Course 5 - Pump piping system design to avoid vibration and fatigue failures

Description:

The goal of this short course is to provide insight into the design considerations and industry best practices for reciprocating and centrifugal pump installations to minimize vibration that can lead to fatigue failures of mainline and small bore piping.

Background:

Industry surveys show that more than 20% of unplanned product releases are due to fatigue failures caused by vibration. These product releases have an immediate impact on the reliability and economics of operating machinery assets as well as posing significant safety and environmental risks. Piping designers are often unaware of the specific requirements for fatigue and vibration control in a vibratory service such as piping in a centrifugal and reciprocating pump installation. Solving fatigue and vibration problems after a project has been completed or commissioned is costly and results in significant downtime.

Participants will gain an understanding of:

• Introduction to centrifugal and reciprocating working principles
• Fundamentals of vibration and pressure pulsations as related to pump systems
• Review of existing standards and industry design practices to avoid fatigue and vibration problems
• Centrifugal and reciprocating pump piping system design practices for vibration control
• Pipe support designs that are suitable for vibration service
• Project management techniques to reduce vibration risksDefinition & Charteristics of a Centrifugal Pump

Who Should Attend:

This short course is for engineers, managers and technical staff involved in the design, commissioning and installation of industrial centrifugal and positive displacement pump and piping systems.

Course Outline:

1. Introduction to reciprocating and centrifugal pumps

This section will discuss centrifugal and reciprocating pump basics. It will focus on the fundamental working   principles of each pump type, performance curves, and the advantages and disadvantages.

2. Demonstration of different components in a centrifugal and reciprocating pump

A pump demo will be used to engage the class and discuss the different components of a centrifugal and   reciprocating pump. Attendees will learn about pulsation dampeners to get an idea about their size and application.

3. Overview of vibration

This section will review key terminology used in the industry, as well as provide an overview of causes of vibrations and the vibration equation.

4. Pressure pulsations in pump systems

This section will discuss pulsation terminology and how pulsations are generated in pumps, as well as how they propagate and amplify in the piping system (acoustic resonance). The class will learn how pulsations create high dynamic forces in the piping that can cause high vibrations, pipe ruptures and fatigue failures. The section will include case studies, class exercises and discussion time.

5. Piping system design for centrifugal and reciprocating pumps

This section will discuss the relevant industry standards and industry best practice for centrifugal and reciprocating pumps. Differences and similarities in the design requirements will be highlighted and demonstrated with case studies. The concepts of dynamic flexibility, mechanical natural frequencies, frequency avoidance, and forced response analysis will be explained. Design of the piping system as well as the foundation requirements will be discussed and demonstrated by case studies and a class exercise.

6. Small-bore connection and small-bore piping design

Failures of small-bore connections and small-bore piping account for many fatigue failures on new pump installations. Little design attention is paid to these items. Design practices and industry best practices will be presented to mitigate small-bore failures. Case studies will be presented.

7. Project management and planning

A key part of a successful pump project is proper project management and planning. Proper definition of the project scope, specifications and project milestones will be discussed as a means of ensuring the necessary measures are taken to reduce the risks of fatigue failures and vibration in the pump and piping system.

Instructors:

Kelly Eberle

Principal Consultant

Wood

Kelly is a Principal Consultant with Wood’s vibration, dynamics and noise team (formerly BETA Machinery Analysis) since 1988. Kelly graduated from the University of Saskatchewan with a Bachelor of Science in Mechanical Engineering in 1986. He has been a professional member of APEGA since 1991. 

Kelly has accumulated a wide range of design and field experience, particularly in the area of pressure pulsation analysis and mechanical analysis of reciprocating compressor and pump installations. The scope of his design experience includes acoustical simulations, thermal flexibility studies, dynamic finite element analysis, structural analysis and foundation analysis.

Nathan Cameron

Design Engineer

Wood

Nathan graduated from the University of Alberta with a Bachelor of Science in Mechanical Engineering

in 2012. He has been a professional member of APEGA since 2016.

Nathan is a Design Engineer with Wood’s vibration, dynamics and noise team (formerly BETA Machinery Analysis) since 2018. His experience includes acoustical simulations for reciprocating compressors and reciprocating pumps.

Prior to joining Wood, Nathan worked as a Project Engineer and Applications Engineer with a compressor packager where he gained experience in reciprocating compressor performance, package design and field troubleshooting.

Jeffrey Ortego

North American Aftermarket Engineering Manager, ClydeUnion Pumps

Celeros

Jeff is the North American Aftermarket Engineering Manager for ClydeUnion Pumps. He graduated with a Bachelor of Science degree in Mechanical Engineering in 2011 and has been a reciprocating pump specialist since joining ClydeUnion in 2014. 

He has performed a variety of reliability improvements and product development projects in a wide range of services including hot oil units, steam pump maintenance improvements, mitigation of packing failures, and metallurgical upgrades. 

Before joining ClydeUnion, Jeff was a design engineer for a dredging equipment manufacturer and was heavily involved in the design and manufacture of mining dredges for the aggregate and fertilizer industries the world over.

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