Case Histories

Screw Compressor
Pulsation &
Vibration
Ethan Clark, Signet Monitoring & Analysis Inc.

June 2017 Windrock User Group

The Whole Story

The Myths The Truths

• Screw compressors are pulsation
& vibration free
• Screw compressors never need
pulsation control
• Pulsation has no effect on
component life
• Screw compressors are positive
displacement compressors which
create fluctuating flow and,
therefore, fluctuating pressure
• Many larger compressors have
custom pulsation control devices
• Bearings, piping and fitting failures
can be due to pulsation & vibration
• Field control of vibration can
include orifice plates for pulsation
control
 Pulsation at
Pocket-
1 2 3 Passing
Frequency
Gas is captured between
the male and female
rotors at the suction
There is pulsating flow
due to the opening and
closing of the rotors to
With pulsating flow,
there is pulsating
pressure – Pulsation!
(PPF)
port, transported down the suction and
the rotors and released discharge ports
at the discharge port at
lobe-passing frequency
(rotor speed X number
Note: Often the male is the driven
of lobes on rotor = PPF) rotor and it has 4 lobes, but
configurations vary.
Over- or Under-Compressing
• A screw compressor has a built-in volume ratio Vi, which is the
amount it compresses the suction gas just before reaches the
discharge port.
𝑉𝑉𝑖𝑖 = 𝑉𝑉𝑉𝑉/𝑉𝑉𝑉𝑉

• Ideal pressure ratio when internal pressure = discharge pressure

when open to discharge port.
𝑃𝑃𝑑𝑑
𝑃𝑃𝑖𝑖 = = 𝑉𝑉𝑉𝑉𝑉𝑉 𝑉𝑉𝑖𝑖 = 𝑃𝑃𝑃𝑃1/𝑘𝑘
𝑃𝑃𝑠𝑠
Ideal pressure and volume ratios based on line conditions and ratio of specific heats, k. Pressure units must be absolute.

• Efficiency decreases and pulsation levels increase with over- or under-

compression.
Acoustical and Mechanical Resonance

• High frequency pulsation (PPF) in the

order of 14,400 cpm (240 Hz) can
excite acoustical resonance in piping
and vessels.
• Large diameter, thin wall coalescing
filter vessels – flexing of vessel walls
amplify pulsation.
Symptoms

• Component Failures
• Pipe and fittings
• Instrumentation
• Vessel internals
• Compressor bearings
• Extreme Noise
• Vessels make excellent “speakers”
• Damage to off-line equipment
Solutions
• Adjust Vi close to ideal
• Adjust speed away from resonance
• Modified or thicker wall vessels (rather costly)
• Orifice plate at compressor outlet flange

Notes:
• Size orifice plate for allowable pressure drop.
• Position hole at bottom if oil collection is a concern.
Case History #1
Refrigeration Compressor
• New package
• Propane Service
• Coalescing filter internal and external failures
• Broken oil diverter caused excessive oil loss
Extreme Pulsation Levels
• 95 psi pk-pk in 200
Talisman EGP North Refridge Pressure FFT Comp Discharge Line Pulsation Run 5 FFT at 3580.0 RPM 03/08/2012 10:09

Peaks

psi discharge line

Overall = 96.14 psi (p-p) # Mag. Freq. Orde
01 = 95.459 @ 14189.5 3
100
X: 02 = 10.103 @ 28374.0 7
03 = 2.850 @ 56733.4 15
1

pressure!!!!
Y: 04 = 2.726 @ 42571.8 11
05 = 2.554 @ 70911.8 19
Phase: 06 = 1.238 @ 63829.1 17
07 = 1.151 @ 21288.8 5
08 = 1.148 @ 35433.4 9
09 = 1.001 @ 71990.3 20
80 10 = 0.636 @ 13417.3 3

psi (p-p)
60

40

20

4 3 5
10 7 8 6 9
00
20000 40000 60000
CPM
 Coalescing Vessel Shell Deformation
• 4 lobe deflected shape amplifies
pulsation and unit vibration
• High vibration destroyed vessel
internals Talisman EGP Refridge Phased Vibe Coalescer Seam 180/225/270 Run 6 Channel 4 FFT at 3564.0 RPM 03/22/2012 11:25

1.4 Peaks
Overall = 1.255 in/sec (peak) # Mag. Freq. Orde
01 = 1.232 @ 14233.8 3
X: 02 = 0.179 @ 118.3 0
03 = 0.144 @ 28460.4 7
1 Y: 04 = 0.028 @ 28325.8 7
1.2 05 = 0.026 @ 28605.3 8
Phase: 06 = 0.022 @ 7216.2 2
07 = 0.010 @ 7109.7 1
08 = 0.010 @ 9479.1 2
09 = 0.008 @ 14832.1 4
10 = 0.008 @ 14961.6 4
1.0

Field generated operating

in/sec (peak)

0.8

deflected shape of coalescing

vessel. – Ethan Clark, March
0.6

0.4 2012
0.2 2
3

45
76 8 910
00 10000 20000 30000
CPM
Case History #1 – Solution & Results
• Installed orifice plate at compressor discharge flange
• Repaired coalescing filter
• Pulsation and vibration reduced to acceptable levels
• It was so good, they didn’t need us to come back!
• No more reported failures.
Case History #2
CO2 Compressor
• Spared process compressors
• Normal operation is one unit operating
• Premature bearing failures
High Vibration on Common Suction Piping
• High pulsation-induced vibration on
shut down machine causes bearing
damage.
• Very short bearing life
Case History #2 – Solution & Results
• Installed orifice plate at
compressor discharge flange
• Suction piping vibration reduced
by >90%
• Bearing life has increased from
days to years

After Orifice
Case History #3
Coalbed Methane Field Booster
• New compressor with high bearing vibration.
• Not bearing faults – pulsation frequencies.
Case History #3 – Solution & Results
• Monitoring for bearing wear
is impractical with high
vibration from pulsation.
• Installed orifice plate at
compressor discharge flange After Orifice
and reduced overall vibration
by >70%.
• Still running!

Before Orifice
Conclusions
• Screw compressors produce pulsation that can be destructive.
• Discharge orifice plates can be a valuable solution.
• Orifice pressure drop should be well-understood!
• Consider lube oil in pressure drop calculations
• Consider hole location in orifice plate
Ethan Clark ethan.clark@signetma.com 1(403)391-1921