Objective of this course

The purpose of this course is to improve the understanding of common vibration

problems of pumping systems.

Piping design practices

for reciprocating and Key takeaways
centrifugal pumps • An understanding of vibration and pulsation fundamentals
• Steps to mitigate vibration issues on pump installations
Kelly Eberle, Wood
Michelle Witkowski, Wood

woodplc.com/vdn
1 2

Safety moment Course contents

• Recent field test on a plunger pump 1. Introduction
• Pump was started when SDV was 2. Pump basics
closed!
3. The vibration equation
• Be alert during start-up!
4. Pulsations and dynamic forces
• Minimize potential for injury by keeping
a safe distance from the equipment 5. Reciprocating and centrifugal pump design for vibration control
6. Small-bore piping and connections
7. Project management and planning
8. Closing comments

3 4

Why is this topic important? Why is this topic important?

Four pumps running smoothly since the 1980s. Startup September 2016
2016: • Severe vibration problems on discharge lines
• Upset highlighted safety risk due to • Six months of field testing and redesign, $300,000
relief system vent to atmosphere • $5,000,000 cost to the owner due to lost production and
• New relief system design construction of new piping, structure and foundation
• Common elevated maintenance
platform
• Piping design did not consider vibration caused by the pumps Goal of this course:
Provide understanding of pump vibration
issues to avoid this result

5 6
 What is a pump?
• Converts mechanical energy into kinetic energy
• Mechanical energy: supplied by motor or engine
• Kinetic energy: fluid is transported or moved from one point to another

2. Pump basics

7 8

Pump categories Working principles – centrifugal

Reciprocating pumps and centrifugal pumps
- Very common in industry applications
- Piping pulsation and vibration are common
Centrifugal forces generated by the rotating impeller moving fluid from the center to
outside of the impeller transporting the fluid from the suction to the discharge
Pumps

9 10

Working principles – centrifugal Working principles – centrifugal

• Generates a near constant or steady flow
• Does it generate pulsation?
– Every time a vane of the impeller passes the
cutwater a small pulse is generated.

11 12
Working principle – reciprocating Working principle – reciprocating
• The expanding volume inside the pump chamber caused by the piston or plunger
motion is filled with fluid
• The fluid is pushed out as the plunger collapses the volume

13 14

Working principle – reciprocating Pros and cons

• Intermittent flow Centrifugal pump Reciprocating pump
• Does it generate pulsation? Flow rate versus Varies with pressure. Very Constant with pressure
– Yes, it is a normal result of operation pressure high flows are possible.
Mechanical An ideal or optimal efficiency Efficiency is constant versus
efficiency on the head-flow curve pressure

Impact of fluid Efficiency drops dramatically Little impact

viscosity for more viscous fluids
Pressure ratio Low ratio High ratio is common (100x)

15 16

Pros and cons – pulsation / vibration

• Reciprocating pumps generate more pulsation
– Low frequency, so relatively easy to control
– Standard industry practices to mitigate effects
• Centrifugal pumps typically generate less pulsation
– But create high-frequency pulsation which, if problematic, can be difficult to
control
– Other possible sources of pulsation (transients, flow-induced) The vibration equation

17 18
Why are pulsation and vibration important? What is vibration?
Vibration = periodic motion about an equilibrium position
Vibration can be described with:
• Pumps generate significant levels of pulsation and vibration § Amplitude and
• Vibration can have a significant impact on reliability § Frequency (number of cycles per
time) or Spring-Mass
§ Period (time to complete one cycle) System

Pulsation Forces Vibration Stress Failure

Period Frequency

Amplitude

19 20
1 second

Vibration frequency Vibration amplitude

Number of cycles per unit of time § Three related units
§ CPM = cycles per minute
§ Displacement (µm, mils)
§ Hz = cycles per second (cps)
§ Velocity (mm/s, in/s or ips)
§ RPM = rotations per minute
§ Acceleration (mm/s2, in/s2,
g’s)
For simplicity, frequency is measured in Hz
§ Only related when vibration is
Convert from CPM or RPM to Hz by dividing by 60 simple
Example: 240 RPM = 4 Hz

21 22

Vibration – time format Vibration frequency format (spectral)

§ Vibration signature is complex
§ Understanding this complex signal requires separating
out the components
Spring-Mass
System

23 24
Vibration = dynamic forces x dynamic flexibilities Vibration = dynamic forces x dynamic flexibilities
There are many dynamic forces on a reciprocating and centrifugal pump There are many dynamic forces

– Rotating machinery unbalance forces and moments – Flow-induced turbulence (FIT)

• Forces created due to operation of machinery • Low-frequency energy created by turbulent flow

25 26

Vibration = dynamic forces x dynamic flexibilities Vibration = dynamic forces x dynamic flexibilities
There are many dynamic force There are many dynamic forces

– Flow-induced excitation (FIE) – Shell transverse acoustical (STA) vibrations

• Pulsations created by flow past dead legs • Pulsations created by vanes, amplified by acoustic resonances

27 28

Vibration = dynamic forces x dynamic flexibilities Vibration = dynamic forces x dynamic flexibilities
There are many dynamic forces • Dynamic flexibility is high at the mechanical natural frequency – small forces result
in large vibration response
– Pulsations
• Design goal is to avoid dynamic forces within ±20% of MNF
• Pulsations created by a PD pump or centrifugal pump
Dynamic Flexibility

Frequency
29 31
How to calculate or measure MNF? Vibration = dynamic forces x dynamic flexibilities
• We define resonance when force frequency is +/- 10% of MNF
• Modal analysis • At resonance, displacement can be magnified by 50 times – can cause fatigue failure
• Finite element analysis (FEA) used
to calculate mechanical natural Resonance avoided
Potential resonance, but
frequencies insufficient force to cause
problems
• Elastic modulus
MNFs
• Geometry
• Density Forces

• Measure MNFs with bump test

Frequency Change design to shift

32 33
MNF away from resonance

Vibration equation Exercise 1 – tuning fork demo

Vibration = dynamic force x dynamic flexibility – What happens when fork is hit?
700
Force vs Frequency – What happens if weight is added?
600

500
– What happens if weight is removed?
lbf (peak to peak)

400
Orders of Run Speed
300

200
3X 4X
(multiples of run speed)
– How did the ping pong ball move?
1X 2X 5X 6X 7X 8X 9X 10X

– Will the ping pong ball still move if weight is added to one of the forks?
100

0
0 10 20 30 40 50 60
Run Speed Frequency (Hz)
(1X) = 330 RPM = 5.5 Hz

We can’t avoid these forces, minimize: We manage dynamic flexibility:

Frame forces from pumping fluid, mass § Calculate MNFs (mechanical natural
unbalance, and pulsation forces frequencies) with FEA (finite element
analysis)
§ Change MNF if resonant
§ Ensure low flexibility at key locations
34 36

Why are pulsation, vibration important?

• Pumps generate significant levels of pulsation and vibration

• Vibration can have a significant impact on reliability

Pulsation
Pulsation Forces Vibration Stress Failure

39 40
What is pulsation? Negative impacts of pulsation
• Pressure pulsation is the steady state variation in pressure about a mean line
pressure • Shaking forces, cavitation
• Pulsations result from the fluctuating flow that a pump delivers by the mechanical • Calculate pressure drop and
components power loss
• Affect pump valves, relief
valves, orifice meter accuracy

Speed of Sound

41 42

Pulsation with centrifugal pumps Pulsation with centrifugal pumps

• Centrifugal pumps do generate pressure pulsations

– Flow and pressure pulse generated at pump speed x
number of vanes (and multiples) vane
1800rpm x 4 vanes = 7,200 cpm or 120 Hz
(high frequency)
– Generally relatively low amplitude

43 44

Pulsation with reciprocating pumps Shaking forces

The nature of the pumping process generates unsteady flow and pressure causing
pulsations. • Pulsations act on direction changes and changes in diameter to create forces
Force (lb) = Pressure (psi) * Area (in²)
• Mean pressure à forces cancel out
• Pulsation à forces different at different times, creates time-varying forces

45 46
Shaking forces Shaking forces

P1
P2

Force2 Force1
47 48

Flow-induced turbulence
• Discontinuities in the system cause turbulence
– Equipment
– Partially closed valves
– Short radius bends
– Tee or reducers
• Broadband energy below 100 Hz, increasing at lower
Other ways to generate dynamic forces frequencies

49 50

Flow-induced vibration (FIV) Flow-induced vibration (FIV)

• High-velocity flow past openings and inserts
creating vortex shedding and vibration Flow creates vortices and
• Mid to low frequency (less than 500 Hz) excitation
• Can fail things like thermowells or piping Frequency (f) = S v
• Generally not a problem with water systems. Can d
occur in liquid hydrocarbon applications but not Where S = Strouhal number
a common problem. (varies between 0.1 and
1.0)

51 52
Transient pulsation and force Cavitation
• Sudden opening or closing of valves; equipment start-up or shutdown; or sudden • Cavitation decrease reliability in centrifugal and positive displacement pumps
changes in flow conditions • Cavitation can result in significant damage to equipment and injury to personnel
• Involve changes in the pressure, flow or boundary conditions in piping system
over very short periods of time
• High dynamic pressures and forces can be created. Results in vibration, dynamic
stress and possible failure.
Force (lb.)

Classic example of cavitation on

a propeller for a ship

ESD piping system Transient event creates Transient travels thru piping
53 pressure wave (force) system, causing vibration 54

What is cavitation? Cavitation

• Formation and collapse of gas bubbles due to a local decrease and increase in
pressure
• Decrease in pressure below vapor pressure causes bubble to form
• Increase in pressure causes bubble to collapse

• Bubble collapse causes micro-jet of

liquid that can damage surrounding
metal

55 56

Video courtesy of https://www.ife.no/en

Cavitation Cavitation
High pulsation increases cavitation potential

Pulsation
Pressure (psi)

Mean Pressure

Vapor Pressure

57 58

Video courtesy of https://www.ife.no/en

Time (s)
Effects of cavitation (centrifugal) Effects of cavitation (PD pump)
• Equipment damage • Liquid end
• Seal failures – Premature packing failures
• Bearing failures – Plunger damage
• Reduced production – Valve spring failure
• Excessive maintenance cost – Valve failures
– Fluid cylinder cracks

59 60

Effects of cavitation (PD pump)

• Power end damage
• Bearing failures
• Crankshaft failures
• Connecting rod failures
• Frame failures
• Bolting failures
Case study 1

Vibration causes redesign of a plunger pump application

61 62

Case study 1 Case study 1: vibration measurements

• (2) Quintiplex pumps
• 297 HP
Max. %
Location Dir'n Amp. Units Freq. (Hz) Comments
GL
PSV top a 1192 9.01 ips Pk 24.1 MR
PSV top h 883 6.85 ips Pk 24.7 MR
220 v 693 5.24 ips Pk 24.1 MR, WS
Dampener top a 628 3.33 ips Pk 16.9 MR
• Liquid propane 416 GPM @ 400 RPM 220 h 579 4.49 ips Pk 24.7 MR, WS
1 h 539 3.28 ips Pk 19.4 MR, WS

• Speed range 200-400 RPM small bore near 5

Dampener top
a
h
399
392
1.84
1.85
ips Pk
ips Pk
14.7
15
MR
MR

Six months in operation, very high vibrations 5

204
a
-h
392
322
1.81
2.56
ips Pk
ips Pk
14.7
25.3
MR, WS
MR
203 h 314 2.5 ips Pk 25.3 MR, WS
220 a 287 2.23 ips Pk 24.7 MR, WS
8 h 272 1.95 ips Pk 22.8 MR, WS
207 h 270 2.06 ips Pk 24.4 MR, WS
215 a 264 2.33 ips Pk 28.1 MR, WS
209 h 223 1.69 ips Pk 24.1 MR, WS
202 a 217 1.66 ips Pk 24.4 MR, WS
10 a 215 0.991 ips Pk 14.7 MR, WS
Pump skid v 782 0.782 ips Pk 25 WS
63 64
Pump Feet v 678 0.678 ips Pk 25 WS
Pump pedestal v 575 0.575 ips Pk 25 WS
Pump foot v 325 0.325 ips Pk 23.1 WS
Pump foot v 226 0.226 ips Pk 67.8 WS
205 a 176 0.862 ips Pk 15.6 MR, WS
207 -a 159 0.781 ips Pk 15.6 MR, WS
Pump foot v 158 0.158 ips Pk 23.8 WS
215 v 108 0.814 ips Pk 24.1 MR, WS
Motor h 120 0.299 ips Pk 24.4 MR, WS
Pump top v 123 0.489 ips Pk 25.3 WS
Valve cap 1 v 102 0.241 ips Pk 15 MR, WS
207 a 135 0.66 ips Pk 15.6 MR, WS
1 a 134 1.04 ips Pk 24.7 MR, WS
Case study 1: vibration measurements Case study 1: vibration measurements

Max. % Max. %
Location Dir'n Amp. Units Freq. (Hz) Comments Location Dir'n Amp. Units Freq. (Hz) Comments
GL GL
PSV top a 1192 9.01 ips Pk 24.1 MR PSV top a 1192 9.01 ips Pk 24.1 MR
PSV top h 883 6.85 ips Pk 24.7 MR PSV top h 883 6.85 ips Pk 24.7 MR
220 v 693 5.24 ips Pk 24.1 MR, WS 220 v 693 5.24 ips Pk 24.1 MR, WS
Dampener top a 628 3.33 ips Pk 16.9 MR Dampener top a 628 3.33 ips Pk 16.9 MR
220 h 579 4.49 ips Pk 24.7 MR, WS 220 h 579 4.49 ips Pk 24.7 MR, WS
1 h 539 3.28 ips Pk 19.4 MR, WS 1 h 539 3.28 ips Pk 19.4 MR, WS
small bore near 5 a 399 1.84 ips Pk 14.7 MR small bore near 5 a 399 1.84 ips Pk 14.7 MR
Dampener top h 392 1.85 ips Pk 15 MR Dampener top h 392 1.85 ips Pk 15 MR
5 a 392 1.81 ips Pk 14.7 MR, WS 5 a 392 1.81 ips Pk 14.7 MR, WS
204 -h 322 2.56 ips Pk 25.3 MR 204 -h 322 2.56 ips Pk 25.3 MR
203 h 314 2.5 ips Pk 25.3 MR, WS 203 h 314 2.5 ips Pk 25.3 MR, WS
220 a 287 2.23 ips Pk 24.7 MR, WS 220 a 287 2.23 ips Pk 24.7 MR, WS
8 h 272 1.95 ips Pk 22.8 MR, WS 8 h 272 1.95 ips Pk 22.8 MR, WS
207 h 270 2.06 ips Pk 24.4 MR, WS 207 h 270 2.06 ips Pk 24.4 MR, WS
215 a 264 2.33 ips Pk 28.1 MR, WS 215 a 264 2.33 ips Pk 28.1 MR, WS
209 h 223 1.69 ips Pk 24.1 MR, WS 209 h 223 1.69 ips Pk 24.1 MR, WS
202 a 217 1.66 ips Pk 24.4 MR, WS 202 a 217 1.66 ips Pk 24.4 MR, WS
10 a 215 0.991 ips Pk 14.7 MR, WS 10 a 215 0.991 ips Pk 14.7 MR, WS
Pump skid v 782 0.782 ips Pk 25 WS Pump skid v 782 0.782 ips Pk 25 WS
65 66
Pump Feet v 678 0.678 ips Pk 25 WS Pump Feet v 678 0.678 ips Pk 25 WS
Pump pedestal v 575 0.575 ips Pk 25 WS Pump pedestal v 575 0.575 ips Pk 25 WS
Pump foot v 325 0.325 ips Pk 23.1 WS Pump foot v 325 0.325 ips Pk 23.1 WS
Pump foot v 226 0.226 ips Pk 67.8 WS Pump foot v 226 0.226 ips Pk 67.8 WS
205 a 176 0.862 ips Pk 15.6 MR, WS 205 a 176 0.862 ips Pk 15.6 MR, WS
207 -a 159 0.781 ips Pk 15.6 MR, WS 207 -a 159 0.781 ips Pk 15.6 MR, WS
Pump foot v 158 0.158 ips Pk 23.8 WS Pump foot v 158 0.158 ips Pk 23.8 WS
215 v 108 0.814 ips Pk 24.1 MR, WS 215 v 108 0.814 ips Pk 24.1 MR, WS
Motor h 120 0.299 ips Pk 24.4 MR, WS Motor h 120 0.299 ips Pk 24.4 MR, WS
Pump top v 123 0.489 ips Pk 25.3 WS Pump top v 123 0.489 ips Pk 25.3 WS
Valve cap 1 v 102 0.241 ips Pk 15 MR, WS Valve cap 1 v 102 0.241 ips Pk 15 MR, WS
207 a 135 0.66 ips Pk 15.6 MR, WS 207 a 135 0.66 ips Pk 15.6 MR, WS
1 a 134 1.04 ips Pk 24.7 MR, WS 1 a 134 1.04 ips Pk 24.7 MR, WS

Case study 1: vibration measurements Case study 1: vibration measurements

Max. % Max. %
Location Dir'n Amp. Units Freq. (Hz) Comments Location Dir'n Amp. Units Freq. (Hz) Comments
GL GL
PSV top a 1192 9.01 ips Pk 24.1 MR PSV top a 1192 9.01 ips Pk 24.1 MR
PSV top h 883 6.85 ips Pk 24.7 MR PSV top h 883 6.85 ips Pk 24.7 MR
220 v 693 5.24 ips Pk 24.1 MR, WS 220 v 693 5.24 ips Pk 24.1 MR, WS
Dampener top a 628 3.33 ips Pk 16.9 MR Dampener top a 628 3.33 ips Pk 16.9 MR
220 h 579 4.49 ips Pk 24.7 MR, WS 220 h 579 4.49 ips Pk 24.7 MR, WS
1 h 539 3.28 ips Pk 19.4 MR, WS 1 h 539 3.28 ips Pk 19.4 MR, WS
small bore near 5 a 399 1.84 ips Pk 14.7 MR small bore near 5 a 399 1.84 ips Pk 14.7 MR
Dampener top h 392 1.85 ips Pk 15 MR Dampener top h 392 1.85 ips Pk 15 MR
5 a 392 1.81 ips Pk 14.7 MR, WS 5 a 392 1.81 ips Pk 14.7 MR, WS
204 -h 322 2.56 ips Pk 25.3 MR 204 -h 322 2.56 ips Pk 25.3 MR
203 h 314 2.5 ips Pk 25.3 MR, WS 203 h 314 2.5 ips Pk 25.3 MR, WS
220 a 287 2.23 ips Pk 24.7 MR, WS 220 a 287 2.23 ips Pk 24.7 MR, WS
8 h 272 1.95 ips Pk 22.8 MR, WS 8 h 272 1.95 ips Pk 22.8 MR, WS
207 h 270 2.06 ips Pk 24.4 MR, WS 207 h 270 2.06 ips Pk 24.4 MR, WS
215 a 264 2.33 ips Pk 28.1 MR, WS 215 a 264 2.33 ips Pk 28.1 MR, WS
209 h 223 1.69 ips Pk 24.1 MR, WS 209 h 223 1.69 ips Pk 24.1 MR, WS
202 a 217 1.66 ips Pk 24.4 MR, WS 202 a 217 1.66 ips Pk 24.4 MR, WS
10 a 215 0.991 ips Pk 14.7 MR, WS 10 a 215 0.991 ips Pk 14.7 MR, WS
Pump skid v 782 0.782 ips Pk 25 WS Pump skid v 782 0.782 ips Pk 25 WS
67 68
Pump Feet v 678 0.678 ips Pk 25 WS Pump Feet v 678 0.678 ips Pk 25 WS
Pump pedestal v 575 0.575 ips Pk 25 WS Pump pedestal v 575 0.575 ips Pk 25 WS
Pump foot v 325 0.325 ips Pk 23.1 WS Pump foot v 325 0.325 ips Pk 23.1 WS
Pump foot v 226 0.226 ips Pk 67.8 WS Pump foot v 226 0.226 ips Pk 67.8 WS
205 a 176 0.862 ips Pk 15.6 MR, WS 205 a 176 0.862 ips Pk 15.6 MR, WS
207 -a 159 0.781 ips Pk 15.6 MR, WS 207 -a 159 0.781 ips Pk 15.6 MR, WS
Pump foot v 158 0.158 ips Pk 23.8 WS Pump foot v 158 0.158 ips Pk 23.8 WS
215 v 108 0.814 ips Pk 24.1 MR, WS 215 v 108 0.814 ips Pk 24.1 MR, WS
Motor h 120 0.299 ips Pk 24.4 MR, WS Motor h 120 0.299 ips Pk 24.4 MR, WS
Pump top v 123 0.489 ips Pk 25.3 WS Pump top v 123 0.489 ips Pk 25.3 WS
Valve cap 1 v 102 0.241 ips Pk 15 MR, WS Valve cap 1 v 102 0.241 ips Pk 15 MR, WS
207 a 135 0.66 ips Pk 15.6 MR, WS 207 a 135 0.66 ips Pk 15.6 MR, WS
1 a 134 1.04 ips Pk 24.7 MR, WS 1 a 134 1.04 ips Pk 24.7 MR, WS

Case study 1: MNF measurements Fig: 2

Pulsation site measurement
T r a n s f e r F u n c t io n T P : H it : p s v t o p / h M e a s u re : p s v to p / -h

PSV is resonant • Measured at several locations in the suction and discharge

C h a n n e l: 2
0 .3 5
D a te : S e p 0 2 , 2 0 1 5 1 7 :3 8
1 S e tu p : 2
N o te :
0 .3 0

• MNF at 25 Hz, close to • Exceed API 674 guideline

F re q . A m p lit u d e
# Hz ip s / lb f
1 2 0 .3 3 .0 9 E -0 1
0 .2 5 2 2 5 .0 1 .4 0 E -0 1
3 4 0 9 .4 7 .4 4 E -0 2

maximum vibration frequency

4 3 6 0 .6 7 .4 1 E -0 2
Max. % 5 4 1 0 .9 7 .2 4 E -0 2

High shaking forces or cavitation likely

Location Dir'n Amp. Units Freq. (Hz) Comments

•
A m p litu d e ( ip s / lb f)

0 .2 0 GL 6 3 8 0 .3 6 .6 3 E -0 2
7 1 3 3 .1 6 .5 3 E -0 2
PSV top a 1192 9.01 ips Pk 24.1 MR 8 1 8 .1 6 .4 9 E -0 2
PSV top h 883 6.85 ips Pk 24.7 MR 9 3 9 1 .9 6 .3 9 E -0 2

Dampener is resonant
0 .1 5 2 10 3 9 3 .1 6 .3 3 E -0 2
220 v 693 5.24 ips Pk 24.1 MR, WS
11 3 9 3 .8 6 .2 8 E -0 2
12 4 1 6 .6 5 .6 8 E -0 2
Dampener top a 628 3.33 ips Pk 16.9 MR 1 3 3 9 5 .9 5 .6 4 E -0 2
0 .1 0 220 h 579 4.49 ips Pk 24.7 14
MR, WS 4 1 5 .0 5 .5 5 E -0 2
15 3 9 6 .6 5 .4 8 E -0 2
4 35
1 h 539 3.28 ips6 Pk 19.4 MR, WS
16 3 9 8 .8 5 .2 2 E -0 2

• MNF at 17 Hz, close to

8 7 191 01
11 35 1 14 2 17 3 9 7 .8 5 .1 4 E -0 2
0 .0 5 20
small bore near 5 a 399 1.84 19 ips Pk 11 76 1 814.7 MR 1 8 4 3 3 .8 5 .1 0 E -0 2
Dampener top h 392 1.85 ips Pk 15 MR 1 9 3 2 6 .6 4 .7 3 E -0 2
20 3 3 .8 4 .2 0 E -0 2
5 a 392 1.81 ips Pk 14.7 MR, WS

maximum vibration frequency 0 .0 0

0
204
50
203
220
100 150
-h
200
h
a
250
322
314
F re q u e n c y (H z )
287
300
2.56
2.5
2.23
350
ips Pk
400
25.3
450
C : \ D r i v e S J \ P r o j e c t s \ U S 0 0 2 4 8 \ U S 0 0 2 4 8 _ b u m p . t r f \MR,
ips
ips Pk
Pk 25.3
24.7
MR
500
A S C I I 0 0WS
MR, WS
0 0 2 \ H 1 , 2 _ I 1 s v 0 0 0 0 0 - p s v t o p h . c Fig: sv 3
T r a n s f e r F u n c t io n T P : H it : p s v t o p / h M e a s u r e : p s v t o p / - h
TC rha an ns nf ee rl : F2u n c8t io n h 272 1.95 ips Pk T P22.8
: H it : D a m p eMR, n e r t o p WS / a M e a s u re : D a m p e n e r to p / -a
2 0 0 C h a n n e l: 2
1 .8 207 h 270 2.06 ips Pk 24.4 MR, WS
D a te : S e p 0 2 , 2 0 1 5 1 7 :3 8
160
215 a 264 2.33 ips Pk 28.1 MR, DSWS ea tt ue p: :S 2e p 0 2 , 2 0 1 5 1 7 : 4 0
1
209 h 223 1.69 ips Pk 24.1 MR, SNWS eo tt ue p: : 2
N o te :
112. 50 202 a Max. 217 % 1.66 ips Pk 24.4 MR, WS F re q . P hase
Location Dir'n Amp. Units Freq. (Hz) Comments F Hr e zq . A dme pg litr e ue ds e
GL #
10 a 215 0.991 ips Pk 14.7 MR, WS #1 2 H0 z. 3 ip s 9/ lb f
80 8
PSV top
Pump skid
a
v
1192782
9.01
0.782
ips Pk
ips Pk
24.1
25
MR
WS 212 12 75 .. 20 1 . 6 3 5E + 0 0
3 42009. .94 9 . 4 -51 E3 - 0 2
1 .2 PSV top
Pump Feet v
h Max. 883
678 %
6.85
0.678
ips Pk
ips Pk
24.7
25
MR
WS 34 32650. .36 8 . 5 -83 E8 - 0 2
Location Dir'n Amp. Units Freq. (Hz) Comments
40 220 vv GL
693 5.24 ips 18
ips Pk 24.1 MR,
WS WS
5 4 1 0 .9 -1 6
Pump pedestal 575 0.575 Pk 25
A m pPlituh a ds e ( ipd es g / r elb ef)s )

PSV top top a 1192 9.01 ips Pk 24.1 MR 6 3 8 0 .3 -2 7

1 2 Dampener
Pump foot a v 628
325 3.33
0.325 ips
ips Pk Pk 16.9
23.1 MR
WS 7 1 3 3 .1 -6
0 PSV top 7 h Max. 883 6.85 19 ips Pk 24.7 MR 8 1 8 .1 72
220 hv 226 %
579 4.49 ips Pk 24.7 MR, WS
35
0 .9 Pump foot
Location Dir'n 0.226
Amp. ips
Units Pk Freq. 67.8 (Hz) WS
Comments 9 3 9 1 .9 -3 6
6 1 14 2
220 v 693GL 5.24 4 ips Pk 24.1 MR, WS
-4 0 20 1205 h a 539
176 3.28
0.862 ips
ips Pk Pk
9
11 01 19.4
15.6 MR,
MR, WS WS 10 3 9 3 .1 -4 4
PSV top top
Dampener
small aa 1192
628
399
9.01
3.33 ips Pk
ips Pk 16 24.1
16.9 MR
MR 11 3 9 3 .8 -4 9
207 bore near 5 a
-a 159 1.84
0.781 ips
ips Pk Pk 111357 14.7
15.6 MR
MR, WS 12 4 1 6 .6 -2 8
PSV top
220
Dampener hh 883
579
392
6.85
4.49 ips Pk
ips Pk 24.7
24.7 MR WS
MR, 13 3 9 5 .9 -6 2
-08. 60 Pump foot top h v 158 1.85
0.158 ips
ips Pk Pk 15
23.8 MR
WS 1 4 4 1 5 .0 -2 9
220
1
5 h
av
v 693
539
392
5.24
3.28
1.81
ips Pk
ips
ips
Pk 24.1
19.4 MR, WS
MR, WS 15 3 9 6 .6 -6 3
215 108 0.814 ips Pk Pk 14.7
24.1 MR,
MR, WS WS
Dampener top a 628 3.33 ips Pk 16.9 MR 16 3 9 8 .8 -5 4
-1 2 0 small
204
Motor
bore near 5 a
-h h 399
322
120
1.84
2.56
0.299
ips
ips
ips Pk
Pk
Pk
14.7
25.3
24.4
MR
MR
MR, WS 17 3 9 7 .8 -5 8
0 .3 220
Dampener
Pump top top
203 h
hh
v
579
392
314
123
4.49
1.85
2.5
0.489
ips Pk
ips
ips Pk
ips Pk
Pk
24.7
25.315
25.3
MR, WS
MR
MR,
WS 1 9
WS 18 4 3 3 .8 38
3 2 6 .6 -1 0
-1 6 0 1
5 ah 539
392 3.28
1.81 ips Pk
ips Pk 19.4
14.7 MR, WS
MR, WS
220
Valve cap 1 a v 287
102 2.23
0.241 ips
ips Pk Pk 24.7 15 MR,
MR, WS WS 20 3 3 .8 -4 4
2 3 small bore near 5
204
8 -h
ha 399
322
272 1.84
2.56
1.95 ips Pk
ips
ips Pk 14.7
25.3 MR WS
MR
-2 0 0 207 a 135 0.66 ips Pk Pk 22.8
15.6 MR,
MR, WS
0 .0 0 Dampener
203
510 1 0 0 top 150 h
2hh
0a0 392
314
2 5270
0134 1.85
3 0 0 2.06 2.5 ips Pk
ips Pk 25.315 MR5 0 0WS
MR,
0
207
50 100 150 2a00 1.04 33 55 00 ips ips Pk Pk 400 24.4
24.7 450 MR,
MR, WS WS
5
220 a F r e q u 2e 5n287
0c y ( H z )
392 3 0 0 1.81
2.23 C : \ D r i v e S J \ P r oips
j e c t s \ UPk
ips Pk S 40 00 02 4 8 \ U S 0 024.7 2 4 48 5_ 0b u m p . t r fMR,
14.7 \ A S C 5I I00 00WS
MR, 0 0 2 \H 1 , 2 _ I1 s v 0 0 0 0 0 - p s v to p h .c s v
WS
215 a F r e q u e n264c y (H z ) C : \ D2.33
r i v e S J \ P r o j e c t s \ Uips
S 0 0 2 Pk 4 8 \ U S 0 0 2 4 8 _ b28.1 u m p . t r f \ A S C I IMR,0 0 0 0 3 \ H WS 1 , 2 _ I1 s v 0 0 0 0 0 - d a m p e n e r to p a .c s v
C o h e re n c e 8
204
209
-h
h
h 322
272
223
2.56
1.95
1.69
ips
ips
ips Pk
Pk
Pk
25.3
22.8
24.1
MR
TMR,
MR,P : H it : WS WS p s v to p / h M e a s u re : p s v to p / -h
TC rha an ns8 1nf ee rl : F2u n 207
c t io n
203 hh 314
270 2.5
2.06 ips Pk
ips T P24.4
: H it : D a m p MR,
25.3 eMR,n e r t o pWS / a M e a s u re : D a m p e n e r to p / -a
ips6 Pk MR, WS
69 1 .0 0
200
C h a n n e l : 2 202
20
220
215
7 a
aa
217
287
264
1.66
2.23
2.33
19
ips Pk
4 ips
Pk
Pk
24.4
24.7
28.1 MR, WS
MR,
WS
WS 70
10 a 215 0.991 ips Pk 13
14.7 MR, WS
D a te : S e p 0 2 , 2 0 1 5 1 7 :3 8
8 h 272 1.95 ips Pk Pk191 01 22.8 MR, WS DSWS
0 .9 0 2 209
Pump skid hv 223
782 1.69
0.782 ips
ips Pk 15 24.125 MR,
WS ea t ue p: :S 2e p 0 2 , 2 0 1 5 1 7 : 4 0
160 17 SN eo t ue p: : 2
207
202
Pump Feet ah
v 270
217
678 2.06
1.66
0.678 ips Pk
ips
ips Pk
Pk 16
24.4
24.425 MR, WS
MR,
WS NWSo te :
0 .8 0 215
10
Pump pedestal a
a
v 264
215
575 2.33
0.991
0.575 ips Pk
ips Pk 28.1
114.7
8
25 MR, WS
MR,
WS WS F re q . M a g n it u d e
120 5 #H z F re q . P hase
209
Pump skid
foot h
v 223
782
325 1.69
0.782
0.325 ips
ips Pk Pk 3 24.1
23.125 MR,
WS WS #1 2 H0 z. 3 9d . e9 g9 rEe -e0 s1
0 .7 0 12 12 75 . 20 8 . 8 -33 E5 - 0 1
80 202
Pump Feet
foot a
v 217
678
226 1.66
0.678
0.226 ips Pk
ips Pk 1 2 24.4
67.825 MR, WS
WS 23 42009. .94 7 . 2 -93 E8 - 0 1
34 32650. .36 9 . 4 -55 E4 - 0 1
10
Pump
205 pedestal a
v
a 215
575
176 0.991
0.575
0.862 ips Pk
ips Pk 1 4 14.7
15.625 MR, WS
WS
MR, WS
0 .6 0 5 4 1 0 .9 7 .5 1 E -0 1
40 Pump foot
Pump
207 skid v
v
-a 782
325
159 0.782
0.325
0.781 ips Pk
ips Pk 25
23.1
15.6 WS WS
WS
MR, 6 3 8 0 .3 9 .7 2 E -0 1
P h a s eM ( ad ge ng itur e ed se )

7 1 3 3 .1 9 .9 5 E -0 1
0 .5 0 Pump foot
Pump Feet v
v 678
226
158 0.678
0.226
0.158 ips Pk
ips Pk 25
67.8
23.8 WS
WS 8 1 8 .1 9 .9 8 E -0 1
0 Pump pedestal
205 v
a 575
176 0.575
0.862 ips Pk
ips Pk 25
15.6 WS WS
MR, WS9 3 9 1 .9 9 .1 0 E -0 1
215 v 108 0.814 ips Pk 24.1 MR,
10 3 9 3 .1 9 .0 2 E -0 1
0 .4 0 1 2 Pump foot
207
Motor hv
-a 325
159
120 0.325
0.781
0.299 ips Pk
ips
ips Pk
Pk 23.1
15.6
24.4 WS WS
MR,
MR, WS
11 3 9 3 .8 8 .9 0 E -0 1
-4 0 3 Pump top
Pump
Pump foot
foot v
v
v 226
158
123 0.226
0.158
0.489 ips Pk
ips
ips Pk
Pk 67.8
23.8
25.3 WS 1 2
WS
WS
4 1 6 .6 6 .7 0 E -0 1
13 3 9 5 .9 9 .1 5 E -0 1
0 .3 0 205 cap 1
215 a
v 176
108 0.862
0.814 ips Pk
ips Pk
Pk 15.6
24.1 MR, WS
MR, WS
WS
14 4 1 5 .0 6 .1 5 E -0 1
-8 0 Valve v 102 0.241 ips 15 MR,
15 3 9 6 .6 8 .8 5 E -0 1
207
Motor
207 -a
h
a 159
120
135 0.781
0.299
0.66 ips Pk
ips
ips Pk
Pk 15.6
24.4
15.6 MR, WS
MR,
MR, WS
WS
16 3 9 8 .8 8 .2 5 E -0 1
0 .2 0
-1 2 0 Pump top
Pump foot v
v 158
123 0.158
0.489 ips Pk
ips Pk 23.8
25.3 WS 1 7
WS 3 9 7 .8 8 .5 1 E -0 1
1 a 134 1.04 ips Pk 24.7 MR, WS
18 4 3 3 .8 7 .8 2 E -0 1
215 cap 1
Valve v
v 108
102 0.814
0.241 ips Pk
ips Pk 24.1
15 MR, WS
MR, WS
19 3 2 6 .6 9 .7 4 E -0 1
0 .1 0 20 3 3 .8 9 .9 8 E -0 1
-1 6 0 Motor
207 ah 120
135 0.299
0.66 ips Pk
ips Pk 24.4
15.6 MR, WS
MR, WS
0 .0 0 Pump top
1 a v 123
134 0.489
1.04 ips Pk
ips Pk 25.3
24.7 WS WS
MR,
-2 0 0 0 50 1 0 01 150 2 0v0 2 5 102
0 3 0 0 0.241 3 5 0 ips Pk 400 450 5 0 0 WS
0 Valve
50 cap
100 150 200 15 MR,
F r e q u 2e 5n 0c y ( H z ) 300 C : \ D r i v e3 S5 J0 \ P r o j e c t s \ U S 40 00 02 4 8 \ U S 0 0 2 4 48 5_ 0b u m p . t r f \ A S C 5I I00 00 0 0 2 \ C 1 , 2 _ I 1 s v 0 0 0 0 0 - p s v t o p h . c s v
207 a F r e q u e n 135c y (H z ) C : \ D 0.66
r i v e S J \ P r o j e c t s \ Uips S 0 0 2 4Pk 8 \ U S 0 0 2 4 8 _ b15.6
u m p . t r f \ A S C I I MR,
0 0 0 0 3 \ H WS 1 , 2 _ I1 s v 0 0 0 0 0 - d a m p e n e r to p a .c s v

C o h e re n c e 1 a 134 1.04 ips Pk T P24.7

: H it : D a m p eMR,
n e r t o pWS
/ a M e a s u re : D a m p e n e r to p / -a
C h a n1 n2 e l : 2
1 .0 0 3
D a te : S e p 0 2 , 2 0 1 5 1 7 :4 0
0 .9 0 S e tu p : 2
N o te :
4
0 .8 0 F re q . M a g n it u d e
#H z
1 1 7 .2 9 .9 7 E -0 1
0 .7 0 2 2 0 .9 9 .9 5 E -0 1
3 2 5 .3 9 .6 7 E -0 1
4 0 .0 8 .0 4 E -0 1
Case study 1: pulsation model Case study 1: shaking forces
Suction Piping
Pump Bypass piping
downstream of
discharge PSV

Discharge Discharge
piping dampener

Common Pump Force acting on bypass piping at same frequency as

piping measured vibrations
Common
piping

71 72

Case study 1: pulsation > cavitation Case study 1: short term solution
Pulsations will lead to cavitation when operating at resonance Pipe Span Existing Existing Short Term Short Term
Gas charged (full speed) (650 bbl/hr) (full speed) (650 bbl/hr)
dampener* 200 – 400 200 – 218.5 200 – 1000 200 – 218.5
rpm rpm rpm rpm

45 – 48 5,100 1,020 1,820 253

API 674 3rd Ed.
Cavitation Guideline 48 - 49 7,220 1,580 1,880 163
49 - 53 14,900 4,920 2,970 410

52 - 200 1,140 275 214 35.1

Orifice plate* 200 - 201 1,440 309 187 47.5

201 - 202 6,980 139 309 53.8
54 - 154 20,800 12,100 2,890 462

* Typical both units 57 - 500 2,410 524 474 43.3

500 - 501 3,180 695 807 55.9
501 - 502 2,150 473 323 45.1

73 74

Case study 1: long-term solution Case study 1: site inspection – NDT

Gas charged
dampener*
Allows for continuous • Predicted forces in pulsation study are well above acceptable limits à operator
operation over the complete decided to assess piping
speed range of 200-400 rpm • NDT completed on piping and found 20 cracks
Orifice plate*
Maintenance free
dampener*

* Typical both units UNITS SHUT DOWN

Suction system
75 76
 Case study 1: replace, reroute piping Case study 1: recs w/ new layout
• Operator had to replace most piping due to cracks Suction SUCTION Force and Pressure Drop Summary
Design # 20 Gal 20 Gal 20 Gal Dampener
• Improve piping layout and supporting: • 3.125” ID Orifice Plates (Pump Dampener Dampener + Orifice Plates

– Reduce number of elbows

New suction Existing Manifold Inlets & Vessel Outlet) + Orifice Plates + Vessel
layout suction layout • 20-Gallon gas-charged dampeners
– Avoid elevated piping (support stiffness related to height3) Lateral Piping 15,000 2,600 1,200
• Vessel 30” OD x 72” S/S Acoustic
– Avoid unsupported elbows Filter Bypass Piping 450 500 100

– Avoid redundant small bore connections Pump Header 19,000 3,500 500

Main Header 1,800 1,800 400

Discharge
Header Pipe Span 1,760 950 184
New discharge Existing
• Secondary 5-gallon gas-charged
layout discharge layout dampeners. Elevated Pipe Span 269
Orifice 204 108
Orifice Plate Internal External
Pressure Drop Plate
• 10” XS line Expansion Element
(Vessel Outlet) Choke Choke
(Manifold
Tube Tube
Inlet)

Pressure Drop (PSI)

2.46 2.44 0.16 0.05
77 78 @ 400 RPM

Case study 1: design implementation Case study 1: conclusions

• Add suction gas charged dampener • Pulsation Study MUST be completed on
• Add orifice plate at suction pump manifold pumps > 50 HP
• Add discharge secondary gas charged dampener • Orifice plates can be crucial to reducing
pulsations and avoiding cavitation
• Add proper supporting
• Interaction between multiple units should be
considered
• Pipe routing and support is vital to mitigating
vibrations

79 80

Case study 2: acoustic resonance

TROUBLESHOOTING
PROBLEM: PSVs popping at line pressures well
under PSV set pressure 1. PSV OEM recommends new model $$$
Cost $5,000 every pop to re-certify PSV 2. Dampener OEM recommends new pulsation
dampeners à $$$
3. Pulsation Design Study ordered, showed
pulsation resonance in PSV piping
4. Root cause: Pulsation resonance in PSV line
Case study 2 PSV SOLUTION:
Move the location of PSV

PSVs popping prematurely

Design tip: Pulsation study can help with the

troubleshooting process
81 82
6. Centrifugal and reciprocating pump design for Centrifugal
vibration control
Pump piping design for vibration control

83 84

Centrifugal pump pipe design Centrifugal pump pipe design

• Usual design basis includes pipe stress • API 686 RP • API 610
analysis to evaluate – No tee or elbow near suction nozzle – Nozzle forces and moments
– Weight – NPSH calculations – Corrosion resistance
– Pressure – No high point – Pressure rating
– Temperature – Straight pipe to avoid turbulences – Orifice size
– Environmental
• Steady state dynamic forces are generally
low

85 86

Centrifugal pump pipe design What about design for vibration?

Hydraulic Institute, Energy Institute, GMRC Guidelines
• Guidance on design of the pump inlet
• General guidance on minimizing fatigue related failures
• Small-bore connection design
• Static design will result in a relatively flexible system
– What do you know about vibration and flexibility?
– Vibration equation: small force can generate high vibration at mechanical
natural frequencies
• What are the dynamic forces?

Summary:
• Industry standards and guidelines focus on pump, the process
application and static loads
• Little emphasis on pipe system design and dynamic loads!

87 88
Vibration = dynamic force x dynamic flexibility
– Rotating machinery unbalance
– Pulsations at vane passing frequency
Unbalance
Cavitation
Pipe design goal
– Turbulence • Reduce dynamic forces as much as is practical
– Cavitation – Balance rotating components
– Transients (water hammer) – Select proper impeller and volute combinations
– Ensure proper head provided
– Reduce flow velocities and disturbance in the flow
– Conduct design studies to evaluate transients (ESD, power failure)
• Pump soft start, check valve for the correct application, ESD stroke time
maybe extended, system set points to avoid exceeding MOP during event

Vane Transients
passing
pulsations Turbulence
89 90

Pipe design goal Vibration = dynamic force x dynamic flexibility

• Reduce dynamic forces as much as is practical • Recall that goal is mismatch frequency of forces and pipe MNF
– Balance rotating components

ility?
– Select proper impeller and volute combinations
–
ipe syst m dynamic flexib
Ensure proper head provided
e • Energy Institute: Guidelines for the Avoidance of Vibration Induced Fatigue
ep
What about th
– Reduce flow velocities and disturbance in the flow Failure in Process Pipework, 2nd Ed.
– Conduct design studies to evaluate transients (ESD, power failure) • Pipe MNF > 7 Hz to reduce flexibility
• Pump soft start, check valve for the correct application, ESD stroke time maybe
extended, system set points to avoid exceeding MOP during event

91 92

Dynamic flexibility Conflict between static and dynamic design

• Dynamic flexibility is a function of • Static solution has large distance between clamps, thermal
static stiffness, mass and damping loops, and resting supports
• Not all supports or pipe restraints Supt A • Dynamic solution has short distance between clamps and
are equal. Which is the best for avoids elbows
vibration control? • Balanced solution has clamps
and thermal loops
Supt C

Supt B

93 94
Conflict between static and dynamic design Conflict between static and dynamic design
• Static solution has large distance between clamps, thermal
• Static solution has large distance between clamps, thermal loops, and resting supports
loops, and resting supports • Dynamic solution has short distance between clamps and
• Dynamic solution has short distance between clamps and avoids elbows
avoids elbows • Balanced solution has clamps
• Balanced solution has clamps and thermal loops
and thermal loops

95 96

Standards
• API 674 is the main standard reference for reciprocating pumps and pipe design
• Controlling vibration relates back to the vibration equation
Vibration = dynamic force x dynamic flexibility

Reciprocating

Pump piping design for vibration control

97 98

API 674 3rd Edition API 674 3rd Edition

Design tips:
• Reciprocating pumps higher
than 50 HP should include a
Design Approach 2 study.
• Pumps as low as 10 HP for high-
pressure applications can cause
vibration problems

99 100
Standards – API 688 Vibration = dynamic force x dynamic flexibility
• Past versions of 688 were an “RP” Recommended Practice document – Machinery unbalance – Cavitation
• New version of 688 drafted and awaiting final release. It will become the standard
reciprocating pumps forces and moments – Pulsations
• The fundamentals of pulsation and piping system vibration analysis are presented,
– Frame Forces
including theoretical basis, modeling techniques and field testing
Unbalance
Frame Forces
Pulsations
Cavitation

101 102

Reducing dynamic forces Pump performance

• Machinery unbalance • Pump performance will change pulsations:
– Generally low for pump, speed is slow – Double acting (DA) versus single acting (SA) plungers has a drastic impact.
• Cavitation – Variation in pressures and temperatures
– Mitigate by proper NPSH and pressure pulsation control – Variation in pump speed
• Frame forces – Swings in fluid properties
– Result of normal operation and pump design (cannot change) – Variable pump geometry (stroke)
• Pulsation forces
– Pulsation controls (best practice or design study)

Design
Point
103 104

Pump valve operation

• Operation of the pump valves defines pressure
pulsation that are generated
• Spring and plate must be properly selected. Bad
valve motion causes extra pulsations.
• “Good” valve closes <10 degrees ADC
• Valve opening must be controlled to prevent high
impact forces
Case study 4

Pipe failure on “noisy” pump

105 106
Case study 4: background Case study 4: vibration measurement
• Two triplex pumps in an amine service
• One unit 100% standby
• Three separate failures causing spills
• Operators comment that pump was very
noisy

107 108

Case study 4: pulsation measurement Case study 4: vibration measurement

• Pulsations measured in the • New valves
pumping chamber – Vibration reduced to less than
• Valve measured to be closing late. 50% of guideline with new valves
Original valves Original valves
Typical 7o to 10o – Valve life improved
• Recommend stiffer springs or – Improved capacity
higher preload to help closing – Quieter pump, no cavitation
• New valve 6o closing angle • Proper valve selection is critical to
reliable operation
New valves New valves

109 110

Pulsation control devices Pulsation dampeners

• Dampener sizes and locations, Gas charged Maintenance free
• Orifice plates, Active/soft element
Reactive/hard element
• Pipe layout changes
• Balance cost of pulsation filters, baffles, etc, vs impact on reliability and
pressure drop
• Ensure practical design for all operating conditions and speeds

111 112
Pulsation dampeners Gas-charged dampeners
Gas charged Maintenance free • DO NOT charge dampener while pump is online
• Charge to 50-80% of system pressure (refer to manufacture manual
Style • Appendage style • Mostly in-line (flow through)

• Compact • No maintenance
Pros • Off the shelf • No spare parts
• Generally lower capital cost • Very reliable, high frequency range Maintenance tip: While pump is online does the gauge on
the dampener provide a good indication of charge?
• Generally higher capital cost
• Effective frequency range limited NO, the gauge will only show the system pressure.
• Often custom design per application
• Maintenance required
Cons • Pulsation amplitude reductions can
• Bladder failures remove pulsation protection
be limited
• Gas charging procedure not always easy

113 114

Gas-charged dampeners Pulsation dampener sizing

Traditional approach
• DO NOT charge dampener too quickly; as gas enters the • Empirical calculations
Empirical sizing methods
dampener it cools and could cause failures on the bladder • API 674 & OEMs have different empirical
sizing methods
• Bladder material may not be compatible with all compounds in •
•
Good first step for quoting, but…
Do not account for acoustic resonances in piping system
the fluid Advanced approach
• Pulsation design study
• Benefits:
ü Complete range of operating conditions
ü All pump speeds
ü Multiple pump interaction
ü Optimized for:
• All piping designs
• Size and Location Pulsation design study
• Type (active vs reactive)
• Number - sometimes none,
one, or two

115 116

Pulsation dampener sizing – empirical Case study 5: empirical sizing

• Many different sizing formula are used Case study from pump installation in Western Canada:
• The dampener volume, !", is calculated using a relationship similar to: • Quintiplex pump with 2.75” bore, 4” stroke
/
$!×&' × $)*+,($ • Dampener charged to 80% of line pressure with nitrogen
-./
!" = / • Sized for 5% pressure pulsation for a line pressure of 350 psig
1 − $)*+,($
-23

$% .123
2.75+ ×4×5×.06× 350/332.5
$! is the pump displacement per stroke !" = 4 .123
&' is a pump constant 1 − 350/367.5
$-42/ is mean line pressure
$-./ and $-23 are the minimum and maximum pressure due to pulsation !" = 216 %67
, is the polytropic expansion coefficient of charge gas Standard dampener size is 300 in3

117 118
Case study 5: empirical sizing Case study 5: empirical sizing
• Empirical sizing shows Determine pulsations at the suction inlet based on the empirical size and pulsation
reduction in the pressure model of the pump and dampener
pulsation with increases
dampener size
• Diminishing returns after
dampener size of 600 in3

Dampener
Pump and dampener pulsation suction
flange
model
119 120

Case study 5: empirical sizing Pulsation dampener design

• Pulsation model shows the PROBLEM: High vibration and pulsation after TROUBLESHOOTING: Pulsation design
pulsation reduction is insensitive adding VFD drive (change in pump speed) study highlighted inadequate
to the dampener size and change in operating conditions pulsation control with new operating
states.
• Small amount of gas has a Solved the problem for new pumps
significant impact Design Tip: Pulsation study is speeds and operating conditions
recommended if:
• Neck geometry and location • VFD added, or flows change by
controls the dampener more than 10% Add Existing
dampener dampener
effectiveness • Pipe layout changes, for example,
• Dampener sizing by empirical moving relief valves to remote
formula is too simplistic location

SOLUTION: Additional pulsation controls

121 122 Orifice

Mechanical natural frequency Mechanical natural frequencies

API 674: Minimum MNF must be greater than 20% above PPF
Most pulsation induced forces occur at Support spacing Nomographs Finite element
Plunger passing frequency (PPF)= RPM X number of plungers charts analysis

Forces Design goal:

MNF > 1.2 x PPF

MNF Pump

| | |
123 1x 2x 3x Orders of PPF 124
 Pipe restraints
Shoe type and rest-only pipe
supports good for thermal loads,
but cannot restrain dynamic
loads of reciprocating pumps
Pipe layout – avoid flexible layout
• Calculate the clamp spacing to raise MNF
above 1.2XPPF- move clamps closer to each Design tip: Eliminate or reduce elevated
other piping for reciprocating pumps
• Appropriate type of clamps should be used,
U-Bolt clamps are not recommended

Design Tip: Perform a full API 674

mechanical review at the design stage Flat-bar-style clamps are
Note: Vibration and thermal pipe recommended for dynamic
force restraints
stress concerns can both be • Route piping as close as possible to the foundation, so it can be easily supported
All restraints must have a accommodated. • Additional friction and head loss will affect system resistance curve – but recips will easily make up
proper
125 foundation 126 the pressure.

Pipe layout – allow room for dampeners Pipe layout – allow room for dampeners
Leave room for dampeners in Leave room for dampeners in piping
piping layout layout
• Maintenance-free dampeners • 20 Gallon gas charged dampener
were the only option, 40” OD required, layout was built with an
Vessel assumed 5 gallon

Design tip: Perform a API 674 pulsation study early in the

design stage
Note: Early review of piping layout can reduce delivery
time and rework

127 128

Beyond MNF calculations Forced response analysis

• API 674 recommends a mechanical analysis to calculate MNF • Requires a comprehensive model of the piping and support structure to simulate
– Indication of the potential for vibration dynamic response
• Forced response analysis is required to calculate expected vibration and dynamic • Finite element model for dynamic analysis needs more refinement that static
stress analysis
– Dynamic forces are used to calculate the response of the piping and structure
due to
– Response is vibration and dynamic stress

Pump 1

Pump 2

Pulsation Forces Vibration Stress Failure

129 130
Forced response analysis Forced response analysis
Apply shaking forces from pulsation model Calculate vibration and dynamic stress vs guideline
• Force at all elbows, tees and changes in areas 250
US00418 - Pump P-21A Online (Design Speed Range: 87.8 - 200 RPM) R322A-R02

• Evaluate range of operating speeds and conditions

HRA31R04.EXE

VIBRATION GUIDELINES (%)

200 SUM22.EXE
07:19:35
02/09/17

• Frequency range up to 150 Hz 150

100

50

Pipe/Vessel Vibration
0
0 Structure Vibration 50 100 150
Guideline

100

STRESS VS GUIDELINES (%)

80

60

40

20

0
0 50 100 150
Pipe/Vessel Stress FREQUENCY (HZ) HRA-R323A-R02-COND001-WS.
Structure Stress
Guideline

131 132

What is damping? Examples of damping

“Restraining of vibratory motion, such as mechanical oscillations and noise, by
dissipation of energy”

Basic pipe restraints resonant at some

frequencies, causing high vibrations

Damping clamps and supports effectively control

vibrations at multiple resonate frequencies
133 134

Examples of damping Examples of damping

Without damping brace
Damping
material With damping brace

Damping
material
Damping
material
135 136
 Small-bore attachments (SBA)
PROBLEM: Small-bore failure
• About 70% of leaks are due to SBA
failures
• Stress concentrations (threaded
connections are trouble)
• Add support
7. Small-bore piping and connections • Eliminate SBA if possible

Eliminate
Christmas
trees!
137 138

Small-bore attachments (SBA) Cause for SBC failures

PROBLEM: Small-bore failure • Typical driving forces are cavitation, turbulence, unbalance, and vane and plunger
passing pulsations
• About 70% of leaks are due to SBA
failures • Frequencies of each driving force for 900-1800 RPM 7-vane pump are shown below
• Cavitation is a large contributor to SBC vibration when flow or pressure control
• Stress concentrations (threaded
valves are used
connections are trouble)
• Add support
• Eliminate SBA if possible Turbulence Unbalance Vane passing
pulsations
Cavitation
Design tip: What can I do if SBA cannot be
Energy

eliminated? Eliminate
• Shorten the length as much as possible Christmas trees!
• Reduce the suspended weight Frequency
15 30 84 105 210 252
139 140
5

Industry standards Industry standards

• Pump and piping vibration • Pipe stress
– “Guidelines for the Avoidance of Vibration Induced Fatigue Failure in Process – EN 13445: “Unfired Pressure Vessels, Part 3: Design”
Pipework”, Energy Institute (“EI AVIFF”) – BS 7608: “Code of Practice for Fatigue Design and Assessment of Steel
– ISO 10816-7: “Mechanical Vibration – Evaluation of Machine Vibration by Structures”, British Standards Institution
Measurements on Non-Rotating Parts” • Small-bore connections
– “Design Guideline For Small Diameter Branch Connections”, GMRC/PRCI

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GMRC SBC guideline GMRC SBC guideline
• Combines frequency avoidance (resonance) with simplified base motion check • Example for vane pump versus plunger
• Guidance for several layouts Natural Frequency Guideline pump Natural Frequency Guideline
Machinery Machinery
(Near) (Far)
• MNF avoidance chart Reciprocating > 4.8 * maximum > 2.4 * maximum • Higher speed of vane pump requires (Near) (Far)
Reciprocating > 4.8 * maximum > 2.4 * maximum
Compressor runspeed runspeed higher MNF for connections near the Compressor runspeed runspeed
Centrifugal Detailed analysis Centrifugal Detailed analysis
Compressor recommended
> 15 Hz pump Compressor recommended
> 15 Hz
Reciprocating > N * 2.4 * > N * 1.2 * Reciprocating > N * 2.4 * > N * 1.2 *
Pump maximum runspeed maximum runspeed Pump maximum runspeed maximum runspeed
Centrifugal > 2.4 * maximum Centrifugal > 2.4 * maximum
> 15 Hz > 15 Hz
Pump runspeed Pump runspeed

Machinery Near Far

1800 RPM mainline 72 Hz 15 Hz
centrifugal pump
344 RPM reinjection 41.3 Hz 20.6 Hz
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triplex pump

Design approaches Design best practices

• Finite element analysis is used • Avoid tall designs that have heavy cantilevered weight
• MNFs are calculated and compared to guideline • Use thicker mainline and SBC pipe
• Allowable vibration (to keep stresses below fatigue limit) is calculated. Important for • Avoid threadolets
comparison with field measurements. • Locate near clamps and flanges, to avoid high mainline piping and shell vibrations

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Design best practices Design best practices

• Brace SBC in direction of vibration (typically two • Block and bleed for pressure indicators are common problems.
directions required)
• Keep as short as possible
– Brace to mainline pipe only, not other
structures
• Use monoflanges
• Add gussets (and welding pads) to vulnerable
connections
– Do not weld directly to pipe!

Worst Best
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SBC – other factors
• Transient vibrations, due to startup, shutdown, switching pumps, valve operation, etc
• These occasional loads can cause fatigue damage which will give small-bore
connection a finite life
• Field audit is recommended on critical connections

Transient conditions
(start, stop, change in flow) Case study 8
Normal operating conditions
(steady state) Centrifugal pumps with SBA failures

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Case study 8: background Case study 8: layout

• Two centrifugal pumps stations experience pipe failures • Large expansion loops
– 2000 – 3950 RPM – Used to reduce thermal loads on nozzles
– 1x: 33.3 – 65.8 Hz – 6m (18 ft) in height
– 6x: 200 – 395 Hz (vane passing frequency, FPF, for 6 vanes)
3/4” vent
– 7x: 233 – 461 Hz (VPF for 7 vanes)
U-3
• Failure on vent valves
– 2” valve connections (U-1, U-2)
– ¾” valve connections (U-3)

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Case study 8: vibration measurement Case study 8: vibration vs guideline

• Suction loop • Vibration screening guideline = 1 ips pk
• Vibration at 1x (due to pump • Based on ASME stress, what is the allowable vibration?
unbalance) • U-bend pipe = 4.8 ips pk
• Vibration at 6x (due to vane passing • NPS 2 vent:
frequency) – At 60 Hz, Vallowable = 1.5 ips pk
• Some energy at 12x (twice vane 6x
– At 48 Hz, Vallowable = 1.2 ips pk
passing frequency)
1x

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Case study 8: vibration Case study 8: recommendations
Vibration is above allowable based on dynamic stress • Remove vent valve
Vibration • Brace vent valves
Location Direction Amp Freq • Reinforce connection
(ips pk) (Hz)
• Remove or reorient
Suction Loop Axial (in-plane) 0.3 149
Horiz (out-plane) 0.3 5.6 thermal loops
Vertical 0.7 364 • Run > 50% of best
Discharge Loop Axial (in-plane) 0.3 5.9 efficiency point
Horiz (out-plane) 0.3 4.7
Vertical 0.8 122
Vent on
Discharge Loop Axial (in-plane) 1.8 61
Horiz (out-plane) 2.0 48
Vertical 0.9 122

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Case study 8: conclusions

• Pipe design must balance between vibration control and thermal expansion issues
• Mainline pipe can endure a significant amount of vibration
• Small-bore piping can endure much less vibration
• Vibration energy in system typically at 1x and VPF
Avoid MNFs in this frequency range

Project management and planning

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Scope and specification

• Your project specification needs to include more than “Perform a Pulsation and
Mechanical Study as per API 674”
Sometimes we’re so pre-occupied • Need to specify analysis details. Standards require interpretation and
with what we’re doing that we don’t see considering your project details.
disaster coming our way! • Studies that should be done are not specified in API 674. For example small bore
piping or transient analysis
J • API 688 will help as it includes more details. Need to consider your project
specifics.

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 Design studies to improve reliability Roles
P Required • Vibration and pulsation does not stop at the
skid edge
? Required based on application
• Many problems avoided when owners:
- Pump power • Hire a specialist consultant directly, and
- Piping complexity • Stay involved at key milestones
- Critical process

See handout or
http://www.betamachinery.com/assets/pdfs/Specifi
cations/SPEC_Pumping_Systems_2014.pdf

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Project timeline activities – late involvement of pulsation specialist leads to problems Successful project: early involvement of pulsation specialist, owner input
Project Preliminary Equipment Detailed Project Preliminary Equipment Detailed
Site survey, Fabrication - Site survey, Fabrication -
initiation, equipment selection, bid equipment Commissioning initiation, equipment selection, bid equipment Commissioning
layout, design construction layout, design construction
planning sizing evaluation design planning sizing evaluation design

Owner Owner

Engineering Engineering
firm Firm

Packager or Packager or
OEM OEM

Pulsation Pulsation
specialist specialist

Consequences of late involvement: Results of early involvement and owner input:

• Limited ability to make changes • Shorter schedule ($$ major savings)
• Project delays • Better design ($$ capital and operating savings, higher reliability, operational
• Potential re-work ($$$) improvements)
• Design compromise (vibration problems) • No rework (saves money)
163 • No input from owner (unhappy about final product) 164 • Owner input (higher satisfaction)

Cost of not doing design upfront Cost of not doing design upfront
• Recent project required overall of flare system and control valves for 4, 300 HP • Vibration causing insulation to wear and fail
plunger pumps in a refinery application • Excessive vibration: valves, actuators and instrumentation
• Design and construction $22M
• Vibration and pulsation design work was not done
• High vibration was obvious
after startup

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Cost of not doing design upfront
Site testing and design work to solve the vibration problems: $300K
If initial design work done, less than $40K.
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9. Closing remarks
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Piping system design
• Piping and support must balance
requirements for flexibility for pipe
stress and stiffness to minimize
vibration
• Design goal of 7Hz as a minimum
piping mechanical natural frequency
• Eliminate or shorten small-bore
attachments as much as possible
• Transients due to ESD, power failure
or fast acting valves can generate
vibration
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Project management and planning
A successful pump project needs to include consideration for:
• Specifications and scope
• Timing of activities
• Roles and involvement of design partners
“Cost of the study is a small percentage of
total costs, but can have a big impact on
system reliability.”
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Piping system design
• Centrifugal and reciprocating pumps
generate dynamic forces that create
vibration
• Remember the vibration equation:
Vibration = dynamic force x dynamic flexibility
• Best practices, standards and design studies
can reduce the risk of fatigue failures
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Piping system design
• Pulsation dampeners and other
Centrifugal pulsation control devices generally Reciprocating
required. Leave room for them!
• API 674 Pulsation Design Study often
necessary
• Piping supports should be designed to
restrain dynamic loads
• Hold-down type clamps
• Clamps at different locations to raise
MNF above 1.2X PPF
• Piping layout close to foundation
• Eliminate or shorten small-bore
attachments as much as possible
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Thanks for participating
• Please complete the course evaluation
• Feel free to contact us for questions or support:
Kelly.Eberle@woodplc.com
Michelle.Witkowski@woodplc.com

Visit our website for more technical content, including papers, videos and calculators:
woodplc.com/vdn

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