Low-Loss Pulsation Control GMC 2010 By Marybeth Nored (SwRI), Buddy Broerman (SwRI), Klaus Brun (SwRI) and

Gary Bourn (El Paso)

Introduction The advancement of reciprocating gas compressor technology for pipeline gas transmission has been made possible, in part, due to the effectiveness of the compressor pulsation control system. The vast majority of current high speed compressors operate less efficiently than low speed compressors due to the higher flow rates which lead to higher associated flow related losses through the valves, orifice plates and the pulsation filter bottles. Also, with higher horsepower machines operating over a large relatively high speed range (8001200 RPM) pulsation amplitudes tend to be significantly higher, leading to higher dynamic losses and high risk vibrations on the manifold and cylinders. Advanced pulsation control techniques are needed to accommodate the increase in compressor horsepower and the range of running speeds as well as the variation in operations. The current GMRC pulsation control research program is developing concepts to control pulsations more efficiently and effectively than the orifice plates and standard approach to filter bottle design, used in the past. Two of the more promising and mature advanced pulsation technologies developed by GMRC at Southwest Research Institute are the Pressure Recovery Insert (PRI) and the Virtual Orifice (VO). Both devices can be used to control high pulsations from a piping resonance, excited by one or more compressor orders. The two devices were developed to reduce the high losses associated with orifice plates (commonly used as insertion plates to reduce the amplitude of high fluid pulses). However, the two technologies are designed differently and mitigate pulsations through entirely different mechanisms. This paper will review both technologies and field test case studies to show the benefit of these low-loss pulsation controls. Options for nozzle resonance control have been one of several areas addressed more recently by the GMRC pulsation research namely because a large population of existing cylinder nozzle orifice plates may be eliminated through advanced methods of pulsation control. The nozzle resonance controls can also be implemented in a retrofit manner relatively easily, at a lower cost than new filter concepts or system / station control concepts. The standard practice for nozzle resonance control has utilized orifice plates to dampen the high pressure pulse at the resonant frequency. This is one method of attenuating a resonant response which can be added to the system design at a low cost. Its primary disadvantages are the pressure loss associated with the orifice plate and a potential for increased pulsations in the lower frequencies (typically at 1x and 2x compressor running speed).

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Modeling of Pulsations in the Gas Passage and Nozzle Area Pulsation models of reciprocating compressor systems commonly utilize a onedimensional (1-D) representation with acoustic length modifications to represent the threedimensional system, given the simplicity and cost-effectiveness of this approach. This has historically been the approach to compressor cylinder modeling for the past 50 years. Onedimensional models are generally accurate for piping systems where the dominant physical length is in the flow direction. In the areas near the compressor cylinder, very close to the fluid force excitation from the piston, the 1-D assumptions break down since many of the highfrequency energy components have not diminished. In the case of the cylinder nozzle responses for modern high speed, high horsepower compressors, three-dimensional models are more appropriate. Without accuracy in both frequency and amplitude predictions of the related gas passage resonances, it is unclear whether a significant acoustic resonance exists. In the past, it was possible to simplify the 3-D geometry to a one-dimensional representation because the higher frequency responses were diminished in lower horsepower machines. This is no longer the case for modern reciprocating compressors. It is very difficult to design pulsation controls properly without accuracy in the gas passage and nozzle resonances in terms of both frequency and amplitude prediction. The combination of a 3-D acoustic response model and a 1-D fluid representation model must be utilized to provide accurate predictions of all gas passage system responses in a cost effective manner. Once the frequencies have been characterized correctly with the 3-D modal analysis, the representative one-dimensional fluid model can be calibrated and can be used to predict the significant amplitudes and attenuation mechanisms. The 1-D fluid model should be a one-dimensional derivation of the Navier Stokes equations and include the non-linear terms which can often affect the shape of the resonant peaks and the accuracy of amplitude predictions. The recent SwRI refinement in combining 3-D acoustic modal analysis and 1-D fluid models has greatly aided SwRI in the ability to design the Virtual Orifice acoustically. Centering the VO absorption frequency directly on the nozzle response is important for controlling the side band responses, which will be present to some extent in any compressor. The Virtual Orifice The Virtual Orifice is an option for nozzle resonance control, which utilizes the concept of absorption of the primary nozzle response frequency. The cylinder nozzle resonance is actually a combined effect of the cylinder gas passage, cylinder nozzle, and primary volume bottle. As such, it should be more correctly termed the passage-nozzle-bottle response. These three component geometries in combination create an originating volume, a small passage way and a final volume which produces an acoustic response that is typically close to the classic Helmholtz type response. Since the gas passage and nozzle dimensions often have dis-similar diameters and lengths, the response is difficult to calculate by hand and must be simulated in a fluid model (see Section 2 on modeling). The nozzle resonance is sometimes misrepresented as a quarter wave acoustic response (with open-end, closed-end boundaries) but it is in typically much closer in its behavior to a Helmholtz type acoustic response. See Figure 1 for examples of
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the primary gas passage / nozzle system responses. Note that the valve to valve response is shown as a velocity profile / first order mode for this response for illustration purposes.

Primary discharge gas passage system responses

(1) Valve to valve (end to end) IGP (length response) (2) Diagonal valve to valve IGP (length response) (3) Cylinder nozzle response (Helmholtz type response) (3) (1) (2)

Figure 1. General Description of Primary Gas Passage and Cylinder Nozzle Response The Virtual Orifice works by absorbing the resonant frequency through a side branch absorber (SBA) or sized such that the resonant frequency is equal to the Helmholtz response of the SBA. The best location for this absorption is at or near the pressure maximum associated with an acoustic response and as such the Virtual Orifice is connected to the cylinder gas passage at one of the valve caps. Absorbing the response with a VO causes the primary frequency to be reflected within the VO volume but results in offset side bands, which vary in amplitude and width based on the size of the VO cavity and the nozzle characteristic response. Recent testing at various field sites has proven the effectiveness of the VO at varying nozzle resonant frequencies and over a large speed range. Compared to a traditional orifice plate installed in the cylinder nozzle, the VO absorbs the nozzle pulsations, reduces pulsation amplitudes over the primary orders of the compressor (up to 8x) and results in a greater compressor efficiency over the entire speed range of the compressor. The VO is comprised of a choke tube (relatively small piping) that connects a volume to the main piping. Frequency placement and effectiveness of the VO are fine tuned by modeling the piping system using proven acoustic modeling tool. Field testing of the VO was necessary to further validate the design. The first field tests were performed in 2007 after the installation of the VO at El Paso Western Pipelines Baxter Station. The compressor station had experienced excessive vibrations and cylinder nozzle failures as a result of uncontrolled cylinder nozzle pulsations generated by the two-throw reciprocating compressor. As a result of the nozzle failures, fairly restrictive cylinder nozzle orifice plates were installed in the suction and discharge side of the cylinder. El Paso Western Pipelines saw an opportunity to install the VO in order to gain back needed efficiency. Figure 2 shows the solid models of the Virtual Orifice developed as part of the GMRC research program.

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Figure 2. Development of the Virtual Orifice for Nozzle Resonance Control

Field test measurements of the compressor pulsation, vibration, and performance were acquired in July 2007. Figure 3 shows the VO installed at the suction valve cap on one side of the compressor. Pulsation measurements were obtained at a single cylinder valve cap for each cylinder. Data were measured for the following configurations: (1) with neither the orifice nor the VO installed (baseline); (2) with only the orifice installed, and (3) with only the VO installed. A summary chart of the pulsation measurements resulting from testing each of the three configurations described above reveals the benefits of installing the VO (see Figure 4). For configuration 1 with no controls in place, the cylinder nozzle response was just above four times compressor running speed (4th order or 4x), and the maximum pulsations resulting from that response placement peaked out at 52 psi [359 kPa]. Pulsation amplitudes at 2x increased significantly when the orifice was installed (configuration 2), resulting in a maximum pulsation amplitude of 30 psi [207 kPa]. The large increase in 2x pulsations is indicative of an undersized orifice. With the VO installed, maximum pulsation amplitudes over the entire 0 to 200 Hz frequency range were reduced to 15 psi [103 kPa].

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Primary Suction Bottle

VO installed Compressor Cylinder

Figure 3: VO installed at on Suction Valve Cap at El Pasos Baxter Station in Wyoming

Figure 4. Field Data Show Reduced Pulsations with VO Installed In summary, maximum pulsation amplitudes over the 0 to 200 Hz frequency range were reduced by 71 percent with the VO installed. Overall pulsations were approximately 50 percent lower with the VO installed as compared with that of the orifice. This demonstration effectively moved the VO to a
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TRL 7 status, but due to the lack of field experience with the VO, additional field testing was warranted on other units. The Baxter Station VOs was were installed on one valve cap of each cylinder of a twocylinder Cooper unit on a suction valve cap. Further testing was necessary to determine acceptability of a discharge valve cap installation and the adaptability of the design to other cylinder types, other manufacturers and various valve cap styles.

The most recent VO testing was performed in May 2010 for Boardwalk Pipelines Destin Compressor Station. Design work for the Destin Station VOs initiated near the end of the pulsation design study. Boardwalk was presented with the predicted pressure drop summary that was associated with the recommended cylinder nozzle orifices, and it was decided that those pressure losses were undesirably high. Therefore, Boardwalk decided to pursue a low pressure loss alternative to the orifices, which was the VO. The Ariel JGC/4 (4-cylinder, 1-stage) unit was installed at Destin Station without any cylinder nozzle pulsation control devices, and VOs were installed after initial/baseline field data was obtained. Data before and after the VOs were installed comprised of pulsation, vibration, and performance measurements. For the performance assessment, both PV card and enthalpy rise measurements were obtained. As described in the following paragraphs, the data generally showed that installing the VOs resulted in reduced pulsation and vibration amplitudes while maintaining essentially the same compressor performance. Field measurements summarizing the measured cylinder valve cap pulsation amplitudes are shown in Figures 5 (suction) and 6 (discharge). Initial suction system data was taken without the VOs or orifices installed, and it revealed a nearly 70 psi pk-pk resonance at approximately 58 Hz (on 4x compressor running speed). After installing the VOs, the 70 psi resonance went down to less than 12 psi at 58 Hz, and a maximum pulsation amplitude of 24 psi was measured for the entire 0-500 Hz frequency range. Initial discharge system data was taken without the VOs or orifices installed, and it revealed a 112 psi resonance at approximately 58 Hz (on 4x compressor running speed). After installing the VOs, the 112 psi resonance went down to less than 15 psi at 58 Hz, and a maximum pulsation amplitude of approximately 28 psi was measured for the entire 0-500 Hz frequency range. Cylinder nozzle pulsation amplitude reductions were significantly attenuated, and as described below, cylinder vibrations were consequently reduced.

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Figure 5. Field Data Showing Reduced Suction Valve Cap Pulsations with VO Installed

Figure 6. Field Data Showing Reduced Discharge Valve Cap Pulsations with VO Installed

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Similar to that of the pulsation measurements, significant cylinder vibration improvements were also observed in the field study. A summary of some field measured vibration is provided in Figures 7 and 8. A 58 Hz resonance is in the red (square data points) plot in the two figures that corresponds with the cylinder nozzle acoustic resonance note previously. Installation of the VOs reduced the 58 Hz vertical vibration amplitude of 1 ips 0-pk down to less than 0.2 ips 0-pk and the 58 Hz horizontal vibration amplitude of 0.3 ips down to less than 0.1 ips. Only minimal differences were observed for the vibrations in the stretch direction of the cylinders. Overall cylinder vibrations were significantly improved with the installation of the VOs.

Figure 7. Field Data Showing Reduced Cylinder Vertical Vibration with VO Installed

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Figure 8. Field Data Showing Reduced Cylinder Horizontal Vibration with VO Installed

Based on the efficiency values measured with the PV cards, the compressor efficiency was reduced by approximately 3% when the VOs were installed. Based on the efficiency values measured with the lateral-to-lateral temperatures and pressures (enthalpy rise method), the efficiency was reduced by approximately 0.5% when the VOs were installed (see Figure 9). When taking into consideration the uncertainties associated with the efficiency measurements, the baseline efficiency is statistically equal to the efficiency with the VOs installed. That was the case for both the PV Card and enthalpy rise methods. No appreciable loss in compressor efficiency was observed when the VOs were installed in the baseline case system, which had no cylinder nozzle resonance controls installed. Another finding of the performance analysis was associated with the measured power per unit flow (horsepower per MMSCFD). The horsepower per MMSCFD indicated that installation of the VOs may have lowered the work requirement, possibly due to the reduced pulsations and dynamic pressure effects.

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Figure 9. Field Data Showing Essentially Unchanged Compressor Performance with VO Installed

Installation of the virtual orifices at Boardwalk Pipelines Destin Compressor Station resulted in generally anticipated data. Installation of the VOs did not result in an appreciable loss in compressor efficiency compared to that of the baseline case, which had no cylinder nozzle resonance controls installed, but did result in significant reductions of pulsation and vibration amplitudes associated with the compressor cylinder nozzle resonance. Cylinder nozzle pulsation amplitude reductions of 66-75% were observed. Cylinder vibration amplitude reductions of 6680% were observed. The virtual orifice has proven to be an effective replacement of cylinder nozzle orifices that also results in a compressor performance boost.

Pressure Recovery Insert (PRI) Nozzle

Lower efficiencies and higher pulsations are more evident for high speed, high horsepower machines due in-part to the higher mean flows and coincidence of the cylinder nozzle acoustic response with lower compressor orders. The Pressure Recovery Insert nozzle was developed to control nozzle pulsations by attenuating the pulsations through a choking effect, similar to an orifice plate. The PRI mounts in the flow stream like an orifice plate between the two flanges. However, this device recovers some of the initial losses from the flow restriction through a low angled pressure recovery outlet. Figure 5+x (left and center) shows a solid model and fabricated PRI nozzle. Figure 5+x (right) shows the installation of a suction side PRI 8-inch diameter nozzle in August 2009 at the first PRI field test.
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The design depends on the beta ratio requirements and the allowable length for the installation. Recent fluid modeling results (see Figure 6+x) from the GMRC research program indicated the sensitivity of the pressure drop to the design of the inlet and outlet fluid angles. The upstream inlet path and the downstream recovery angle are designed custom to each application to provide sufficient pulsation reductions but also reduce the separation and recirculation as these flow disturbances significantly add horsepower losses to the system. Other design aspects that need to be considered are material compatibility and pre-existing piping tap holes. Depending on material requirements and the gas composition, the PRI nozzle can be made from stainless or carbon steel using CNC fabrication or from rapid prototyping using Selective Laser Sintering, which creates a stainless / bronze matrix. Testing is ongoing to determine if pressure measurements can still be made (accurately) at a pressure tap which is effectively measuring pressure on the back side of the PRI. For temperature measurements, the RTD probes must be adjusted to not overlap with the outside wall of the PRI nozzle.

Figure 5+x. Pressure Recovery Insert nozzle developed through GMRC pulsation research

Figure 6+x. Flow modeling for optimized design of the Pressure Recovery Insert nozzle

The first field site PRIs were installed in August 2009 at the El Paso Elk Basin station on three first-stage suction nozzles of Unit 11. At this station, two units operate in parallel in two stages of compression over a wide pressure ratio and flow rate range (42-66 MMSCFD). The speed range is 240-300 PRM. The first stage PRI nozzles were installed to replace orifice plates, utilized to control pulsations in the range of 30-50 Hz. Figure 7+x shows the first stage suction bottle and cylinders with the indicated location of the PRI nozzles.
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Upstream DP tap and bottle dynamic pressure

Downstream DP tap and valve cap dynamic pressure PRI located in suction nozzle

Figure 7+x. PRI installation on Unit 11 suction nozzle at El Paso Elk Basin Station Test dates for were not available on Unit 11 until March 2010. At the request of El Paso Pipeline Company, SwRI conducted a vibration and pulsation field study during the period of March 23-24, 2010. SwRI recorded measurements of the vibrations and pressure pulsations at the facility to assess dynamic characteristics. Measurements of the differential pressure between the suction bottle and the suction valve cap were also recorded with dynamic pressure transducers to assess pressure losses associated with the Pressure Recovery Insert (PRI) devices. The location of the dynamic pressure upstream and downstream taps is shown in Figure 7+x. PRIs were installed at the first stage suction connections on cylinders 1, 2 and 3. Testing was also performed to verify the addition of a side-branch absorber volume to control 1x piping pulsations in the inter-stage piping. Tests were performed with Unit 11 (with PRIs) and Unit 12 (no PRIs installed) at both double acting and single acting conditions. SwRI modeled the piping and cylinders initially to determine the recommended pulsation controls. First stage suction nozzle pulsations were expected to be in the range of 10-12 psi pkpk at 33-38 Hz with no controls in place. The second order pulsations at 9 Hz were also expected be in the range of 10-12 psi pk-pk. At the field site with the PRIs installed and for double acting conditions, the pulsation amplitudes measured between 1.1 to 6.4 psi pk-pk, resulting in a reduction of approximately 50% in peak amplitudes compared to the SwRI pulsation model (see Figure 8+x). The single acting case confirmed a similar reduction in the nozzle pulsation amplitudes compared to the SwRI pulsation model.

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SwRI pulsation model predicted 10-12 psi pk-pk for nozzle resonant pulsations

Pressure drop measurements were also taken to determine PRI pressure loss. SwRI utilized high frequency pressure transducers to determine the average loss (associated with a steady flow situation) and the additional dynamic loss contributed by the pulsating flow. Total pressure drop at the field site was measured at 0.85-0.99 psi from the suction bottle, through the nozzle with the PRI in place, to the suction valve cap (including the gas passage). Steady flow pressure drop for the PRI would have been 0.13-0.15 psi. The difference between the steady flow and total measured pressure drop includes the dynamic effects. The table shown below reveals the calculation for the orifice plate pressure drop for one cylinder at 14.3 MMSCFD and the expected pressure drop improvement. The PRI is expected to save approximately 1.5-3.0 psi per cylinder for a total horsepower gain (for the entire compression process) of approximately 0.7%. Additional savings are expected on each stage of compression. Table 1. Pressure drop improvement / horsepower savings per first stage PRI
El Paso Elk Basin - First Stage Suction qm(lbm/sec)= Vel (ft/sec) Q(ft^3/min) ReD= Q (MMSCFD)= 7.325 13.976 292.703 1,770,824 14.383

OP perm press loss 0.689112941 Venturi perm ploss 0.150444417 (* Above Based on chart from Miller, p.6.42, reproduced) Total Ploss improve per PRI Q (MMSCFD)= PRI HP gain per PRI No. of cyl / PRI's in this stage Horsepower recov total for stage Total hp recov for unit Estimated total hp Percent horsepower recovery 3.13 14.38 4.00 3 12.004 12.004 1770 0.68%

The field test data showed that the modifications to the piping system from SwRI 2009 analysis resulted in reduced pulsations and vibrations for all load conditions. The study also demonstrated the use of the PRI device as an acceptable nozzle resonance control (instead of a cylinder nozzle orifice plate). Due to the success of the first field test, SwRI has designed eight more PRIs to provide a complete set of first stage suction and discharge and second stage
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discharge PRIs for Unit 12. Fabrication of these new PRIs (shown below) has been completed. Testing is planned on Unit 12 for September 2010 after installation. The tests will compare the Unit 11 performance (with some orifice plates in place) to Unit 12 (which is completely outfitted with the new PRIs). Summary SwRI advanced pulsation control designs for the Virtual Orifice and the Pressure Recovery Insert nozzle have both shown to control pulsations in the compressor cylinder nozzle but without the pressure losses associated with typical orifice plates. The methods of modeling the pulsations near the cylinder valve (sources) and mechanical / structural loads are critical to designing these technologies successfully for different compressor cylinders and applications. Through the field test cases, these designs have proven to be robust and reliable. Both of these advanced technologies possess over one year of field service and have been designed and tested for multiple field sites on low speed and high speed machines. References
[1] Broerman, E. , Bourn, G., McKee, R. and Nored, M., Benefits of the Virtual Orifice: Pulsations and Vibrations Reduced, Performance Improved, Gas Machinery Conference 2008. [2] Brun, K., Development of a Transient Fluid Dynamic Solver for Compression System Pulsation Analysis, Gas Machinery Conference 2007, Dallas, Texas, 2007. [3] Brun, K., Nored, M. G., Smalley, A. J., and Platt, J. P., Reciprocating Compressor Valve Plate Life and Performance Analysis, proceedings of 4th Conference of the EFRC, Antwerp, Belgium, June 9-10, 2005. [4] Deffenbaugh, D. M., et al, Advanced Reciprocating Compression Technology (ARCT), Southwest Research Institute Final Report, SwRI Project No. 18.11052, prepared for U.S. Department of Energy National Energy Technology Laboratory, December 2005. [5] Foreman, S., Compressor Valves and Unloaders for Reciprocating Compressors An OEMs Perspective, Dresser-Rand Literature, 2002. [6] Woollatt, D., Reciprocating Compressor Valve Design, Optimizing Valve Life and Reliability, Dresser-Rand Literature, 2003. [7] Chaykosky, S., Resolution of a Compressor Valve Failure: A Case Study, Dresser-Rand Literature, 2002.

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