Analysis of Vibration and Failure Problems in

Reciprocating Triplex Pumps for Oil Pipelines

J. C. WACHEL, President
Member ASME
Engineering Dynamics

Inc.

F. R. SZENASI, Senior Project Engineer

Member ASME
Engineering Dynamics Inc.
San Antonio, Texas

S. C. DENISON, Production Engineer Consultant

Member
ABSTRACT

AIME/SPE

Tenneco Oil Exploration & Production, Inc.

Houston, Texas

An a n a l y s i s was made t o i d e n t i f y t h e c a u s e s of
v i b r a t i o n and f a i l u r e problems w i t h t h e p i p i n g and
r e c i p r o c a t i n g pump i n t e r n a l s on an o i l p i p e l i n e pump
station.
A f i e l d i n v e s t i g a t i o n was made t o o b t a i n
v i b r a t i o n s and p u l s a t i o n s over t h e e n t i r e range of
The d a t a showed t h a t
plant operating conditions.
cavitation
was p r e s e n t a t n e a r l y a l l o p e r a t i n g
c o n d i t i o n s due t o t h e h i g h p u l s a t i o n s i n t h e s u c t i o n
system.
The
d i s c h a r g e system e x p e r i e n c e d h i g h
vibrations
and
piping
failures
due
to
the
i n e f f e c t i v e n e s s of t h e accumulator. An a c o u s t i c a l
a n a l y s i s o f t h e s u c t i o n and d i s c h a r g e system was
made t o d e s i g n t h e optimum a c o u s t i c a l f i l t e r systems
t o a l l e v i a t e t h e problems. The a c o u s t i c a l a n a l y s e s
were performed w i t h a d i g i t a l computer program which
p r e d i c t s t h e a c o u s t i c a l r e s o n a n t f r e q u e n c i e s and t h e
p u l s a t i o n a m p l i t u d e s over t h e speed r a n g e . T h i s
paper
discusses
the
investigations
and g i v e s
recommendations f o r p r e v e n t i o n of t h e s e t y p e s of
problems i n t h e f u t u r e .

INTRODUCTION
experienced
with
four
triplex
Problems
were
r e c i p r o c a t i n g crude o i l pumps o p e r a t i n g i n p a r a l l e l
a t t h e Dina Pumping S t a t i o n l o c a t e d i n Colombia
(Figure 1 ) .
The pumps had a r a t e d speed o f 275 rpm
w i t h a c a p a c i t y of 388 g a l l o n s p e r minute. The
nominal s u c t i o n p r e s s u r e was 60 p s i g (414 kPa) and
t h e d i s c h a r g e p r e s s u r e was 1800 p s i g (12400 k P a ) .
The D e l r i n pump v a l v e s had r e p e a t e d f a t i g u e f a i l u r e s
beginning t h r e e months a f t e r s t a r t u p . The d i s c h a r g e
v a l v e d i s k s were r e p l a c e d w i t h s t e e l and t h e D e l r i n
d i s k s used on t h e s u c t i o n v a l v e s were r e p l a c e d e v e r y
90 days t o avoid f a t i g u e f a i l u r e s . Valve f a i l u r e s
were c o n t r o l l e d a f t e r t h e f i r s t 9 months o f s t a t i o n
operation.
For t h e f i r s t f o u r months t h e r e were no
p u l l rod f a i l u r e s ; however, t h e r e have been 1 8
f a i l u r e s i n t h e f o l l o w i n g y e a r and a h a l f . Many of
failures
required
replacement
of
the
these

c r o s s h e a d , t h e guideways, and on two o c c a s i o n s a

broken o r b e n t c o n n e c t i n g r o d .
The s u c t i o n and
discharge
piping
systems
vibrated excessively,
resulting
In
several piping fatigue failures.
Attempts t o c o n t r o l t h e p i p i n g v i b r a t i o n s with p i p e
clamps and a d d i t i o n a l s u p p o r t s were u n s u c c e s s f u l .
The f o u r pumps had a common s u c t i o n h e a d e r s u p p l i e d
by a c h a r g e pump which was c a p a b l e of supplying
p r e s s u r e s up t o 90 p s i (621 k P a ) . The d i s c h a r g e of
t h e f o u r pumps f e d i n t o a common h e a d e r which
connected t o t h e main p i p e l i n e . The o r i g i n a l p i p i n g
d e s i g n i n c l u d e d bladder- type accumulators on both
t h e s u c t i o n and d i s c h a r g e .
was d i f f i c u l t t o keep t h e pumps running smoothly
s i n c e c o n s t a n t maintenance was needed t o keep t h e
accumulator
bladder
pressures
charged
to
a p p r o x i m a t e l y 60 t o 70 p e r c e n t of l i n e p r e s s u r e .
The s t a t i c d i s c h a r g e p r e s s u r e could change from 700
p s i g (4826 kPa) t o more than 1600 p s i g (11032 kPa)
I n a few minutes i f t h e down-line b o o s t e r s t a t i o n
went down. When t h i s happened, t h e accumulator was
ineffective.
It

The c o s t o f t h e p a r t s and l a b o r t h a t could be

attributed
to
this
problem was i n e x c e s s of
$500,000.
Tenneco, t h e p i p i n g d e s i g n e r and t h e pump
manufacturer began a s t u d y t o determine t h e cause o r
c a u s e s of t h e v i b r a t i o n s and f a i l u r e s . However, t h e
complex r e l a t i o n s h i p of t h e system v a r i a b l e s made i t
d i f f i c u l t t o develop d e f i n i t e c o n c l u s i o n s .
There were s e v e r a l changes made i n t h e p i p i n g system
d u r i n g t h i s phase i n an a t t e m p t t o improve t h e
v i b r a t i o n s and reduce t h e f a i l u r e s . These i n c l u d e d
changing t h e p i p i n g ( a t t h e recommendation of t h e
accumulator
vendor) s o t h a t t h e flow would be
directed a t the bladder. This piping modification
d i d n o t improve t h e p u l s a t i o n c h a r a c t e r i s t i c s of t h e
sy s tem.

Presented at the Energy-Sources and Technology Conference and Exhibition

Dallas, Texas - February 17-21, 1985

Another m o d i f i c a t i o n which was t r i e d on t h e s u c t i o n

s i d e of pumps 1 and 3 was t h e replacement of t h e
accumulators
with nitrogen- charged,
bladder- type
flow- through accumulators ( F i g u r e 1 ) . No n o t i c e a b l e
imurovements were observed a f t e r t h e s e changes were
implemented.
BLADDER
ACCUMULATOR

PDF\

G ABSO- C
TH
TA
LR
EO E D J

FIGURE 1 .

101 I (

PUMP CASE

s u c t i o n and d i s c h a r g e p i p i n g i l l u s t r a t i n g some of
t h e p r e s s u r e t e s t p o i n t s a r e shown i n F i g u r e 1. The
p u l s a t i o n and v i b r a t i o n s i g n a l s were analyzed f o r
frequency c o n t e n t w i t h a two c h a n n e l Hewlett- Packard
3582A FFT a n a l y z e r and documented on a HP 74708
digital plotter.
The a n a l y z e r and i n s t r u m e n t s were
controlled
by an Apple 11+ microcomputer u s i n g
software w r i t t e n s p e c i a l l y for analyzing vibration
and
pulsation
data.
T o r s i o n a l v i b r a t i o n s were
measured w i t h a HBM t o r s i o g r a p h mounted on t h e s t u b
end o f t h e p i n i o n g e a r s h a f t on pump 1 .

1I

Pump P i p i n g Layout Showing P r e s s u r e

Measurement L o c a t i o n s

The s e v e r i t y of t h e problems brought t h e b a s i c

d e s i g n of t h e system i n t o q u e s t i o n s i n c e t h e s u c t i o n
and d i s c h a r g e l e a d l i n e s
from t h e h e a d e r s t o t h e
pump manifold were s h o r t e r than normal f o r most
pipeline stations.
The pumps were l o c a t e d on 16
f o o t (4.88 m) c e n t e r s w i t h t h e s u c t i o n and d i s c h a r g e
h e a d e r s l o c a t e d 10 t o 12 f e e t (3.05 t o 3.66 m) away
from t h e pump f l a n g e s

The s t a t i o n c a p a c i t y was 39900 b a r r e l s p e r day (264

m 3 /h) when t h e pumps were a t t h e i r r a t e d c a p a c i t y of
388 g a l l o n s p e r minute (88 m3/h). T h i s r e s u l t s i n a
f t / s ( 1 m/s) i n t h e 12 i n c h
f l u i d v e l o c i t y of 3.3
s c h e d u l e 40 s u c t i o n manifold and 6.9 f t / s (2.1 m/s)
i n t h e 10 i n c h s c h e d u l e XS d i s c h a r g e m a n i f o l d . The
flow v e l o c i t i e s i n t h e i n d i v i d u a l pump p i p i n g were
1.1
f t / s (0.34
m/s) i n t h e 12 i n c h s t a n d a r d weight
s u c t i o n p i p e and 2.7 f t / s (0.82 m/s) i n t h e 8 inch
e x t r a heavy d i s c h a r g e p i p e .
Engineering
Dynamics
Incorporated
(EDI) was
r e q u e s t e d t o i n v e s t i g a t e and make recommendations t o
a l l e v i a t e t h e problems.
The f i r s t s t e p i n t h e
a n a l y s i s was t o model t h e a c o u s t i c a l c h a r a c t e r i s t i c s
of t h e p i p i n g systems on a d i g i t a l computer program
t o d e f i n e t h e expected p u l s a t i o n r e s o n a n c e s and t h e
o v e r a l l amplitudes i n t h e s u c t i o n and d i s c h a r g e
piping.
A d e t a i l e d f i e l d i n v e s t i g a t i o n was then
made
to
evaluate
t h e p u l s a t i o n and v i b r a t i o n
c h a r a c t e r i s t i c s of t h e pumps. S o l u t i o n s were t h e n
developed t o e l i m i n a t e t h e problems.
FIELD INVESTIGATION
I n s t r u m e n t a t i o n And T e s t P r o c e d u r e s
The i n s t r u m e n t a t i o n and d a t a a c q u i s i t i o n system used
to
determine
the
pulsation
and
vibration
characteristics
are
shown
in
Figure
2.
Piezoelectric
pressure
transducers
and
a c c e l e r o m e t e r s were used t o measure t h e p r e s s u r e
p u l s a t i o n s and t h e v i b r a t i o n s . A s k e t c h of t h e pump

DESCRIPTION

ITEM

2 Channel FFT Analyzer

~icro-Computer
Floppy Disk Drive
Digital Plotter
Tuneable F i l t e r s
2 Channel Oscilloscope
Transducer Signal Conditioner and Power Supply
8 Channel FH Tape Recorder
Function Generator
Strain Gage Amplifier and Frequency Demodulator

FIGURE 2.

Data A c q u i s i t i o n System

V i b r a t i o n And P u l s a t i o n T e s t i n g
The
initial
vibration
surveys
revealed
high
v i b r a t i o n amplitudes on t h e p i p i n g , i n d i c a t i n g l a r g e
e x c i t a t i o n f o r c e s p r e s e n t i n t h e p i p i n g systems.
Analysis
of
the
pressure
p u l s a t i o n waveforms
revealed severe c a v i t a t i o n i n the suction piping
system.
T h i s c a v i t a t i o n was t h e s o u r c e of t h e h i g h
energy c a u s i n g t h e h i g h p i p i n g v i b r a t i o n s , v a l v e
f a i l u r e s , and pump p a r t f a i l u r e s .
Cavitation.
For l i q u i d r e c i p r o c a t i n g pumps,
t h e s t a t i c p r e s s u r e i n t h e s u c t i o n system must be
adequate t o compensate f o r f r i c t i o n a l p r e s s u r e drop
losses,
the r e q u i r e d a c c e l e r a t i o n head, and t h e
p u l s a t i o n s p r e s e n t i n t h e system. T h i s e n s u r e s t h a t
t h e p r e s s u r e remains above t h e vapor p r e s s u r e . The
vapor p r e s s u r e of t h e o i l was l e s s than 2 p s i a (13.8
kPa).
When p u l s a t i o n s e x i s t i n a system, they w i l l
c o n s i s t of a p o s i t i v e peak of p r e s s u r e which w i l l be
added t o t h e s t a t i c p r e s s u r e and a n e g a t i v e peak
which w i l l be s u b s t r a c t e d from t h e s t a t i c p r e s s u r e .
If
the
negative
peak of t h e p u l s a t i o n , when
s u b t r a c t e d from t h e s t a t i c p r e s s u r e , r e a c h e s t h e
vapor p r e s s u r e , t h e f l u i d w i l l c a v i t a t e , r e s u l t i n g
i n h i g h p r e s s u r e s p i k e s a s t h e l i q u i d v a p o r i z e s and

then collapses
vapor p r e s s u r e .

as

t h e p r e s s u r e i n c r e a s e s above t h e

To i l l u s t r a t e t h e e f f e c t s of c a v i t a t i o n , c o n s i d e r
t h e plunger p r e s s u r e - t i m e wave shown i n F i g u r e 3
which shows t h a t c a v i t a t i o n o c c u r s on t h e s u c t i o n
stroke.
Note t h a t when t h e c a v i t a t i o n p o r t i o n o f
t h e waveform i s expanded, t h e p r e s s u r e s p i k e s a r e
approximately 800 p s i (5516 kPa) w i t h a time p e r i o d
of a p p r o x i m a t e l y 0.00025
seconds. The p r e s e n c e of
c a v i t a t i o n c a n u s u a l l y be observed on t h e complex
wave
since
pulsations,
which
are
generally
sine- shaped waves, w i l l " square- off" a t t h e t r o u g h
of t h e waves when t h e vapor p r e s s u r e i s reached.
The type of d a t a t o s u b s t a n t i a t e c a v i t a t i o n ( F i g u r e
4)
illustrates
the
squaring- off of t h e wave,
followed by t h e s h a r p s p i k i n g c h a r a c t e r i s t i c o f
s e v e r e c a v i t a t i o n . T h i s d a t a , t a k e n on pump u n i t 1 ,
showed p r e s s u r e s p i k e s of 600 p s i (4137 k P a ) .

p u l s a t i o n s were found w i t h l e v e l s i n e x c e s s of 200

A t a suction pressure
p s i peak- to- peak (1379 kPa)
of 76.5 p s i a (527 k P a ) , p u l s a t i o n s of approximately
75 p s i (517 kPa) zero- peak a r e r e q u i r e d t o cause
cavitation.
T h i s v a l u e i s o b t a i n e d by s u b t r a c t i n g
the
negative
~ u l s a t i o n peak
from t h e s t a t i c
pressure.
S i n c e p u l s a t i o n s g r e a t e r t h a n 75 p s i (517
kPa) were always p r e s e n t a t t h e h i g h e r s p e e d s ,
c a v i t a t i o n always o c c u r r e d .

I n t h e p r e s e n c e of c a v i t a t i o n , i t i s p r a c t i c a l l y
i m p o s s i b l e t o e v a l u a t e t h e i n f l u e n c e of v a r i a b l e s ,
such a s t h e e f f e c t of o t h e r u n i t s , s p e e d s and t h e
accumulator d e s i g n .
Obviously, a r e d u c t i o n of t h e
p r e s s u r e p u l s a t i o n s was n e c e s s a r y i n o r d e r t o o b t a i n
meaningful t e s t d a t a on t h e u n i t s .
A c o u s t i c a l Resonances.
The major s u c t i o n
p u l s a t i o n components were a t f r e q u e n c i e s n e a r 110 t o
150 Hz w i t h p u l s a t i o n amplitudes of approximately
100
150 p s i (689
1034 kPa) peak- to- peak, which,
when combined w i t h t h e p u l s a t i o n a t t h e lower pump
harmonics, caused t h e o v e r a l l s t a t i c p r e s s u r e t o
I t was determined
d r o p below t h e vapor p r e s s u r e .
t h a t a c o u s t i c a l resonances were c a u s i n g t h e h i g h
amplitude p u l s a t i o n s . A c o u s t i c a l resonances amplify
t h e p u l s a t i o n s whenever one of t h e harmonics of the
pump speed p a s s e s through t h e r e s o n a n t frequency.
Hz
was a
The
acoustical
resonance
at
130
quarter- wave resonance of t h e s u c t i o n p i p e and was
a s s o c i a t e d w i t h t h e 9 f o o t (2.74 m) l e n g t h from t h e
end of t h e s u c t i o n manifold t o t h e accumulator.

FIGURE 3 .

Pump Plunger Pressure- Time Wave

Showing C a v i t a t i o n

EMINEERING DYNAMICS INCORPORATED

FIGURE 4 .

C a v i t a t i o n Caused By High P u l s a t i o n s

The e f f e c t of t h e s t a t i c p r e s s u r e on t h e c a v i t a t i o n
was i n v e s t i g a t e d by r a i s i n g t h e s u c t i o n p r e s s u r e t o
The
the
maximum
possible
(90 psig/621 kPa).
increase
in
suction
pressure
alone
was n o t
sufficient
t o eliminate the c a v i t a t i o n .
Severe

When an a c o u s t i c a l resonance i s encountered i n a

system, t h e p r e s s u r e p u l s a t i o n s can be reduced by
e l i m i n a t i n g t h e resonance o r by a t t e n u a t i n g t h e
amplitudes
through t h e a d d i t i o n of a r e s i s t i v e
element, such a s an o r i f i c e . T h e r e f o r e , an o r i f i c e
p l a t e was i n s t a l l e d a t t h e s u c t i o n f l a n g e i n an
a t t e m p t t o a t t e n u a t e t h e p u l s a t i o n a m p l i t u d e s and
p o s s i b l y move t h e a c o u s t i c a l n a t u r a l frequency. A
diameter r a t i o ( o r i f i c e diameter t o inside diameter
of p i p e ) of approximately 0.4 was used t o e n s u r e a
significant
a c o u s t i c a l e f f e c t . When t h e o r i f i c e
p l a t e was i n s t a l l e d , t h e p u l s a t i o n s were reduced;
however,
the
reduction
was n o t s u f f i c i e n t t o
completely e l i m i n a t e t h e c a v i t a t i o n .
I n t e r a c t i o n With Other Pumps.
All
the
o t h e r pumps were s h u t down and pump 1 was r u n t o
by
determine
if
the
cavitation
was
caused
i n t e r a c t i o n w i t h t h e o t h e r pumps o r was a f u n c t i o n
of
the
individual piping design.
These t e s t s
i n d i c a t e d t h a t t h e p u l s a t i o n s were caused by t h e
i n d i v i d u a l pumps and t h a t t h e major f a c t o r was the
a c o u s t i c a l resonances n e a r 130 Hz. T h i s t e s t a l s o
gave evidence t h a t t h e l o c a t i o n of t h e pump i n t h e
manifold system was n o t a major f a c t o r i n the
cavitation.
T h i s i s v e r i f i e d by t h e f a c t t h a t
c a v i t a t i o n o c c u r r e d on u n i t s 1 and 3 a t t h e e x a c t
same speed under t h e same o p e r a t i n g c o n d i t i o n s .
U n i t s 1 and 3 a r e s e p a r a t e d by 32 f e e t (9.75 m) with
u n i t 2 midway between them. I f t h e l o c a t i o n of t h e
pump i n t h e header was a prime f a c t o r , t h e r e would
have
been
different
pulsation
and c a v i t a t i o n
characteristics.
To
further
investigate
the
i n t e r a c t i o n of t h e o t h e r pumps, t e s t s were made w i t h
pump 1 on t h e v e r g e o f c a v i t a t i o n and t h e a d j a c e n t
u n i t 2 was swept through t h e e n t i r e speed range t o
it
a f f e c t e d t h e speed a t which
determine
if
c a v i t a t i o n occurred.
T h i s t e s t showed t h a t t h e
adjacent u n i t did not influence the c a v i t a t i o n .

I n an a t t e m p t t o determine whether t h e a c o u s t i c a l
resonance was a s s o c i a t e d w i t h a p i p i n g l e n g t h from
t h e o t h e r u n i t s , t h e s u c t i o n b l o c k v a l v e was pinched
momentarily t o s e e i f a p r e s s u r e d r o p t a k e n on t h e
upstream s i d e o f t h e accumulator would a f f e c t t h e
resonances i n t h e 130 Hz r a n g e . The p r e s s u r e drop
of approximately 10 p s i i n t h e b l o c k v a l v e d i d n o t
have a s i g n i f i c a n t e f f e c t .
F i n a l T e s t i n g . A f t e r t h e o r i f i c e p l a t e was
installed
and
the
nitrogen- charged accumulator
b o t t l e on t h e s u c t i o n system had t h e maximum g a s
c h a r g e , t h e c a v i t a t i o n was e l i m i n a t e d o v e r much of
t h e speed range making it ~ o s s i b l e t o s t u d y t h e
e f f e c t of v a r y i n g system p a r a m e t e r s .
The normal
procedure f o r t h e t e s t i n g was t o e s t a b l i s h a s e t of
steady- state conditions,
(such as suction pressure,
gas volume i n t h e b o t t l e , o r c h a r g e p r e s s u r e i n t h e
b l a d d e r accumulator,
speeds on t h e o t h e r pumps,
etc.)
and t h e n change t h e pump speed from 190 rpm t o
290 rpm.
During t h e speed r u n , t h e p u l s a t i o n s i n
t h e s u c t i o n and d i s c h a r g e p i p i n g were t a p e recorded
for
later
evaluation.
The
resulting
data
p r e s e n t a t i o n f o r t h e speed v a r i a t i o n i s g i v e n i n
Figure
5, showing t h e harmonics of pump speed
p u l s a t i o n p r e s s u r e s i n t h e s u c t i o n manifold of pump
3 o v e r t h e speed range.
The d a t a shows t h a t t h e
primary cause of t h e c a v i t a t i o n was t h e h i g h l e v e l
pulsations a t the acoustical n a t u r a l frequencies i n
t h e system n e a r 130 and 140 Hz which were e x c i t e d by
t h e 2 1 s t through t h e 3 0 t h harmonics of pump speed.

p u l s a t i o n amplitude was n e a r t h e vapor p r e s s u r e and

t h e wave became f l a t t e n e d on t h e trough. As t h e
speed was f u r t h e r i n c r e a s e d , t h e c a v i t a t i o n became
more s e v e r e .

FIGURE 6.

Complex Wave Of P r e s s u r e P u l s a t i o n Versus

Speed For S u c t i o n P r e s s u r e Of 60 P s i g

ENQlNEERlNO OVNUAlC.5 INCORPORATED

S t a t i c Pressure Effects.
When t h e s t a t i c
s u c t i o n p r e s s u r e was i n c r e a s e d t o 90 p s i g , t h e
p u l s a t i o n a m p l i t u d e s were reduced and t h e u n i t could
be r u n a t 280 rpm w i t h o u t c a v i t a t i o n ( F i g u r e 7).
The h i g h e r s u c t i o n p r e s s u r e seemed t o i n h i b i t t h e
amplitude of t h e p u l s a t i o n s . The r e s u l t s of t h e s e
tests
indicated
that
t h e c a v i t a t i o n could be
minimized by i n c r e a s i n g t h e s u c t i o n p r e s s u r e t o t h e
maximum p o s s i b l e , i n s t a l l i n g an o r i f i c e p l a t e t o
reduce t h e p u l s a t i o n a m p l i t u d e s , and e n s u r i n g t h a t
t h e accumulator was p r o p e r l y charged.

FIGURE 5.

Speed R a s t e r Of Pump S u c t i o n P u l s a t i o n s

ts.
The e f f e c t of speed on
Speed E f f e cc a v i t a t i o n can be s e e n i n F i g u r e 6 which g i v e s t h e
complex p r e s s u r e wave f o r speeds from 220 t o 270 rpm
f o r a s u c t i o n p r e s s u r e of 60 p s i g (414 k P a ) .
Pulsations
g e n e r a l l y i n c r e a s e w i t h speed u n l e s s
t h e r e a r e a c o u s t i c a l r e s o n a n c e s . As shown, when t h e
speed
increased
above 250 rpm, t h e p u l s a t i o n s
increased to the point t h a t the negative pressure

FIGURE 7.

Complex Wave Of P r e s s u r e P u l s a t i o n Versus

Speed For S u c t i o n P r e s s u r e Of 90 P s i g

The e f f e c t i v e n e s s of t h e gas- charged flow- through

accumulator was s t r o n g l y i n f l u e n c e d by t h e volume of

t h e n i t r o g e n gas i n t h e accumulator b o t t l e , F i g u r e
8.
The i n c r e a s e d g a s c h a r g e volume e l i m i n a t e d
p u l s a t i o n components of 46 p s i a t 12 Hz and 22 p s i
a t 65 Hz.

FIGURE 8 .

E f f e c t Of I n c r e a s e d Gas Volume I n S u c t i o n
Accumulator

Discharge Pulsations.
The measured f i e l d
high
a m ~ l i t u d e pulsations i n the
data
showed
d i s c h a r g e p i p i n g w i t h l e v e l s exceeding 1000 p s i
(6895 kPa) peak- to- peak i n some t e s t s ( F i g u r e 9).
An
i n v e s t i g a t i o n was made t o d e t e r m i n e i f t h e
d i s c h a r g e p u l s a t i o n s were a f f e c t e d by t h e c a v i t a t i o n
on t h e s u c t i o n s i d e . The complex p r e s s u r e wave a t
the
s u c t i o n and d i s c h a r g e v a l v e s were c a p t u r e d
simultaneously
during
the
time
that
severe
c a v i t a t i o n was p r e s e n t and showed t h a t t h e d i s c h a r g e
side
was i s o l a t e d from t h e s u c t i o n s i d e .
The
p u l s a t i o n a m p l i t u d e s were v e r y h i g h ; however, they
were n o t caused by t h e c a v i t a t i o n on t h e s u c t i o n .
The p u l s a t i o n s were a f u n c t i o n of t h e e n e r g y o u t p u t
from t h e p l u n g e r s and were s t r o n g l y i n f l u e n c e d by
t h e v a l v e r i n g i n g and t h e a c o u s t i c a l r e s o n a n c e s a s
dictated
by
the
a c o u s t i c a l p r o p e r t i e s of t h e
bladder- type accumulator and t h e p i p i n g system.
Whenever
t h e s t a t i o n d i s c h a r g e p r e s s u r e dropped
below t h e c h a r g e p r e s s u r e i n t h e b l a d d e r of t h e
d i s c h a r g e accumulator, a n o t i c e a b l e i n c r e a s e i n t h e
pulsations occurred.

FIGURE 9 .

Complex Wave O f Discharge ~ u l s a t i o n e

ACOUSTIC SIMULATION
The r a p i d advances of d i g i t a l computers has made i t
more
practical
to
analyze
the
acoustical
(pulsations)
of
p i p i n g s y s tems
characteristics
digitally.
A comprehensive computer program has
been
w r i t t e n by ED1 t o p r e d i c t t h e a c o u s t i c a l
attenuation
characteristics,
pass
bands,
and
p u l s a t i o n l e v e l s f o r p i p i n g systems w i t h l i q u i d
pumps o r gas compressors. The program can be used
t o design pulsation f i l t e r s o r t o evaluate the
liquidfgas
effectiveness
of
systems
with
accumulators.
The program i s based on c l a s s i c a l f l u i d mechanics
( Navier- Stokes
equation,
the continuity
theory
e q u a t i o n , and t h e thermodynamic e q u a t i o n of s t a t e ) .
The assumption is made t h a t plane-wave p r o p o g a t i o n
w i l l a d e q u a t e l y s i m u l a t e t h e motion of p r e s s u r e
d i s t u r b a n c e s and t h e a c o u s t i c r e s p o n s e o f t y p i c a l
p i p i n g systems found i n most i n d u s t r i a l p l a n t s . The
c l a s s i c a l e q u a t i o n s of f l u i d mechanics a r e combined
with
the
p i p e element geometry t o d e f i n e t h e
response of t h e p i p i n g system t o dynamic v a r i a t i o n s
i n t h e p r e s s u r e and flow. The e f f e c t s of mean flow
on damping ( p r e s s u r e drop, r e s i s t a n c e , e t c ) a r e
i n c l u d e d i n t h e a n a l y s i s . The program i s w r i t t e n i n
a g e n e r a l manner s o t h a t any p i p i n g system can be
s i m u l a t e d by combinations of d i s t r i b u t e d o r lumped
elements

In
liquid
pump
systems,
the pressure pulses
g e n e r a t e d by t h e plunger can be q u i t e complex.
Because of t h e i n c o m p r e s s i b l e medium, t h e f l o w r a t e
i s a f u n c t i o n of p i s t o n v e l o c i t y , which i s not
s i n u s o i d a l because of a f i n i t e c r a n k l r o d r a t i o .
distortions
produce
higher
Geometrically- caused
harmonics which must be i n c l u d e d i n t h e f o r c e d
pulsation analysis.
The computer program g e n e r a t e s
t h e plunger p r e s s u r e - t i m e wave and u s e s i t t o e x c i t e
t h e p i p i n g system.
The f i e l d t e s t s i d e n t i f i e d an a c o u s t i c resonance a s
t h e cause of t h e problem. T h e r e f o r e , t h e s o l u t i o n
was t o move t h e a c o u s t i c a l resonances away from t h e
s t r o n g pump harmonics.
The ED1 d i g i t a l a c o u s t i c a l
program was used t o s i m u l a t e t h e p i p i n g system and
t o develop t h e s o l u t i o n .
The p i p i n g geometry and
the
l i q u i d thermophysical p r o p e r t i e s d e f i n e t h e
a c o u s t i c n a t u r a l f r e q u e n c i e s of t h e s u c t i o n and
discharge
piping
systems.
The r e s u l t s o f t h e
computer a n a l y s i s of t h e o r i g i n a l s u c t i o n p i p i n g
system w i t h t h e gas- charged f i l t e r a r e g i v e n i n
Figure
10.
The
data
presents the predicted
p u l s a t i o n s a t each harmonic of pump speed from
minimum t o maximum speed. The harmonic numbers a r e
i n d i c a t e d a d j a c e n t t o t h e a p p r o p r i a t e curve. The
i n t e r a c t i o n of t h e i n d i v i d u a l harmonics w i t h t h e
a c o u s t i c r e s o n a n t f r e q u e n c i e s a t 130 and 140 Hz can
be s e e n .
T h i s d a t a can be compared t o t h e measured
p u l s a t i o n s g i v e n i n F i g u r e 5. G e n e r a l l y , t h e r e was
good agreement w i t h t h e a c o u s t i c a l r e s o n a n c e s a t 130
and 140 Hz; however, t h e c a l c u l a t e d a m p l i t u d e s were
I t must be remembered i n t h e assessment of
lower.
t h e f i e l d d a t a t h a t c a v i t a t i o n was s t i l l o c c u r r i n g
and t h e amplitudes measured would be expected t o be
higher
than
calculated
for
the steady s t a t e
operating conditions.
Note t h a t t h e lower o r d e r
harmonics, 3X, 6X, 9X, 12X, e t c . a r e c l o s e t o t h e
calculated values.

FIGURE 12.
FIGURE 10.

Pulsations Predicted In Existing Suction

P i p i n g System

Whlle i n t h e f i e l d , an o r i f i c e p l a t e was i n s t a l l e d
i n t h e s u c t i o n f l a n g e and was s u c c e s s f u l i n r e d u c i n g
t h e p u l s a t i o n s and c a v i t a t i o n ( F i g u r e 1 1 ) .
The
field
data
i n d i c a t e s t h a t t h e p u l s a t i o n s were
reduced and a s l i g h t s h i f t down i n t h e f r e q u e n c y of
t h e major r e s p o n s e s i s noted. T h i s was analyzed on
t h e computer and t h e r e s u l t s a r e g i v e n i n F i g u r e 12.
The major r e s p o n s e was lowered t o 120 Hz and some
r e d u c t i o n i n t h e o v e r a l l peak-peak a m p l i t u d e s was
predicted.

I n t h e development of t h e s o l u t i o n , t h e a n a l y s e s
showed
that
a gas- charged, flow- through l i q u i d
accumulator l o c a t e d a t t h e pump f l a n g e i n s t e a d of
two
feet
away,
would have r e s u l t e d i n lower
p u l s a t i o n s a s p l o t t e d i n F i g u r e 13. The a m p l i t u d e s
a t t h e r e s o n a n t f r e q u e n c i e s were reduced a s w e l l a s
t h e lower pump harmonics.

FIGURE 1 3 .
FIGURE 11.

Speed R a s t e r Of Pump S u c t i o n P u l s a t i o n s
With O r i f i c e P l a t e And Maximum Gas
Volume I n S u c t i o n Accumulator

P u l s a t i o n s P r e d i c t e d In S u c t i o n P i p i n g
With O r i f i c e P l a t e I n s t a l l e d

P u l s a t i o n s P r e d i c t e d In S u c t i o n P i p i n g
With Gas-Charged, Flow-Through Accumulator
A t S u c t i o n Flange

The
pulsation
c h a r a c t e r i s t i c s of t h e d i s c h a r g e
p i p i n g system were analyzed and i n d i c a t e d t h a t t h e
bladder- type accumulator was n o t e f f e c t i v e d u r i n g
some
of the s t a t i o n operating conditions.
For
example, t h e d i s c h a r g e p r e s s u r e would sometimes f a l l
t o 700 p s i (4826 kPa) from t h e normal 1600 p s i g
(11032 kPa). When t h i s happens, t h e b l a d d e r becomes
f u l l y expanded, b l o c k i n g o f f t h e e n t r a n c e of t h e
accumulator and v o i d i n g t h e b e n e f i c i a l e f f e c t s of
the g a s volume.
Also, t h e h i g h l e v e l p u l s a t i o n s
caused b l a d d e r f a i l u r e s which then e l i m i n a t e d t h e
g a s c u s h i o n on t h e back s i d e of t h e b l a d d e r . The
e f f e c t i v e volume of t h e accumulator was reduced
significantly.
These e f f e c t s were analyzed w i t h t h e
d i g i t a l computer program.
F i g u r e 14 compares t h e
p r e d i c t e d p u l s a t i o n f o r t h e normal c o n d i t i o n s and
t h e c a s e w i t h low d i s c h a r g e p r e s s u r e . It can be
s e e n t h a t t h e p u l s a t i o n a m p l i t u d e s a t t h e lower
harmonics
significantly
i n c r e a s e d when t h e g a s
cushion was e l i m i n a t e d .

t o c a u s e t h e a b s o l u t e s t a t i c p r e s s u r e t o drop below
t h e vapor p r e s s u r e , c a v i t a t i o n can o c c u r .
This
c r e a t e s l a r g e f o r c e s which can cause such problems
a s f a t i g u e of t h e v a l v e s , c r o s s h e a d s , r o d s , and
o t h e r r o t a t i n g o r r e c i p r o c a t i n g p a r t s o f pumps.
2.
C a v i t a t i o n c a u s e s shock type p u l s e s t o be
t r a n s m i t t e d through t h e s u c t i o n p i p i n g . These can
e x c i t e a c o u s t i c a l resonances and cause h i g h p i p i n g
v i b r a t i o n a t t h e mechanical n a t u r a l f r e q u e n c i e s of
t h e p i p i n g spans, p i p i n g w a l l ( s h e l l r e s o n a n c e s ) ,
and p i p i n g appendages, such a s v e n t s , d r a i n s , gage
lines, etc.
The f o r c e s can be s o h i g h t h a t normal
p i p e clamps and s u p p o r t s may be i n e f f e c t i v e i n
controlling the vibrations.
3.
The g e n e r a t e d p u l s a t i o n s i n t h e s u c t i o n p i p i n g
a r e a s t r o n g f u n c t i o n of t h e type and l o c a t i o n of
the pulsation f i l t e r .
For t h i s p i p i n g system, t h e
flow- through
accumulator
was more
gas- charged,
effective
than
t h e bladder- type accumulator i n
attenuating the pulsations.
D i s c h a r g e System

4.
The p u l s a t i o n s i n t h e d i s c h a r g e p i p i n g were
e x c e s s i v e , p a r t l y due t o t h e changing s t e a d y s t a t e
c o n d i t i o n s which made t h e bladder- type accumulator
i n e f f e c t i v e f o r many of t h e o p e r a t i n g c o n d i t i o n s .
An a l l - l i q u i d a c o u s t i c f i l t e r was d e s i g n e d f o r a l l
o p e r a t i n g c o n d i t i o n s t o minimize t h e p u l s a t i o n s and
piping vibrations i n the discharge piping.
L i q u i d Pumps

5.
Many
vibration
and
failure
problems i n
r e c i p r o c a t i n g pumps i n o i l p i p e l i n e a p p l i c a t i o n a r e
caused by system r e l a t e d a c o u s t i c a l r e s o n a n c e s which
cause h i g h l e v e l p u l s a t i o n s i n t h e s u c t i o n and
discharge piping.
5.
The
acoustical
c h a r a c t e r i s t i c s of a pump
i n s t a l l a t i o n a r e a f u n c t i o n of t h e speed of sound i n
t h e f l u i d and t h e a c o u s t i c a l c h a r a c t e r i s t i c s o f t h e
p i p e s i z e s ( d i a m e t e r s and l e n g t h s ) o f a l l t h e p i p i n g
elements i n t h e l i n e from t h e plunger v a l v e s t o t h e
s u p p l y header and beyond.

FIGURE 14.

P r e d i c t e d Discharge P u l s a t i o n s For Normal

O p e r a t i o n (------ ) And Low Discharge P r e s s u r e
1-(
With Bladder Type Accumulator And
For Proposed All- Liquid F i l t e r (
.)

.....

An a l l - l i q u i d a c o u s t i c f i l t e r d e s i g n was analyzed
f o r t h e d i s c h a r g e system which s h o u l d s i g n i f i c a n t l y
lower t h e p u l s a t i o n energy a s i n d i c a t e d i n F i g u r e
14.
An a l l - l i q u i d p u l s a t i o n f i l t e r system c o n s i s t s
of a volume-choke-volume o r a volume-choke p i p i n g
arrangement which i s s p e c i a l l y d e s i g n e d t o a t t e n u a t e
t h e p u l s a t i o n s above s p e c i f i e d f r e q u e n c i e s .
The
a l l - l i q u i d f i l t e r d e s i g n f o r d i s c h a r g e and s u c t i o n
systems is based on t h e a l l o w a b l e p r e s s u r e drop i n
t h e choke t u b e and t h e Helmholtz frequency.

The r e s u l t s of t h e f i e l d t e s t s and t h e a c o u s t i c a l
analyses led t o these conclusions:
S u c t i o n System
Whenever

8.
When t h e p i p i n g systems d i s c u s s e d i n t h i s paper
were
simulated
u s i n g t h e d i g i t a l program, the
a c o u s t i c a l resonances and t h e p r e d i c t e d p u l s a t i o n
amplitudes were i n agreement.
9.

Commercially
available
accumulators
and
pulsation
filters
can
be
quite effective in
controlling
pulsations;
however,
they
should
normally be i n s t a l l e d a s c l o s e a s p o s s i b l e t o t h e
pump p l u n g e r s . S p e c i f i c accumulators can be modeled
using
the
digital
computer program and t h e i r
performance
studied
under
proposed
operating
conditions

CONCLUSIONS

1.

7.
The a c o u s t i c a l n a t u r a l f r e q u e n c i e s and t h e
p u l s a t i o n amplitudes t h a t w i l l o c c u r i n any g i v e n
p i p i n g system can be p r e d i c t e d by modeling t h e
entire
system
using
a computer program which
i n c l u d e s a l l t h e important v a r i a b l e s .

pulsation levels are s u f f i c i e n t l y high

10.
A l l - l i q u i d a c o u s t i c f i l t e r systems can be
designed f o r p r a c t i c a l l y any s u c t i o n and d i s c h a r g e
system t o minimize p u l s a t i o n s .
All- liquid f i l t e r
a r e advantageous f o r some i n s t a l l a t i o n s
sy s tems
s i n c e they r e q u i r e p r a c t i c a l l y no maintenance once

they a r e i n s t a l l e d .
11.
The f i n a l recommended s o l u t i o n f o r t h i s o i l
pumping
station
was
t o move t h e gas- charged,
flow- through accumulator t o t h e s u c t i o n f l a n g e and
t o i n s t a l l an a l l - l i q u i d f i l t e r i n t h e d i s c h a r g e
system a t t h e pump f l a n g e . These recommendations
a r e b e i n g implemented and t h e u n i t s w i l l be t e s t e d
a f t e r the i n s t a l l a t i o n .
Field Testing
12.
The t e s t i n g showed t h a t , f o r t h i s system, t h e
p u l s a t i o n s g e n e r a t e d were p r i m a r i l y a f u n c t i o n of
t h e i n d i v i d u a l s u c t i o n and d i s c h a r g e p i p i n g and t h e
b a s i c pump d e s i g n and n o t s t r o n g l y i n f l u e n c e d by t h e
i n t e r c o n n e c t i n g p i p i n g w i t h t h e o t h e r u n i t s . Other
systems t e s t e d have shown t h a t t h e p u l s a t i o n s can be
i n f l u e n c e d by t h e p i p i n g from o t h e r pumps and t h e
l o c a t i o n of t h e pumps i n t h e system. The e f f e c t s of
the i n t e r c o n n e c t i n g p i p i n g can be s t u d i e d i n t h e
d e s i g n phase by t h e d i g i t a l a c o u s t i c a l s i m u l a t i o n .
13.
T e s t i n g r e v e a l e d t h a t an i n c r e a s e d s t a t i c
p r e s s u r e l e v e l lowered t h e l e v e l o f t h e p u l s a t i o n s
i n t h e pump manifold and i n h i b i t e d t h e c a v i t a t i o n .
The t e s t i n g a l s o showed t h a t t h e p u l s a t i o n l e v e l s
i n c r e a s e d w i t h speed.
14.
When p u l s a t i o n and v i b r a t i o n problems occur i n
a r e c i p r o c a t i n g pump i n s t a l l a t i o n , f i e l d d a t a can be
o b t a i n e d t o d e f i n e t h e b a s i c cause u s i n g f i e l d
measurement t e c h n i q u e s a s d e s c r i b e d i n t h i s paper.
REFERENCES

1.

Hicks, E. J . and G r a n t , T. R., " Acoustic F i l t e r

C o n t r o l s Recip Pump P u l s a t i o n , ' ' The O i l and
Gas J o u r n a l , J a n u a r y 1 5 , 1979, pp 67-73.

2.

Ludwig, M., "Design of P u l s a t i o n Dampeners f o r

High Speed R e c i p r o c a t i n g Pumps," D i v i s i o n of
T r a n s p o r t a t i o n , American Petroleum I n s t i t u t e
Vol 36 [V] 1956, pp 47-54.

3.

S p a r k s , C. R. and Wachel, J. C., " P u l s a t i o n s i n

C e n t r i f u g a l Pumps and P i p i n g Systems,"
Hydrocarbon P r o c e s s i n g J u l y 1977,
pp 183-189.

4.

Wachel, J. C. and S z e n a s i , F. R., " V i b r a t i o n and

Noise i n Pumps," Pump Handbook, 1 s t E d i t i o n ,
McGraw-Hill, 1976, pp 9-87 t o 9-97.

5.

M i l l e r , J . E., " Liquid Dynamics of R e c i p r o c a t i n g

Pumps - P a r t s 1 and 2," The O i l and Gas
J o u r n a l , A p r i l 18, 1983.

This paper received t h e Eugene W . Jacobson Award on February 26, 1986,

f o r t h e most o r i g i n a l , timely and outstanding t e c h n i c a l paper presented
a t t h e Energy-Sources Technology Conference & Exhibition, D a l l a s , Texas,
February, 1985.