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2.1 INTRODUCTION
6.1
6.2 CHAPTER SIX
Normally, model processes are separated into areas which efficiently exhibit the
desired properties. Many models are limited intentionally so that the designer will
not make an effort to misuse the model. Therefore, it is not uncommon to see
several seemingly isolated simulations being performed which are then applied
simultaneously. The use of a simultaneous design philosophy is very beneficial. To
this end, we will be illustrating simulations in a focused effort to indicate the nature
and use of simulations realizing that they will all be combined in a unified effort
to optimize machine reliability and efficiency.
P1 21 P2 22
Z1 ⫹ ⫹ ⫽ Z2 ⫹ ⫹
1 2g 2 2g
Z1 and Z2 ⫽ potential head at condition 1 and 2
P1 and P2 ⫽ static pressure at condition 1 and 2
1 and 2 ⫽ density at condition 1 and 2
V1 and V2 ⫽ velocity at condition 1 and 2
g ⫽ acceleration due to gravity
All practical formulas for fluid flow are derived from this theorem, with modifi-
cations to account for frictional losses.
Mechanically related models dealing with temperature, weight and static pres-
sure forces are usually included in a thermal flexibility analysis. The major static
issues are pipe stress, displacement, machinery forces and moments, and cooler
nozzle forces and moments. These will be discussed in detail in the section reserved
specifically for them.
Pulsation, vibration and dynamic stress can best be understood in terms of a dy-
namic energy source and systems which can be resonant. Initially, the energy is
generated by the machinery (reciprocating compressor). If the piping natural fre-
quencies are frequency coincident, the energy is magnified through acoustic reso-
nance. The unbalanced pressure forces in piping systems couples into the mechan-
ical piping system causing vibration. If the mechanical natural frequency of the
piping is frequency coincident with the pulsation energy, secondary magnification
results. When large vibrational displacements occur in stiff systems, excessive
stress results at the points of stress concentration. If the cyclic stresses exceed the
endurance limit of the piping material, fatigue failure results.
6.4 CHAPTER SIX
FIGURE 6.2 Spectrum of head end discharge flow pulse showing compressor orders.
occurs due to the crank shaft phase and the piping acoustics between the cylinders.
The models to analyze simple systems are almost trivial compared to the level of
sophistication required to analyze multiple cylinders with complex piping systems.
It is always good to keep in mind the transfer of energy through a system is:
cylinder excitation; acoustic transfer and amplification; mechanical transfer and
amplification; acoustical to mechanical coupling; resultant shaking force; mechan-
ical vibration; and eventual pipe material strain and stress.
The piping system can be viewed as a complex organ pipe network. The normal
piping system will have several acoustic natural frequencies which, if excited, de-
velop standing wave patterns (acoustic mode shapes). As the flow and pressure
wave travel out from the compressor, they are transmitted and reflected in the piping
system. Whether a wave is reflected or transmitted is determined by the change in
impedance from element to element. The simple acoustic impedance (Z) is deter-
mined by the gas velocity of sound (c ⫽ ft/sec), the gas density ( lb/cu ft) and
cross sectional flow area (A ⫽ sq ft) of the acoustic element.
c
Z⫽
A
This type of simplistic thinking is actually the basis for more complex models that
are used in everyday acoustic analysis.
6.6 CHAPTER SIX
of the piping tend to introduce a smoothing process to the more severe interruptions
characteristic of the opening and closing compressor valves.
The performance of reciprocating compressors can be generally inferred from
the internal cylinder pressure and the manner in which it interacts with the pressures
outside the suction and discharge compressor valves. The cylinder external pres-
sures can be helpful or harmful to the overall cylinder compression and flow pro-
cess. It is important to note that the piston motion, mechanical valve model, and
outside pressures should be represented in the time domain to allow for proper
interaction.
When acoustic standing waves are present in the piping system, they can couple
through elbows and capped ends, resulting in significant shaking forces. The major
contributor of acoustic shaking force is due to the standing wave which is a by-
product of acoustic resonance. Therefore, acoustic resonance has two disadvan-
tages: the amplitude of the pulsative is magnified; and the energy is concentrated
in a form that efficiently couples to shaking forces. By limiting or controlling the
pulsation amplitude, the coupled shaking force can also be limited. The control of
shaking forces reduces vibration that can cause maintenance problems or fatigue
failures.
Through design analysis, non resonant acoustical and mechanical systems can
be designed which limit vibration, ensure efficiency and increase reliability of the
machine and its piping system.
In simple systems, the design analysis approach can be closed form equations
in combination with past successful experience. However, in most cases, the com-
plexity associated with multiple cylinders and extensive piping configurations re-
quires the use of Analog or digital techniques.
The most popular model used in piping acoustics is based on the transfer matrix
approach. The development of the equations used in constructing the model follows
the following path:
flow and fluid pressure are directly analogous to electrical current and electrical
voltage. Even today the pro and cons of ‘‘analog’’ versus digital continues to be a
matter of much debate.2 The real test of any model is its ability to produce faithful
results that allow a knowledgeable piping designer to produce safe efficient com-
pression systems.
Dynamic stresses can be calculated in both piping systems and manifold systems
with proper attention to the element properties and the forces and moments at each
end of the element. In most cases, a finite element type of approach can be used
to calculate the dynamic stresses. Experience has shown that a distortion energy
theory algorithm correlates well with practical field failure experience. The im-
provements of the distortion energy theory over the total strain energy theory ac-
count for the experimental observation that hydrostatic states of stress must be
properly assessed. The later contributions of Von Mises and Hencky have led to
the best overall techniques. The effort associated with a complete FEA analysis is
not necessary and would be prohibitive (if performed correctly) from a time and
cost viewpoint. Practically, the most conservative and reliable dynamic stress cri-
teria is to simply ensure the maximum dynamic peak-to-peak stress is less than
6,000 psi. This accounts for worse case mean stress, stress concentration, surface
effect and size effects.3
Compressor system models are composed of both the compressor and the piping
system. Therefore, when a compressor simulation analysis is performed, a PV
(pressure vs. volume) and PA (pressure vs. crank angle) display of the cylinder
internal pressure is available. Figure 6.3 illustrates the PA display along with actual
pressure levels at the suction and discharge valves. Figure 6.4 illustrates a typical
PV card. The advantage of this PV card is the inclusion of the pulsation effects.
Ideal PV calculations yield four basic components.
FIGURE 6.3 Cylinder pressure and valve pressure vs. crank angle.
During the period of time the suction or discharge valve is open, the internal
cylinder pressure is influenced by the pressure beyond the valve in the piping. The
changes in acoustic impedance cause pulsative energy to reflect back upon the
compressor valve and to actually enter the valve port. This influence is very sig-
nificant. The nature of the pressure profile on the PV card during these time periods
is very similar to the pressure immediately outside the valves. A primary influence
is on the area of the card which is proportional to the work performed for each
rotation of the shaft. The work combined with the rpm yields the horsepower of
the compressor. High frequency pulsative energy tends to produce numerous waves
during the inlet or outlet flow time. Low frequency pulsative energy tends to cause
the PV card to balloon or swell. A ballooning card usually suggests the horsepower
is increased with a corresponding increase in flow. Therefore, the efficiency of the
compressor is deteriorated. The compression and re-expansion lines can also be
displaced, causing very significant increases in required horsepower with a small
increase in flow. Displaced compression and re-expansion lines in many cases are
symptoms of increased valve impact velocities and limited valve life.
The suction and discharge valve motion is determined by the dynamic properties
(mass, stiffness and damping) of the valve elements and the differential pressure
COMPRESSOR AND PIPING SYSTEM SIMULATION 6.11
across the valve. The differential pressure and the effective pressure area determines
the force that operates the valve. The differential pressure is composed of both
static and dynamic components. The valve motion cannot be properly predicted
without including the pulsative energy present in the system. Figure 6.5 illustrates
the pulsative pressure at the exit of the discharge valve and also in the common
nozzle. This data shows the complex nature of pulsative energy and why this would
surely influence the valve motion. The energy content is quite different as you
move from the valve exit to the common nozzle. Figure 6.6 illustrates the spectral
content of the energy in the nozzle. This spectral energy content shows the domi-
nance of the basic double acting cylinder (dominate rpm ⫻ 2 energy) and acoustic
response associated with the cylinder internal passage at approximately 64 to 69
Hertz. This is typical and illustrates the requirement of the modeling process.
An adequate compressor model will include a mechanical valve model coupled
into the driving pulsative energy and the open and closed limits of valve element
travel. It is important that this model be evaluated in the time domain. The results
of the model should yield valve spring and weight parametric analysis capabilities.
The valve displacement, velocity and acceleration are directly available, allowing
for direct evaluation of impact velocities and forces. At present, several valve man-
ufacturers have impact velocity criteria which are used to screen valve reliability.
These criteria have not proven totally reliable up until now, and are used as a
simple criteria which should not be over emphasized.