Predicting the Power Loss of Reciprocating Compressor Manifolds
NOVA Research: Kamal K. Botros John Geerligs
Beta Machinery: Kelly Eberle Brian Howes Gordon Sun Russ Barss Bryan Long
TransCanada: Thomas Robinson Peerless Mfg: Dave Breindel
PSC: Martin Hinchliff - chair Rainer Kurz Christine Scrivner Steve O’toole Clint Lingel
Project Team:
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Project Motivation
How much power does my
compressor need?
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Compressor Performance Calculation
Why Estimated Total Load? - Compression (ideal) power - Mechanical Efficiency - Manifold (bottle) power loss - Orifice power loss - Other system loss
How do you calculate the unknown power losses?
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Compressor Performance Calculation
How much, assume 1%, 2%? Is it accurate?
Unknown Power Losses are estimated by the pressure drop
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Pressure Drop Calculation… easy, right?
OK, but…does this work for my recip compressor?
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Challenges to Industry
• Manifolds (pulsation bottles) have complicated geometry. K-factors are not published.
• Recip compressors create high flow fluctuations.
• How to relate pressure drop to power loss?
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How important is power loss?
Inaccurate power calculation effects performance and reliability (3% to 12% error in results)
RED = Unsafe
YELLOW = Conditionally Safe
GREEN = Safe
Suction Pressure (psia)
Disc
harg
e Pr
essu
re (p
sia)
Consequences: Driver size inadequate Unable to meet
contract flow Reliability (rod load,
reversal, and discharge temperature)
Inefficient operation
Design Point move to Unsafe Zone
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Overall Project Objectives
1. Develop a methodology to predict the mean and pulsating power losses across Reciprocating Compressor Manifolds (bottles).
2. Validate the methodology via experimental means, either from:
Measurements of actual recip. compressor in the field, or
Scale-down test rig involving a custom-design bottle and a Pulse-generator.
3. Ultimate Goal is to:
Recommend a standard methodology to quantify the pulsating flow power loss.
Come up with adjustment factor(s) to be applied to the mean pressure drop coefficient (K) in the presence of pulsating flow.
9 GMC Nashville Oct 5-8, 2014
Overall Project Objectives
1. Develop a methodology to predict the mean and pulsating power losses across Reciprocating Compressor Manifolds (bottles).
2. Validate the methodology via experimental means, either from:
Measurements of actual recip. compressor in the field, or
Scale-down test rig involving a custom-design bottle and a Pulse-generator.
3. Ultimate Goal is to:
Recommend a standard methodology to quantify the pulsating power loss.
Come up with adjustment factor(s) to be applied to the mean pressure drop coefficient (K) in the presence of pulsating flow.
Completed 2013
Focus of this presentation
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Outline
1. Test Program 2. Measurements and Results 3. Key Findings 4. Next Steps
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Test Setup at TCPL’s GDTF in Didsbury, Alberta
Pipeline quality gas
Nozzle Bank
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Pulse Generator
Pulsations will be created by a hydraulically driven rotating paddle • Not a recip compressor • Operate at 300 to 1200
rpm. • Double acting • Pulse amplitude 1% to 2%
line pressure
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Test Setup Details
Configuration A: Bottle Upstream, Orifice Downstream
Configuration B: Orifice Upstream, Bottle Downstream
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Custom Bottle Design (donated by Peerless Mfg.)
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End Treatments
2” x 3”Diffuser
Taper
Normal (Square)
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Square End Treatment
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Diffuser End Treatment
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Photos of Configuration A Setup
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Sonic Nozzles Bank
Pulse Generator
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Static P & T Transducers (Upstream)
Pair of Dynamic P Transducers (1.5 m apart)
Kulite P Transducers
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Pair of Dynamic P Transducers (1.5 m apart)
Kulite P Transducers
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Rosemount Differential P Transducer
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Pair of Dynamic P Transducers (1.5 m apart)
Rosemount Differential P Transducer
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Pair of Dynamic P Transducers (1.5 m apart)
Kulite P Transducers
Static P & T Transducers (Downstream)
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Photos of Configuration B Setup
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Taper Diffuser
Β = 0.5
Β = 0.7
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Example of Pulsating Pressure Measurements (Across the Bottle)
-90
-60
-30
0
30
60
90
0 50 100 150 200 250
Pre
ssu
re O
scill
ati
on
(k
Pa
)
PT1
-90
-60
-30
0
30
60
90
0 50 100 150 200 250
Pre
ssu
re O
scill
ati
on
(k
Pa
)
PT2
-90
-60
-30
0
30
60
90
0 50 100 150 200 250
Pre
ssu
re O
scill
ati
on
(k
Pa
)
PT3
-90
-60
-30
0
30
60
90
0 50 100 150 200 250
Pre
ssu
re O
scill
ati
on
(k
Pa
)
Time (ms)
PT4
0
0
0
1
10
100
0 10 20 30 40 50 60 70 80 90 100 110 120
Pre
ssu
re A
mp
litu
de
(k
Pa
)
PT1PT1
0
0
0
1
10
100
0 10 20 30 40 50 60 70 80 90 100 110 120
Pre
ssu
re A
mp
litu
de
(k
Pa
)
PT2
0
0
0
1
10
100
0 10 20 30 40 50 60 70 80 90 100 110 120
Pre
ssu
re A
mp
litu
de
(k
Pa
)
PT3
0
0
0
1
10
100
0 10 20 30 40 50 60 70 80 90 100 110 120
Pre
ssu
re A
mp
litu
de
(k
Pa
)
Frequency (Hz)
PT4
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Example of 1st Harmonic Mapping (Configuration A)
kk uandP
0.00.51.01.52.02.53.03.54.04.55.05.56.06.57.07.58.0
0
10
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Velo
city
Am
plitu
de (m
/s)
Pres
sure
Am
plitu
de (k
Pa)
Distance From Upstream 8"/4" Reducer (m)
Pressure Amplitude (kPa)Velocity Amplitude (m/s)
Puls
atio
n Bo
ttle
OrificeP. Gen.
Test 27(40.5 Hz,
6 Nozzles, 0.5 Beta)
Acoustic Power= 0.2W
Acoustic Power= 334W
Acoustic Power= 380W
Acoustic Power=229W
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Example of 1st Harmonic Mapping (Configuration B)
kk uandP
0.00.51.01.52.02.53.03.54.04.55.05.56.06.57.07.58.0
0
10
20
30
40
50
60
70
80
90
100
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Velo
city
Am
plitu
de (m
/s)
Pres
sure
Am
plitu
de (k
Pa)
Distance From Upstream 8"/4" Reducer (m)
Pressure Amplitude (kPa)Velocity Amplitude (m/s)
Puls
atio
n Bo
ttle
Orifice
P. Gen.
Test 209(15.875 Hz,
6 Nozzles, 0.5 Beta)
Acoustic Power= 44W
Acoustic Power= 248W
Acoustic Power= 391W
Acoustic Power=100W
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Test Results (Configuration A)
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Configuration A Test Scope
TestNumber of
Sonic NozzlesEnd Treatments Orifice β Hole(s)
1 3 and 6 Square/Square 1 -
1a 3 and 6 Square/Square 0.5 Single
1b 3 and 6 Square/Square 0.5 Multiple
1c 3 and 6 Square/Square 0.7 Single
1d 3 and 6 Square/Square 0.7 Multiple
2 3 and 6 Square/Diffuser 0.5 Single
3 3 and 6 Taper/Diffuser 0.5 Single
4 3 and 6 Taper/Square 0.5 Single
4a High flow Taper/Square O.7 Single
Configuration A Test Scope
For each of the sub-configuration and flow rate, a total of 10 tests were conducted at the following frequencies: 0, 11, 13, 15, 17, 22, 27, 31, 35, and 41 Hz. (Total for Configuration A = 180 Tests).
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Normalized Pulsating Power Loss (Bottle)
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 0.2 0.4 0.6 0.8 1 1.2 1.4
Nor
mal
ized
Puls
atio
n Po
wer
Los
s (W
P/ρc
Aurm
s2)
Normalized Velocity Oscillation at Bottle Flange or Orifice Plate (urms/U)
Square/Square Orifice, Beta = 0.5, Single Hole
Square/Square Orifice, Beta = 0.5, Multiple Holes
Square/Square Orifice, Beta = 0.7, Single Hole
Square/Square Orifice, Beta = 0.7, Multiple Holes
Square/Square No Orifice
Square/Diffuser Orifice, Beta = 0.5, Single Hole
Taper/Square Orifice, Beta = 0.5, Single Hole
Taper/Diffuser Orifice, Beta = 0.5, Single Hole
Configuration A:Bottle
TGP St54 (Original Bottles)
TGP St54 (New Bottles)
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Normalized Velocity Oscillation urms/U
TGP Station 54: 8350 HP compressor, 6 throw • urms/U=0.7-1.3
Gathering compressor: 1775 HP, 4 throw • urms/U=0.75
Vapour Recovery Compressor: 1200 HP, 6 throw • urms/U=0.4
Test Setup: Hydraulic driven rotating paddle, 2 HP urms/U=0.3 max
Current test setup representative of lower power/throw applications. Pulse Generator modifications could generate urms/U=0.6
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Normalized Pulsating Power Loss (Orifice)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
0 0.1 0.2 0.3
Nor
mal
ized
Puls
atio
n Po
wer
Los
s (W
P/ρ c
Aurm
s2)
Normalized Velocity Oscillation at Bottle Flange or Orifice Plate (urms/U)
Square/Square Orifice, Beta = 0.5, Single Hole
Square/Square Orifice, Beta = 0.5, Multiple Holes
Square/Square Orifice, Beta = 0.7, Single Hole
Square/Square Orifice, Beta = 0.7, Multiple Holes
Square/Diffuser Orifice, Beta = 0.5, Single Hole
Taper/Square Orifice, Beta = 0.5, Single Hole
Taper/Diffuser Orifice, Beta = 0.5, Single Hole
Configuration A:Orifices
Beta = 0.5
Beta = 0.7
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10
12
14
16
18
20
22
24
26
28
30
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Mea
n Fl
ow P
ress
ure
Loss
Coe
ffici
ent,
K
Normalized Velocity Oscillation at Bottle Flange or Orifice Plate (urms/U)
Square/Square Orifice, Beta = 0.5, Single HoleSquare/Square Orifice, Beta = 0.5, Multiple HolesSquare/Square Orifice, Beta = 0.7, Single HoleSquare/Square Orifice, Beta = 0.7, Multiple HolesSquare/Square No OrificeSquare/Diffuser Orifice, Beta = 0.5, Single HoleTaper/Square Orifice, Beta = 0.5, Single HoleTaper/Diffuser Orifice, Beta = 0.5, Single Hole
Configuration A:Bottle
Normalized Mean Flow Pressure Loss Coefficient (Bottle) – zoomed in
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Theoretical K Factor for the Bottle with Square End Treatments
K1
K2 K3
K4
K5
NPS 4, ID (d2) 4.026 in
Choke Tube ID (d1) 1.939 in
Vessel ID (D) 14.29 in
Choke tube (L) 26 in
Element Local K-FactorK-Factor
(Ref NPS4)
Entrance to Bottle, K1 0.85 0.85
Emtrance to Choke Tube (square), K2 0.49 9.11
Choke Tube (f=0.014), K3 0.19 3.49
Choke Tube Exit (square), K4 1.00 18.59
Entrance from Bottle to NPS4, K5 0.42 0.42
Sum (Overall K) 32.45
Measured K Factor 25
Bottle Theoretical K Coefficient
K is 21% lower than expected. Why?
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Thoughts about why the Measured K Factor for the Bottle is Lower than Theoretical Value
Flow
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Quasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating Flow
0
5
10
15
20
25
30
0
50
100
150
200
250
300
350
0 0.01 0.02 0.03 0.04
Velo
city
(m/s
)
Pres
sure
Dro
p (k
Pa)
Time (s)
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
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Quasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating Flow
0
5
10
15
20
25
30
0
50
100
150
200
250
300
350
0 0.01 0.02 0.03 0.04
Velo
city
(m/s
)
Pres
sure
Dro
p (k
Pa)
Time (s)
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
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Quasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating Flow
0
5
10
15
20
25
30
0
50
100
150
200
250
300
350
0 0.01 0.02 0.03 0.04
Velo
city
(m/s
)
Pres
sure
Dro
p (k
Pa)
Time (s)
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
op
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Quasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating Flow
0
5
10
15
20
25
30
0
50
100
150
200
250
300
350
0 0.01 0.02 0.03 0.04
Velo
city
(m/s
)
Pres
sure
Dro
p (k
Pa)
Time (s)
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
Mean Pressure DropWith Pulsation)
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
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Quasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating Flow
0
5
10
15
20
25
30
0
50
100
150
200
250
300
350
0 0.01 0.02 0.03 0.04
Velo
city
(m/s
)
Pres
sure
Dro
p (k
Pa)
Time (s)
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
Mean Pressure DropWith Pulsation)
Freq (Hz) 27Omega (rad/s) 169.646T (s) 0.037037U (m/s) 16K 25Density (kg/m3) 40Mean DP, no pulsation (kPa) 128
op
y = x2 + 1
1
1.05
1.1
1.15
1.2
1.25
1.3
1.35
1.4
1.45
1.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
K effe
ctiv
e/
K no-
puls
atio
n
urms/U
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0.95
1
1.05
1.1
1.15
1.2
0 0.1 0.2 0.3 0.4
K effe
ctiv
e/
K no-
puls
atio
n
urms/U
Quasi-Steady Pressure Drop Relationship
Square/Square
Square/Diffuser
Taper/Square
Taper/Diffuser
Current Measurements of Mean Flow Pressure Loss Coefficient (Representative of Suction Bottle)
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Normalized Mean Flow Pressure Loss Coefficient (Orifice) – Referenced to NPS4
0
5
10
15
20
25
30
35
40
45
0 0.1 0.2 0.3
Mea
n Fl
ow P
ress
ure
Loss
Coe
ffici
ent,
K
Normalized Velocity Oscillation at Bottle Flange or Orifice Plate (urms/U)
Square/Square Orifice, Beta = 0.5, Single Hole
Square/Square Orifice, Beta = 0.5, Multiple Holes
Square/Square Orifice, Beta = 0.7, Single Hole
Square/Square Orifice, Beta = 0.7, Multiple Holes
Square/Diffuser Orifice, Beta = 0.5, Single Hole
Taper/Square Orifice, Beta = 0.5, Single Hole
Taper/Diffuser Orifice, Beta = 0.5, Single Hole
Configuration A:Orifices
Ktheoretical (for β = 0.5) = 29.7
Ktheoretical (for β = 0.7) = 4.3
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Test Results (Configuration B)
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Configuration B Test Scope
For each of the sub-configuration and flow rate, a total of 10 tests were conducted at the following frequencies: 0, 11, 13, 15, 17, 22, 27, 31, 35, and 41 Hz. (Total for Configuration B = 160 Tests)
TestNumber of
Sonic NozzlesEnd Treatments Orifice β Hole(s)
1 3 and 6 Square/Square 1 -
1a 3 and 6 Square/Square 0.5 Single
1b 3 and 6 Square/Square 0.5 Multiple
1c 3 and 6 Square/Square 0.7 Single
1d 3 and 6 Square/Square 0.7 Multiple
2 3 and 6 Square/Diffuser 0.5 Single
3 3 and 6 Taper/Diffuser 0.5 Single
4 3 and 6 Taper/Square 0.5 Single
Configuration B Test Scope
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Normalized Pulsating Power Loss (Bottle)
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0 0.2 0.4 0.6 0.8 1 1.2 1.4
Nor
mal
ized
Puls
atio
n Po
wer
Los
s (W
P/ρc
Aurm
s2)
Normalized Velocity Oscillation at Bottle Flange or Orifice Plate (urms/U)
Square/Square Orifice, Beta = 0.5, Single Hole
Square/Square Orifice, Beta = 0.5, Multihole
Square/Square Orifice, Beta = 0.7, Single Hole
Square/Square Orifice, Beta = 0.7, Multihole
Square/Diffuser Orifice, Beta = 0.5, Single Hole
Taper/Square Orifice, Beta = 0.5, Single Hole
Taper/Diffuser Orifice, Beta = 0.5, Single Hole
Configuration B:Bottle
TGP St54 (Original Bottles)
TGP St54 (New Bottles)
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Current Measurements of Mean Flow Pressure Loss Coefficient (Representative of Discharge Bottle)
0.95
1
1.05
1.1
1.15
1.2
0 0.1 0.2 0.3 0.4
K effe
ctiv
e/
K no-
puls
atio
n
urms/U
Quasi-Steady Pressure Drop Relationship
Square/Square
Square/Diffuser
Taper/Square
Taper/Diffuser
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Summary of Site Testing
1. Methodology: Successful in validating the Flow Energy (acoustic power) methodology developed in Phase I.
2. Bottle: Differences measured between the bottle loss factor in steady flow and fluctuating flow as compared to published data. A 21% difference for steady flow, 5% for fluctuating flow in the test rig.
3. Orifice: Loss factor for single hole vs multi hole agreed well with published data. Some divergence at maximum test frequency of 41 Hz. Additional testing to investigate higher frequencies.
4. Pulse Generator: could create sufficient pressure fluctuations (2% of line) but flow fluctuations were lower than high power compressor cylinder (urms/U
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2014 Project Plan
Task Status
Field Test - Design test rig - Fabricate and Install - Execute Test Plan - Data Analysis
Testing completed July 25 Data review and analysis 95% completed.
Report Complete by end of 2014
Optional Scope: Testing on reciprocating compressor facility
Need a site: TGP Stn 54, lots of information from Phase 1. Other site possible. Design test: - Fluctuation flow measurement - Compressor performance (P-V curves) and
power measurements (torque, motor power)
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Suggestions for Future Work
Addition testing proposed at the TCPL site. Redesign of pulse generator or test rig required to create high flow fluctuations. CFD analysis of components.
4 possible journal publications resulting from the work completed.
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Thank You and Acknowledgements
GMRC for Funding the Research Program PSC Oversight committee Peerless Mfg. (Dave Breindel) for fabricating and donating the
Custom Bottle Design used in the present testing program. TCPL (Thomas Robinson) for the in-kind contribution of the use
of the GDTF in Didsbury, Canada. The following individuals for assisting in conducting the tests
and data analysis: ₋ Matthew Kindree, Alex Mantey (NRTC) ₋ Bill Eckert, Mark DuBois, Mehdi Arjmand (Beta)
Predicting the Power Loss of Reciprocating Compressor Manifolds
NOVA Research: Kamal K. Botros John Geerligs
Beta Machinery: Kelly Eberle Brian Howes Gordon Sun Russ Barss Bryan Long
TransCanada: Thomas Robinson Peerless Mfg: Dave Breindel
PSC: Martin Hinchliff - chair Rainer Kurz Christine Scrivner Steve O’toole Clint Lingel
Project Team:
Predicting the Power Loss of Reciprocating Compressor Manifolds Project MotivationCompressor Performance CalculationCompressor Performance CalculationPressure Drop Calculation… easy, right?Challenges to IndustryHow important is power loss?Overall Project ObjectivesOverall Project ObjectivesOutlineTest Setup at TCPL’s GDTF in Didsbury, AlbertaPulse GeneratorTest Setup DetailsCustom Bottle Design (donated by Peerless Mfg.)End TreatmentsSlide Number 16Slide Number 17Photos of Configuration A SetupSlide Number 19Slide Number 20Slide Number 21Slide Number 22Slide Number 23Slide Number 24Photos of Configuration B SetupSlide Number 26Slide Number 27Slide Number 28Example of Pulsating Pressure Measurements (Across the Bottle)Example of 1st Harmonic Mapping�(Configuration A)Example of 1st Harmonic Mapping�(Configuration B)Test Results�(Configuration A)Configuration A Test ScopeNormalized Pulsating Power Loss (Bottle)Normalized Velocity Oscillation urms/UNormalized Pulsating Power Loss (Orifice)Normalized Mean Flow Pressure Loss Coefficient (Bottle) – zoomed inTheoretical K Factor for the Bottle with Square End TreatmentsThoughts about why the Measured K Factor for the Bottle is Lower than Theoretical ValueQuasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating FlowQuasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating FlowQuasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating FlowQuasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating FlowQuasi-Steady Hypothesis of Mean Flow Pressure Drop in the Presence of Pulsating FlowCurrent Measurements of Mean Flow Pressure Loss Coefficient (Representative of Suction Bottle)Normalized Mean Flow Pressure Loss Coefficient (Orifice) – Referenced to NPS4Test Results�(Configuration B)Configuration B Test ScopeNormalized Pulsating Power Loss (Bottle)Current Measurements of Mean Flow Pressure Loss Coefficient (Representative of Discharge Bottle)Summary of Site Testing2014 Project PlanSuggestions for Future WorkThank You and AcknowledgementsPredicting the Power Loss of Reciprocating Compressor Manifolds