Reciprocating Triplex Pumps for J. C. WACHEL, President Member ASME Engineering Dynamics Inc. Problems in Oil Pipelines F. R. SZENASI, Senior Project Engineer Member ASME Engineering Dynamics Inc. San Antonio, Texas S. C. DENISON, Production Engineer Consultant Member AIME/SPE Tenneco Oil Exploration & Production, Inc. Houston, Texas An a na l ys i s was made t o i d e n t i f y t he causes of vi br a t i on and f a i l u r e problems wi t h t he pi pi ng and r e c i pr oc a t i ng pump i n t e r n a l s on an o i l pi pe l i ne pump s t a t i o n . A f i e l d i nve s t i ga t i on was made t o obt a i n vi br a t i ons and pul s a t i ons over t he e n t i r e range of pl a nt oper at i ng condi t i ons . The da t a showed t h a t c a v i t a t i o n was pr es ent a t ne a r l y a l l oper at i ng condi t i ons due t o t he hi gh pul s a t i ons i n t he s uc t i on system. The di s char ge system exper i enced hi gh vi br a t i ons and pi pi ng f a i l u r e s due t o t he i ne f f e c t i ve ne s s of t he accumul at or. An a c o u s t i c a l a na l ys i s of t he s uc t i on and di s char ge system was made t o des i gn t he optimum a c o u s t i c a l f i l t e r syst ems t o a l l e v i a t e t he problems. The a c o u s t i c a l anal ys es were performed wi t h a d i g i t a l computer program which pr e di c t s t he a c o u s t i c a l r esonant f r equenci es and t he pul s a t i on ampl i t udes over t he speed r ange. Thi s paper di s c us s e s t he i nve s t i ga t i ons and gi ves recommendations f o r pr event i on of t hes e t ypes of problems i n t he f ut ur e . INTRODUCTION Problems were exper i enced wi t h f our t r i p l e x r e c i pr oc a t i ng crude o i l pumps oper at i ng i n p a r a l l e l a t t he Dina Pumping St a t i o n l ocat ed i n Colombia ( Fi gur e 1 ) . The pumps had a r a t e d speed of 275 rpm wi t h a c a pa c i t y of 388 ga l l ons per mi nut e. The nominal s uc t i on pr es s ur e was 60 ps i g (414 kPa) and t he di s char ge pr es s ur e was 1800 ps i g (12400 kPa) . The De l r i n pump va l ve s had r epeat ed f a t i g u e f a i l u r e s begi nni ng t h r e e months a f t e r s t a r t u p . The di s char ge val ve di s ks were r epl aced wi t h s t e e l and t he Del r i n di s ks used on t he s uc t i on val ves were r epl aced ever y 90 days t o avoi d f a t i gue f a i l u r e s . Valve f a i l u r e s were c ont r ol l e d a f t e r t he f i r s t 9 months of s t a t i o n oper at i on. For t he f i r s t f our months t he r e were no p u l l rod f a i l u r e s ; however, t he r e have been 18 f a i l u r e s i n t he f ol l owi ng year and a h a l f . Many of t hes e f a i l u r e s r equi r ed repl acement of t he cr osshead, t he guideways, and on two occasi ons a broken o r bent connect i ng r od. The s uc t i on and di s char ge pi pi ng syst ems vi br a t e d exces s i vel y, r e s u l t i n g I n s e ve r a l pi pi ng f a t i g u e f a i l u r e s . At t empt s t o c ont r ol t he pi pi ng v i b r a t i o n s wi t h pi pe clamps and a d d i t i o n a l suppor t s were unsuccessf ul . The f our pumps had a common s uc t i on header suppl i ed by a char ge pump which was capabl e of suppl yi ng pr es s ur es up t o 90 p s i (621 kPa) . The di s char ge of t he f our pumps f ed i n t o a common header which connect ed t o t he main pi pel i ne. The o r i g i n a l pi pi ng des i gn i ncl uded bl adder- type accumul at ors on bot h t he s uc t i on and di s char ge. It was d i f f i c u l t t o keep t he pumps runni ng smoothly s i nc e cons t ant maintenance was needed t o keep t he accumul at or bl adder pr es s ur es charged t o appr oxi mat el y 60 t o 70 per cent of l i n e pr es s ur e. The s t a t i c di s char ge pr es s ur e coul d change from 700 ps i g (4826 kPa) t o more t han 1600 ps i g (11032 kPa) I n a few mi nut es i f t he down-line boos t er s t a t i o n went down. When t h i s happened, t he accumul at or was i n e f f e c t i v e . The c os t of t he p a r t s and l abor t h a t could be a t t r i b u t e d t o t h i s problem was i n excess of $500,000. Tenneco, t he pi pi ng des i gner and t he pump manufact urer began a s t udy t o det ermi ne t he cause o r causes of t he vi br a t i ons and f a i l u r e s . However, t he complex r e l a t i o n s h i p of t he system v a r i a b l e s made i t d i f f i c u l t t o devel op d e f i n i t e concl usi ons. There were s e ve r a l changes made i n t he pi pi ng system dur i ng t h i s phase i n an at t empt t o improve t he vi br a t i ons and reduce t he f a i l u r e s . These i ncl uded changi ng t he pi pi ng ( a t t he recommendation of t he accumul at or vendor) s o t h a t t he fl ow would be di r e c t e d a t t he bl adder . Thi s pi pi ng modi f i cat i on di d not improve t he pul s a t i on c h a r a c t e r i s t i c s of t he sy s tem. Presented at the Energy-Sources and Technology Conference and Exhibition Dallas, Texas - February 17-21, 1985 Another modi f i cat i on which was t r i e d on t he s uc t i on s i d e of pumps 1 and 3 was t he repl acement of t he bl adder-t ype accumul at ors wi t h ni t r ogen- char ged, flow-through accumul at ors ( Fi gur e 1 ) . No not i c e a bl e imurovements were observed a f t e r t he s e changes were implemented. BLADDER PDF\ ACCUMULATOR I I I PUMP CASE I 101 I ( GAS- CHAROEDJ BOTTLE 1 I FIGURE 1. Pump Pi pi ng Layout Showing Pr es s ur e Measurement Locat i ons The s e ve r i t y of t he problems brought t he ba s i c des i gn of t he syst em i n t o que s t i on s i nc e t he s uc t i on and di s char ge l ead l i n e s from t he header s t o t he pump mani fol d were s hor t e r t han normal f o r most pi pe l i ne s t a t i o n s . The pumps were l ocat ed on 16 f oot (4.88 m) c e nt e r s wi t h t he s uc t i on and di s char ge header s l ocat ed 10 t o 12 f e e t (3.05 t o 3.66 m) away from t he pump f l anges . The s t a t i o n capaci t y was 39900 b a r r e l s per day (264 m 3 / h) when t he pumps were a t t h e i r r a t e d capaci t y of 388 ga l l ons per mi nut e (88 m3/h). Thi s r e s u l t s i n a f l u i d ve l oc i t y of 3.3 f t / s ( 1 m/s) i n t he 12 i nch schedul e 40 s uc t i on mani fol d and 6.9 f t / s (2. 1 m/s) i n t he 10 i nch schedul e XS di s char ge mani f ol d. The fl ow v e l o c i t i e s i n t he i ndi vi dua l pump pi pi ng were 1.1 f t / s (0.34 m/s) i n t he 12 i nch s t andar d wei ght s uc t i on pi pe and 2.7 f t / s (0.82 m/s) i n t he 8 i nch e x t r a heavy di s char ge pi pe. Engi neeri ng Dynamics I ncor por at ed (EDI) was r equest ed t o i n v e s t i g a t e and make recommendations t o a l l e v i a t e t he problems. The f i r s t s t e p i n t he a na l ys i s was t o model t he a c o u s t i c a l c h a r a c t e r i s t i c s of t he pi pi ng syst ems on a d i g i t a l computer program t o de f i ne t he expect ed pul s a t i on r esonances and t he o v e r a l l ampl i t udes i n t he s uc t i on and di s char ge pi pi ng. A d e t a i l e d f i e l d i n v e s t i g a t i o n was t hen made t o e va l ua t e t he pul s a t i on and vi br a t i on c h a r a c t e r i s t i c s of t he pumps. Sol ut i ons were t hen developed t o e l i mi na t e t he problems. FIELD INVESTIGATION I ns t r ument at i on And Te s t Pr ocedur es The i ns t r ument at i on and da t a a c q u i s i t i o n system used t o det ermi ne t he pul s a t i on and v i b r a t i o n c h a r a c t e r i s t i c s a r e shown i n Fi gur e 2. Pi e z o e l e c t r i c pr es s ur e t r ans ducer s and accel er omet er s were used t o measure t he pr es s ur e pul s a t i ons and t he vi br a t i ons . A s ket ch of t he pump s uc t i on and di s char ge pi pi ng i l l u s t r a t i n g some of t he pr es s ur e t e s t poi nt s a r e shown i n Fi gur e 1. The pul s a t i on and v i b r a t i o n s i g n a l s were anal yzed f or frequency cont ent wi t h a two channel Hewlett-Packard 3582A FFT anal yzer and documented on a HP 74708 d i g i t a l p l o t t e r . The anal yzer and i nst r ument s were c ont r ol l e d by an Apple 11+ microcomputer usi ng sof t war e wr i t t e n s p e c i a l l y f or anal yzi ng vi br a t i on and pul s a t i on d a t a . Tor s i onal vi br a t i ons were measured wi t h a HBM t or s i ogr aph mounted on t he s t ub end of t he pi ni on gear s h a f t on pump 1. ITEM DESCRIPTION 2 Channel FFT Analyzer ~icro-Computer Floppy Disk Drive Di gi t al Pl ot t er Tuneable Fi l t e r s 2 Channel Osci l l oscope Transducer Signal Conditioner and Power Supply 8 Channel FH Tape Recorder Function Generator Strai n Gage Amplifier and Frequency Demodulator FIGURE 2. Data Acqui s i t i on System Vi br a t i on And Pu l s a t i o n Te s t i ng The i n i t i a l v i b r a t i o n sur veys r eveal ed hi gh v i b r a t i o n ampl i t udes on t he pi pi ng, i ndi c a t i ng l a r ge e x c i t a t i o n f or ces pr es ent i n t he pi pi ng syst ems. Anal ysi s of t he pr es s ur e pul s a t i on waveforms r eveal ed s ever e c a v i t a t i o n i n t he s uc t i on pi pi ng syst em. Thi s c a v i t a t i o n was t he sour ce of t he hi gh energy causi ng t he hi gh pi pi ng v i b r a t i o n s , val ve f a i l u r e s , and pump p a r t f a i l u r e s . Cavi t at i on. For l i qui d r e c i pr oc a t i ng pumps, t he s t a t i c pr es s ur e i n t he s uc t i on system must be adequat e t o compensate f or f r i c t i o n a l pr es s ur e drop l os s e s , t he r equi r ed a c c e l e r a t i on head, and t he pul s a t i ons pr es ent i n t he system. Thi s ens ur es t h a t t he pr es s ur e remains above t he vapor pr es s ur e. The vapor pr es s ur e of t he o i l was l e s s t han 2 p s i a (13. 8 kPa). When pul s a t i ons e x i s t i n a syst em, t hey wi l l c o n s i s t of a p o s i t i v e peak of pr es s ur e which w i l l be added t o t he s t a t i c pr es s ur e and a negat i ve peak which w i l l be s ubs t r a c t e d from t he s t a t i c pr es s ur e. I f t he negat i ve peak of t he pul s a t i on, when s ubt r a c t e d from t he s t a t i c pr es s ur e, r eaches t he vapor pr es s ur e, t he f l u i d w i l l c a v i t a t e , r e s u l t i n g i n hi gh pr es s ur e s pi ke s a s t he l i q u i d vapor i zes and t hen c ol l a ps e s a s t he pr es s ur e i nc r e a s e s above t he vapor pr es s ur e. To i l l u s t r a t e t he e f f e c t s of c a v i t a t i o n , cons i der t he pl unger pr essur e- t i me wave shown i n Fi gur e 3 which shows t h a t c a v i t a t i o n occur s on t he s uc t i on s t r oke . Note t h a t when t he c a v i t a t i o n por t i on of t he waveform i s expanded, t he pr e s s ur e s pi kes a r e approxi mat el y 800 p s i (5516 kPa) wi t h a t i me per i od of appr oxi mat el y 0.00025 seconds. The pr esence of c a v i t a t i o n can us ua l l y be observed on t he complex wave s i nc e pul s a t i ons , which a r e ge ne r a l l y sine-shaped waves, w i l l "square-off" a t t he t r ough of t he waves when t he vapor pr e s s ur e i s reached. The t ype of d a t a t o s u b s t a n t i a t e c a v i t a t i o n ( Fi gur e 4 ) i l l u s t r a t e s t he squari ng-off of t he wave, fol l owed by t he s har p s pi ki ng c h a r a c t e r i s t i c of sever e c a v i t a t i o n . Thi s da t a , t aken on pump u n i t 1, showed pr es s ur e s pi ke s of 600 p s i (4137 kPa) . FIGURE 3. Pump Pl unger Pressure-Time Wave Showing Cavi t at i on EMINEERING DYNAMICS INCORPORATED FIGURE 4 . Ca vi t a t i on Caused By High Pul s at i ons The e f f e c t of t he s t a t i c pr es s ur e on t he c a v i t a t i o n was i nve s t i ga t e d by r a i s i n g t he s uc t i on pr es s ur e t o t he maximum pos s i bl e (90 psi g/ 621 kPa). The i ncr eas e i n s uc t i on pr es s ur e al one was not s u f f i c i e n t t o e l i mi na t e t he c a v i t a t i o n . Severe pul s a t i ons were found wi t h l e v e l s i n excess of 200 p s i peak-to-peak (1379 kPa) . A t a s uc t i on pr es s ur e of 76.5 p s i a (527 kPa) , pul s at i ons of approxi mat el y 75 p s i (517 kPa) zero-peak a r e r equi r ed t o cause c a v i t a t i o n . Thi s val ue i s obt ai ned by s ubt r a c t i ng t he negat i ve ~ u l s a t i o n peak from t he s t a t i c pr es s ur e. Si nce pul s a t i ons g r e a t e r t han 75 p s i (517 kPa) were always pr es ent a t t he hi gher speeds, c a v i t a t i o n always occur r ed. I n t he pr esence of c a v i t a t i o n , i t i s p r a c t i c a l l y i mpossi bl e t o e va l ua t e t he i nf l uence of va r i a bl e s , such a s t he e f f e c t of ot he r u n i t s , speeds and t he accumul at or desi gn. Obviously, a r educt i on of t he pr es s ur e pul s a t i ons was necessar y i n or der t o obt ai n meani ngful t e s t d a t a on t he u n i t s . Acous t i cal Resonances. The major s uc t i on pul s a t i on components were a t f r equenci es near 110 t o 150 Hz wi t h pul s a t i on ampl i t udes of approxi mat el y 100 - 150 p s i (689 - 1034 kPa) peak-to-peak, which, when combined wi t h t he pul s a t i on a t t he lower pump harmoni cs, caused t he o v e r a l l s t a t i c pr es s ur e t o dr op below t he vapor pr essur e. I t was det ermi ned t h a t a c o u s t i c a l resonances were causi ng t he hi gh ampl i t ude pul s a t i ons . Acous t i cal resonances amplify t he pul s a t i ons whenever one of t he harmonics of t he pump speed passes t hrough t he r es onant frequency. The a c o u s t i c a l resonance a t 130 Hz was a quarter-wave resonance of t he s uc t i on pi pe and was a s s oc i a t e d wi t h t he 9 f oot (2.74 m) l engt h from t he end of t he s uc t i on mani fol d t o t he accumul at or. When an a c o u s t i c a l resonance i s encount ered i n a syst em, t he pr es s ur e pul s at i ons can be reduced by e l i mi na t i ng t he resonance or by a t t e nua t i ng t he ampl i t udes t hrough t he a ddi t i on of a r e s i s t i v e el ement , such a s an o r i f i c e . Ther ef or e, an o r i f i c e p l a t e was i n s t a l l e d a t t he s uc t i on f l ange i n an at t empt t o a t t e nua t e t he pul s a t i on ampl i t udes and pos s i bl y move t he a c ous t i c a l n a t u r a l frequency. A di amet er r a t i o ( o r i f i c e di amet er t o i ns i de di amet er of pi pe) of approxi mat el y 0.4 was used t o ensur e a s i g n i f i c a n t a c o u s t i c a l e f f e c t . When t he o r i f i c e p l a t e was i n s t a l l e d , t he pul s a t i ons were reduced; however, t he r educt i on was not s u f f i c i e n t t o compl et el y e l i mi na t e t he c a v i t a t i o n . I n t e r a c t i o n With Ot her Pumps. Al l t he ot he r pumps were s hut down and pump 1 was r un t o det ermi ne i f t he c a v i t a t i o n was caused by i n t e r a c t i o n wi t h t he ot he r pumps o r was a f unct i on of t he i ndi vi dua l pi pi ng desi gn. These t e s t s i ndi cat ed t h a t t he pul s at i ons were caused by t he i ndi vi dua l pumps and t h a t t he major f a c t o r was t he a c o u s t i c a l resonances near 130 Hz. Thi s t e s t a l s o gave evi dence t h a t t he l oc a t i on of t he pump i n t he mani fol d system was not a major f a c t o r i n t he c a v i t a t i o n . Thi s i s v e r i f i e d by t he f a c t t h a t c a v i t a t i o n occur r ed on u n i t s 1 and 3 a t t he exact same speed under t he same oper at i ng condi t i ons . Uni t s 1 and 3 a r e s epar at ed by 32 f e e t (9.75 m) wi t h u n i t 2 midway between them. I f t he l oc a t i on of t he pump i n t he header was a prime f a c t o r , t he r e would have been d i f f e r e n t pul s a t i on and c a v i t a t i o n c h a r a c t e r i s t i c s . To f u r t h e r i n v e s t i g a t e t he i n t e r a c t i o n of t he ot he r pumps, t e s t s were made wi t h pump 1 on t he ver ge of c a v i t a t i o n and t he adj acent u n i t 2 was swept t hrough t he e n t i r e speed range t o det ermi ne i f it a f f e c t e d t he speed a t which c a v i t a t i o n occur r ed. Thi s t e s t showed t h a t t he adj acent u n i t di d not i nf l uence t he c a v i t a t i o n . I n an at t empt t o det ermi ne whether t he a c o u s t i c a l resonance was a s s oc i a t e d wi t h a pi pi ng l engt h from t he ot he r u n i t s , t he s uc t i on bl ock val ve was pinched momentarily t o s ee i f a pr es s ur e dr op t aken on t he upstream s i d e of t he accumul at or would a f f e c t t he resonances i n t he 130 Hz r ange. The pr e s s ur e drop of approxi mat el y 10 p s i i n t he bl ock val ve d i d not have a s i g n i f i c a n t e f f e c t . Fi n a l Tes t i ng. Af t er t he o r i f i c e p l a t e was i n s t a l l e d and t he ni t rogen-charged accumul at or b o t t l e on t he s uc t i on system had t he maximum gas char ge, t he c a v i t a t i o n was el i mi nat ed over much of t he speed range making it ~ o s s i b l e t o s t udy t he e f f e c t of var yi ng system par amet er s. The normal procedure f or t he t e s t i n g was t o e s t a b l i s h a s e t of s t eady- s t at e condi t i ons , ( such a s s uc t i on pr e s s ur e , gas volume i n t he b o t t l e , o r char ge pr e s s ur e i n t he bl adder accumul at or, speeds on t he ot he r pumps, e t c . ) and t hen change t he pump speed from 190 rpm t o 290 rpm. During t he speed r un, t he pul s a t i ons i n t he s uc t i on and di s char ge pi pi ng were t ape recorded f or l a t e r eval uat i on. The r e s u l t i n g d a t a pr e s e nt a t i on f or t he speed v a r i a t i o n i s gi ven i n Fi gur e 5, showing t he harmonics of pump speed pul s a t i on pr es s ur es i n t he s uc t i on mani fol d of pump 3 over t he speed range. The d a t a shows t h a t t he primary cause of t he c a v i t a t i o n was t he hi gh l e ve l pul s a t i ons a t t he a c o u s t i c a l n a t u r a l f r equenci es i n t he system near 130 and 140 Hz which were e xc i t e d by t he 21s t t hrough t he 30t h harmonics of pump speed. ENQlNEERlNO OVNUAlC.5 INCORPORATED FIGURE 5. Speed Rast er Of Pump Suct i on Pul s a t i ons Speed Ef f e c t s . The e f f e c t of speed on - c a v i t a t i o n can be seen i n Fi gur e 6 which gi ve s t he complex pr es s ur e wave f or speeds from 220 t o 270 rpm f or a s uc t i on pr es s ur e of 60 ps i g (414 kPa) . Pul s a t i ons ge ne r a l l y i ncr eas e wi t h speed unl es s t he r e a r e a c o u s t i c a l r esonances. As shown, when t he speed i ncr eas ed above 250 rpm, t he pul s a t i ons i ncr eas ed t o t he poi nt t h a t t he ne ga t i ve pr es s ur e pul s a t i on ampl i t ude was near t he vapor pr es s ur e and t he wave became f l a t t e n e d on t he t rough. As t he speed was f u r t h e r i ncr eas ed, t he c a v i t a t i o n became more s ever e. FIGURE 6. Complex Wave Of Pr es s ur e Pul s at i on Versus Speed For Suct i on Pr essur e Of 60 Ps i g S t a t i c Pr e s s ur e Ef f e c t s . When t he s t a t i c s uc t i on pr es s ur e was i ncr eased t o 90 ps i g, t he pul s a t i on ampl i t udes were reduced and t he u n i t coul d be r un a t 280 rpm wi t hout c a v i t a t i o n ( Fi gur e 7). The hi gher s uc t i on pr es s ur e seemed t o i n h i b i t t he ampl i t ude of t he pul s a t i ons . The r e s u l t s of t hes e t e s t s i ndi cat ed t h a t t he c a v i t a t i o n coul d be minimized by i nc r e a s i ng t he s uc t i on pr es s ur e t o t he maximum pos s i bl e , i n s t a l l i n g an o r i f i c e p l a t e t o reduce t he pul s a t i on ampl i t udes, and ens ur i ng t h a t t he accumul at or was pr oper l y charged. FIGURE 7. Complex Wave Of Pr es s ur e Pul s at i on Versus Speed For Suct i on Pr es s ur e Of 90 Ps i g The e f f e c t i ve ne s s of t he gas-charged flow-through accumulator was s t r ongl y i nf l uenced by t he volume of t he ni t r oge n gas i n t he accumul at or b o t t l e , Fi gur e 8. The i ncr eas ed gas char ge volume el i mi nat ed pul s a t i on components of 46 p s i a t 12 Hz and 22 p s i a t 65 Hz. FIGURE 8. Ef f e c t Of I ncr eased Gas Volume I n Suct i on Accumulator Di schar ge Pul s a t i ons . The measured f i e l d da t a showed hi gh a m~ l i t u d e pul s a t i ons i n t he - di s char ge pi pi ng wi t h l e v e l s exceedi ng 1000 p s i (6895 kPa) peak-to-peak i n some t e s t s ( Fi gur e 9). An i n v e s t i g a t i o n was made t o det er mi ne i f t he di s char ge pul s a t i ons were a f f e c t e d by t h e c a v i t a t i o n on t he s uc t i on s i d e . The complex pr es s ur e wave a t t he s uc t i on and di s char ge val ves were capt ur ed si mul t aneousl y dur i ng t he t i me t h a t s ever e c a v i t a t i o n was pr e s e nt and showed t h a t t he di s char ge s i d e was i s o l a t e d from t he s uc t i on s i d e . The pul s a t i on ampl i t udes were ver y hi gh; however, t hey were not caused by t he c a v i t a t i o n on t he s uct i on. The pul s a t i ons were a f unct i on of t he ener gy out put from t he pl unger s and were s t r ongl y i nf l uenced by t he val ve r i ngi ng and t he a c o u s t i c a l r esonances a s d i c t a t e d by t he a c o u s t i c a l p r o p e r t i e s of t he bl adder-t ype accumul at or and t he pi pi ng system. Whenever t he s t a t i o n di s char ge pr es s ur e dropped below t he char ge pr es s ur e i n t he bl adder of t he di s char ge accumul at or, a not i c e a bl e i nc r e a s e i n t he pul s a t i ons occur r ed. FIGURE 9. Complex Wave Of Di scharge ~ulsatione ACOUSTIC SIMULATION The r a pi d advances of d i g i t a l computers has made i t more p r a c t i c a l t o anal yze t he a c ous t i c a l c h a r a c t e r i s t i c s ( pul s a t i ons ) of pi pi ng s ys tems d i g i t a l l y . A comprehensive computer program has been wr i t t e n by ED1 t o pr e di c t t he a c ous t i c a l a t t e nua t i on c h a r a c t e r i s t i c s , pass bands, and pul s a t i on l e v e l s f o r pi pi ng syst ems wi t h l i qui d pumps or gas compressors. The program can be used t o des i gn pul s a t i on f i l t e r s o r t o e va l ua t e t he e f f e c t i ve ne s s of syst ems wi t h l i qui df ga s accumul at ors. The program i s based on c l a s s i c a l f l u i d mechanics t heor y ( Navier-Stokes equat i on, t he c ont i nui t y equat i on, and t he thermodynamic equat i on of s t a t e ) . The assumpt i on is made t h a t plane-wave pr opogat i on w i l l adequat el y s i mul at e t he motion of pr es s ur e di s t ur bances and t he a c ous t i c r esponse of t y p i c a l pi pi ng syst ems found i n most i n d u s t r i a l p l a n t s . The c l a s s i c a l equat i ons of f l u i d mechanics a r e combined wi t h t he pi pe el ement geometry t o de f i ne t he response of t he pi pi ng system t o dynamic v a r i a t i o n s i n t he pr es s ur e and flow. The e f f e c t s of mean fl ow on damping ( pr e s s ur e drop, r e s i s t a n c e , e t c ) a r e i ncl uded i n t he a na l ys i s . The program i s wr i t t e n i n a ge ne r a l manner s o t h a t any pi pi ng system can be si mul at ed by combi nat i ons of d i s t r i b u t e d o r lumped el ement s . I n l i q u i d pump syst ems, t he pr es s ur e pul s es gener at ed by t he pl unger can be q u i t e complex. Because of t he i ncompr essi bl e medium, t he f l ow r a t e i s a f unct i on of pi s t on ve l oc i t y, which i s not s i nus oi da l because of a f i n i t e cr ankl r od r a t i o . Geomet ri cal l y-caused d i s t o r t i o n s produce hi gher harmonics which must be i ncl uded i n t he f or ced pul s a t i on a na l ys i s . The computer program gener at es t he pl unger pr essur e- t i me wave and us es i t t o e x c i t e t he pi pi ng system. The f i e l d t e s t s i d e n t i f i e d an a c ous t i c resonance a s t he cause of t he problem. Ther ef or e, t he s ol ut i on was t o move t he a c o u s t i c a l resonances away from t he s t r ong pump harmonics. The ED1 d i g i t a l a c o u s t i c a l program was used t o s i mul at e t he pi pi ng system and t o devel op t he s ol ut i on. The pi pi ng geometry and t he l i q u i d t hermophysi cal p r o p e r t i e s de f i ne t he a c ous t i c n a t u r a l f r equenci es of t he s uc t i on and di s char ge pi pi ng systems. The r e s u l t s of t he computer a na l ys i s of t he o r i g i n a l s uc t i on pi pi ng system wi t h t he gas-charged f i l t e r a r e gi ven i n Fi gur e 10. The d a t a pr e s e nt s t he pr edi ct ed pul s a t i ons a t each harmonic of pump speed from minimum t o maximum speed. The harmonic numbers a r e i ndi cat ed adj acent t o t he appr opr i at e curve. The i n t e r a c t i o n of t he i ndi vi dua l harmonics wi t h t he a c ous t i c r esonant f r equenci es a t 130 and 140 Hz can be seen. Thi s da t a can be compared t o t he measured pul s a t i ons gi ven i n Fi gur e 5. Gener al l y, t he r e was good agreement wi t h t he a c ous t i c a l r esonances a t 130 and 140 Hz; however, t he c a l c ul a t e d ampl i t udes were lower. It must be remembered i n t he assessment of t he f i e l d d a t a t h a t c a v i t a t i o n was s t i l l occur r i ng and t he ampl i t udes measured would be expect ed t o be hi gher t han c a l c ul a t e d f o r t h e s t eady s t a t e oper at i ng condi t i ons . Note t h a t t he lower or der harmonics, 3X, 6X, 9X, 12X, e t c . a r e c l o s e t o t he c a l c ul a t e d val ues . FIGURE 10. Pul s a t i ons Pr edi ct ed I n Exi s t i ng Suct i on Pi pi ng System Whlle i n t he f i e l d , an o r i f i c e p l a t e was i n s t a l l e d i n t he s uc t i on f l ange and was s uc c e s s f ul i n r educi ng t he pul s a t i ons and c a v i t a t i o n ( Fi gur e 11) . The f i e l d d a t a i n d i c a t e s t h a t t he pul s a t i ons were reduced and a s l i g h t s h i f t down i n t he f r equency of t he major r esponses i s not ed. Thi s was anal yzed on t he computer and t he r e s u l t s a r e gi ven i n Fi gur e 12. The major r esponse was lowered t o 120 Hz and some r educt i on i n t he o v e r a l l peak-peak ampl i t udes was pr edi ct ed. FIGURE 11. Speed Rast er Of Pump Suct i on Pul s a t i ons With Or i f i c e Pl a t e And Maximum Gas Volume I n Suct i on Accumulator FIGURE 12. Pul s a t i ons Pr edi ct ed In Suct i on Pi pi ng With Or i f i c e Pl a t e I n s t a l l e d I n t he development of t he s ol ut i on, t he anal yses showed t h a t a gas-charged, flow-through l i q u i d accumul at or l ocat ed a t t he pump f l ange i ns t e a d of two f e e t away, would have r e s ul t e d i n lower pul s a t i ons a s p l o t t e d i n Fi gur e 13. The ampl i t udes a t t he r esonant f r equenci es were reduced a s we l l a s t he lower pump harmonics. FIGURE 13. Pul s a t i ons Pr edi ct ed In Suct i on Pi pi ng With Gas-Charged, Flow-Through Accumulator A t Suct i on Fl ange The pul s a t i on c h a r a c t e r i s t i c s of t he di s char ge pi pi ng system were anal yzed and i ndi c a t e d t h a t t he bl adder-t ype accumul at or was not e f f e c t i v e dur i ng some of t he s t a t i o n oper at i ng condi t i ons . For example, t he di s char ge pr es s ur e would sometimes f a l l t o 700 p s i (4826 kPa) from t he normal 1600 ps i g (11032 kPa). When t h i s happens, t he bl adder becomes f u l l y expanded, bl ocki ng of f t he ent r ance of t he accumul at or and voi di ng t he b e n e f i c i a l e f f e c t s of t he gas volume. Al so, t he hi gh l e v e l pul s a t i ons caused bl adder f a i l u r e s which t hen el i mi nat ed t he gas cushi on on t he back s i d e of t he bl adder . The e f f e c t i v e volume of t he accumul at or was reduced s i g n i f i c a n t l y . These e f f e c t s were anal yzed wi t h t he d i g i t a l computer program. Fi gur e 14 compares t he pr edi ct ed pul s a t i on f o r t he normal condi t i ons and t he cas e wi t h low di s char ge pr es s ur e. It can be seen t h a t t he pul s a t i on ampl i t udes a t t he lower harmonics s i g n i f i c a n t l y i ncr eas ed when t he gas cushi on was el i mi nat ed. FIGURE 14. Pr edi ct ed Di scharge Pul s at i ons For Normal Oper at i on (------ ) And Low Di scharge Pr es s ur e ( - 1 With Bl adder Type Accumulator And For Proposed Al l -Li qui d F i l t e r ( . . . . . .) An a l l - l i q u i d a c ous t i c f i l t e r des i gn was anal yzed f or t he di s char ge system which shoul d s i g n i f i c a n t l y lower t he pul s a t i on energy a s i ndi cat ed i n Fi gur e 14. An a l l - l i q u i d pul s a t i on f i l t e r syst em c o n s i s t s of a volume-choke-volume or a volume-choke pi pi ng arrangement which i s s p e c i a l l y desi gned t o a t t e nua t e t he pul s a t i ons above s pe c i f i e d f r equenci es . The a l l - l i q u i d f i l t e r desi gn f or di s char ge and s uc t i on syst ems is based on t he al l owabl e pr es s ur e drop i n t he choke t ube and t he Helmholtz frequency. CONCLUSIONS The r e s u l t s of t he f i e l d t e s t s and t he a c ous t i c a l anal yses l ed t o t hes e concl us i ons : Suct i on System 1. Whenever pul s a t i on l e v e l s a r e s u f f i c i e n t l y hi gh t o cause t he abs ol ut e s t a t i c pr es s ur e t o drop below t he vapor pr es s ur e, c a v i t a t i o n can occur . Thi s c r e a t e s l a r g e f or ces which can cause such problems a s f a t i gue of t he val ves , cr ossheads, r ods, and ot he r r o t a t i n g or r e c i pr oc a t i ng p a r t s of pumps. 2. Ca vi t a t i on causes shock t ype pul s es t o be t r ans mi t t ed t hrough t he s uc t i on pi pi ng. These can e x c i t e a c o u s t i c a l resonances and cause hi gh pi pi ng vi br a t i on a t t he mechani cal n a t u r a l f r equenci es of t he pi pi ng spans, pi pi ng wa l l ( s h e l l r esonances) , and pi pi ng appendages, such a s vent s , d r a i n s , gage l i n e s , e t c . The f or c e s can be s o hi gh t h a t normal pi pe clamps and s uppor t s may be i n e f f e c t i v e i n c o n t r o l l i n g t he vi br a t i ons . 3. The gener at ed pul s at i ons i n t he s uc t i on pi pi ng a r e a s t r ong f unct i on of t he t ype and l oc a t i on of t he pul s a t i on f i l t e r . For t h i s pi pi ng system, t he gas-charged, flow-through accumul at or was more e f f e c t i v e t han t he bl adder-t ype accumul at or i n a t t e nua t i ng t he pul s a t i ons . Di schar ge System 4. The pul s a t i ons i n t he di s char ge pi pi ng were exces s i ve, p a r t l y due t o t he changi ng s t e a dy s t a t e condi t i ons which made t he bl adder-t ype accumul at or i n e f f e c t i v e f or many of t he oper at i ng condi t i ons . An a l l - l i q u i d a c ous t i c f i l t e r was desi gned f o r a l l oper at i ng condi t i ons t o minimize t he pul s a t i ons and pi pi ng vi br a t i ons i n t he di s char ge pi pi ng. Li qui d Pumps 5. Many v i b r a t i o n and f a i l u r e problems i n r e c i pr oc a t i ng pumps i n o i l pi pe l i ne a ppl i c a t i on a r e caused by system r e l a t e d a c o u s t i c a l r esonances which cause hi gh l e v e l pul s a t i ons i n t he s uc t i on and di s char ge pi pi ng. 5. The a c o u s t i c a l c h a r a c t e r i s t i c s of a pump i n s t a l l a t i o n a r e a f unct i on of t he speed of sound i n t he f l u i d and t he a c o u s t i c a l c h a r a c t e r i s t i c s of t he pi pe s i z e s ( di amet er s and l engt hs ) of a l l t he pi pi ng el ement s i n t he l i n e from t he pl unger val ves t o t he suppl y header and beyond. 7. The a c ous t i c a l n a t u r a l f r equenci es and t he pul s a t i on ampl i t udes t ha t w i l l occur i n any gi ven pi pi ng system can be pr edi ct ed by modeling t he e n t i r e syst em us i ng a computer program which i ncl udes a l l t he i mport ant va r i a bl e s . 8. When t he pi pi ng syst ems di s cus s ed i n t h i s paper were si mul at ed us i ng t he d i g i t a l program, t he a c o u s t i c a l resonances and t he pr edi ct ed pul s a t i on ampl i t udes were i n agreement. 9. Commercially a va i l a bl e accumul at ors and pul s a t i on f i l t e r s can be q u i t e e f f e c t i v e i n c o n t r o l l i n g pul s a t i ons ; however, t hey shoul d normal l y be i n s t a l l e d as c l os e a s pos s i bl e t o t he pump pl unger s. Spe c i f i c accumul at ors can be modeled usi ng t he d i g i t a l computer program and t h e i r performance s t udi e d under proposed oper at i ng condi t i ons . 10. Al l - l i qui d a c ous t i c f i l t e r syst ems can be desi gned f or p r a c t i c a l l y any s uc t i on and di s char ge system t o minimize pul s a t i ons . Al l - l i qui d f i l t e r sy s tems a r e advantageous f or some i n s t a l l a t i ons s i nce t hey r e qui r e p r a c t i c a l l y no maintenance once t hey a r e i n s t a l l e d . 11. The f i n a l recommended s o l u t i o n f o r t h i s o i l pumping s t a t i o n was t o move t he gas-charged, flow-through accumul at or t o t he s uc t i on f l ange and t o i n s t a l l an a l l - l i q u i d f i l t e r i n t he di s char ge system a t t he pump f l ange. These recommendations a r e bei ng implemented and t he u n i t s w i l l be t e s t e d a f t e r t he i n s t a l l a t i o n . Fi e l d Te s t i n g 12. The t e s t i n g showed t h a t , f o r t h i s syst em, t he pul s at i ons gener at ed were pr i mar i l y a f unc t i on of t he i ndi vi dua l s uc t i on and di s char ge pi pi ng and t he ba s i c pump des i gn and not s t r ongl y i nf l uenced by t he i nt er connect i ng pi pi ng wi t h t he ot he r u n i t s . Other syst ems t e s t e d have shown t h a t t he pul s a t i ons can be i nf l uenced by t he pi pi ng from o t h e r pumps and t he l oc a t i on of t he pumps i n t he syst em. The e f f e c t s of t he i nt er connect i ng pi pi ng can be s t udi e d i n t he desi gn phase by t he d i g i t a l a c o u s t i c a l s i mul at i on. 13. Tes t i ng r eveal ed t h a t an i ncr eas ed s t a t i c pr es s ur e l e v e l lowered t he l e v e l of t he pul s a t i ons i n t he pump mani fol d and i nhi bi t e d t he c a v i t a t i o n . The t e s t i n g a l s o showed t h a t t he pul s a t i on l e v e l s i ncr eas ed wi t h speed. 14. When pul s a t i on and v i b r a t i o n problems occur i n a r e c i pr oc a t i ng pump i n s t a l l a t i o n , f i e l d d a t a can be obt ai ned t o de f i ne t he ba s i c cause us i ng f i e l d measurement t echni ques a s des cr i bed i n t h i s paper. REFERENCES 1. Hi cks, E. J . and Gr ant , T. R., "Acoust i c F i l t e r Cont r ol s Recip Pump Pul s at i on, ' ' The O i l and Gas J our na l , Januar y 15, 1979, pp 67-73. 2. Ludwig, M., "Design of Pul s a t i on Dampeners f or High Speed Reci pr ocat i ng Pumps," Di vi s i on of Tr ans por t at i on, American Pet rol eum I n s t i t u t e Vol 36 [V] 1956, pp 47-54. 3. Spar ks, C. R. and Wachel, J. C., "Pul s at i ons i n Ce nt r i f uga l Pumps and Pi pi ng Systems," Hydrocarbon Pr oces s i ng J u l y 1977, pp 183-189. 4. Wachel, J. C. and Szenasi , F. R., "Vi br at i on and Noise i n Pumps," Pump Handbook, 1 s t Edi t i on, McGraw-Hill, 1976, pp 9-87 t o 9-97. 5. Mi l l e r , J . E., "Liquid Dynamics of Reci pr ocat i ng Pumps - Pa r t s 1 and 2, " The O i l and Gas J our na l , Apr i l 18, 1983. Thi s paper recei ved t he Eugene W . Jacobson Award on February 26, 1986, f o r t he most or i gi na l , t i mel y and out st andi ng t echni cal paper present ed a t t he Energy-Sources Technology Conference & Exhi bi t i on, Dal l as, Texas, February, 1985.