International Journal of Engineering and Advanced Research Technology (IJEART)

Volume-1, Issue-2, August 2015

Pipe Vibration Analysis and Structural Improvements

of Reciprocating Compressor
Zheng Liang, Qiangbing Dong

II. CAUSE ANALYSIS OF PIPE VIBRATION

Abstract Avoiding pipe vibration is an important aspect of

reciprocating compressor system design. By modal analysis
upon a secondary compressor inlet pipe to get the natural
frequency of the pipe, using the transfer matrix method to
calculate the natural frequency of the pipe column. Compared
with the excitation frequency of the compressor, it reveals the
cause of the pipe vibration is mainly due to the natural
frequency of pipe column in the region of the compressor
excitation frequency. Calculating the pipe stresses under the
pulsating action of the exciting force and it far exceeds the
allowable stress of pipe. By changing the secondary intake pipe
length, increasing intake surge tank and theoretical analysis of
the system show that changes in the structure of solution
effectively avoids the resonance length of the pipe, significantly
reduces the stress and vibration of the pipe. The field secondary
inlet pipe of the reciprocating compressor after transformation
doesnt lead severe vibration and break accident again. It
confirms the feasibility of theory study.

Generally think that, in addition to the unit itself caused by

manufacture and installation of vibration, the main causes of
the compressor pipe vibration are as follows. One is pipe
mechanical resonance, namely pipe natural frequency in the
resonance region of compressor excitation frequency. The
other is the pipe column, while any rank innate frequency of
gas column coincides with the resonance region of
compressor excitation frequency, it will cause the column
resonance [2]-[5].
Due to the dynamic balance of the unit performance, pipe
resonance, as well as factors such as the flow fluctuation
occurs in the gas pipeline, it will produce a considerable
periodic exciting force to the pipes, and cause the destruction
of the pipeline structure. A secondary stage inlet pipes and the
cylinder intake port flange welding is shown in figure 1, this
causes pipe rupture because of severe pipe vibration.
The reciprocating compressor is balanced opposed type with
two stages of two column distribution, its main parameters are
shown in Table 1 below.

Index Termsreciprocating compressor, piping vibration,

modal analysis, natural frequency, exciting force

Table.1. Reciprocating compressor main parameters

Parameter name
Value

I. INTRODUCTION
Reciprocating compressor, as a kind of universal
equipment, already is widely used in petroleum, chemical,
and other fields, the pipe vibration is an important aspect of
the compressor reliability design, determines the overall
performance of the compressor. In actual production
application, the pipe vibration will do great harm to
production safety: On the one hand, it will reduce the
volumetric efficiency of the compressor, reduce the
displacement, and can shorten the service life of the valve and
control instrument; On the other hand, it can cause loose
joints of pipelines and their accessories, moreover a pipeline
vibration fatigue and sudden rupture during use. Pipeline
vibration lightly leads to media leaks, or explode, the seeds of
major production safety accidents [1]-[8].
In this paper, a reciprocating compressor used oilfield
associated gas recycling is shown as an example. Using
SolidWorks to establish three-dimensional solid modeling of
compressor pipes, and accordingly modal analysis through
ANSYS Workbench, obtain pipe natural frequency in the case
of low-level. Transfer matrix method is used to calculate the
air column natural frequency, compared with frequency of the
compressor do a simple analysis for the causes of pipe
vibration, and thus make structural improvements.

Spindle speed (r/min)

1500

Cylinder characteristic

double-action

Pipe wall thickness (mm)

Pipe material

20 steel

Pipe pressure (MPa)

1.5-2.1

Pipe medium

natural gas

Medium density(kg/m3)

2.5

Medium molecular weight

20

Medium temperature ()

40

Fig.1. Secondary cylinder intake pipe

Use SolidWorks to establish secondary of the compressor
inlet pipe of the three-dimensional entity modeling , as shown
in Figure 2. The specification of the pipes
is60.3476.2442.44, connected by uniform

Zheng Liang (1960-), male, Professor, the main research direction is

design and manufacturing of oil and gas equipment.
Qiangbing Dong (1990-), male, master graduate student, the main research
direction is the oil and gas compressors

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Pipe Vibration Analysis and Structural Improvements of Reciprocating Compressor

thickness variable diameter tube. Elastic modulus and

Poisson's ratio are respectively 206GPa and 0.28.

(b) The second order modal shape

Fig.2. Three-dimensional solid model of pipe
A. Mechanical resonance analysis
When the natural frequency of the pipe is in the resonance
region of compressor excitation frequency, it will cause
severe vibration of the pipe. The excitation frequency of
compressor is calculated according to Eq. (1) as follow:
Nm
fe
(1)
60
where: Ncompressor spindle speed,
mthe order of excitation frequency, while a
single-action cylinder is 1, 2 double-action.

Fig.3. The first and second pipe mode shape

Through the Response Spectrum module of ANSYS
Workbench, the pipe stress distribution under the excitation
modal frequency can be shown as clearly as in figure 4. The
figure shows the maximum stress appears in the joint of
variable diameter tube and flange, pipe rupture in the
maximum possibility here because of the diameter of the
mutation.

It is generally believed in engineering, the resonance region

of compressor excitation frequency is calculated according
to (0.8 1.2) fe , and the value is 40-60 Hz.
Introduce the three-dimensional entity model established
by SolidWorks into ANSYS Workbench for modal analysis.
The first six natural frequencies of pipe are shown in Table 2,
the first two modal shapes shown in Figure 3.
Fig.4. Stress size distribution diagram
Table.2. The first six order natural frequencies of pipe / Hz
order
frequency

1
165.1
1

2
471.7
4

3
508.4
1

4
684.
9

5
845.0
1

6
1000.
7

Accordingly, due to the natural frequency of the pipeline is

not in the resonance region of excitation frequency, and its
value is far greater than the area, that it will not occur
mechanical resonance.

B. Column resonance analysis

Pulsating air flow in the pipe elbow, variable cross-section,
valves and blind pipes can produce larger alternating
loadexciting force, may lead to mechanical vibrations of
the pipe. In the column close to the compressor end, as a result
of intermittent reciprocating compressor suction and
discharge of cycles, the column is subjected to periodic
exciting force. While any rank innate frequency of gas column
coincides with the resonance region of compressor excitation
frequency, it will cause the air column resonance, so that
pipes have a strong mechanical vibration [2]. In the study, the
natural frequency of the air column can be calculated through
transfer matrix method, the second inlet pipe diagram as
shown in figure 5.

(a) The first order modal shape

Fig.5. Secondary air inlet pipe diagram

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International Journal of Engineering and Advanced Research Technology (IJEART)

Volume-1, Issue-2, August 2015
In Figure 5, 12 and 34 are equal section pipe element,
23 and 45 are different-diameter pipe element. The
transfer matrix of volume element is shown as Eq. (1) [1]-[4].
p5
p1
M 4 5 M 3 4 M 2 3 M 1 2
u1
u5

l1
l

0 c sin 1
cos c
c

M 1 2 1
l1
l1

cos
c sin c

(2)
l2
l

0 c sin 2
cos c

M 3 4
l2
l2
1

sin
cos
c

c
c
0

1 0
1 0

,
M

A
2 3 0
4 5
2
0 A4

A3
A5

pulsation when passing elbow and variable diameter tube, a

greater excitation stress will be caused, thus it may result in
rupture of the pipe welding. From figure 5, the airflow from
endpoint 1 to the end endpoint pipe 5 of the pipe, endpoint 1
connect with a large container (splitter), and the length of pipe
from 12 is short enough. It could be regarded as no pulse
excitation force when the airflow through the first variable
diameter tube. The excitation force pulsation at the bend is
shown in figure 6[6]-[8].

Endpoint 1 is connected to the second intake separator,

regarded opening, p1 0 , u1 1 , endpoint 5 cylinder is

Fig.6. Excitation force pulsation at the bend

The component amplitude of excitation force pulsation at
the bend is as follows:
F1 F2 p A
(7)

connected with the second stage cylinder, regarded as closed,

p5 1 , u5 0 , A1 A2 , l1 0.23 m , A3 A4 , l2 1.07 m ,

p p / 2

so there is:

1
0
(3)
M 4-5 M 3-4 M 2-3 M1-2
0
1
Equation (3) can be expanded:
l l
cos( 1 2 ) 0
(4)
c
c
Equation (4) is the column natural frequency equation of
the second stage compressor intake pipe. When n is a positive
integer, there is:

(l1 l2 ) n (5)

2n 1

l1 l2

( n 1, 2, )

pmax pmin

(9)
( pmax pmin ) / 2
The excitation force pulsation at the variable diameter tube
is shown in figure 7.

c
2
Then f the natural frequency of the pipe can be obtained:

(8)

Fig.7. Excitation force pulsation at the variable diameter tube

Reference [6] shows that the component amplitude of
excitation force pulsation at the variable diameter tube is as
follow:
F3 p( A1 A2 )
(10)

(6)

where: cSound velocity in the gas, c kgRT ,

kAdiabatic exponent, k 1.3 ,
gAcceleration of gravity, g 9.8 m/s2 ,
RGas constant, R 20 ,
TTemperature, T 313.15 K ,
lColumn length, equal to the length of the pipe.
The first six natural frequencies of pipe column obtained as
shown in Table 3.
Table 3. The first six natural frequencies of pipe column
order
1
2
3
4
5
6
54.3
162.9
271.
380.2
488.8
597.5
frequency
2
6
6
4
8
2
As can be seen from Table 3, the first natural frequency of
column falls exactly in the resonance region of excitation
frequency, it shows that column resonance would be
produced, and column resonance tube length should be
avoided when carrying pipe improvements.

In these vibrations, some may partly offset because of the

force direction, so that the pipe vibration is weakened without
causing harm. However, in some cases, superposition of
exciting force makes the pipe vibration violently [6]. At the
variable diameter tube, suppose outer diameter of the small
end is D, inner diameter is d, the height from the small end to
the bend is h (in the study h 450 mm ). As in [7], axial stress
at small end of the variable diameter tube is:
F1 F3
1
(11)
2
2
(D d ) / 4
Radial stress at small end of the variable diameter tube is:
F h
2 2
(12)
WZ
3
d d
4

WZ

32

1-

(13)

C. Calculation exciting force

Gas inside the compressor pipes will create pressure

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Pipe Vibration Analysis and Structural Improvements of Reciprocating Compressor

According to the fourth strength theory, the maximum

stress of the small end of the variable diameter tube suffered
as follow:

1 3 2
2

(14)

After calculation, the maximum stress is 376.8MPa.

According to the provision of the national standard
GB50316-2008, the allowable stress of 20 steel at 40 is
130MPa. Obviously the variable diameter tube cannot meet
the strength requirements and result in a fracture accident.

III. PIPE CONSTRUCTION IMPROVEMENT

Based on the analysis and calculation above, unreasonable
design of the inlet pipe is the main cause of pipe rupture,
causing the pipe and gas column resonance, and leading to
excessive pulse exciting force. To solve this problem, the
following measures should be taken:
1) Adding an intake surge tank, at the entrance of second
stage cylinder. According to API618 regulations, surge
tank is a pulsation suppression device, increases damping
and effectively cushions system pressure fluctuations.
2) Using non-standard flange at the entrance of second stage
cylinder, increasing the outer diameter to DN65 (76.2
mm) and removing the variable diameter tube.
The three-dimensional solid model of the secondary intake
pipe improved shown in Figure 8. At this time, the length
secondary intake pipe decreased from 1.3 m becomes 0.98m,
the resonance length calculated by Eq. (6) corresponding to
the first-order excitation frequency is 1.13-1.7m, effectively
avoid the resonance length of pipe. The natural frequency of
improved pipe is shown in table 4. Now, the natural frequency
of the pipe is not in the resonance region of excitation
frequency, will not cause the mechanical resonance. The first
order modal shape of improved pipe is shown in Figure 9. The
maximum deformation of the pipe decreases more
significantly than before.

allowable of pipe stress 130MPa. After rectification, the

vibration of pipe is decreased obviously and there are no
related accidents. It confirms the correctness of the theoretical
research.

IV. CONCLUSIONS
1) The pipe resonance and column resonance can cause
severe vibration of compressor pipes. By changing the
length of pipe, adding a surge tank and other measures to
avoid the pipe column resonance caused by the excitation
frequency of compressor.
2) Because of the intermittent suction and exhaust of the
reciprocating compressor, the pressure and airflow rate
will change periodically. When the pulse airflow passes
through the elbow, variable diameter tube and other
parts, it will make a great exciting force, makes the
rhythmic vibration of pipe.
3) By shortening the length of the pipe, reducing the
pressure unevenness, reducing the number of elbows and
variable diameter tubes, the airflow pulsation caused by
vibration force can decrease obviously, and it also can
reduce the accident rate of the pipe.
4) When laying pipes, reducing diameter of mutation and
avoiding stress concentration as far as possible. Using
larger diameter pipe to increase the cross sectional area
of pipe, reduce pipe stress, but also through other
methods such as increasing the pipe supports to reduce
pipe vibration and enhance the stability of pipe.
REFERENCES
[1]
[2]

[3]

[4]

[5]
[6]

[7]

[8]

Fig.8. Three-dimensional solid model of the improved pipe

[9]

Xiqi DANG, Shouwu CHEN, Gas Pulsation and Pipeline Vibration of

Piston Compressor. Xian:Xian Jiaotong University Press, 1984.
Wenquan JIANG, Fan YANG, Maoting WANG, Calculation of the
Natural Frequency of the Gas Columns in Reciprocating Compressor
Pipelines on ANSYS, Compressor Technology, 2008.
Chengwu ZHANG, Compressor Outlet Pipeline Vibration Cause
Analysis and Improvement, Equipment and Anti-corrosion, 2004,
32(3).
Zhiyong LIU, Mengli GAO, Yanfei JI, Calculation Method of the Gas
Pole Immanence Frequency in the Design of the Pipelines of a
Reciprocating Compressor, Chemical Machinery, 2008, 35(4).
Huiying XIONG, Piston Compressor Piping Vibration and Vibration
Control Measures, Operation & Maintenance, 2006.
Zhongwen YUAN, Gas Exciting Force Calculation of Straight Pipe
Elbow and Different Diameter Pipe, OIL FIELD EQUIPMENT, 2001,
30:34~35.
Mingliang WU, Yongfei LI, Failure Analysis of Reducer and
Optimum Structural Design Based on Pro/E, Process Equipment &
Piping, 2010, 47(3).
Changbo FAN, Laibin ZHANG, Chaohui WANG, Analysis of
Reciprocating Compressor Gas Pipeline Vibration and Control
Methods, Science Technology and Engineering, 2007, 7(7).
Biao DONG, Cause Analysis of Raw Materials Gas Compressor
Pipeline Vibration and Reduction Measures, Fault Analysis, 2013.

Table.4. The first six order natural frequencies of

improved pipe / Hz
order
1
2
3
4
5
6
frequen 7 425.
427.
487.
545.
690.
cy
7
61
44
92
45
61
By adding an intake surge tank and removing the variable
diameter tube, the exciting force and vibration of the pipe
triggered by airflow pulsation are both reduced, and the pipe
stress is also significantly decreased. The maximum stress of
improved pipe is only 76.55MPa, which is far less than the

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