6/6/2018 API 618 Pulsation & Mechanical Analysis: Reciprocating Compressor | Vibration, dynamics and noise

Services
Static Equipment & Structures (Piping
Pulsation & Mechanical Analysis: Reciprocating
Vibration & Fatigue)

Machinery Analysis
Compressor
Bottle Sizing Service
Pulsation study, mechanical review and frequency avoidance analysis, forced
Compressor Package Engineering response analysis (when required); per API 618, API 688 and GMRC High-Speed
Finite Element Analysis (FEA) and Compressor Guideline.
Computational Fluid Dynamics
(CFD)
Foundation Design and Dynamic
Analysis
Fuel Gas Compressor Piping
Transient Analysis
Lateral Vibration Analysis
Pulsation & Mechanical Analysis:
Reciprocating Compressor
Pulsation & Mechanical Analysis:
Reciprocating Pump
Pulsation & Mechanical Analysis:
For compressors below 750 RPM the study is conducted per API 618 requirements, the pulsation and vibration standard for slow-
Screw Compressor
speed compressors.
Pump RCF Analysis
Review & Design Support Services For higher-speed compressors, the GMRC High-Speed Compressor Guideline and API RP 688 are used to define the vibration
Shell Transverse Acoustical (STA) requirements. The GMRC guideline is based on the API standards but has been augmented for the unique requirements of higher-
Analysis speed compressors.
Skid Design and Analysis
Surge Control Design for This pulsation and mechanical analysis is applied during the design stage. Along with this analysis, it is common to also have a
Centrifugal Compressor Systems torsional vibration analysis, small-bore piping analysis, and other related engineering studies completed for a compressor package.
Torsional Vibration Analysis (TVA)

Rotating Equipment Reliability CONTENTS [ hide ]

Noise Management 1 Scope

Field Engineering & Troubleshooting 1.1 Pulsation (Acoustical) Analysis

1.2 Mechanical Analysis
Anti-Vibration Products
1.2.1 Frequency Avoidance
Training
1.2.2 Forced Response Analysis
1.3 Options
2 Wood Group Advantages
3 Customer Benefits
4 Related Information
5 Related Services
6 Key Words

1 SCOPE
A vibration study includes different design components, depending on the risk and application. The standard requirements often
include:
Pulsation and Mechanical Analysis (see 1.1 and 1.2 below)
TORSIONAL VIBRATION ANALYSIS (TVA)

PIPE STRESS ANALYSIS (THERMAL/PIPING FLEXIBILITY ANALYSIS)

SMALL-BORE CONNECTIONS (SBC) ASSESSMENT

Depending on the application, the following studies may be required:

SKID DESIGN AND ANALYSIS

FOUNDATION DESIGN AND DYNAMIC ANALYSIS (ONSHORE)

STRUCTURAL VIBRATION AND DYNAMIC DESIGN (OFFSHORE)

These services are typically bundled together to address all vibration risks associated with the compressors, including the off-skid
piping system. Note that Wood Group can also support in managing vibration on pumps and associated piping systems at your facility.

The following two steps will help you determine which services are required for your compressor application:
1. Determine the risk category for the application. Contact our application support for assistance or use WOOD GROUP'S (BETA) RISK
RATING CHART (EXCEL)

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2. Based on the risk, determine the recommended scope of work. For more about the scope and options, see DESIGN
REQUIREMENTS FOR RECIPROCATING COMPRESSORS

1.1 PULSATION (ACOUSTICAL) ANALYSIS

REDUCTION IN PULSATION FORCES

As found Piping System After Wood Group Pulsation Study

(No Pulsation Study) (Using Time Domain Solver)

Forces above 11,000 lbf Forces below 200 lbf, well below guideline

Pulsation (Acoustical) Analysis applies to “medium” and "high" risk units.

See our RISK RATING CHART (EXCEL)

Features include:
Bottle Sizing An ONLINE BOTTLE SIZING TOOL is available as a starting point
for compressor layouts. To enable early ordering of heads and shells, Wood
Group can complete a more detailed pulsation bottle sizing assessment in 2-4
business days (typically).
Performance Verification A compressor performance analysis can be used to
assess the compressor’s operation across the entire operating envelope.
The standard service is to evaluate up to 20 operating conditions.
CAUTION: For some applications, the operating map cannot be thoroughly
evaluated with just 20 points. Some important regions will be missed and could
result in excessive pulsations. In these cases, additional conditions should be
evaluated (see option 1.3, below).
Wood Group will assess pulsations and other dynamic loads for the supplied
conditions, including pressures, temperatures, gas composition, clearances,
valve unloading and speed ranges.
Pressure Pulsations Wood Group will assess the magnitude of pressure
pulsations and pulsation induced shaking forces in the piping system using its
MAPAK simulation software. Time Domain acoustic simulation is recommended
for a more accurate pulsation analysis, as compared to the older Frequency
Domain approach. MORE ON PULSATION SOFTWARE
Pulsation Control Pulsations are controlled using acoustic filters, bottles, DataMiner™ post processing tool analyzes

orifice plates, resonators and/or piping modifications. Pulsations (pressure and pressure pulsations, forces and other vibration

forces) are controlled to API 618 (most recent edition) or other field proven issues – across hundreds of conditions and

guidelines. locations in the piping system. See why DataMiner

provides extra value for your projects. READ MORE
Cylinder Forces Pulsations forces between the cylinder and pulsation bottles
are also evaluated using Wood Group’s guideline, an advantage over other
approaches.
Pressure Drop As a standard feature, Wood Group will assess static and total pressure drop (per API 618 guidelines) for pulsation
control devices such as orifice plates and choke tubes. Total pressure drop includes dynamic pressure drop losses. The impact of
pulsation control on compressor load is evaluated and included in the report results.
Piping Restraint Analysis (Mechanical Review) This includes an evaluation of pipe support locations using charts, empirical
calculations and good engineering design practices.
Results and Reporting Wood Group’s DataMiner software tool and reporting approach provide valuable information on the
compressor’s pulsation predictions and performance.

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The acoustic model of the piping system (left) is used to determine pulsation pressure and unbalanced forces at all operating
conditions and locations in the system. This example illustrates the 3rd interstage system.
The red arrows represent the magnitude of the forces. Pulsation control bottles (right) contain choke tubes, baffles and volume
chambers. This will filter and dampen pulsation and reduce forces to acceptable levels.

1.2 MECHANICAL ANALYSIS

1.2.1 FREQUENCY AVOIDANCE
The first step in a mechanical analysis is to determine the Mechanical Natural Frequencies (MNFs) in the system, identify where and
when resonance may occur, and provide recommendations to improve the design.

This study is part of a Design Approach 3 (DA3) per API 618 terminology and includes the following features:
Finite Element (FE) Model Wood Group will quickly generate an accurate FE model of the compressor, vessels, piping system
and key areas of the skid (if applicable). For even more accurate results, a detailed model of the compressor frame and/or the full
skid and foundation can be included in the model. Wood Group uses ANSYS for all FE models to ensure accurate results. Some
piping FE analysis programs are not recommended for this application.
Accuracy Complex geometries are accurately modeled using shell or solid elements. Rotational inertias are included. Boundary
conditions such as scrubber base connections and cylinder details are accurately modeled based on Wood Group’s database from
over 40 years of field testing actual compressor cylinders for most OEM’s.
Mechanical Natural Frequencies (MNFs) The MNFs and mode shapes are determined for the key components in the system,
with results published in the report.
Frequency Avoidance MNFs shall have a 20% margin of separation above 2X compressor run speeds, and 20% away from other
orders that have significant forces.
Results and Report A detailed report is provided, summarizing recommendations and mechanical results.

Find out more in this video: MECHANICAL ANALYSIS FOR RECIPROCATING COMPRESSORS (VIDEO)

A mechanical analysis requires accurate FE models (above) of the compressor piping system to determine MNFs and avoid
resonance. Models are also used in Forced Response Studies (option below) to determine vibration and stress amplitudes. Field
experience and measurements are required to accurately define boundary conditions, dynamic forces, and practical
recommendations to avoid problems.

1.2.2 FORCED RESPONSE ANALYSIS

This analysis is required by API 618 when frequency avoidance recommendations cannot be achieved or implemented. The
study includes all significant compressor forces (including cylinder gas forces, pulsation forces, torsional to lateral excitation –
options noted below, etc.) and will evaluate vibration and stress to API 618 guidelines. There are two locations where this option is
conducted:
Compressor Manifold System (step 3b1, formerly study M.6 per API) involves analysis of the bottles, scrubber, and piping
around the compressor frame; and
Piping away from the Manifold (step 3.b.2 Piping Dynamic Stress Analysis (formerly study M.7). This is recommended when the
pulsation force guideline cannot be met, or the Frequency Avoidance Analysis recommendations cannot be implemented.

1.3 OPTIONS
The following options are often added to the API 618 Design Approach 3 (DA3) study (or GMRC High Speed Guideline) described in
Sections 1.1 and 1.2:
Small-Bore Connections (SBC) Wood Group provides a range of
services to design, analyze, and test SBC, depending on the application
and customer’s risk tolerance. FOR SBC SERVICE OPTIONS

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Additional Operating Conditions (beyond the 20 conditions included in
the standard study). For some applications defining 20 operating points
will not sufficiently cover the range of operating conditions and load steps
to ensure all potential pulsation and vibration problem areas are
evaluated. Wood Group can provide assistance in defining the
recommended number of conditions to analyze.
Torsional to Lateral Excitation Evaluate the risk of torsional to lateral
excitation on the compressor frame and manifold, vibration impact and
mitigation options. This feature is recommended for high horsepower
applications. When Wood Group conducts the torsional analysis, this
service fee is minimal because there is close integration between torsional
and mechanical analysis. The forces created by the torsional response of
the crankshaft are calculated and are included as additional input in the
forced response analysis. By including ALL significant forces acting on the
compressor, Wood Group evaluates the vibrations and stresses as a
system.
Off-skid or Station Piping Wood Group will assess pulsations in piping
away from the compressor package (if information is available). This
added level of analysis is valuable when coolers and/or scrubbers are
located away from the compressor package, or when pulsations need to
analyzed in the headers and plant piping system.
Multi-unit Analysis (Interaction between units) When multiple
compressors are connected together in series or parallel, Wood Group will
evaluate pulsations in headers and plant piping system, including
interaction between units. This option applies to multiple reciprocating
compressors, or a combination of reciprocating and centrifugal
compressors.
Pulsation Power Loading (System Performance Analysis) Pulsation
control will result in pressure drop and power losses in the piping system. For a more accurate understanding of the power loss and
the impact on compressor performance, this option will evaluate the pulsation loading in the entire piping system (including
pulsation control elements). An updated compressor performance report is then provided, based on the accurate understanding of
pulsation losses. This service is valuable to ensure the driver/compressors are adequately sized for critical applications such as
pipeline compressors.

The following options are occasionally required:

Vessel Internal Stress Calculation (formerly called M8, per API 618).
This analysis applies pulsation-induced shaking forces and pressure-
induced static forces to the shell and vessel internals and calculates
stress levels.
Compressor Valve Dynamic Analysis (formerly called M9, per API
618). This limited analysis will ensure that compressor valve natural
frequencies are not within +/- 10% of any acoustical resonances and that
pulsation levels at the valve do not exceed 2% of the line pressure at
frequencies within +/-10% of the valve natural frequency. The full
(enhanced) analysis will evaluated the interaction between the
compressor valves and system pulsation.
Low Cycle Fatigue Analysis (formerly called M10, per API 618). This
analysis is used to predict the stresses from thermal gradients, thermal
transients, and pressure cycles on the pulsation-suppression devices and
internal components when required by Division 2 of the ASME code. The stresses are compared to ASME-code.
Fuel Gas Booster Compressor - Receiver Sizing/Transient Study This analysis will size a receiver to prevent transient
starvation induced surge on a centrifugal compressor due to a sudden reduction in upstream pressure (often as the result of the
loss of a reciprocating compressor). Wood Group will review the customer’s compressor control system logic and response
characteristics and determine the appropriate system capacity between the reciprocating compressors and the centrifugal
compressor to ensure surge will be avoided. READ MORE
Transient Surge Analysis of ESD Piping (Gas Blow Down) With high pressure application such as gas storage with multiple
compressors, high ‘fluid hammer’ forces and vibration will be generated when blow down valves are opened for ESD. The blow
down analysis will help to determine the sequences and time interval of opening of blow down valves, and vibration impact to
piping and supports. Wood Group will provide recommendations to control the time required for blowdown.

Modal Analysis on pulsation bottle showing MNF and Low-cycle fatigue analysis (M10) on Vessel internal stress calculation
mode shape. pulsation bottle. (M8).

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2 WOOD GROUP ADVANTAGES
Wood Group is a global leader in pulsation analysis because of these unique factors:
VDN (formerly BETA) pioneered the development of digital acoustic
simulation in the 1970’s. Every year since then, the Company makes
significant investments in acoustic simulation tools and field based
verification to ensure its MAPAK software is world class. This Time
Domain-based simulation includes non-linear fluid dynamics and time-
varying boundary conditions; an important feature for modeling higher
frequency acoustics. This important feature is not available with
commercially available software used by small firms.
More standard features, including improved performance analysis, more
accurate boundary conditions, and improved analysis of off-skid piping.
Better quality control and project management expertise. A focus on
quality, technical reviews, and effective client communication yields a
more successful project.
Responsive application advice and ongoing customer service.
Studies are compliant with API 618.
Timely and practical recommendations.
Wood Group has a full-time field engineering team to assist with start-up checks or onsite support on a global basis.
Pulsation and mechanical vibration modeling techniques are field verified. Other firms provide theoretical results because they lack
full-time field engineers who provide the necessary field input and model verification into the design process.
Customer support through its staff located in Houston Texas; Calgary, Canada; Kuala Lumpur, Malaysia; and Tianjin, China.
Wood Group offers a fully integrated vibration solution – including compressors, pumps and piping design and field support. This
approach ensures you meet your reliability and integrity management requirements.
Wood Group conducts industry research projects for the Gas Machinery Research Council. As a result Wood Group has gained
superior knowledge and expertise.
Active member in API and GMRC vibration task force committees.

3 CUSTOMER BENEFITS
As the global market leader in compression design services, Wood Group is able to offer a number of unique services and features,
including accurate pulsation and mechanical analysis that benefit the packager, OEM, and customer. These benefits include higher
system reliability, minimized pressure drop and performance losses, faster turnaround in the design, optimized vessel sizes, and lower
overall costs.

Other benefits include:

Pulsation forces controlled throughout the piping system
Piping and vessel vibration minimized
Complete range of operating conditions evaluated
Recommendations provided that represent a balance of all competing
requirements (pulsation control, added pressure drop, mechanical constraints
and practicality of implementation)
Effective reporting and analysis for useful field analysis and monitoring

4 RELATED INFORMATION
RISK RATING CHART (TO ASSESS VIBRATION RISKS, AND RECOMMENDED SCOPE FOR YOUR PROJECT)(EXCEL)  

TIPS FOR MANAGING A SUCCESSFUL VIBRATION PROJECT

RECOMMENDED GUIDELINES AND REFERENCES

SPECIFICATION FOR PURCHASING A VIBRATION DESIGN STUDY (PDF)

BACKGROUND ON API 618 PULSATION AND VIBRATION STUDIES (PDF)

BOTTLE SIZING SERVICE (FREE ONLINE SERVICE)

PIPE CLAMPS FOR VIBRATORY LOADS

APPLICATION GUIDE FOR DISCHARGE BOTTLE SUPPORTS (PDF)

VIDEOS AND ANIMATIONS

TRAINING COURSES

Popular Articles:
PIPELINE STATION PULSATION CASE STUDY (PDF)

DESIGN CHALLENGES FOR RECIPROCATING COMPRESSORS IN SPECIALTY GAS SERVICES

(PDF)

TORSIONAL VIBRATION CASE STUDY HIGHLIGHTS DESIGN CONSIDERATIONS (PDF)

GMRC PROJECT: EQUIPMENT MOUNTING - STIFFNESS TESTING OF DIFFERENT CHOCKS AND SUPPORT DESIGNS (2014)

CompressorTech2:
PRIMER - VIBRATION CONTROL STRATEGIES (PDF)

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5 RELATED SERVICES
Common studies that may be coordinated with the Pulsation & Mechanical Analysis:
SMALL-BORE CONNECTIONS (SBC) ASSESSMENT

TORSIONAL VIBRATION ANALYSIS (TVA) 

PIPE STRESS ANALYSIS (THERMAL FLEXIBILITY STUDY)

SKID DESIGN AND ANALYSIS

FOUNDATION DESIGN AND DYNAMIC ANALYSIS

COMPRESSOR PACKAGE ENGINEERING SERVICES

6 KEY WORDS
API 618
API 688
Acoustic analysis
Acoustic study
DA2, DA3, M2, M4, M5, M5, M7
Forced response
Analog study

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MORE INFO
Design Requirements for Reciprocating Compressors • Machinery Condition & Performance Monitoring • Evaluating Compressor
Operating Risks • Tips for Managing a Successful Vibration Project • Specifications •

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