Case Studies
Advanced Analysis & Problem Solving
Shock Propagation & Supersonic Flow
A gas compressor station was experiencing high vibrations in the gas piping while performing gas turbine commissioning and compressor surge testing. The discharge piping, recycle valve, and recycle piping was observed to have high vibrations that exhibited as shocks to the piping under certain operating conditions. A simulation was created using 3D models provided by the customer, as well as valve geometry and detail from equipment datasheets and diagrams.
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FEA Structural Mechanical
An auxiliary generator skid had suffered failures at the welded joints of several structural members. A vibration analysis and ODS was completed to determine the operating mode shapes under specific operating conditions. Based on the results an FEA study was performed to determine the stress intensity in the welded connections.
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Vibration Analysis
The motor and gearbox for the was replaced in early 2020. The cold alignment was performed during cold ambient temperatures < 40°F. In March of 2020, the compressor train shaft vibrations began to increase. Vibration levels continued to increase with operation but had not reached alarm or trip levels. A thermal growth study was requested to determine the potential impact that improper hot alignment may have on the unit.
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Rotor Dynamics Analysis
An offshore oil and gas platform had been experiencing unpredictable vibration issues with two of their turbine-driven high pressure gas compressors. The compressors are identical in design, but both exhibited unpredictable elevations in vibration over time. Gas analysis shows minimal changes over time, suggesting that the compressors are not surging due to Molecular weight changes of the gas.
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Steam Turbine Analysis
Fertilizer manufacturer with a double controlled-extraction steam turbine, requested assistance with a condenser vacuum leak. The vacuum leak was contributing to a loss of system performance. “Hogging jets” were required in service to maintain proper vacuum in the surface condenser. During site visit, it was discovered that LP extraction was operating at less than design pressure. Several leak locations were detected, and later sealed with industrial sealant. Customer wanted to determine impact of LP extraction operating at pressure lower than design.
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Process Modeling
A leading Power Provider was evaluating the performance of their compressed air energy storage train, which had been plagued by acoustic resonance in the discharge piping of an intermediate stage of compression. A field performance test was conducted to determine if there was an aerodynamic instability in the compressor, or whether one of the intermediate stages of compression was experiencing surge.
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Visual ODS of Piping and Structural Support
Structural supports for high-pressure piping have sustained fatigue cracking failures. Visual ODS was used to determine the resonant frequencies, which were compared to the frequencies of the acoustic and pulsation forces.
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