>PULSIM</strong> environment (Smeulers, 1988. Egas, 1988, Van<br />

Bokhorst <strong>and</strong> Korst, 1993, Van Bokhorst, 1995).<br />

In the second step. the mechanjcaJ response study. vjbratjonal res- ponse <strong>of</strong> the pjpe<br />

system. jncludjng pulsatjon dampers. js calcu- lated on the basjs <strong>of</strong> predjcted pulsation<br />

forces.<br />

In the mechanjcal response studjes. a finjte element model js made <strong>of</strong> the pjpe system<br />

<strong>and</strong> the supportjng structure. The finjte element program ANSYS (14) js used for thjs<br />

purpose.<br />

In the mechanjcal response studjes. the pu1satjon forces used have been calculated wjth<br />

the <strong>PULSIM</strong> program. A Ijnk js made be- tween the <strong>PULSIM</strong> <strong>and</strong> ANSYS programs. so<br />

that the ampljtude <strong>and</strong> phase <strong>of</strong> the calculated pulsatjon forces can be transferred to the<br />

ANSYS program for a11 the jmportant acoustjc resonance<br />

condjtjons (worst-case condjtjons).<br />

COMPRESSOR MANIFOLD VIBRATIONS<br />

Compressor manifold vibrations are a specialized <strong>and</strong> com- plicated form<br />

<strong>of</strong> vibration <strong>of</strong> part <strong>of</strong> the piping, pulsation dampers <strong>and</strong> compressor parts<br />

such as cylinders, distance pieces <strong>and</strong> cros- shead guides. If not proper I y<br />

controlled, these vibrations can cause fatigue failure <strong>of</strong> the system. Figure l<br />

shows an example <strong>of</strong> a compressor manifold. Some <strong>of</strong> the common<br />

compressor manifold vibrations have special narnes <strong>and</strong> are summarized as<br />

follows:<br />

Low mode<br />

This mode is shown in figure 2 <strong>and</strong> is generally the lowest mode <strong>of</strong> the compressor<br />

system. This mode is a rigid body mo- tion <strong>and</strong> the cylinders <strong>and</strong> dampers vibrate inphase<br />

horizontally to the combined flexibility <strong>of</strong> the distance piece <strong>and</strong> the crosshead<br />

guide. As the nozzles must twist to accommodate this motion, high torsional stresses in<br />

the cylinder nozzles can occur.<br />

Rotary mode<br />

This mode is shown in tigure 3. The suction <strong>and</strong> discharge<br />

dampers move out-<strong>of</strong>-phase in a horizontal direction. In this mo- de, high bending<br />

stresses can occur, <strong>and</strong> the highest stress points are at the cylinder flanges <strong>and</strong> in the<br />

joints between bottIes <strong>and</strong> nozzles (named branch connections).<br />

Cylinder resonance mode<br />

This mode is shown in tigure 4. The cylinders move out-<strong>of</strong>- phase relative to each<br />

other. With more than two cylinders, vari- ous combinations <strong>of</strong> one cylinder moving<br />

out-<strong>of</strong>-phase in relation to the others will occur. In this mode, high bending stresses can<br />

occur <strong>and</strong> the highest stress points are at the cylinder flanges <strong>and</strong> branch connections.<br />

Suction damper cantilever mode<br />

This mode is shown in tigure 5. In this case, the suction dam- per moves out-<strong>of</strong>plane<br />

<strong>and</strong> the cylinder nozzles will bend. There may be a component <strong>of</strong> cylinder<br />

"diving" associated with this mode. This mode will cause high bending stresses <strong>and</strong> can<br />

cause fatigue failure <strong>of</strong> the system.<br />

If the discharge damper is not supported, it is also possible for a discharge damper<br />

cantilever mode to occur. The highest stress points are at the cylinder flanges <strong>and</strong> at the<br />

branch connections.<br />

416<br />

Suction damper angular mode<br />

This mode is shown in tigure 6. The two ends <strong>of</strong> the dampers move out-<strong>of</strong>-phase in<br />

the horizontal direction. In this case, high torsional stresses can occur. If the discharge<br />

damper is not sup- poned, a discharge damper angular mode may also occur. The<br />

highest stress points are at the cylinder flanges <strong>and</strong> at the branch connections.<br />

The compressor manifold vibration modes as mentioned above, occur only<br />

in systems without connecting piping. In most practi- cal cases, a part <strong>of</strong> the<br />

connected pipe system will also contribute to the compressor manifold<br />

vibrations.<br />

SIMUL.ATIONS<br />

Calculation <strong>of</strong> the Dulsation forces<br />

The pulsation forces which act on the pulsation dampers are the most<br />

important cause <strong>of</strong> compressor manifold vibrations. Por example, st<strong>and</strong>ing<br />

wave type resonances in the pulsation dampers will generate large pulsation<br />

forces.<br />

With <strong>PULSIM</strong>, the pulsation forces which act on pulsation dam- pers, bends,<br />

reducers, T -joints, orifice plates etc., <strong>and</strong> the gas force in the cylinders,<br />

which cause stretching <strong>of</strong> the cylinders, are calculated in detail.<br />

The amplitude <strong>and</strong> phase <strong>of</strong> the calculated forces are stored for worst-case<br />

conditions so that they can be used later in the me- chanical response study.<br />

Finite element model (FEM) <strong>of</strong> the nine svstem with comol"es- SOl" ual"ts<br />

Pipe system<br />

The pipe system as weIl as the structure on which the sup- ports are<br />

mounted are modelled with Timoshenko beam-type elements (ANSYS<br />

elements: PIPEI6, PIPEI8 <strong>and</strong> BEAM4). lnasmuch as numerous mechanical<br />

response studies are carried out each year at the <strong>Flow</strong> <strong>and</strong> <strong>Structural</strong><br />

<strong>Dynamics</strong> Department, special piping pre- <strong>and</strong> postprocessors have been<br />

developed to carry out mechanical response studies in an easy <strong>and</strong> cost-effec-<br />

tive way. Pre- <strong>and</strong> postprocessors have been written with the ANSYS<br />

Parametric Design Language (APDL) <strong>and</strong> use ANSYS piping comm<strong>and</strong>s.<br />

Preprocessor databases include st<strong>and</strong>ardized pipes, ASA <strong>and</strong> DlN flanges,<br />

<strong>and</strong> DlN beams. With the postpro- cessor, vibration velocities, support<br />

reactions <strong>and</strong> cyclic stresses in the pipe system are calculated <strong>and</strong> compared<br />

with permissible levels.<br />

Some components <strong>of</strong> the pipe system, such as fianged connecti- ons <strong>and</strong><br />

branch connections, always require special attention because the fiexibility <strong>of</strong><br />

these parts can have a distinct influence on the natural frequencies <strong>of</strong> some<br />

compressor manifold vibration modes, such as suction bottIe cantilever<br />

modes, suction bottIe angular modes <strong>and</strong> cylinder resonance modes (Lifson<br />

<strong>and</strong> Smal- ley, 1989, Tjeng <strong>and</strong> Wickert, 1994).<br />

Branch connections can be modelled by means <strong>of</strong> 3 translation <strong>and</strong> 3 rotation springs,<br />

<strong>and</strong> for the calculation <strong>of</strong> spring constants <strong>and</strong> stress intensification factors (SIFs), a<br />

finite element model<strong>of</strong> the branch connection is made which is built up with shell elementso<br />

For this purpose, the finite element program FE-PIPE ( 13) is used. which is a specialpurpose<br />

program developed for detailed


stress analysis <strong>of</strong> piping coroponents such as elbows, T -joints, etc. Calculated<br />

spring constants <strong>and</strong> SIFs are used in ANSYS bearo type roodels <strong>of</strong> the pipe<br />

systeros.<br />

Compressor parts<br />

The flexibility <strong>and</strong> mass distribution <strong>of</strong> compressor parts such as cylinders.<br />

di stance pieces <strong>and</strong> crosshead guides are very impor- tant. because these<br />

parameters determine some <strong>of</strong> the possible compressor manifold vibration<br />

modes described previously. It strongly depends on the construction <strong>of</strong> the<br />

machine what parts have to be included in the calculations. In most cases. the<br />

di stance piece is the most flexible part <strong>of</strong> the compressor. Most <strong>of</strong> the<br />

cylinders can be modelled by means <strong>of</strong> concentric pipe elements. Field<br />

measurements have also shown that the flexibility <strong>of</strong> the connection <strong>of</strong> the di<br />

stance piece with the crosshead guide can have an important effect on the<br />

natural frequencies <strong>of</strong> some com- pressor manifold vibration modes (see also<br />

the case study in this paper).<br />

Compressor parts such as the di stance piece <strong>and</strong> crosshead guide can <strong>of</strong>ten be<br />

modelled with shell elements (ANSYS elements: SHELLA3 <strong>and</strong> SHELL63),<br />

but this depends largely upon the com- pressor type.<br />

In compressor manifold vibration studies. cyclic stresses in the compressor<br />

parts are not calculated <strong>and</strong> models can therefore be kept relatively simple.<br />

Nevertheless, the number <strong>of</strong> degrees <strong>of</strong> freedom <strong>of</strong> compressor parts is very<br />

large ( 10.000-20,000) in comparison with the number <strong>of</strong> degrees <strong>of</strong> freedom<br />

<strong>of</strong> the pipe system. The number <strong>of</strong> responses to be calculated in the mechanical<br />

response study can also be considerable (1,500 responses is no<br />

exception). This leads to unacceptable computer times. which is why it is not<br />

feasible to include the shell element models in the pipe system model. One<br />

solution is the use <strong>of</strong> so-calIed substruc- tures. Substructuring is a technique<br />

that simp I y condenses a group <strong>of</strong> elements into a single element represented<br />

as a matrix (ANSYS element: MA TRIX50). This single matrix element is<br />

called a substructure or superelement. The number <strong>of</strong> degrees <strong>of</strong> freedom <strong>of</strong><br />

the superelement (called master degrees <strong>of</strong> freedom: MDOF) will be only a<br />

few hundred. However. accuracy <strong>of</strong> stiffness <strong>and</strong> mass is preserved. As the<br />

ANSYS program uses Guyan (or static) reduction in the substructure<br />

technique. this is only applicable for linear systems. Substructures can be<br />

easily included in the beam type model<strong>of</strong> the pipe system using a procedure<br />

that has been developed especially for this purpose.<br />

Each substructure <strong>of</strong> the di stance piece <strong>and</strong> crosshead guide is stored in a<br />

central database <strong>and</strong> can be employed by several users in various projects.<br />

Mechanical reSDOnSe studv<br />

The fust step in the mechanical response study is the calcu!a- tion <strong>of</strong> !ower<br />

mechanica! natura! frequencies <strong>of</strong> the system (moda! ana!ysis). The maximum number<br />

<strong>of</strong> natura! frequencies which are <strong>of</strong> interest depend on the maximum frequency <strong>of</strong><br />

pu!sation forces. The second step is the harrnonic response ca!cu!ation <strong>of</strong> the sy- stem.<br />

In the harrnonic response ca!cu!ation, the system is excited sepa- rately by pressure<br />

pulsation forces originating from the piston action (this force wil! cause stretching <strong>of</strong> the<br />

compressor cy!inder, di stance piece <strong>and</strong> crosshead guide), by pu!sation forces <strong>and</strong> by<br />

unbalanced forces <strong>and</strong> unbalanced moments <strong>of</strong> the compressor.<br />

The amplitude <strong>and</strong> phase <strong>of</strong> pu!sation forces for acoustic resonan- ce conditions. which<br />

have been ca!culated by <strong>PULSIM</strong>. are rcad<br />

417<br />

into the ANSYS program. Due to the fact that boundary conditi- ons, for<br />

instance. are not weIl defined, calculated resonance fre- quencies will be<br />

established with a cenain inaccuracy. In harmo- nic response calculations, it<br />

is therefore assumed that the frequen- cy <strong>of</strong> pulsation forces. or equivalently,<br />

mechanical natural fre- quencies can shift to such an extent as to coincide.<br />

This may seen very conservative but, panicularly for compressors with a<br />

variabIe speed, it is possible that this wiII occur in practice.<br />

The amplitude <strong>of</strong> the response at resonance is direct I y dependent on the<br />

damping in the system. <strong>and</strong> in the harmonic response calculations a damping<br />

ratio <strong>of</strong> 4% is taken into account.<br />

The last step is postprocessing <strong>of</strong> harmonic response calculation results. At<br />

the postprocessing stage, vibration velocities <strong>of</strong> the pipe system <strong>and</strong><br />

compressor pans, pipe suppon reactions <strong>and</strong> cyclic stresses in the pipe system<br />

are calculated <strong>and</strong> presented in easy-to-read tables, which provide a quick<br />

overview <strong>of</strong> how the system responds in several acoustic resonance<br />

conditions (worst- case conditions). Cyclic stresses in the compressor pans<br />

are not calculated because. in most cases, this is not a pan <strong>of</strong> a compres- sor<br />

manifold vibration study <strong>and</strong> therefore. as mentioned previ- ously, sheII<br />

element models <strong>of</strong> the compressor pans can be kept relatively simple. When a<br />

stress analysis <strong>of</strong> compressor pans has to be made. more accurate models <strong>of</strong><br />

the compressor pans must be generated. The required computer time wiII also<br />

increase con- siderably because so-calIed ex pansion passes <strong>of</strong> the<br />

substructures have to be carried out to calculate stresses in the sheII models.<br />

Evaluatian af the results<br />

When the vibration levels <strong>and</strong>/or cyclic stresses exceed per- missible values. design<br />

modifications are investigated to reduce system responses. In most cases extra pipe<br />

supports or modifica- tions <strong>of</strong> the supporting structures are advised.<br />

The calculated cyclic stresses include stress intensification factors for T -joints, flanges,<br />

elbows <strong>and</strong> reducers <strong>and</strong> are taken accor- ding the piping code ASME B31.3 ( 12 ). If the<br />

peak value <strong>of</strong> cyclic stresses exceeds the endurance limit <strong>of</strong> the material, fatig- ue<br />

problems will occur. Unless the client specifies another crite- rion, a pennissible cyclic<br />

stress value according to the API St<strong>and</strong>ard 618 <strong>of</strong> 179 N/mm2 peak-to-peak (pp) will be<br />

used. This value has been based on the endurance limit <strong>and</strong> is only valid for carbon steel<br />

pipe with an operating temperature below 371° C. AII other stresses must be within the<br />

applicable code limits (API St<strong>and</strong>ard 618, paragraph 3.9.2.2.1.).<br />

Ta ensure that small-diameter side branches <strong>and</strong> equipment such as temperature<br />

transmitters, pressure gauges, valves, etc. will nat fail due ta high vibratians, vibratian<br />

levels are alsa calculated <strong>and</strong> shauld be belaw a velacity level af 80 m mis pp.<br />

Static effects<br />

To determine static effects on the pipe system such as pres- sure, weight <strong>and</strong> therm al<br />

expansion, it is advisable to carryout a static analysis <strong>of</strong> the pipe system as part <strong>of</strong> the<br />

total study. Por the static stress calculation we use the pipe stress program CAESAR-II.<br />

The calculated static stresses in the pipe system can be compared with permissible values<br />

as stated in several piping codes, but we will apply the ASME 831.3 code in most cases.


CASE STUDY OF A COMPRESSOR MANIFOLD VIBRA- T!ON<br />

ANAL YS!S<br />

The following is a summary <strong>of</strong> the results <strong>of</strong> a compressor manifold<br />

vibration analysis <strong>of</strong> a 1485 kW compressor system used for underground<br />

storage <strong>of</strong> natura! gas in a salt dome in Germany. The compressor is a onestage<br />

compressor with 4 cylinders. Gas is pumped into the dome mainly in<br />

summer at a discharge pres- sure <strong>of</strong> 152 bar. The stored gas is used for peak<br />

shaving times in the winter when dem<strong>and</strong> is high.<br />

The two cylinders at each side <strong>of</strong> the crankcase have one common suction<br />

pu!sation damper, while each cylinder has a discharge pulsation damper.<br />

Pulsation study <strong>and</strong> mechanica! response studies have been carried out for the<br />

complete pipe system from the compressor up to a few hundred metres from<br />

the compressor. However, only the resu!ts <strong>of</strong><br />

the compressor manifold vibration ana!ysis will be discussed here. For this<br />

system, the compressor cylinders have been modelled by means <strong>of</strong> concentric<br />

pipe elements. The di stance piece <strong>and</strong> the crosshead guide have been<br />

modelled by means <strong>of</strong> shell-type ele- ments <strong>and</strong> the plots <strong>of</strong> the FEM models<br />

are shown in figure 7 through 9. The FEM model consists <strong>of</strong> 5,046 shell<br />

elements with 27 ,660 degrees <strong>of</strong> freedom. The crankcase, the concrete<br />

founda- tion on which the compressor has been insta!led <strong>and</strong> the connec- tion<br />

<strong>of</strong> the compressor with the foundation have been assumed to be infinitely stiff<br />

for this project. For this study, the crankcase has therefore been modelled as<br />

an anchor point.<br />

From this model, several substructures have been made with diffe- rent master<br />

degrees <strong>of</strong> freedom (MDOF). Tab!e I gives an over- view <strong>of</strong> natural<br />

frequencies <strong>of</strong> the substructures with different MDOF, <strong>and</strong> the differences<br />

between natural frequencies <strong>of</strong> the substructures <strong>and</strong> the shell model.<br />

The two lowest natural frequencies are bending modes <strong>of</strong> the distance piece,<br />

while the next three are natural frequencies <strong>of</strong> the stiffening parts <strong>of</strong> the<br />

crosshead guide. The substructure with 300 MDOF has been included in the<br />

piping models because the two lowest natura! frequencies, which are the<br />

most important natura! frequencies for the compressor manifo!d vibrations,<br />

differ by less than I. 1% from the natura! frequencies <strong>of</strong> the shell model.<br />

Summarv or the results<br />

A so-calied solid model representation <strong>of</strong> the compressor ma- nifold system is shown<br />

in tigure 10.<br />

The pulsation study revealed that pipe system pulsation levels were within permissible<br />

levels by installing oritice plates at the line connection <strong>of</strong> the suction aod discharge<br />

dampers. Pulsation forces acting on the suction <strong>and</strong> discharge dampers were extre- mely<br />

high, however, which was caused by st<strong>and</strong>ing wave-type resonances in the dampers. The<br />

maximum amplitude <strong>of</strong> the forces on the suction damper was 80 KN peak-to-peak (pp)<br />

<strong>and</strong> 40 KN pp on the discharge damper, both with frequen


Figures 18 <strong>and</strong> 19 (mode shape numbers 7 <strong>and</strong> 8) show that rela- tive<br />

displacement exists between the distance piece <strong>and</strong> crosshead guide at the<br />

location where these parts are bolted to each other. The differences <strong>of</strong> -25.0%<br />

<strong>and</strong> -28.7% between measured <strong>and</strong> calculated natural frequencies can be<br />

explained by the fact that the prestressed bolted connection <strong>of</strong> the crosshead<br />

guide to the distan- ce piece <strong>and</strong> cylinder has been modelled with too great a<br />

stiffness in FEM calculations. To calculate these natural frequencies more<br />

accurately. it is necessary to model the prestressed bolted connec- tions with<br />

greater precision.<br />

CONCLUSIONS<br />

A cost-effective <strong>and</strong> accurate tooi has been developed to cal- culate compressor<br />

manifold vibrations, so that fatigue failure <strong>of</strong> the pipe system can be predicted at the<br />

design stage, avoiding unsafe situations, high maintenance costs <strong>and</strong> production losses.<br />

With this tool, vibration velocities, suppon reactions <strong>and</strong> cyclic stresses in<br />

critical pans <strong>of</strong> the pipe system can be calculated easi- I y <strong>and</strong> costeffectively,<br />

<strong>and</strong> can be presented in easy-to-read tables for the most imponant<br />

resonance conditions (worst-case situati- ons). Special piping pre- <strong>and</strong> postprocessors<br />

have been developed for this purpose.<br />

Important compressor parts, such as distance pieces, crosshead guides <strong>and</strong><br />

crankcases, which determine the mechanica! characte- ristics <strong>of</strong> a compressor,<br />

are modelled with shell elements, which are used as a basis for model<br />

substructures, so that with a relati- vely small number <strong>of</strong> (master) degrees <strong>of</strong><br />

freedom, the stiffness <strong>and</strong> mass <strong>of</strong> compressor parts can be included in the<br />

beam-type analysis <strong>of</strong> the pipe system. This technique will cut computer time<br />

quite considerably.<br />

Each substructure is stored in a central database, so that the sub- structures can all be<br />

easily incorporated into a piping analysis without the need for tedious finite element<br />

modelling.<br />

Pulsation forces have been calculated with the <strong>PULSIM</strong> digital program. An<br />

easy-to-use interface has been developed to transfer the amplitude <strong>and</strong> phase<br />

<strong>of</strong> the pulsation forces from the <strong>PULSIM</strong> program to the ANSYS program, so<br />

that a whole range <strong>of</strong> respon- se calculations can be carried out in an easy <strong>and</strong><br />

cost-effective way.<br />

Modal analysis measurements have been carried out to verify the accuracy <strong>of</strong><br />

FEM models <strong>of</strong> the compressor pms. Measurements have been carried out on<br />

a compressor configuration consisting <strong>of</strong> a cylinder, distance piece, crosshead<br />

guide <strong>and</strong> crankcase. These measurements showed that there is only a minor<br />

deviation between measured <strong>and</strong> calculated natural frequencies for the most<br />

important (lower) natural frequencies. The measurements also showed that.<br />

for the higher modes, the prestressed bolted connec- tions <strong>of</strong> the compressor<br />

parts <strong>and</strong> stiffness <strong>of</strong> the crankcase play an important role. To calculate<br />

natural frequencies <strong>of</strong> the higher compressor manifold vibration modes more<br />

accurately, the pres- tressed bolted connections <strong>and</strong> stiffness <strong>of</strong> the crankcase<br />

should also be incorporated into the FEM models in greater detail.<br />

419<br />

REFERENCES<br />

[1] Smeulers, J.P.M., "Simulation <strong>of</strong> flow dynamics in pipe systems,"<br />

Proceedings ImechE Seminar "Gas <strong>and</strong> liquid pul- sations in piping<br />

systems-prediction <strong>and</strong> control, London, 1988, pp.97-105.<br />

[2] Egas, G., "Gas pulsations in pipe systems-a case history <strong>and</strong> solutions,"<br />

Proceedings ImechE Seminar "Gas <strong>and</strong> liquid pulsations in piping<br />

systems-prediction <strong>and</strong> control, London, 1988, pp.107-116.<br />

[3] Van Bokh~rst, E., <strong>and</strong> Korst, H., "The centrifugal pump as a source <strong>of</strong><br />

pu1sations in pipe systems-a comparison <strong>of</strong> me- asurements <strong>and</strong><br />

simulation results," Proceedings <strong>of</strong> the fifth European Congress on<br />

Fluid Machinery for the Oil, Petro- chemical <strong>and</strong> Related Industries,<br />

1993, pp. 83-91.<br />

[4] Van Bokhorst, E., Korst, H., Smeulers, J.P.M., <strong>and</strong> Brug- geman, J.C.,<br />

"The simulation <strong>of</strong> pulsating flow generated by centrifugal pumps by<br />

means <strong>of</strong> the simulation program <strong>PULSIM</strong>," Proceedings <strong>of</strong> the lst.<br />

International Symposium organized by SHF, 1993, Clamart (France).<br />

[5] Van Bokhorst, E., Korst, H. <strong>and</strong> Smeulers, J.P.M., "PUL- SIM3, a<br />

program for the design <strong>and</strong> optimization <strong>of</strong> pulsa- tion dampers <strong>and</strong><br />

pipe systems," Proceedings <strong>of</strong> the Euro- Noise, 1995, pp. 751-756.<br />

[6] Lifson, A. <strong>and</strong> Smalley, A.J., "Bending Flexibility <strong>of</strong> Bolted Flanges <strong>and</strong><br />

lts Effects on Dynamical Behaviour <strong>of</strong> Struc- tures," Volume III,<br />

Joumal <strong>of</strong> Vibration, Stress <strong>and</strong> Relia- bility in Design, October 1989,<br />

pp. 392-398.<br />

[7] Palazzolo, A.B., Smalley, A.J., <strong>and</strong> Lifshits, A. "Recent Developments in<br />

Simulating Reciprocating Compressor Manifolds for Vibration<br />

Control," ASME 85-DET-179, presented at the ASME Design<br />

Engineering Division Con- ference <strong>and</strong> Exhibit on Mechanical<br />

Vibration <strong>and</strong> Noise, Cincinnati, Ohio, September 10-13, 1985.<br />

[8] Lifson, A. , <strong>and</strong> Dube, J.C., "Specifying Reciprocation Ma- chinery<br />

Pulsation <strong>and</strong> Vibration Requirements Per API- 618," DT-66, American<br />

Gas Association Operating Section Proceedings, 1987, pp. 50-58.<br />

[9] Tseng, J.G., <strong>and</strong> Wickert, J.A., "On the vibration <strong>of</strong> bolted plate <strong>and</strong><br />

flange assemblies," Joumal <strong>of</strong> Vibration <strong>and</strong> Acoustics," Volume 116,<br />

1994, pp.468-473.<br />

[10] API St<strong>and</strong>ard 618, third edition, February 1986, "Recipro- cating<br />

Compressors for General Refinery Services.<br />

[11] API St<strong>and</strong>ard 618, fourth edition, June 1995, "Reciprocating<br />

Compressors for Petroleum, Chemical, <strong>and</strong> Gas Industry Services.<br />

[12] ASME B31.3-1993, "Chemical Plant <strong>and</strong> Petroleum Refi- nery Piping."<br />

[13] FE-PIPE Manual, version 2.8.<br />

[14] ANSYS Users' Manual Volume I, II, III <strong>and</strong> IV (DN- R301:50A).


Freq.<br />

no.<br />

2<br />

3<br />

4<br />

5<br />

100<br />

195.391'2.36<br />

206.591'2.81<br />

313.16/3.40<br />

316.58/3.12<br />

320.93fJ.72<br />

200<br />

194.17/1.72<br />

204.08/1.56<br />

307.75/1.61<br />

310.93/1.28<br />

319.79/3.35<br />

Master degraes <strong>of</strong> treeOOm (MDOF)<br />

300<br />

192.99/1.10<br />

202.79/0.92<br />

307.47/1.52<br />

310.24/1.06<br />

318.93/3.08<br />

400<br />

192.42/0.81<br />

202.4~.74<br />

308.39/1.16<br />

309.81/0.92<br />

311.96/0.82<br />

1000<br />

191.29/0.21<br />

201.40/0.22<br />

304.~.40<br />

307.61/0.20<br />

309.7~.11<br />

Table 1 Table with the natural frequencies <strong>of</strong> the substructure with different master degrees <strong>of</strong> freedom (MDOF) <strong>and</strong> the natural<br />

frequencies <strong>of</strong> the shell rnodel. The figure af1er the slash (/) Indicates the diffe- rence in % between the natural frequency <strong>of</strong> the<br />

substruCture <strong>and</strong> the natural frequency <strong>of</strong> the shell model.<br />

Mode<br />

shape<br />

nunj)er<br />

Measured<br />

frequentie<br />

Hz<br />

CaJculaled<br />

frequentie<br />

Hz<br />

Difference .<br />

%<br />

40.6<br />

43.6<br />

-7.4<br />

2<br />

62.1<br />

51.2<br />

17.6<br />

3<br />

82.0<br />

74.6<br />

9.0<br />

4<br />

90.6<br />

75.0<br />

17.2<br />

5<br />

128.0<br />

190.7 -<br />

6<br />

170.6<br />

219.3 49.0<br />

7<br />

182.6<br />

228.0 -<br />

8<br />

186.8<br />

240.4 28.6<br />

-<br />

25.0<br />

Table 2 Measured <strong>and</strong> calculated natural frequencies<br />

-<br />

.((measured-calculated)/measured))x100% 28.7<br />

suction<br />

damper<br />

cyltnders<br />

dlsd1arge<br />

damper<br />

Fig. 2 Low mode<br />

Fig. 3 Rotary mode<br />

420<br />

Fig.1 Example <strong>of</strong> a compressor manifold<br />

Fig. 4 Cylinder resonance mode<br />

Shell model<br />

190.88<br />

200.95<br />

302.87<br />

306.99<br />

~.41


Fig. 5 Suction damper cantilever mode<br />

Fig. 7 FEM model<strong>of</strong> the distance piece<br />

Fig. 6 Suction damper angular mode<br />

Fig. 8 FEM model<strong>of</strong> the crosshead guide<br />

Fig. 9 FEM model<strong>of</strong> the distance piece with crosshead guide<br />

421

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