The Application Of Computer Simulation And Real-Time Monitoring To Minimize The Pressure Pulsations In Complex Pumping Systems

Abstract

Chemical and process plants usually contain numerous valves and pumps in a complex network of pipe runs. Plant design and pump selection are usually based on steady state design conditions. However, the opening or closing of valves, or the starting or tripping of pumps, in the system can generate high unsteady pressures that can damage piping and components in the system along with the pumping machinery itself. These unsteady pressures can result in large forces that are reacted at the pump nozzles. These loads can lead to casing failures or extrusion of the flange gasket. The radial and axial thrust bearings are directly impacted and premature failure is a possibility well before the B10 life based on steady loading has been reached. There are several simple formulae that can be used to determine the order of magnitude of the pressure pulsations that are generated due to various system upsets. However, accurate modelling requires a numerical solution that can be performed on today’s high end personal computers. The numerical simulation is used together with a new remote monitoring system recently introduced by the authors’ company. This technology has simplified the collection of real-time accurate field data during all phases of pump operation. The ability to retrieve the data remotely has provided a cost effective means of expanding the piping simulator’s database. This has enhanced the simulator’s ability to accurately predict a pump piping system response to anomalous flow conditions.