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AG EQUIPMENT CO.
BROKEN ARROW, OK
JUNE, 2001
ECSI JOB #201-1050
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SUBMITTED TO:
AG EQUIPMENT
BROKEN ARROW, OK
JUNE, 2001
INTRODUCTION
Engineering and Consulting Services, Inc. recently performed an acoustical analysis on
an Ariel JGE/4 compressor, driven by a Waukesha L5790GL engine. This unit was packaged by
AG Equipment Company, Broken Arrow, OK for Petrofac, LLC, Tyler, TX.
Included in this acoustic analysis were on-skid suction, interstage, and discharge piping
with scrubbers, intercooler and aftercooler. General arrangement piping plans and elevations,
scrubber, bottle and cooler details, as well as compressor information including performance
analyses were provided by AG Equipment Company. AG predetermined the pulsation bottle and
scrubber sizes; these were not modified unless it was determined to be critical to the analysis.
API 618, Section 3.9 -Reciprocating Compressor Code was utilized for acceptance
criteria. Design approach 2 was considered for all systems.
ANALYSIS
The computer program, Gas Compressor Pulsation Analysis , used in this study
utilizes classical fluid theory and considers both steady and dynamic (acoustic) flow in the
pulsation analysis calculations. The computer program utilizes digital analysis techniques to
simulate the acoustic response of the piping system to cylinder harmonic excitation.
Cylinders were modeled by considering bore, stroke, rod diameter, clearance, suction and
discharge temperatures and pressures, and gas compressibility. The compressor model included
speed, connecting rod length and crank phase angles.
Two performance analyses were provided for review. This compressor utilizes a side
stream between the 1st and 2nd stages to provide the majority of the gas for the 2nd stage
compression. Steady state performance was calculated using 1,200 rpm.
Gas composition was used to determine fluid mixture physical properties such as density,
sonic velocity, viscosity, specific heat ratios and compressibility.
Simulation of the piping system included pipe diameters, length, flow rate and pressure
drop. Influence of pressure drop on acoustic attenuation with changes in sonic velocity due to
steady flow velocity was also included in this study.
Bottles and scrubbers were included in the model. Physical dimensions were obtained
from the provided drawings and details.
Suction and discharge pressures were held to 170 PSIG and 1,285 PSIG for this analysis.
Flow rates used for these models were 3.91 & 4.01 MMSCF/D through the 1st stage and 13.14 &
10.44 MMSCF/D for the 2nd stage operation.
A sketch is attached with node numbers identified for reference to the acoustic response
spectrums. The spectral response plots of pulsation pressure versus frequency at critical points
within each piping system are included.
Recommendations
RECOMMENDATIONS
Inlet Piping System
Suction Bottle V-2604 (V-2) overall dimensions remain as proposed. Extend inlet to bottle
center. Reduce portion in bottle to 3 S XS. Refer to sketch PD-01 for details.
Interstage Piping System
Discharge Bottle V-2605, V-3, overall dimensions remain as proposed. Extend outlet to bottle
center. Reduce portion in bottle to 2 S XS. Refer to sketch PD-02.
Change suction bottle V-2606A, V-5, to a 3-chamber design. Overall dimensions should be 14
OD x 72 S-S. Refer to sketch PD-05 for details and critical dimensions.
Increase diameter of suction bottle V-2606B to 12 OD.
Install a 1.750 diameter orifice plate at the outlet of discharge bottle V-2605.
Install a 2.750 diameter orifice plate at the inlet nozzle of suction bottle V-2606A.
Install a 1.625 diameter orifice plate at the inlet nozzle of suction bottle V-2606B.
Discharge Piping System
Change discharge bottle V-2607A, V-6, to a 3-chamber design. Overall dimensions should be
14 OD x 72 S-S. Refer to sketch PD-06 for details and critical dimensions.
Increase diameter of discharge bottle V-2607B to 12 OD. Refer to sketch PD-08.
Install a 1.625 diameter orifice plate at the outlet flange of bottle V-2607A.
Install a 1.125 diameter orifice plate at the outlet flange of discharge bottle V-2607B.
01113
K-2601
CONTACT: Ed Jackson
ECSI NO. 201-1018
MODIFICATIONS
Suction Bottle V-2604 (V-2) overall
dimensions remain as proposed. Extend inlet
to bottle center. Reduce portion in bottle to 3
S XS. Refer to sketch PD-01 for details.
ORIFICE
SIZE
PRESS.
PSI / %
DATE: 01/20/01
COMMENTS
API design approach 2 design limit for this
system is between 0.3% and 4.5%, depending
on pipe diameter and frequency.
The modified system should meet API
guidelines for both cases reviewed.
Bottle unbalanced shaking forces are low.
The maximum force will be 15 lbs, or less.
Change suction bottle V-2606A (V-5) to a 3chamber design. Overall dimensions should
be 14 OD x 72 S-S. Refer to sketch PD-05
for details and critical dimensions.
1.750
3.94 / 0.83
2.750
2.32 / 0.49
1.625
3.55 / 0.75
1.625
7.39 / 0.57
1.125
Conclusions
CONCLUSIONS
Compressor packages are fabricated utilizing complicated sub assemblies such as skid,
motor/engine base, compressor base, scrubbers, pipe supports and others. Every effort should be
used to insure a rigid assembly during construction; scrubbers and pipe supports should be
welded to supporting I-beams and not just to the decking.
With the compressor, bottle, scrubber, and piping system constructed as per the above
system analysis, along with adequate piping clamps, and proper cylinder/bottle bracing and
supports, an acceptable level of vibration should be obtained.
Compressor cylinder passages and valve interactions are generally not included in the
compressor model. Reliable, and exact, information on cylinder passages and valve natural
frequencies is difficult to obtain. It is assumed that the cylinder manufacturer has designed the
passages to minimize the effects of reflected pulsation pressure waves in the valve area.
Normally, natural frequencies of the valves are substantially different than the frequency
of any reflected pulsation. However, experience has shown that in some instances, a system that
meets API design criteria may have unacceptable valve life. These systems will require further
analysis to eliminate the problem.
Engineering and Consulting Services, Inc. has used proven advanced design techniques
and utilized state-of-the-art computer simulations and computer modeling in an attempt to
accurately represent actual system response. The programs used in this study have been used
successfully for analysis, design and troubleshooting of gas piping systems in onshore and
offshore field gas compressor stations, gas processing plants, fuel gas booster stations, pipeline
transmission stations, refineries, and chemical plants. Well over a thousand studies have been
successfully performed in the last 15 years.
In general, very good comparisons of measured pulsation pressures to calculated
pressures have been obtained. If differences exist, calculated pulsation pressures are usually
found to be somewhat higher than measured pressures. However, compressor systems are
governed by complex relationships and piping interactions; and often react differently than
expected. Therefore, Engineering and Consulting Services, Inc., and its representatives, make no
claims or guarantees to the accuracy or correctness of the data presented in this report. ECSI
cannot be held responsible for results different than those predicted.
Do not hesitate to contact us if you have questions, or need additional information
concerning this study.
Piping Systems
Technical Data