Vibration Mitigation in Reciprocating Pumping Systems

MITIGATION OF VIBRATION ISSUES IN RECIPROCATING PUMPING SYSTEM A CASE STUDY
1

MITIGATION OF VIBRATION ISSUES IN RECIPROCATING PUMPING SYSTEM A
CASE STUDY

Sulgay Satyapal, Deputy General Manager (Production)
1, a

Manjeet Singh Katoch, Chief Engineer (Production)
1, b

Indrajit Borah, Executive Engineer (Production)
1, c

1
Bassein and Satellite Asset
Oil and Natural Gas Corporation Limited, India

ABSTRACT
Natural gas condensate handling requirement exists for many offshore installations. Use
of reciprocating plunger pump for pumping the condensate to high pressure dispatch lines is a
source of vibration in the system. As such the pulsation of reciprocating plunger type pumping
system is inherent to the very principle of its operation. Suitable measures should be taken up at
the initial design stage and provided with adequate dampening equipments in the system. It is
necessary to carry out acoustic analysis of the complete pumping system at the design stage or
prior to any modification of an existing system.
The paper is primarily based on a case study of vibration problems of reciprocating
plunger type pumping system handling hydrocarbon condensate in offshore process plant and its
mitigation measures.
The condensate handling system at BPB offshore sour gas processing complex was with
very high vibration and knocking sound. The effects of subsequent modifications, varying
operating parameters, use of different dampeners, piping support arrangements and deck
vibration had provoked to re-assess the system in totality. The system acoustic analysis and
implementation of vibration reduction measures helped in mitigation of the vibration problem.
The paper deliberates the theoretical and analytical approach to address the problems
faced over the years and the measures taken from time to time. The ideas presented in the paper
can be implemented in reciprocating pump systems especially in the offshore process plants.

a
email: satyapal83@gmail.com
b
email: manjeet_2000ad@yahoo.co.in
c
email: indrajitborah@yahoo.co.in

2

Introduction

The condensate handling system at the gas processing complex consists of condensate
surge vessel, pumps and coalescers. This system was subjected to severe vibration and noise.
The increase in severity of vibration with decrease in pump suction pressure and the role of
recycle capacity control valve were studied. The pulsation dampeners were ineffective in taking
care of both pressure and flow pulses.

The propagation of vibrations in both fluid and structural medium in the piping system
results in fluid-structure coupling. The interaction of pump plunger generated dynamic flow with
acoustical resonances in piping system results in high pressure pulsation levels and excessive
vibration. The primary objective of suitable vibration control measure is to avoid any hydraulic
and acoustic resonance between the active systems - cylinders of the pumps and passive systems
- piping network. The secondary objective is to reduce the amplitudes of the remaining pressure
pulses to negligible levels by decoupling the mechanical resonance.

The system was tested with acoustical simulation techniques for new all-liquid type
dampeners and orifice plates at suction and discharge piping. The pulsation levels were within
the API 674 guideline and 2% pulsation criteria.

Condensate and its stabilization

The colorless gas condensate is a low-density mixture of hydrocarbon liquids that are
present as gaseous components in the raw natural gas
1
. The decrease in operating pressure of
condensate stabilization system reduces the vapor pressure of condensate. The stabilization of
condensate is critical as majority of pump problems start at the suction side. The forces of

3

acceleration are overwhelming disturbances at the suction system. Acceleration head is the
highest factor of NPSHA i.e. 10 times the total of all other losses
2
.

The acceleration head (H
Ac
) at the suction piping of condensate pumps can be calculated
as follows
3
.

The rated flow of a condensate pump = 66 m
3
/hr = = 0.0183 m
3
/sec
Considering the condensate pump P-670A,
After modifications in the commissioning stage, suction stabilization is done in two
stages: suction degasser vessel and pulsation dampeners.
The suction length of the pump can be divided in to three parts,
(a) 16 main suction header 21.673 m
(b) 8 individual suction line up to degasser vessel 8.388 m
(c) 8 suction line after degasser 5.425 m
Now, calculating the acceleration head loss in the absence of both degasser and
dampener,
The total length (L) of the condensate pump suction pipe is having two sizes:
(a) 16 common suction header of 21.673 meter length (C/S = X 0.4
2
= 0.1257 m
2
)
V = Velocity in 16 pipe = = 0.2912 m/sec, for two running pumps
(b) 8 individual pump suction of 13.813 meter length (C/S = X 0.2
2
= 0.03142 m
2
)
V = Velocity in 8 pipe = = 0.5824 m/sec
N (RPM) = 181; C = 0.066 for triplex pump; K = 2.0 for condensate; g = 9.8 m/sec
2

Acceleration head for 8 pipe = = 4.903 m

Acceleration head for 16 pipe = = 3.846 m

Total acceleration head at the pump suction = 4.903 + 3.846 = 8.749 m
NPSH Available for a condensate pump = 14 m (without acceleration head loss)
Actual NPSH available = 14 8.749 = 5.251 m

As per the pump data sheet, the required NPSH is 6.5 m. The suction stabilizer has to
reduce acceleration head loss from 8.749 m to 1 m such that the actual NPSH available is 13 m
(as per pump design basis) instead of 5.251 m.

Installation of suction pulsation dampener adjacent to the pump suction connection will
reduce pulsation fluid mass inertia effect by changing the suction piping length portion in the
acceleration head equation to approximately 20 to 25 times suction pipe diameter for bladder
types and to approximately 8 to 10 times for larger volume flow through types
4
.

4

Implications of recycle capacity control

The most efficient method of capacity control for reciprocating pump is not to vary the
pump capacity but to change the proportion of the displacement delivered into the piping
system
5
. The recycle control discharges condensate production rate to the export lines by the
design capacities of two pumps. The fail to open type recycle control valve is installed in the
line teeing off from the discharge header.

The operation of recycle valve results in pump discharge header pressure fluctuation from
suction pressure to export line pressure. The variation of discharge pressure and corresponding
flow in the main and recycle lines result in high pulsation amplitude and mechanical resonance
in the pipelines at particular discharge pressure. Severe fluctuation of discharge header pressure
makes the dampening system ineffective.
There are two established approaches to deal with the issue of fluctuation of condensate
discharge header pressure
6
. The first solution is to design the recycle control valve for this kind
of severe applications of high differential pressure. The second is to put a fixed or variable
restriction i.e. suitable choke at the downstream of the existing control valve.
The required sizing conditions are proposed for the recycle control valve. If the recycle
control valve does not conform to the required sizing conditions, a suitable variable choke valve
should be installed at the downstream of it.
Reciprocating pumps and dampening equipments

A plunger-type reciprocating pump consists of a number of in-line cylinders with
reciprocating plungers driven by a rotating crank and connecting rod mechanism. Pressure waves
or pulses are the consequence of the alternating acceleration and deceleration of fluid in each
crankshaft revolution at a frequency of crank rotational speed.

A pulsation dampener stores the volume of liquid above mean flow momentarily before
discharging it during the portion of the cycle below mean flow. The liquid volumes above mean
flow decreases with increase in number of cylinders and thereby the size of dampener decreases.
A triplex pump generates primary hydraulic excitation force at 3 times per revolution of the
pump and secondary hydraulic force at 6 times per revolution of the pump. The coincidence of
excitation harmonics with acoustical natural frequencies of the system amplifies pulsations.
Amplification factors are typically 10-40 for pulsation resonances, 10-20 for mechanical
resonances and a combined amplification factor of 800 for coincidence of mechanical resonance
with acoustical resonance
7
.

Pulsation control equipment is important in reducing the hydraulic pressure forces
applied to all the mechanical components in the pumping system. The discharge pulsation
dampener removes pulses only from the downstream of it. The suction pulsation dampener
smoothen pressure pulses at the upstream of the dampener. It thereby reduces the effective
suction length of the pump. The recommended location for the pulsation control equipment is
within 6 times the nominal pipe diameter of the pump suction and discharge connections
7
.

5

An accumulator or filter induces a new set of acoustic natural frequencies and mode
shapes in the system by shifting natural frequency of the hydraulic system away from initially
existing resonances. An orifice at the pump flange or entrance to the accumulator controls
cavitation in the suction system and high pulsation in the discharge manifold. The acoustic
elements of a typical appendage accumulator are gas volume, liquid volume and neck elements.
The inductance provided by throat area has a large effect on the performance of the accumulator.

The appendage bladder type accumulators reduce system pulsation levels at low
frequency. The accumulators with larger neck diameter are more effective in reducing the
pulsations. Resistance and acoustic filters attenuate pulsation energy over a wide frequency
range. Wave blockers installed at specific locations eliminate the hydraulic response to the
system piping. The flow-through type gas filled/blanket accumulators have improved frequency
response because of no throat restriction. Any desired attenuation can be achieved by all-liquid
type acoustic filters as these are designed based on Helmholtz frequency and allowable pressure
drop. As a rule of thumb, a liquid filled dampener, as compared to bladder type, needs, at
pressure level of around 100 bar, around 150 times the volume to provide a comparable elasticity
co-efficient.

The selection of pulsation control equipments based on traditional approach of pressure
and flow criteria without considering the systems acoustical pulsation characteristics may result
in high piping vibration with exception in some cases.

Traditional approach to dampener sizing and its limitations

The sizing calculations for installed bladder type appendage dampeners done in the
following are based on the thermodynamic isothermal relationship and the empirical formulae of
the manufacturer FOX
8
. These approaches are considered to be traditional based on pressure and
flow pulses.

The rated flow and speed of the pumps are 1100 lit/min and 181 RPM respectively
Capacity per revolution of the pump(C) = 1100/181 = 6.11 lit/revolution

The empirical relationship of pulsation liquid volume above mean flow by FOX is
, where, K = pump type co-efficient (for triplex pump 0.12)
= 0.732 liter for condensate pumps

The Theoretical formula for dampener size
9
,

The pressure values P
1
and P
2
are function of desired residual pressure pulsation.
The pre-charge pressure P
0
for triplex pump is

6

In practical use, the dampener volume can be calculated by the following equation
developed by the manufacturer FOX:

Where, Z is the coefficient of displacement of delivery in one revolution (C) in liter to
obtain the volume of desired residual pulsation. For triplex pump to achieve the desired residual
pulsation of 1.5%, Z = 6.
The dampener volume for residual pulsation 1.5% = 6 x 6.11 = 36.67 liter.
Practically, this is the volume of dampener required for our application. The selection of
presently installed 10 liters of pulsation dampener might have been based on rated maximum
discharge pressure (135.4 kg/cm
2
) for desired residual pulsation of 5%.
The dampener volume at discharge pressure of 135.4 kg/cm
2
for 5% residual pulsation,

The nitrogen pre-charge pressure for this case is P
0
= 0.7 x 128.63 = 90.04 kg/cm
2
.
The dampener volume at discharge pressure 135.4 kg/cm
2
for residual pulsation of 1.5%,

This value can be approximated to the empirical calculation of M/S FOX for 1.5%
residual pulsation (36.67 liter). In both the cases, is calculated by FOX empirical equation.

The operation of recycle control valve widens the range of discharge pressure. If the
discharge pressure comes down to suction pressure of 39.5 kg/cm
2
, the isothermal compression
gives the volume ratio for 1.5% desired residual pulsation,

The dampener volume for discharge pressure variation of 39.5-135.4 kg/cm
2
to achieve
1.5% desired pulsation is 34.41 X 3.53 = 121.47 liters. The nitrogen pre-charge pressure for this
range of discharge pressures P
0
= 0.7 X 38.91 = 27.24 kg/cm
2
.

The suction pulsation dampener size for 39.5 kg/cm
2
will be V
0
= 36.67 liter based on
FOX formula similar to discharge dampener. The size calculated by theoretical formula for
desired residual pulsation of 1.5% will be,

, which is same as the discharge dampener size.

From the above calculations, we can conclude that the installed dampeners are not
adequate both in terms of size i.e. 10 liters and type i.e. nitrogen charged bladder appendage. The
functionality of this type of dampener is a big challenge in terms of maintaining constant pre-
charge pressure. The pulsation dampener will have no effect when the system pressure is below
the pre-charge pressure
10
.

The system response study: Acoustic analysis

It is mandatory to carry out pulsation study of reciprocating pump piping system as per
API 674 Design Approach 3 (DA3) which includes Digital Pulsation Study, Valve Dynamics,

7

and Mechanical Analysis of the Piping System
11
. Pulsation analysis recommends pulsation
control solutions based on the operating conditions, speed range and other operating factors.

The hydraulic pressure disturbances generated in the system are the result of fluid flow
and acceleration. The crank driving mechanism of the pump induces flow rate variation. On the
other hand, acceleration induced pressure disturbances occur when the pump valves open and
close that result in step changes in the fluid velocity, i.e. acceleration. Dynamic pressure
pulsations of plunger pumps interact with the piping system to create acoustical resonances and
excessive vibrations. The pressure pulsations are sent into the system at regular intervals due to
the cyclic nature of plunger pumps accompanied by fluctuating flow. The interaction of the
piping system with the pulsations results in unbalanced forces.

Pump suction and discharge piping systems can have two forms of response to the fluid
dynamics - hydraulic and mechanical resonance. Hydraulic resonance occurs when the pump
driving frequency harmonic matches the hydraulic resonant frequency of the piping system.
Stiffer pipe or piping supports are used to reduce the pipe vibration but the hydraulic forces
affecting the pump and the energy transferred to support structure remain unchanged.
Mechanical resonant frequency is a function of a differential equation solution for the pipe
mechanical properties divided by the pipe free length
12
. The mechanical resonance with piping
system generates high amplitude vibration even if the hydraulic pulsation levels are low. The
measures like piping supports or deck strengthening decouple piping and structural mechanical
resonance. It is ensured that the lowest natural frequency be 20% above first excitation frequency
as per API 674 requirements.

The piping vibration amplitudes in a system are evaluated to determine if the levels are
acceptable. In case of excessive vibration levels, the piping configuration, support structure, span
length or material have to be modified to make the system acceptable. If these factors cannot be
changed, the excitation mechanisms must be altered or eliminated
13
.

The piping vibrations are most often excited by pulsation forces inside the piping or
secondarily, by mechanical excitation from machinery unbalanced forces. The pulsation
amplitudes depend on the amplitude of the pulsation generated and reflected amplitudes of the
frequency components as they interact with the acoustical resonances in the system. Pulsation
amplitudes can be predicted by modeling the acoustic characteristics of the piping, the pulsations
generated by the pump and the interaction of the two.

There must be an energy generating source plus a coupling mechanism to convert
pressure forces into shaking forces for vibration in the piping system. Reducing excitation forces,
eliminating coupling mechanisms, mechanical resonance and pulsation resonance are the
solutions to most piping vibration problems. The most effective measure is to eliminate the
resonances since the amplification factors for both mechanical and pulsation resonances are very
high. A combination of mechanical and pulsation changes are needed to reduce the severity of
the problem to the point where the vibrations are acceptable. Pulsation control is achieved by
judicious use of acoustic filters and side branch accumulators.

8

The piping span natural frequency should not be coincident with excitation frequencies to
avoid mechanical resonance. The vibration frequencies of the piping should be compared with
pulsation frequencies to evaluate potential pulsation excitation of mechanical resonances. A
check of the piping mechanical natural frequencies from the monogram should be made to
evaluate the possibility of a mechanical resonance. High vibrations produced by low-level
pulsations at a particular frequency are indicative of a mechanical resonance The most effective
way to solve a mechanical resonance is to add pipe restraints to shorten the vibration span or
snubbers
3
. Acoustic changes in the piping system can be the most effective way to detune or
reduce the amplitudes of the pulsations. The most effective element that can be conveniently
used in the existing systems is an orifice plate, which is an acoustical resistance element and is
the most effective when located at a pressure pulsation node.

The acoustic analysis of the condensate system was performed using proprietary
acoustical simulation and piping design software by M/s Engineering Dynamics Incorporated.
The proprietary software base facilitates an efficient, state-of the-art technique for evaluation,
analysis and design of piping systems. Piping systems with multiple pumps of virtually any size
and complexity can be modeled by this software. The analysis technique allows simulation of
simultaneous multiple cylinder and stage excitations, including the effect of interaction between
piping characteristics and cylinders.

Pressure forces interact with the piping to produce vibration at force coupling points
e.g., closed ends, elbows, diameter changes. The individual piping spans or components of a
piping system should not be mechanically resonant to system excitation forces. Therefore, all
unnecessary force coupling points are eliminated since they can provide strong coupling points
between pulsation excitation forces and the mechanical system. Large masses such as block or
regulator valves lower the mechanical natural frequency of the piping.

Computer programs for structural analysis are used to calculate the natural frequencies
and mode shapes of three-dimensional piping systems; however, their accuracy is highly
dependent upon the assumptions used to evaluate support stiffness. Simplified tools or design
procedures can be used, with experience, to provide effective designs which will not have
excessive vibration or stresses.

The vibration mitigation measures for condensate system
Modifications in the suction side during commissioning: Intermittent knocking was
observed in all the four pumps during commissioning stage when suction pressures of the pumps
were as high as 99 kg/cm
2
. The main cause of knocking was due to intermittent liquid surges
experienced during operation. Due to surges, gas separation in the surge vessel was not adequate
which resulted in sucking of gas through the condensate to condensate pumps emitting
intermittent knocking sound. The vapor pressure of condensate was almost equal to the
operating pressure of the surge vessel.
The suction header size of condensate pumps was increased from 8 to 10 in 1995 and
then to 16 in 2002. Additional vertical suction vessels as degassers sized 600 mm ID x 2200
mm T/T were installed in 2002. Even if the knocking problem could be resolved, the severity of

9

vibration levels of the piping had been increasing with decrease in condensate surge vessel
pressure.

Condensate pump piping support plan: Based on the signature analysis carried out by
IIPM-India, the system piping supports were re-evaluated. The existing supports were
strengthened and new supports were installed in required locations. The present support
arrangements conform to the recommendations of the Acoustic Analysis done by M/s EDI later.

Structural strengthening plan: The strengthening of BPB cellar deck plate was carried
out by weld-fitting total 30 numbers of 125X65 channels below all four condensate pumps. The
deck vibration could be avoided by altering deck natural frequency of vibration. The detail
drawing for the structural strengthening plan is attached as Appendix-I.

Replacement of non-functional dampeners: The original non-functional dampeners
were replaced with the ones of same size (10 liters) and design specifications (appendage bladder
type accumulators). The original dampeners were having challenges in maintaining pre-charge
pressure due to frequent failure of bladders. The bladder material was incompatible for the
service. The newly installed dampeners are functional and the severity of vibration is reduced
considerably. The problem of non-functionality once the discharge pressure is lowered below the
pre-charge pressure of discharge dampeners persisted.

Acoustic analysis of condensate system: M/s Peroni Pumpe was hired to carry out
acoustic analysis of the condensate pumping system. Accordingly, M/s Engineering Dynamics
Incorporated (EDI) carried out an acoustical design study of condensate pumps. This analysis
documents the simultaneous operation of any two pumps at a constant speed of 181 RPM and
two pumps on stand-by with isolation block valves closed
14
.

The acoustical analysis evaluated the pulsation and unbalanced force levels in the suction
and discharge piping with new dampeners in conjunction with orifices plates. Larger dampener
sizes required to meet the pulsation limits and to control cavitation were also investigated. Even
when pulsation levels are within allowable levels, high vibration and cyclic stress levels can
occur due to resonance. The acoustic analysis for the system was carried out and the
modifications as proposed for the piping supports are being implemented.

Suction System:

The recommended design for all four condensate pumps consists of a 100-gallon all-
liquid dampener installed near the pump inlet. The residual pulsation levels of the piping are
predicted to exceed the 2% (4.6 psi peak-to-peak) pulsation criteria (020 Hz range), but are
calculated to be near or below the API 674 guideline at most test point locations. Although the
force levels have been optimized with this design, residual unbalanced forces are still considered
marginally high for this elevated piping system. To alleviate the residual pulse levels and
unbalanced forces, orifice plates are recommended for this design as listed in the Table 1.

10

Table 1: Pressure Drop Summary With 100 Gallon All-Liquid Dampener

Suction
DESCRIPTION ID PRESSURE DROP (PSI)
Orifice At Pump Inlet (Damp Outlet) 2.25 5.0
Orifice At Line Side (Damp Inlet) 2.25 5.0
Orifice At V-670 Inlet (Line Side) 1.9375 10.0
Total 20.0

Discharge
DESCRIPTION ID PRESSURE DROP (PSI)
Orifice At Pump Outlet (Damp Inlet) 2.25 5.0
Orifices at Line Side (Damp Outlet) 1.625 20.0
Total 25.0

The cavitation calculations were based on a minimum suction pressure of 10.0 kg/cm
2
a
(156.9 psia) and a maximum vapor pressure of 1.0 kg/cm
2
a (28.9 psia). Appendix-II shows that a
margin above the vapor pressure is maintained for the designs presented in columns 1 and 2. The
calculations indicate that cavitation will not occur due to pulsation.

Discharge System:

The recommended design for all four condensate pumps consists of a 100-gallon all-
liquid dampener installed near the pump outlet. Residual pulsation levels slightly exceed the API
674 guideline, but are near or below the 2% (25.9 psi peak-to-peak) pulsation criteria (050 Hz
range) at most test point locations. Although the resulting force levels are the lowest that can be
achieved with the all-liquid dampener without a much larger volume, the forces are considered
somewhat high for this elevated piping system, especially with the unsupported lead lines.
Orifice plates are recommended at the pump outlet flange connection and each dampener (all-
liquid) outlet flange connection. A summary of the orifice plates recommended for this design
are listed in Table 1.

Support System:

The suction and discharge piping systems are supported in accordance with the
recommendations given in Table 2. These supports are designed to restrain a dynamic force of at
least 500 lbf peak-to-peak (near ground) and 250 lbf peak-to-peak (elevated piping) in at least
two directions over a frequency range of 040 Hz.

11

Table 2: Recommended Maximum Pipe Clamp Spacing for 40 Hz Spans

NOMINAL PIPE
DIAMETER (IN)
MAXIMUM CLAMP
SPACING FT (MM)
1.5 5.9 (1,798)
2 6.7 (2,042)
3 8.1 (2,469)
4 9.2 (2,804)
6 11.1 (3,383)
8 12.7 (3,871)
10 14.1 (4,298)

Acknowledgement

We are privileged to express our gratitude to all our colleagues and friends in different
departments for their sincere support. Different agencies including EIL-India, IIPM-India and
Peroni, Italy did commendable job. We would like to express our sincere thanks to IEOT-
ONGC, India for structural solution to the problem. Finally, the study was commendably
executed by BPB Process Complex team with full support, co-operation and guidance from B &
S Asset Management at Base Office, ONGC, Mumbai, India.

Conclusion

The series of studies including system acoustic analysis of the condensate pump piping
system led to following conclusions:

(1) The response of the system to pump dynamics manifested as specific dynamic liquid flow
and pressure conditions are due to system operating conditions and specific piping
arrangements having different natural frequencies of vibration. Both hydraulic and
mechanical resonance should be avoided.

(2) The commercially available accumulators and pulsation filters are effective in controlling
pulsations. They should normally be installed as close as possible to the pump plungers.
All-liquid acoustic filter systems are designed for practically any suction and discharge
system to minimize pulsations. All liquid filter systems are advantageous since they
require practically no maintenance once they are installed.

(3) Adequately sized pulsation dampeners and pulse filters are the answers for condensate
pump vibrations. The proposed 100 gallon sized all liquid dampener for the suction and
discharge of the reciprocating pumps are tested by acoustic simulation study of the
complete pump and piping system. The analysis done with this enlarged sized dampener
along with wave blockers in appropriate locations shows reduction in pressure pulsation
and the pulsation amplitudes were much below the allowable limits.

12

(4) Whenever pulsation levels are sufficiently high to cause the absolute static pressure to
drop below the vapor pressure, cavitation can occur. At high pressure case, the vapor
pressure is nearer to or exactly the condensate surge vessel operating pressure; whereas
the vapor pressure is lower than the operating pressure at low pressure case. At the initial
high pressure operating case, to alleviate high vibration and knocking due to flashing of
condensate at the suction piping, degasser vessels at the individual pump suction lines
were installed. At low pressure operating condition, the calculation plot indicates that
cavitation will not occur due to pulsation.

(5) The discharge piping of the condensate pumps are subjected to variation of discharge
pressure due to recycle control which makes the bladder type accumulators ineffective.
This creates wide range of hydraulic pulsations and getting coupled with the mechanical
resonance of discharge piping leading to high vibration. A suitable recycle control valve
for severe service application of high pressure drop or a compatible choke valve at the
downstream of it are the solutions for it.

(6) The acoustical characteristics of a pump installation are a function of the speed of sound
in the fluid and the acoustical characteristics of the pipe sizes (diameters and lengths) of
all the piping elements. The acoustical natural frequencies and the pulsation amplitudes
of condensate piping system are predicted by modeling the entire system using a
computer program.

(7) The acoustic simulation analysis showed that for this system, the pulsations generated
were primarily a function of the individual suction and discharge piping, the basic pump
design and partially influenced by the interconnecting piping with the other units. The
pulsations are influenced by the piping from other pumps and the location of the pumps
in the system. The effects of the interconnecting piping are studied in the design phase by
the digital acoustical simulation.

(8) All unnecessary strong coupling points between pulsation excitation forces and the
mechanical system should be removed. The removal of different unnecessary small bore
attachments and large masses like valves from the suction degasser vessel lowered the
mechanical natural frequency of the piping system and corresponding failures.

(9) The piping support and deck strengthening measures can take care of residual pulses. The
decoupling of hydraulic and mechanical pulses can be achieved by these measures.
Structural strengthening of the deck could prevent occurring of structural resonance. The
piping supports are proposed with maximum allowable clamp spacing. Otherwise, the
pulsation resonance forces are so high that normal pipe clamps and supports are
ineffective in controlling the vibrations.

References:

1. McCain William D., The properties of petroleum fluids, PennWell Books, 1990.

13

2. Wachel J. C., Szenasi Fred R., Displacement pump performance, instrumentation, and
diagnostics, Section 3.4.
3. Michael W. Volk, Pump Characteristics and Applications, Second Edition, CRC Press,
2005.
4. Tackett Herbert H., Cripe James A., Dyson Gary, Positive displacement reciprocating pump
fundamentals power and direct acting types, Proceedings of 24
th
International Pump Users
Symposium, 2008.
5. Smith Will, Displacement pump flow control Section 3.5.
6. White Rock Engineering Services, 6 Horizon Point Frisco TX 75034-6840, Reciprocating
Pump System Dynamic Analysis, 2009.
7. Wachel J. C., Price S M, Engineering Dynamics Incorporated, San Antonio, Texas,
Understanding how pulsation accumulators work Paper No. 51.
8. FOXSRL, Accumulator Catalogue, 2010.
9. Gimeno Manuel Carcar, Hidracar SA, Some technical and practical recommendations about
pulsation dampers in circuits with dosing pumps, Technical Article, 2000.
10. Howes Brian, Beta Machinery Analysis, Calgary, AB, Canada, T3C 0J7, Observations
about rotating and reciprocating equipment, 2005.
11. American Petroleum Institute, Washington, D.C., Positive Displacement Pumps:
Reciprocating, API Standard 674, 2nd ed., 1995.
12. M/s MATTCO Manufacturing, WR Mattco Reciprocating Pump Pulsation Control
Equipment, Catalogue, Rev 1107.
13. Wachel J. C., Morton Scott J., Atkins Kenneth E., Piping vibration analysis, Proceedings
of 19
th
Turbo machinery Symposium, 1990.
14. Escobedo Gabriel L., Hanes David, Broom M. A., Engineering Dynamics Incorporated,
Acoustical Design Study, 2010.

14

Appendix-I: Structural Strengthening Plan

15

Appendix-II: Acoustic Analysis Report
(Cavitation Evaluation & Pulsation Data)

16

17

About the Authors:

1) Sulgay Satyapal, Deputy General Manager (Production) Oil and Natural Gas Corporation
Limited, India

Sulgay Satyapal is a chemical Engineering graduate from Osmania University,Andhra
Pradesh, India. Later, he did M.Tech from IIT Madras in Chemical Engineering.
He joined ONGC, India in 1983 as Graduate Trainee (Production) and is the Surface
Area Manager of Bassein Field A giant Gas field under Bassein and satellite Asset situated at
ONGC Western Offshore as Deputy General Manager (Production). The job profile includes
managing the Surface operations and maintenance activities of Bassein field including the
process platforms and the wellhead platforms falling under Bassein field.

2) Manjeet Singh katoch , PMP, Chief Engineer (Production)- Oil and Natural Gas
Corporation Limited, India

18

Manjeet Singh katoch, PMP is a Mechanical Engineering graduate from Regional
Engineering College, Warangal, Andhra Pradesh, India. The institute is now an NIT-National
institute of Technology.
He joined ONGC, India in 1989 as Graduate Trainee (Production) and presently posted at
sour gas processing complex BPB under Bassein and satellite Asset situated at ONGC Western
Offshore as process manager. The job profile includes managing the process operations and
maintenance activities of BPB sour gas processing complex and the wellhead platforms falling
under BPB Complex.

3) Indrajit Borah- Executive Engineer (Production) Oil and Natural Gas Corporation
Limited, India

Indrajit Borah is a Mechanical Engineering graduate from Karnataka Regional
Engineering College, Surathkal,India. Later, he acquired MBA from Sikkim Manipal University
via distance mode.
He joined ONGC, India in 2003 as Graduate Trainee (Production) and presently posted at
sour gas processing complex BPB under Bassein and satellite Asset situated at ONGC Western
Offshore as Executive Engineer (Production). The job profile includes operation and
maintenance activities of both wellhead platforms and gas processing complex.

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Vibration Mitigation in Reciprocating Pumping Systems

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MITIGATION OF VIBRATION ISSUES IN RECIPROCATING PUMPING SYSTEM A CASE STUDY

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