Pulsation damping in suction pipe of Ammonia pump

Paper 16

By: J. Neuschäfer/M. Sauter

Uraca GmbH & Co.
Germany

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Table of Contents

Page:

1. Summary 1

2. Introduction 2

3. Fundamental principals of reciprocating pumps 3

4. Functional description of the suction pulsation damper 5

5. CFD - Analysis of the suction pulsation damper 7

6. Verification 12

7. Conclusion 13

This paper, which is included in the symposium binder of the Ninth Stamicarbon Urea
Symposium was not prepared by Stamicarbon and therefore does not necessarily
reflect Stamicarbon’s technical opinion. Stamicarbon shall not accept any responsibility
nor liability for its contents.
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1. Summary

In the urea synthesis high pressure reciprocating pumps are used to handle liquid
Ammonia. Depending on process, pressures of up to 250 bar have to be reached and
capacities may well reach 2500 l/min.

One main feature of reciprocating pumps is the hydrodynamic independence of

capacity and pressure and vice versa. The backflow of the displaced volume is
prevented by means of displacement pumps due to the mechanics of the generation of
pressure. This principle allows to reach extremely high efficiencies. However, one
inconvenience is caused by the oscillating of the piston displacing the fluid: the
fluctuation of pressure and flow.

In this paper reasons will be given as to how and to what extent pulsations are
produced. The requirements needed for a possible damping of pressure oscillations are
thus determined.

Different kinds of pulsation dampers are applied to prevent pressure pulsation. On the
suction side of pumps in particular, dampers operating like air chambers are used. The
design and function of a special air chamber used for the handling of liquid Ammonia
will also be presented.

The damping performance of a suction pulsation damper has different effects. Special
attention should be given to the fluid passing through the damper. By means of CFD
analysis (Computational Fluid Dynamics) the flow conditions in the damper are
examined.

After calculations all noted problems are eliminated by modifying the flow conduct in the
damper. Further CFD analysis confirm these results.

Practical experience during the operation at DSM Urea 2 Plant in Geleen shows that
the suction pulsation dampers optimized by means of CFD analysis are extremely
effective. Thus high frequency pressure oscillations due to capacity pulsation of the
piston pumps could be completely eliminated.

1.
2. Introduction

URACA reciprocating pumps in different designs have been used for many decades as
Ammonia high pressure pumps in the urea synthesis.

Reciprocating pumps produce pulsations in the suction and discharge line. This is a
special feature of all reciprocating equipment handling fluids. Reciprocating engines
and piston compressors are also oscillation generators for the fluid in the systems
leading to and from the equipment. Pulsation and oscillation lead to forces and
pressure losses thus reducing the efficiency of a pump, engine or compressor.

But not only the efficiency is a problem, far more problematic are the pressure
pulsations resonating with the pipe line system. Sometimes excessive stress occurs in
the pipe line leading to failure. This is why pressure pulsations must be prevented, i.e.
reduced to a minimum in order to exclude any risks.

Pulsations on the discharge side of pumps are mostly damped by resonators. Based on
the reflection principle they are designed in a way that pressure waves, arriving in the
resonator, are partly eliminated by the reflecting pressure waves.

On the suction side of the pump not only resonators, but also bladders and various air
chambers are used. The functioning and use of a special air chamber for ammonia
pumps will be explained later on.

2.
3. Fundamental principals of reciprocating pumps

The exact dimensioning of a pulsation damper is subject to a clear understanding of the

flow fluctuations. The course and size of fluctuations depend on the kinematics of the
crankdrive (diagram 1) and the periodical change between suction and discharge stroke
of the piston.
piston speed

discharge stroke

90°

180° 0°

270°
stroke

suction stroke

Diagram 1: Kinematics of crank gear

Most reciprocating pumps are usually designed as three-plunger pumps. In diagram 2

the fine lines in green, orange and blue show the capacity of the individual plungers
related to the mean capacity in accordance with the kinetics of crank gears. The three
plungers operate one after the other in the discharge stroke, with a crankangle offset of
120°.

The bold red line shows the cumulative curve of three plungers. The curve deviates
from the blue line for the mean capacity. The diagram shows the periodical excess and
deficit volume. Periodical pressure fluctuations result due to the incompressibility of the
fluid.

3.
 1.2

0.8
Q/Qm

0.6

0.4

0.2

0
0 60 120 180 240 300 360
crank angle [°]

Diagram 2: capacity pulsation of a three plunger pump

The surplus can be calculated by integration above the crank angle. In this case, i.e.
handling of Ammonia with URACA pump type KD 823, a simple formula applies
resulting from the calculated integral:

d2 × π
± Q üges = 0.0347 × ×h
4

With plunger diameter d = 115 mm

stroke h = 180 mm

the result is: Q = ±65 cm³

-1
At a speed of n = 149 min the exciting frequency is

3·n/60 = 7.45Hz

i.e. 7.45 times per second a total volume of 130cm³ must be exchanged.

4.
4. Functional description of the suction pulsation damper

Pulsation dampers operating according to the air chamber principle can absorb and
supply the above mentioned excess and deficit volume by means of a compressible
gas cushion.

In the case of liquid Ammonia, the upper part of the vessel could be filled with nitrogen.
However, the gas cushion of the described suction pulsation damper is formed by
evaporation of liquid Ammonia. The heat required for evaporation is provided from
outside by a heating coil. (diagram 3).

steam heating
Evaporation
p=3,5bar temperature NH3
T=148°C
at p=14bar:
ÞT= 310K= 37°C

NH3-suction side
p=14bar
T=10°C = 283K
Qm=788l/min

Diagram 3 Ammonia suction pulsation damper

Due to the suction pressure of 14 bar the Ammonia has to be heated up to a minimum
of 310K for evaporation. The gas volume in the pulsation damper has to be big enough
to buffer a volume of V = ± 65 cm³. During operation the gas volume is compressed
and decompressed adiabatically at a frequency of f = 7.45 Hz

For the evaluation of the gas volume, the formula for adiabatic change of condition
applies:
k
k
p1 æ V2 ö æ T1 ö k -1
=ç ÷ =ç ÷
p 2 çè V1 ÷ø çè T2 ÷ø

5.
The admissible pressure fluctuation in the suction line is subject to the experimental
value p = ±0.2 bar.

Calculation of the required size:

1 1
æ p1 ö k V + DV æ 14 ö k
çç ÷÷ = 1 =ç ÷ = 0.9899
è p1 + Dp ø V1 è 14 + 0.2 ø

Result: V= 6435.6 cm³ = 6.44 l

The condensate capacity at the outlet of the heating coil was measured with 6 l/h,
corresponding to 0,00167 kg/s. Under these conditions, the supplied heat flow can be
calculated with the condensate enthalpy r of the water vapour as follows:

& =m kg kJ
Q & × r = 0.00167 × 2120 = 3.53 kW
s kg

Assuming that further heat losses are negligible, the max. volume of vaporable
Ammonia at a suction temperature of 10° C amounts to:

Q& 3.5 kW kg
& =
m = = 0.0028
h 37°C¢¢ - h10°C¢ (1708.8 - 465.2) kJ s
kg
This corresponds to a max. vapour generation of 15.3 l/min.

As a result, the pulsation damper is sufficiently heated for creating the required gas
cushion. In practice sufficient gas is quickly produced before start-up of the installation.

However, a few hours after start-up, strong pressure pulsations occur leading to the
conclusion that the gas volume is decreasing due to fluid passing through the damper.

Flow simulations (CFD) have been executed by DSM Research for a better
understanding of this mechanism and also for taking countermeasures.

6.
5. CFD-Analysis of the suction pulsation damper

Diagram 4 shows the distribution of velocity in vertical sectional view through the
suction line and the suction pulsation damper. Flow velocities of up to 0.65 m/s are
reached in the pipe elbow and in the damper’s inlet area.

Turbulences in the pulsation damper are clearly recognizable. Whereas the turbulence
below the in- and outlet flange is less important for its function, the ascending flow on
the upper right-hand side of the damper is significant. Due to continuity, the fluid must
flow down again (not shown in the sectional drawing). One can assume that the
decending flow at the opposite vessel wall will be similar to the ascending flow.

With the colour scaling one can see that the flow velocity in the damper has several
cm/s. According to bibliographical references the ascending velocity of boiling Ammonia
bubbles amounts to 2 cm/s only. This shows that boiling gas bubbles produced by
heating cannot ascend, but are transported down to the pump with the current.

Diagram 4: Distribution of speed - vertical sectional view through the suction pulsation
damper.

The distribution of temperature subject to flow is shown in diagram 5. In the upper 1/3
part of the suction pulsation damper the thermal input over the total heat exchange area
is 3,5 kW.

7.
The fluid enters at a temperature of 283K. In the proximity of the heating a very slight
increase of temperature can be recognized. With the maximum value of the colour
scaling maximum temperatures of 310 K can be expected in a extreme small area.

Altogether the mean temperature in the damper is approx. 285K. Therefore Ammonia
cannot vaporize since the vaporization temperature is 310K at a given suction pressure
of 14bar.

The thermal output is completely discharged to the pump thus leading to slight heating
of the total fluid handled.

3.5 kW

Diagram 5: Distribution of temperature - vertical sectional view through the suction

pulsation damper.

The suction pulsation damper can only be effective if the turbulence in the damper is
prevented. Therefore a crossover pipe is introduced leading the fluid from the inlet to
the outlet flange.

8.
Diagram 6 shows a flanged pipe on the inlet side. On the outlet side there are ring
segments connecting the interior of the damper with the suction line. By means of these
ring segments, the excess and deficit volumes can flow in and out due to discharge
pulsations of the pump.

Diagram 6: Suction pulsation damper with crossover pipe

Diagram 7: Distribution of speed - vertical sectional view with crossover pipe

Diagram 7 shows the distribution of velocity in vertical sectional view with a crossover
pipe installed. Here the effective flow pattern is shown contrary to the previous CFD`s
according to diagram 4. Through the small inlet diameter, maximum velocities of 2.75
m/s can now be reached. Due to the selected scale there are no significant flow
velocities in the damper itself.

9.
On closer inspection of the processes in the damper, the distribution of velocities
according to diagram 7 was rescaled and the important section was zoomed out
(diagram 8). On this scale maximum velocitys of 5 mm/s are visible which are partly
seen at the lower end of the damper . The flow capacity directed downwards in the
upper part of the damper shows velocities of below 1mm/s. This means that the fluid in
the damper is more or less static. The boiling bubbles at the heated wall can ascend
and are collected in the upper part of the damper.

Diagram 8: Distribution of speed – vertical sectional view with crossover pipe

The previously missing convective heat input is now supplied, due to modification of
flow. This leads to a significant change of temperature in the damper. Contrary to
diagram 5, diagram 9 shows an important increase of temperature in the upper part of
the damper. The marking in red shows temperatures ranging above the boiling
temperature of Ammonia (310K). Within these ranges gas developement can be
reckoned with.

Altogether the temperatures are not as high as required so that due to this simulation
the perfect functioning of the pulsation damper cannot be totally guaranteed.

10.
In this connection the actual operational conditions of the system have to be observed.
Before start-up of pump the pulsation damper is heated, i.e. a gas cushion has already
been created before starting the pump. Due to flow conditions during operation
important heat losses are not expected.

A further favourable effect is that the gas volume is steadily compressed and
decompressed due to pressure oscillations resulting from flow fluctuation. Such
processes are irreversible and lead to a slight heating thus conserving the gas bubble.

3.5 kW

Diagram 9: Distribution of temperature in vertical sectional view with crossover pipe

11.
6. Verification

Diagram 10 shows the pressure pulsations recorded at plant site from March 4 to 9.
On March 4, the operation changed from machine B (suction pulsation damper without
crossover pipe) to machine A with the modified damper installed.

It clearly shows that after the change, short-wave pressure pulsations do not occur any
more in the suction line. The existing pressure oscillations produced during process
continue for several hours

On March 9 after changing to the non modified machine B, short-wave pressure

oscillations occured again immediately.

Measured pressure in the ammonia suction line of Urea2 plant Geleen

suction pressure

March 4th March 5th March 6th March 7th March 8th March 9th

Diagram 10: Pressure curve recorded in the suction line

12.
7. Conclusion

The installation of a crossover pipe in the suction dampener results in an almost

pulsation free suction pressure. Subsequently this leads to trouble free plant operation.
This pulsation damper can be obtained from:

URACA Pumpenfabrik GmbH + Co. KG

Postfach 1260, D-72574 Bad Urach
Germany
http://www.uraca.de

However to obtain a fit for use design a proper interaction between Client / Contractor
and URACA is essential. In case CFD’s are required, Stamicarbon is prepared to assist
in such endeavour.

13.