Chronic Pulsation Issues at Power Plant in Central PA
Industry Served: Energy
Problem:
The facility experienced persistent pulsation and vibration in a process line operating with two pumps. Operators noted:
- Poor pulsation control
- Unstable pressure readings
- Concerns that the dampener was “not working”
- Consideration of taking the dampener offline
Initial discussions suggested potential equipment malfunction. However, system layout and installation practices had not yet been fully evaluated.
During the site visit, the system configuration was reviewed in detail. Two critical issues were identified:
1. One Dampener Serving Two Pumps
Both pumps were discharging into a single pulsation dampener—an arrangement not suitable for proper attenuation or balanced operation.
2. Improper Dampener Placement
The dampener was installed well outside the recommended 10 pipe diameters from the pump discharge. At this distance, the unit could not effectively mitigate pressure fluctuations.
These conditions explained the apparent performance issues despite the dampener itself being fully functional.
Solution:
Following the engineering review, two corrective actions were recommended and implemented:
Corrective Action 1: Reposition Existing Dampener
The original dampener was relocated to within the 10 pipe-diameter zone, allowing it to operate within its design parameters and effectively manage pulsations.
Corrective Action 2: Add a Second Dampener
To properly support the dual-pump configuration, the facility purchased and installed a second dampener on the discharge of the second pump.This ensured each pump had dedicated pulsation control.
Result:
Within days of completing the installation adjustments, the power station reported:
- Significantly improved pulsation control
- Stable and reliable system pressure
- Elimination of prior vibration concerns
- Restored confidence in equipment performance
The system has been operating smoothly and without issue since the second dampener was added.