Advances for Pipelines

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Clare Casey
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1 Advances for Pipelines Eugene Buddy Broerman Jeffrey Bennett Gas/Electric Partnership Conference 2016 Houston, T

Southwest Research Institute Non-profit organization founded in 1947 Over 2,700 staff members 9 technical divisions 1,200 acre facility 2 million ft 2 of labs/offices Over 1,100 patents

2 Southwest Research Institute Non-profit organization founded in 1947 Over 2,700 staff members 9 technical divisions 1,200 acre facility 2 million ft 2 of labs/offices Over 1,100 patents Applied R&D in the physical sciences and engineering disciplines 38 R&D 100 Awards Revenue of $549 million in /03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 2

Pipeline Modeling at SwRI Pipeline modeling used to evaluate and optimize: Pump and compressor stations Transmission lines Gathering systems Pipeline networks Valve manifolds Applicable to: New

3 Pipeline Modeling at SwRI Pipeline modeling used to evaluate and optimize: Pump and compressor stations Transmission lines Gathering systems Pipeline networks Valve manifolds Applicable to: New installation designs Modifications to existing systems Pipeline modeling began at SwRI in the 1950s Developed unique analog resistance simulator for the gas transmission and compression industry 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 3

4 Why Avoid Surge? SURGE EVENT = $$$$ Surge: condition where reverse flow occurs through compressor SURGE AVOIDANCE = NO $ May cause permanent damage to the compressor impeller or thrust bearings 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 4

5 Mixed (Recip/Centrifugal) Compressor Stations Approx. 30% of time spent across surge line A portion of pulse from recips takes the flow across the surge line Surge margin is fluctuating = aaaa 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 5

Mixed (Recip/Centrifugal) Compressor Stations Solution Dominant 1x response Pulsation (psi p-p) Extend API 618 Pulsation Analysis to centrifugal compressor flanges Low frequency pulsations travel

6 Mixed (Recip/Centrifugal) Compressor Stations Solution Dominant 1x response Pulsation (psi p-p) Extend API 618 Pulsation Analysis to centrifugal compressor flanges Low frequency pulsations travel long distances Predict unsteady compressor operating map area Determine net effective surge margin reduction Use GMRC guideline criteria to determine safe operating ranges, add margin to surge control line, or install filter bottles between the two compressor types 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 6

shown Acoustic/pulsation analyses are typically performed for reciprocating compressor installations, not centrifugal compressor

Primary lesson learned from this experience --- Coincidences of vortexshedding (Strouhal) excitation frequencies & piping ANFs can be

7 Vortex-Shedding Analysis: Why do it? During startup high vibration observed on 2 nd elbow downstream of the ASV/FSV piping Grout beneath recycle line pipe support cracking as shown Acoustic/pulsation analyses are typically performed for reciprocating compressor installations, not centrifugal compressor installations since vortex shedding not addressed by most piping design codes. Primary lesson learned from this experience --- Coincidences of vortexshedding (Strouhal) excitation frequencies & piping ANFs can be accurately predicted & avoided by performing an acoustic and mechanical response analysis in the piping design phase. Cost of post-installation piping modifications can be approximately ten times that of typical upfront analysis. 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 7

8 Vortex-Shedding Analyses Comparison Energy Institute Guideline SwRI Vortex- Shedding Screening SwRI V-S Amplitude Estimation Requires all acoustic frequencies to be above the shedding frequency Only works for very simple stubs configurations Coincidence avoidance method must make piping changes if coincidence predicted Allows for a separation margin between frequencies Includes flow energy Accounts for low acoustic natural frequencies (long lengths of piping) Estimates pulsation amplitudes Can eliminate the need for piping changes 8

Pipeline Machinery Simulation Services Dynamic Compressor Simulation and Surge Analysis Studies Gas Networks and Compression Facility Analyses Liquid Networks and Pumping Facility

9 Pipeline Machinery Simulation Services Dynamic Compressor Simulation and Surge Analysis Studies Gas Networks and Compression Facility Analyses Liquid Networks and Pumping Facility Analyses Training Simulators Flow Assurance and Multiphase Flow Modeling Leak Detection Field Services 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 9

Emergency Shutdown (ESD) Process Control (Low flow periods, controlled shutdown, etc.

10 Transient Surge Analysis Overview Review system layout and planned operation to determine scenarios that may cause upset conditions Typical events investigated: Start-up of compressor Emergency Shutdown (ESD) Process Control (Low flow periods, controlled shutdown, etc.) Process upset conditions 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 10

11 Validated Modeling Technique Models are created and calibrated with detailed system information including: Measurements Compressor curves Deceleration time Rotating inertia Valve response time Piping dimensions Heat exchanger size and performance Vessel dimensions Isentropic Head [ft-lbf/lbm] Compressor Map with ESD Transient Event Cooler Friction Factor Comparison DATA SURGE LINE Modeling Modeling with tuned Cooler Friction F RPM RPM Actual Flow [cfm] Calibrated model compares well with measurements 1/20/ GMC Tech Update: Centrifugal Compressor Station Dynamic Simulation 11

Training Simulator Development Simulator interface mimics equipment control screens Tuned computational engine predicts system response to

12 Training Simulator Development Simulator interface mimics equipment control screens Tuned computational engine predicts system response to trainee inputs Additional screens provide insight into system behavior 2/03/ Gas/Electric Partnership Tech Update: Advances for Pipelines 12

13 Thank you for your attention! Benefiting government, industry and the public through innovative science and technology

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