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CS Softdesk’s Reduces Vibrations on Aging Compressor Station on Large Natural Gas Field in Poland

CS Softdesk’s Reduces Vibrations on Aging Compressor Station on Large Natural Gas Field in Poland
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CS Softdesk’s Reduces Vibrations on Aging Compressor Station on Large Natural Gas Field in Poland - 1

CASE STUDY Project Summary Organization CS Softdesk Solution Manufacturing Location Stara Gora, Poland Project Objectives • Reduce damaging vibrations from additional installations at a compressor station • Design an innovative solution to eliminate dynamics-related problems and ensure cost-effective operation • Preserve basic elements of the initial installation Products Used AutoPIPE®, AutoPLANT®, MicroStation® CS Softdesk's Reduces Vibrations on Aging Compressor Station on Large Natural Gas Field in Poland Bentley's Integrated Design and Analysis Applications Optimize Engineering Workflows and Improve Productivity Fast Facts • CS Softdesk identified the cause of the vibrations and eliminated the dynamics-related problems. • CS Softdesk created the 3D model of the installation in AutoPLANT and imported it to AutoPIPE to perform iterative engineering analysis. • CS Softdesk leveraged iModels to produce visual results for stakeholders and enable multi-discipline coordination. Bentley's software facilitated real-time data exchange and streamlined workflows. CS Softdesk automated repetitive tasks to accelerate design time and reduce overall costs. CS Softdesk used half the resource hours to deliver the EUR 12 million project. A Need for a Connected Modeling Environment Located in Stara Gora, Poland, Zuchlow natural gas field is the largest deposit of natural gas in the area, with available gas resources estimated at up to 24.5 billion cubic meters. The compressor station started production in 1979, extracting over 23 billion cubic meters of natural gas in over 35 years of operation. To increase gas input pressure to the existing pipeline and modernize the station to increase production, four large compressor units were installed in 1994, with two more aggregates subsequently added, and additional modifications, installations, and extensions performed over the years. The additional installations caused significant vibrations resulting in noise and accelerated component wear. So Gazoprojekt, the fields owner, undertook a comprehensive redesign and reconstruction on the compressor units to reduce the vibrations. The designers contracted CS Softdesk to determine the cause and develop a solution to eliminate the dynamics-related problems. CS Softdesk performed pulsation simulations as well as static and dynamic analysis on the 3D model of the entire installation, and then designed and implemented the necessary changes to fulfill normative operational requirements for the compressor's piping system. Moreover, the project team had to preserve the basic elements of the initial installation, while redesigning the routing of 14 piping structures, redefining the location of 20 primary supports, and rebuilding 12 anti-pulsation bottles. With tight deadlines and budget restraints imposed on this complex engineering project, CS Softdesk needed to work in a connected modeling environment to streamline workflows and ensure accurate data sharing and coordination among the project team and with the designers. AutoPLANT and AutoPIPE Drive Innovative Solution The designers developed a 3D model of the entire reconstruction using AutoPLANT, which CS Softdesk imported into AutoPIPE to perform research and analysis. The team conducted a study of pressure pulsations and initial analyses of the dynamics of the compressor structure to identify the vibrations occurring in the operation process. After locating the sources and causes of vibration, the team decided to design and construct a new pressure pulsation system, requiring that pulsation dampening bottles, interconnecting ducts, and anti-pulsation tanks be mounted to the compressor. Considering the influence of gravity, pressure, temperature, and shock pulsations using AutoPIPE, CS Softdesk designed the new tanks with reactive filters to effectively reduce pressure pulsation level, and, as a result, reduce the structural vibrations and associated noise level by several hundred percent. The internal research conducted on the nature of the dampening of vibrations induced by pressure pulsations revealed unique results that CS Softdesk implemented in this specific engineering case of a Polish natural gas field. It was the first project in Poland where a pressure pulsation system with pressure dampeners characterized by a distinct internal construction known as "multi-compartment bottles" was implemented as part of an industrial initiative. Using Bentley's design and analysis applications to investigate a high-power compressor at one of Poland's largest volume natural gas fields in the gas extraction and transport industry enabled CS Softdesk to design an innovative solution, optimizing time and costs. "Without this software, the implementation of this project would be much more expensive and prolonged," stated Maciej Rydlewicz, CEO of research and development at CS Softdesk. Interoperability Facilitates Iterative Design and Analysis An important factor of this project was the coordination between the designers and CS Softdesk, as CS Softdesk performed its analysis and recommended solutions, and the different disciplines on the CS Softdesk project team. Using Bentley's interoperable software provided a connected environment that enabled real-time, quality data exchange to streamline engineering workflows and enhance collaboration. Given the advanced and specialized design, calculations, and analysis required, including static, dynamic, and pressure pulsation analyses, CS Softdesk relied on AutoPLANT,

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CS Softdesk’s Reduces Vibrations on Aging Compressor Station on Large Natural Gas Field in Poland - 2

"Bentley applications allow us to preserve a multi-discipline approach in our design processes, and, at the same time, maintain a unique and specialized approach. The software allows for the engineering analyses to be performed at the scientific research level, provided that the applied method is implemented properly by knowledgeable staff." - Maciej Rydlewicz, Ph.D. Eng, CEO Research and Development, CS Softdesk Find out about Bentley at: www.bentley.com Contact Bentley 1-800-BENTLEY (1-800-236-8539) Outside the US +1 610-458-5000 Global Office Listings www.bentley.com/contact AutoPIPE,...

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