DYNAMIC MODULE OF CAESAR II Is it of any use?? lectures 2007 DYNAFLOW 30 th August 2007 -2- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Why is dynamics not used more Coade: < 5% of Caesar II license holders also makes use of dynamic module Dynamical effects are overlooked Dynamical effects are underestimated Pipe stress engineers prefer quasi static approach Dynamic load * 2 Pipe stress engineer feels uncomfortable with dynamics -3- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Function of the dynamical module Facilitate accurate assessment of the dynamical effects Effects of unsteady loads on stress and load levels in piping systems. When is it used?? During design (avoid fatigue, overloading, large displacements) Control of Vibration problems (development of mitigation measures) -4- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Piping Incidents due to dynamic loads Few examples of what might go wrong!! -5- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Collateral Damage due Dynamic Effects from Flange Failure -6- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Support Damage (I) -7- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Support Damage (II) -8- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Support Damage (II) -9- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Support Damage (III) -10- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved More Incidents due to fluid/gas transients ( small bore piping ) -11- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Examples of incidents as a result of fluid transients -12- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Deluge FF System on Jetty when Tested First Time (I) -13- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Deluge FF System on Jetty when Tested First Time (II) -14- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Flange Failure -15- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Dynamic loads are classified based on time history Sustained dynamic loads Periodic loads of moderate amplitude and long duration (minutes- days) - Forces due to pressure oscillations in pump/compressor suction or discharge systems - Imposed oscillating displacements at pump/compressor nozzle connections. - Oscillating forces originating from flow fluctuations/instabilities Transient, intermittent dynamic loads Relati vely large forces of relati vely short duration (seconds) - Slug Loads - Relief Loads - Waterhammer, surge loads - Earthquake -16- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Effect of dynamic loads Sustained dynamic loads Vibration with a periodicity equal to the excitation mechanism Vibration amplitude depends on separation between excitation frequency and natural frequency of the piping system Failure mechanism: High cycle fatigue Transient dynamic loads All natural mode shapes and natural frequencies of the piping system are affected. Response may show large amplitude vibrations of short duration. Failure mechanism: Excessi ve support loads Accumulation of strain, low or high cycle fatigue -17- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Required data for dynamic analysis Dynamic model of piping system Good distribution of lumped masses, additional nodes Sufficient number of DOF - For lumped mass (FE) type calculations typically only the first 33% of the modes shapes are accurate. Accurate boundary conditions Magnitude of the excitation forces Mechanical Fluid mechanical - Slug load calculation (manual??) - Acoustical simulation (pulsation study) - Waterhammer (surge) load calculation, simulation or manual (Measurement results for bench marking the simulations) -18- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Assessment of dynamic results Material Fatigue data, ASME B&PV section VIII div 2 appendix 5 API 579 AD Merkblatter BS-5500 EN-13445 -19- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Vibration Assessment conform VDI 3842 Typical Vibration Level Limits conform VDI 3842, Vibrations in Piping Systems 1.0 10.0 100.0 1000.0 1 10 100 1000 Frequency [Hz.] V i b r a t i o n
V e l o c i t y
[ m m / s ]
R M S design marginal correction danger -20- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Three Options for Dynamic Response Analysis in Caesar II 1 2 3 0 -21- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Harmonic analysis Application Sustained vibrations (compressors & pumps) Input Periodic Loads can be applied at any node in the system Per load case one excitation frequency Many load cases are possible Solution method Since response frequency equals excitation frequency solution procedure is quasi static (fast) Output Stress, displacement and load amplitude per frequency -22- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Spectrum Analysis Application Transient vibrations: slug, waterhammer, relief Input Load time histories at many nodes in the system Calculation method Load time histories are translated into response spectra (time phase between different loads is lost) Natural frequencies and mode shapes are calculated Response for each mode shape is determined Mode shape responses are combined into a final system response Output Maximum stress, largest modal contribution Maximum loads, largest modal contribution Maximum displacements -23- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Response Spectrum Generation -24- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Response Spectrum Generation DLF Related to 4 harmonic cycles DLF may grow > 2 if time history contains only a limited amount of consistent periodicity -25- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Time History Analysis Application Transient vibrations: slug, waterhammer, relief Input Load time histories at many nodes in the system Calculation method Load time histories are maintained (time phase between different loads is conserved) Natural frequencies and mode shapes are calculated Response of each mode shape is determined Mode shape responses are combined into a final system response Output Maximum stress, actual stress at user defined times (snapshots) Maximum loads, actual load at user defined times Maximum displacements, actual displacement at user defined times By combination of several runs a time history of stress, loads displacements can be composed -26- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Missing Mass correction Only limited number of mode shapes are extracted and participating in the response Only a fraction (preferably close to 100%) of the system mass is participating Only a fraction of the total excitation force is participating The missing force fraction is calculated and applied statically after multiplication by the largest DLF value above the frequency cut-off. Important when large axial loads are applied (axial mode shapes have relatively high natural frequencies. -27- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Spectrum versus Time History Spectrum Frequency domain Conservati ve results: only maximum response per mode shape is calculated and combined in system response Mode making maximum contribution is identified (advantage for vibration control) Only maxima are calculated, time phase is lost Number of participating modes is finite (missing mass) Time history Time domain More accurate results: time history response per mode is conserved and time phasing between model maxima is maintained during combination. Load, stress time histories (enables fatigue assessment by means of cumulati ve damage, counting of cycles) Graphical response is possible Modal info is not available Calculation is memory intensi ve (limits simulation duration, number of participating modes, time step resolution) Number of participating modes is finite (missing mass) -28- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Quasi-Static Approach Dynamic Load amplitude (maximum) * DLF=2 as static load Quasi static approach is simple and fast Quasi static approach works when there is only one dominant mode shape that is excited Quasi static approach focuses on loads (dynamic response is not considered), i.e. solution by change/elimination of modes is not possible. -29- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Best Method for Transient (Impact) Loads Analysis Quasi static Simple but only if there is one dominant mode shape Spectrum Time phase between several impacts on one system is lost (e.g. slug hitting consecuti ve elbows) Conservati ve but output provides clues for problem solving. Mode with largest contribution is identified. Time history Exact, timing relation between impacts is maintained (slug, waterhammer) Clues for diagnosis are less obvious For transient loads a combination of spectrum and time history runs provides the best opportunities -30- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Protective Measures Sustained dynamic loads Control of mechanical natural frequencies of the piping system in relation to the excitation frequency Support functions and support stiffness (in general high stiffness) Analysis accuracy is increased if support structure is included in the model Transient dynamic loads Control of support and nozzle loads Support flexibility is sometimes useful Elimination of damaging mode shapes Protecti ve measures for dynamics may be conflicting with statics -31- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved -32- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved -33- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Example 1 Problem High vibration level in compressor suction piping Steps to solution Vibration Measurements, identification of main contributions in frequency domain Verification of acoustical natural frequencies of piping system (acoustical resonance) Verification of mechanical natural frequencies (mechanical resonance) Identification of source of vibration problem Modification proposal -34- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Compressor Location -35- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Steel Supporting (I) -36- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Steel Supporting (II) -37- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Compressor Layout -38- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Step 1. Vibration Measurements and Compressor Harmonics 0.00 20.00 40.00 60.00 80.00 100.00 120.00 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 Frequency (Hz) A m p l i t u d e
( d B ) 66 Hz 99 Hz 49 Hz 33 Hz 83 Hz 16 Hz -39- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Intermediate Conclusion from Step 1 Vibrations are at compressor harmonics Vibrations must be result of: Acoustical resonance or Mechanical resonance or High pulsation forces without resonance (compressor bottle sizing problem) -40- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Step 2. Acoustical Natural Frequencies & Compressor Harmonics (Search for acoustical resonance) 0 50 100 150 200 250 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 Frequency (Hz) A m p l i t u d e 16 Hz Purple vertical lines represent compressor harmonics -41- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Intermediate Conclusion from Step 2 Maybe near to resonance condition at first compressor harmonic (16.5 Hz.). No further acoustical resonance Vibration peak at 16.5 Hz, most probably is due high shaking forces as a result of near resonant condition. The other vibration peaks must be the result of: Mechanical resonance or High pulsation forces without resonance (compressor bottle sizing problem) -42- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Step 3. Vibration Measurements & Calculated Mech. Natural Frequencies (Search for Mechanical Resonance) 0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 Frequency (Hz) A m p l i t u d e
( d B ) 66 Hz. 33 Hz 83 Hz Purple vertical lines represent pi pe system natural frequencies -43- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Conclusion from Step 3 & Identification Cause of Vibration Problem Apparently there is mechanical resonance at 33 Hz and 66 Hz and near mechanical resonance at 83 Hz. No mechanical resonance condition at the first compressor harmonic (16.5 Hz.) and at 49 Hz. and 99 Hz. The high vibration levels 33 Hz, 66 Hz and 83 Hz are of mechanical nature. The high vibration level at 16.5 Hz most probably is an acoustical resonance problem. The high vibration level at 49 Hz and 99 Hz. must be the result of: High pulsation forces without resonance (compressor bottle sizing problem) -44- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Examination of Mechanical Behavior 66 Hz. Mode Shape Large amplitude movement in suction manifold -45- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Step 4. Modifications The high vibration levels 33 Hz, 66 Hz and 83 Hz are of mechanical nature and need a mechanical solution Better supporting Improved support stiffness The high vibration level at 16.5 Hz is due to acoustical resonance and needs an acoustical solution, I.e. different bottles and/or orifice plates to introduce more damping The high vibration level at 49 Hz and 99 Hz. are the result of high pulsation forces without resonance and must be resol ved by compressor bottle (re)sizing. -46- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved As Built Supporting Structure of Compressor Manifold -47- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Modified/Improved Supporting Structure of Compressor Manifold -48- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Modified Structure Implemented & Connected to Attached Piping -49- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Conclusion from Example 1 Compressor vibration problems are of a mixed nature Part is mechanical Part is acoustical Each category requires a different approach and result in different solutions Not all vibration problems can be sol ved by mechanical measures. -50- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Example 2 Problem Failure in cooling pump discharge line (possibly vibration induced) Steps to solution No vibration measurements just visual observation Identification of excitation mechanism thru fluid simulations (pump trips & start-up and check val ve closures) Time history mechanical simulation to verify stress levels Identification of source of vibration problem Modification proposal -51- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Steady State Volume Flowrate [m 3 /s] Model of the System -52- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Pump trips at t=1 seconds, Pump inertia: 8 kgm 2 Time History of Pumps -53- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Check val ve closes in 0.5 second Time History of Valve -54- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Flow thru checkval ve Time History of Flow through Valve -55- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Maximum Transient Pressure during pump trip [Barg] Maximum Transient Pressure -56- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Unbalanced Load Time Histories (I) Load i n Newton * 10 4 -57- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Load i n Newton * 10 4 Unbalanced Load Time Histories (II) -58- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Load i n Newton * 10 4 Unbalanced Load Time Histories (III) -59- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Load i n Newton * 10 4 Unbalanced Load Time Histories (IV) -60- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Unbalanced Load Time Histories available in CAESAR -61- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Conclusion from Example 2: Alternating stress amplitude of 233 MPa results in stress range of 466 MPa may be responsible for LCF -62- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Example 3 Problem Excessi ve pressure in injection line. Steps to solution Assumed mechanism entrapped (undrained) fluid propelled by gas at gas velocity during start-up hits val ve that is cracked open Identification of source of problem thru simulation -63- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Valve Damage -64- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Model of the System -65- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Pressure Time History at the Ball Valve in Case of Entrapped Gas at the Valve Val ve cracked open at t=0 Pressure in Barg -66- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Maximum Transi ent Pressure in trapped gas 0 50 100 150 200 250 300 350 400 450 500 0 100 200 300 400 500 600 700 800 900 1000 Trapped gas volume [Liter at atmospheric pressure] M a x i m u m
P r e s s u r e
[ B a r g ]
. Slug 29 liter, 20 meter Slug 130 liter, 90 meter Pressure Time History of Entrapped Gas -67- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved Conclusions for presentation Dynamic analysis is an important and sometimes a critical element in integrity analysis Many failure modes are to be addressed Excessi ve loads are to be handled CAESAR offers several types of dynamic analyses to assist in the demonstration of integrity: 1. Harmonic Analysis 2. Spectrum Analysis 3. Time History Analysis Solutions to possible problems are often found by introduction of the right supporting and/or supporting steel structure -68- Copyright 2007 by Dynaflow Engineering B.V. All rights reserved END Thank you for your attention