GUIDE TO API 618 ACOUSTIC-MECHANICAL DESIGN

VALIDATIONS FOR REPURPOSED OR MODIFIED

RECIPROCATING GAS COMPRESSOR SYSTEMS

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Guide to API 618 Acoustic-Mechanical Design Validations for Repurposed or Modified Reciprocating Gas Compressor Systems

Guide to API 618 Acoustic- Newsletter

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 November 28, 2023(https://e2g.com/2023/11/28/) archive/)

Author: Michael F.P. Bifano (https://e2g.com/profile/michael-f-p-

Recently
bifano-ph-d-p-e/), Ph.D., P.E., ISO VCAT-IV, Rotating Equipment,
Vibration, & Dynamics Team Leader
Published
Many compressor piping vibration results from modifying a
compressor system without performing adequate redesign validation
(https://e2g.com/industry-
(https://e2g.com/indus
steps. Modifications to reciprocating compressor piping systems
usually necessitate some if not all of the original API 618 insights- insights-

required acoustic-mechanical design assessment depending on the ar/guide- ar/addressing-

complexity of the type of system modifications. The objective of this to-api- piping-

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 article is to convey basic knowledge regarding the fundamentals of 618- vibration-
acoustic pulsation, what API 618 acoustic-mechanical analysis acoustic- in-the-
accomplishes, and why it is critical to perform aspects of this mechanical- oil-gas-
analysis prior to repurposing compressors or modifying compressor design- and-
piping so occurrences of in-service piping vibration problems can be validations- petrochemical-
reduced in our industry. for- industries-
repurposed- the-
Excessive pulsation-induced gas forces are responsible for the
or- upcoming-
deterioration of the compressor foundations, reduction in
modified- api-579-
compressor valve life, vibration fatigue damage of piping and piping
reciprocating-part-15/)
components, failure of small-bore connections, and damage to
gas-
supports and structural members. Addressing
compressor-
systems/)
Piping
API 618 Reciprocating Compressors for Petroleum, Chemical, and
Vibration
Gas Industry Services and API 688 Pulsation and Vibration Control Guide
in Positive Displacement Machinery Systems for Petroleum, in the
to API
Petrochemical, and Natural Gas Industry Services outline the Oil,
618
minimum requirements for performing the necessary design Gas,
assessments to prevent vibration-related fatigue damage to the Acoustic-
and
compressor, pulsation control/suppression devices (PSDs), and Mechanical Petrochemical
attached piping network due to pulsation-induced vibration as well Design Industries:
as other gas-related forces. Validations
The
for
This article will provide practical guidance on which aspects of the Upcoming
original design analysis should be considered when modifying or Repurposed
API 579
repurposing an existing system and why. Let’s first address the or
Part 15
why, and for that, let’s look at the fundamentals. Modified
(https://e2g.com/in
Reciprocating
System Acoustics insights-
Gas
ar/addressing-
When discussing potential acoustic pulsation problems with Compressorpiping-
reciprocating equipment, we deliberately use the term Systems vibration-
“system.” Acoustic pulsation problems, and specifically a subset of
(https://e2g.com/industry-
these problems referred to as acoustic resonance, in their various in-the-
insights-
forms affect the machinery, vessels, and piping and are closely oil-gas-
ar/guide-
connected with operating and process variables such as gas mole and-
weight, pressure, temperature, and valve positions. The to-api- petrochemical-
multidisciplinary assessment requires knowledge and input from 618-
industries-
typically segregated engineering disciplines such as rotating acoustic-
the-
machinery engineering, structural, process, piping and fixed mechanical-upcoming-

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 equipment. Adequate collaboration of these teams during an design- api-579-
acoustic-mechanical design assessment is critical. validations-part-
Acoustic resonances in piping occur because pressure pulses from for- 15/)
the reciprocating cylinder travel at the sound speed of the gas repurposed-Nov
2023
28,

(~1000-1500 ft/s) through the piping system and will reflect off of or-
Author:
deadlegs, adjacent compressors, partially closed valves, or any modified- Michael
substantial diametrical change in the piping (i.e., discharge cooler, reciprocating-
F.P.
suction scrubber or upstream separator, etc.). If the reflected Bifano,
gas-
portion of the wave meets the next incoming pressure pulse such Ph.D.,
compressor-
that the phases of the waves add, the resulting amplitude can be P.E., ISO
magnified as much as 50x. The piping experiences unbalanced systems/) VCAT-IV,
Nov 28, Rotating
shaking forces as the area of the pipe times the peak-to-peak 2023
Equipment,
pressure. This mechanism is called acoustic resonance and
Author: Vibration,
creates the most substantial type of vibration problems in Michael &
reciprocating machinery systems that can affect the compressor, F.P. Dynamics
piping, vessels, foundations, and supports. Bifano, Team
Ph.D., P.E. Leader
The underlying physics of acoustic resonance, though complex, can Pulsation- This article
be understood through a simple everyday experience: blowing over induced was
the top of an empty bottle. This action generates oscillating forces can previously
pressure waves at the bottle’s opening, akin to the compressor, damage published
compressor on
which are significantly amplified by the bottle’s unique air-space
foundations, Hydrocarbon
geometry, representing the piping system. This phenomenon is
reduce Engineering,
known as 1/4-wave resonance. Intriguingly, adding water to the
valve life, August
bottle shortens the air column, thereby raising the wave’s pitch or and lead 2023.
frequency – a clear demonstration of how piping length critically to fatigue As one of
influences acoustic natural frequencies in compressor in piping the task
systems. Similarly, the 1/2-wave resonance can be experienced and group lead
with a flute, where oscillating pressure waves, pleasing to the ear, components. co-authors
In this of the API
are produced. The flute’s open end and the next open hole create
article, Dr. 579 Part
an oscillating pressure wave, with pressure peaks and troughs (anti-
Bifano 15
nodes) at both ends.Acoustic natural frequencies for 1/4-wavelength explains Methodologies
and 1/2-wavelength resonances can be accurately predicted using acoustic on the
the following equations for lengths of piping only containing elbows. pulsation Assessment
basics in of Piping
reciprocating Vibration,
gas Mike

compressor Bifano
systems offers

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 systems offers
and offers insight into
practical the future
guidance upcoming
on changes to
applying the
original sStandard.
acoustic- In this
mechanical article,
design you’ll learn
principles about the
during new three-
system tiered
modifications evaluation
or system
repurposing. and
It’s understand
essential how
to vibration
understand fits into a
how these mechanical
changes integrity
may affect program.
system Read
acoustics more and
to prevent gain
future insight into
vibration the highly
issues. anticipated
improvements
Read More
to our
» industry
Figure 1: Illustration of 1/2- and 1/4-wavelength resonances in
(https://e2g.com/industry-
standards.
piping.
insights-
Read More
Figure 1 illustrates Equations 1 and 2 and shows the difference ar/guide-
»
between dynamic pressure oscillations based on boundary to-api-
(https://e2g.com/industry-
conditions. 618-
insights-
acoustic-
The simplified hand calculations illustrate: ar/addressing-
mechanical-
piping-
1. Accurate predictions can be made. design-
vibration-
2. The dominant variables are pipe length and wave speed. validations-
in-the-oil-

3. Gas composition, operating temperature, pressure, and pipe for- gas-and-

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 diameter come into play via the wave speed. The diameter repurposed- petrochemical-
and wall thickness affect the sound speed due to pipe wall or- industries-

flexibility. modified- the-

reciprocating- upcoming-
Over what distance can acoustic effects occur? Does changing my
gas- api-579-
piping 100 feet away from the compressor affect the system
compressor- part-15/)
acoustics? To answer these questions, let’s rearrange Equation 2 to
systems/)
solve for the longest length, L, over which an acoustic standing
wave equals to only one 1/2 wavelength. For typical hydrocarbons,
the wave speeds can range from 1000-1500 ft/s, with hydrogen
(https://e2g.com/industry-
(https://e2g.com/indus
being on the lower end and methane being on the upper end of the
insights- insights-
spectrum. For a low-speed API 618 refinery machine, a running
ar/hot- ar/leveraging-
speed of 300 RPM (5 Hz) is realistic.
tap- ep-7-3-
evaluations- 3-series-
and- for-
practical- equipment-
Clearly, system acoustic problems (i.e., resonant standing waves) guidance- repairs/)
can easily extend far from the machinery. Lastly, it is important to for-in-
note that damping is the only attenuating mechanism that reduces service- Leveraging
the magnitudes of acoustic resonances once resonances occur. As repair- EP-7-3-
compared to liquid systems, gases have order of magnitude less welding/) 3
damping. Series
Considering the capability of acoustic waves to traverse for
Hot Tap
considerable distances within piping systems, a key insight for Equipment
Evaluations
examining piping vibration lies in understanding the relationship Repairs
and
between the compressor and the piping. Specifically, if the (https://e2g.com/in
Practical
frequency of observed vibration in the piping aligns with the insights-
compressor’s running speed, or an integer multiple thereof, this Guidance
ar/leveraging-
connection can be established. This holds true regardless of how for In-
ep-7-3-
far the site of the vibration is from the actual compressor. Such an Service
3-
insight is helpful in accurately diagnosing and addressing vibration Repair
issues in compressor piping systems. series-
Welding
for-
System Acoustics – Computer-Based Analysis (https://e2g.com/industry-
equipment-
insights-
repairs/)
ar/hot- Nov 1, 2023
tap-
Computer-based numerical analysis is required for predicting evaluations-Authors:
Derek L.

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 acoustic natural frequencies, the interaction effects between Derek L.
and-
Rinas,
compressors and compressor cylinders, effects of control valves practical- P.Eng.,
and orifice plates, and system pressure magnitudes, especially
guidance- Consulting
when considering secondary effects like fluid damping. Engineer I;
for-in-
Neal
Figure 2 shows a basic acoustic model used to predict the system service- Wagner,
acoustic response on the suction side of a mid-stream, high-speed repair- Staff
natural gas compressor unit that operates at 1500 RPM. The welding/) Engineer II
system is modeled from the cylinder valves to the compressor skid Nov 1, 2023 The need
inlet where a non-reflective boundary condition is applied (i.e., for post-
Author:
pressure waves can exit but are not reflected back). This approach construction
Raj K.
equipment
is an example of a comprehensive API 618 DA3 assessment for a Patadia,
repairs
new design. E.I.T., Staff
and
Engineer I
maintenance
Figure 3 illustrates the pulsation solver results for a natural gas In-service
best
compressor design for a mid-stream client. In this figure, the welding as
practices
numerical results for various locations in the suction line and within part of a
has led to
the suction PSD bottle are plotted as a function of excitation maintenance
ASME
frequency. To produce the results, a sinusoidal excitation frequency program is
PCC-1
a practical
of unit amplitude is swept through the range of frequencies and PCC-
and
presented. The figure also illustrates the accuracy and usefulness 2
economical
standards
of the simplified hand calculations in predicting potential problems way to
becoming
with this design. However, the figure just shows the acoustic natural address
valuable
frequencies for a unit excitation frequency swept through a wide leak
resources
band of frequencies, and not necessarily at the compressor repairs or
for many
excitation frequency. If the excitation is not there, the response will new
owner-
nozzle
be zero. Therefore, the purpose is the evaluation of the interaction operators,
installations;
of the compressor excitation frequencies and the acoustic response yet these
however, it
standards
of the piping to keep dynamic pressures below code-required limits does come
inherently
(for on-resonance conditions) and shaking forces below code limits with a few
maintain a
for instances where the piping is not mechanically resonant. This is risks,
level of
the first major objective in performing either an API 618 DA2 or DA3 including
generality.
analysis, or the acoustic portion of the acoustic-mechanical burn-
In this
through
analysis. Typical API 618 assessments excite a range of excitation article,
and
frequencies, typically +/- 20% of the running speed(s), and ensure Derek and
hydrogen-
Neal will
that the code-required limits are satisfied at harmonic multiples induced
explain
cracking.
how the
In this
Equity
usually up to 10x running speed, but the largest emphasis is placed article, Raj Engineering
will Practices

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 on the lower harmonics between 1x and 4x running speed where will Practices
discuss (EEPs),
higher excitation pressures occur.
the risks specifically
involved EP 7-3-3,
with in- address
service the gaps
welding, and
thermal provide
analysis to the extra
quantify context,
the risks, details,
and and
practical guidance
in-service to provide
welding more
considerations comprehensive
to ensure solutions
safe and for post-
successful construction
hot tap equipment
connections. repairs.

Read More Read More

» »
Figure 2: Example of a compressor suction-side computational
acoustic model with choice of boundary conditions. (https://e2g.com/industry-
(https://e2g.com/industry-
insights- insights-
ar/hot-tap- ar/leveraging-

evaluations- ep-7-3-3-
and- series-for-
practical- equipment-
guidance- repairs/)

for-in-
service-
repair-
welding/)

Figure 3: Comparison of computational versus hand-calculated

acoustic natural frequencies for the compressor suction shown in
Figure 2.

Before moving on to the discussion of mechanical behavior and its

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 response to the acoustics, the following is a list of pulsation-related
excitation mechanisms and the potential effect they can have on a
system. Each of these mechanisms can be tested for and predicted
in the design/re-design stage.

Mechanism Description Damage/Symptom

Areas

Non-resonant Excessive dynamic Vibration of

pulsation-induced pressures/forces in mainlines
shaking forces piping combined with
insufficient piping
support
stiffnessPiping not
mechanically
resonant

Acoustic resonance in Oscillating pressures Vibration of

piping (standing waves) in mainlinesVibration/fat
the piping that igue small-bore
develop at the connectionsDamage
compressor running to
speed or one of its supports/structures
integer multiplesCan
occur over very long
distances (hundreds
of feet) away from the
compressor

Acoustic pulsation or Oscillating pressures Fatigue cracks in

excessive non- (standing waves) in bottle nozzle and
resonant shaking the PSD chambers at cylinder flange
force within suction the compressor weldsFatigue
and discharge bottles running speed or one cracking of bottle
(pulsation of its integer internalsIncreased
suppression devices multiplesVibration compressor
or PSDs) typically closer to the vibrationFoundation
machine damage

Compressor cylinder Oscillating pressures Increased

flange pulsation (standing waves) that compressor
develop between the vibrationFoundation
PSD bottles and the damage

cylinder gas
passages

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 passages

Cylinder gas passage High-frequency Chattering and

shaking force oscillating pressures reduced valve life
(standing waves)
within the cylinder
gas passages

Table 1: Summary of acoustic pulsation mechanisms, descriptions,

and symptoms.

Mechanical Response

The second major aspect of an API 618 computational acoustic-

mechanical analysis is the mechanical portion. Many engineers are
at least somewhat familiar with the concept of mechanical natural
frequencies and that good engineering design will ensure that the
mechanical natural frequencies of the piping/vessel/structure have
sufficient separation margin (typically 20% is standard) from a
known excitation frequency. The same can be said for the acoustic
natural frequencies in the process gas and the known excitation
frequencies from the pistons. The complexity of the mechanical
analysis portion of an acoustic-mechanical analysis is what
distinguishes between DA2 and DA3.

Predicting the future occurrence of vibrations in compressor

systems – including the frame, cylinders, PSD bottles, and piping –
hinges on the accurate calculation of mechanical natural
frequencies. One of the primary sources of error in this prediction is
using finite element analysis (FEA)-based methods that oversimplify
model boundary conditions. Common oversights include assuming
that piping supports are completely rigid, that suction knock-out
drums or separators are firmly attached to their bases, or that the
compressor crankcase is mounted on an immovable
foundation. Such assumptions, explicitly cautioned against in API
618, lead to significant errors in vibration prediction. This scenario
exemplifies the principle of “garbage-in, garbage-out,” emphasizing
the importance of realistic assumptions in modeling for accurate
outcomes.

Figure 4 and Figure 5 show the cross section of the same

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 compressor case and the associated FEA mesh discussed in Figure
2. These figures illustrate the typical model complexity required for
predicting accurate mechanical responses of compressor PSD
bottles and compressor cylinder heads due to the stiffness or lack of
stiffness in the compressor crankcase and foundation. In this
example, the suction PSD bottles are supported at their nozzle
necks on structural steel that also supports the piping and is
mounted to the compressor skid. Therefore, a single model to
predict the shared response of the entire structure is necessary.

Figure 5: Comparison of
Figure 4: Comparison of
computational versus hand-
computational versus hand- (https://web-stage.e2g.com/wp-
calculated acoustic natural
(https://web-stage.e2g.com/wp-
calculated acoustic natural
content/uploads/2023/11/image-
frequencies for the compressor
content/uploads/2023/11/image-
frequencies for the compressor
suction shown in Figure 2.
suction shown in Figure 2. 7.png)
6.png)

Using this model, mechanical natural frequencies were identified in

the suction piping within 7% of 2x the compressor running speed,
which was a frequency with substantial excitation energy (see
Figure 6 and Figure 7). Support modifications were made to stiffen
this frequency above 2.4x the running speed, and the compressor
has experienced successful operation over the past
year. Additionally, Figure 7 shows the importance of the detailed
modeling of the suction scrubber vessel and piping support nearest
the scrubber to accurately identify this potentially problematic
natural frequency. If the support or the vessel nozzle was assumed
rigid, the predicted natural frequency would be extremely
inaccurate.

The question of the required separation margin in these systems is

important. Can we realistically achieve it every time? In complex
systems like these, we often find many mechanical natural
frequencies that fall within 20% of a certain running

speed. According to Section 7 of API 618 5th Edition, there should

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 be a 20% separation margin between these frequencies and any
excitation frequencies that have significant energy. This
requirement, which can be somewhat unclear, typically calls for
expert judgment or the use of a forced response analysis. This
analysis involves applying the shaking forces, as determined by the
acoustic model, to the mechanical FEA model to assess how severe
the vibrations might be.

Figure 6: Comparison of
computational versus hand- Figure 7: Comparison of
(https://web-stage.e2g.com/wp-
calculated acoustic natural computational versus hand-
content/uploads/2023/11/image-
frequencies for the compressor (https://web-stage.e2g.com/wp-
calculated acoustic natural
suction shown in Figure 2. content/uploads/2023/11/image-
frequencies for the compressor
8.png)
suction shown in Figure 2.
9.png)

Why the common rule-of-thumb 20% separation margin? A 20%

separation margin is to ensure a true 10% separation margin by
accounting for an additional 10% in modeling errors. Therefore,
when performing simple design changes or piping modifications for
existing systems, experimental field testing/measurement of the
mechanical natural frequencies via impact testing or experimental
modal analysis is more accurate and leads to less identification of
false positives when compared to detailed FEA modeling that may
flag more problems and lead to more design iterations. The
experimental field-based approach to piping modifications can be
more cost-effective if paired with simplified calculations and field
adjustments/additions of supports if mechanical natural frequencies
are identified within the more narrow 10% separation margin. Start-
up testing of the machinery and piping is always advised even if API
618 design analysis is used.

Modifications to piping supports, such as adding braces or gussets

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 to small-bore cantilevered connections, carry the risk of
inadvertently negatively altering the mechanical natural
frequency. This alteration can shift the mechanical natural
frequency, potentially bringing it within 10% of a higher-order
running speed harmonic. Such a shift might introduce new vibration
issues that did not exist before. This phenomenon is often
colloquially described as “bracing the vibration here only to transfer
it elsewhere.” While not technically accurate, this saying captures
the unintended consequences that can arise from seemingly minor
adjustments to the piping supports.

Vibration failures of small-bore piping on reciprocating compressor

systems are clearly the most common type of failure that occurs in
our industry. E2G has years of experience evaluating and
surveying small-bore cantilevered connections and failures. Even
for low-speed reciprocating compressors, we have found small 10-
inch-long cantilevered connections excited by very high orders of
running speed, i.e., 13x running speed. Clearly, assuming the
excitation occurs only at low orders of running speed is not
accurate. Given the complexity of including these small connections
into mechanical FEA models as the ones shared above, the
connections are typically omitted. Practically, small-bore
connections are best managed using adequate design practices and
field-testing following commissioning or following any modification of
the small-bore connections. Not including small-bore connections
in the design assessment, lack of good engineering standards for
their design, and lack of inspection practices involving vibration are
the reason for small-bore connections failures in our industry.

Summary of API 618 Design Approaches

Now that we have covered the basics of acoustic and mechanical

design, the API 618 design approaches are reviewed here.

The acoustic-mechanical analysis has three levels of complexity

called design approaches (DA1, DA2, and DA3). DA1 uses hand
calculations that are often used by equipment packagers to initially
size the compressor suction and discharge PSDs. Alternatively, this
approach is only used on low pressure-low HP systems. DA2 and
DA3 require specialist engineering firms familiar with compressor

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 and piping acoustics, mechanical compressor and piping design,
process design, and structural design to make adequate predictions
of how the system will behave prior to its commissioning.

Table 2 below (taken from API 618 5th Edition) differentiates the
requirement for each design level based on the compressor’s
absolute discharge pressure and the rated power per cylinder.

DA2 focuses on acoustic simulation coupled with a

mechanical review of the piping restraint system. It involves using
pulsation suppression devices, such as dampeners, and sound
engineering practices to control the vibrational response of the
piping system. This approach evaluates the interaction between the
compressor and suppression devices, considering the effects on
compressor performance and the evaluation of shaking forces within
the suppression devices. The evaluation stops short of a full
mechanical analysis of the piping system. Instead, the mechanical
response of the piping is handled via the use of maximum piping
span tables and more simplified hand-based calculations to ensure
an adequate separation margin between excitation and natural
frequencies.

In contrast, DA3 includes all the elements of DA2 but adds a

comprehensive mechanical analysis of the compressor cylinder,
suppression devices, and associated piping systems. It looks at the
interaction between acoustic and mechanical responses, including
the forced mechanical response when necessary. DA3 aims to
predict mechanical natural frequencies and ensure they are
designed to meet specific separation margin criteria, and ensure
shaking forces do not exceed set limits. This approach starts at a
rigid point in the compressor system and includes analysis up to the
second rigid pipe clamp on the suction and discharge piping away
from the pulsation suppression devices.

DA3 is more thorough than DA2 because it not only considers the
acoustic behavior of the system but also integrates a mechanical
perspective to avoid resonances that could amplify shaking
forces. It includes the evaluation of cyclic stresses in the

compressor components based on their flexibility and dynamic

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 movements, and it takes into account the allowable vibration limits
for components.
(https://e2g.com)

Table 2. Design approach requirements for new design of

reciprocating compressors per API 618 5th Edition.

Recommendations When Repurposing or Modifying Systems

For evaluating excessive vibration in existing in-service machinery

and piping systems or when modifications are made to existing
compressor systems, several aspects of API 618 and API 688
should be leveraged to ensure that modifications do not alter the
system acoustics, creating excessive piping vibration. As part of
any revamp or alteration project, E2G recommends an initial risk
assessment of the project to identify which aspects of the system
could be affected (either acoustically or mechanically, or both). The
outcome of this risk assessment will identify which aspects of the
API 618 acoustic-mechanical analysis should be performed as part
of the modification or repurposing.

Computational Acoustic Pulsation Analysis (Per DA2 and

DA3):
Used when the lineal feet of the process-wetted piping
are altered from their original as-designed condition.
Recommended full DA3 analysis (acoustic and
mechanical) when repurposing compressors for different
services.
Not required when mechanical only changes are made,
i.e., modified piping support(s).

Does not need to be performed for alteration of small-

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 bore branch piping less than NPS 2.
Modifying an old compressor piping system and missing
drawings? Do the suction and discharge PSD bottles
have internals? Either radiography or visual inspection
of the PSDs is an option, or a comparative analysis of
the before and after system can be performed by making
the assumption that no bottle internals exist (volume-only
bottles).
Because the important dimensional variables of the
compressor gas passages are not likely available for in-
service machines, modifications to piping lengths do not
require detailed analysis of high-frequency, short-
wavelength, gas-passage dynamics because the
compressor is unchanged. Therefore, more simplified
acoustic boundary conditions can be assumed on the
compressor cylinder heads.
Can omit cylinder gas passage and valve dynamics,
cylinder flange pressure pulsation and shaking force
checks, and PSD shaking force checks when only
making modifications to the piping.
Areas especially sensitive to piping modifications are the
inlets of pressure relief piping, addition of bypass or
recirculation piping, modification of the size of the
suction scrubber or separator vessels, rerating of
compressor cylinders to increase capacity, and addition
of valve unloaders to add capacity control. The objective
is to ensure that the modified piping does not create
acoustic standing waves (acoustic resonances) that did
not previously exist in the original system.
DA3 Mechanical Analysis:
Recommended following computational acoustic
analysis for any alteration or modification to mainline
piping or service conditions.
Recommended for alteration or modification to piping
supports only unless a pre-start-up field testing of the
mechanical natural frequencies is not performed. Pre-
start-up field testing of the mechanical natural

frequencies and use of a less conservative 10%

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 separation margin (because the natural frequency is
directly measured and not predicted) followed by an in-
service vibration assessment at all operating conditions
is recommended.
Can usually omit forced response analysis when
coupling separation margin analysis with pre-start-up
field testing and potential in-field piping support
modifications.
Simple Mechanical Design Review:
Often sufficient for modification to any small-bore
cantilevered connections (i.e., vents, drains, pressure or
temperature gauges, etc.) or auxiliary piping systems
(i.e., coolant lines, fuel gas lines, lube oil systems, etc.).
However, due to the risk of creating new resonance
conditions at higher frequencies when adding supports,
an in-service field inspection for abnormal vibration is
always advised.
Static Pipe Stress Analysis for Compliance to ASME B31:
The necessity of this analysis increases when operating
temperatures exceed 200°F.
Recommended when interstage or discharge coolers are
mounted off-skid.
Recommend including nozzle loads on separation or
scrubber vessels, exchangers, or cooler header-boxes if
major piping reroutes take place.
Torsional Vibration Analysis:
While not the focus of this article, any modification that
includes changing of the driver (motor to engine, etc.) or
modification of the operating conditions or service should
include an updated torsional vibration analysis of the
compressor and driver system.
Field Analysis:
Recommended as the starting point if a prior
modification or equipment repurposing has led to a new
systemic vibration problem with the compressor and/or
piping.
High-speed pressure testing using special field testing

equipment at the compressor cylinders and at available

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 vent, drain, or pressure taps is a valuable approach and
produces useful data for acoustic model validation of
existing systems that are currently problematic.
Valid approach when making modifications to small-bore
connections.

A decision-making flow diagram is provided in Figure 8 to help you

make appropriate decisions when modifying or repurposing your
equipment.

Figure 8: Flowchart of recommendations when considering alteration or

(https://web-stage.e2g.com/wp-
modification to reciprocating compressors and attached piping systems.
Click the image to enlarge.
content/uploads/2023/11/v39_FIG-3.jpg)

In summary, adhering to certain aspects of API 618 and API 688 is

crucial when modifying reciprocating compressors and piping
systems. These standards provide a comprehensive approach to
managing the complexities of acoustic pulsation and vibration. By
following these guidelines, organizations can ensure the safety,
efficiency, and longevity of their compressor systems, maintaining
optimal performance and reliability.

If you have any questions for the author, please submit the form

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 below:

Guide to API 618 Acoustic-Mechanical

Design Validations for Repurposed or
Modified Reciprocating Gas Compressor
Systems
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 E2G | The Equity Engineering
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 E2G’s Quality Management System is certified to the ISO 9001:2015 quality ©2023 E2G | The Equity Engineering
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