Pulsation Dampeners for smooth flow in pipes

Written by
Joe Cheema
Stopping and starting is expensive. Cars last longer and get better mileage with
freeway rather than city driving. Corporations leave computers running 24/7 to extend
their life. Industrial gas turbine maintenance schedules are determined as much by
number of starts as number of operating hours.
But there is something that stops and starts more often than rush hour traffic in
Los Angeles the water or oil coursing through a hydraulic system. Each pump piston
stroke sends a shockwave through the system at the speed of sound, hammering the
fittings and lowering the life expectancy of equipment. Unless, that is, one uses a
pulsation dampener to provide a constant pressure and smooth the fluid flow.
The K Factor
In most liquid handling systems, the primary source of pulsations is the pump.
This applies to both hydraulic motion systems as well as chemical injection pumps. With
any type of positive displacement pump - whether it uses a diaphragm, gear, piston or
vane the pump breaks down the inlet flow into a series of discrete parts. The pump then
applies energy to each of these discrete parts, raising its pressure and then releasing it into
the general high-pressure flow.
Since piston-type pumps are most commonly used, we will look at these in more
depth, recognizing that the same principle applies to other types of pumps. Reciprocating
piston pumps are an efficient means of achieving high pressures, however they also tend
to produce the strongest output pulsations. While the average pressure and flow rate of
the fluid remains relatively constant, it is subject to wide fluctuations, particularly in the
area immediately following the pump output. The pump operates by taking a finite
amount of fluid into its chamber and then rapidly compressing it. This action produces a
sinusoidal pattern of fluid pressure and speed fluctuating around the average pressure and
speed of the system.
As the high-speed, high-pressure fluid exits the discharge port on the pump, it
creates a compression wave. That wave travels through the fluid at the speed of sound
until it reaches a bend or restriction in the pipe. At that point, the joint or restriction
absorbs some of the compression waves energy, while the rest is reflected back against
the flow coming from the pump. This back-and-forth hammering the compression wave
causes lowers the lifetime of the pump and the plumbing.
One way to smooth out the flow is to use a double-acting pump or one with
multiple pistons. Since each piston stroke reaches its maximum at a different point in
time, this smoothes out the pressure highs and lows the same way a 12-cylinder Jaguar
engine runs much smoother than a single piston lawnmower. The K Factor of a pump is a
figure showing how much the flow volume varies from the average flow volume at
different points of the piston stroke. A simplex, single-acting pump has a K Factor of .60,
meaning the fluid volume at the discharge port varies 60% above and below the average
flow. Adding more pistons lowers the K Factor to the point where, with seven pistons, the

K Factor drops to only 0.02. Of course, not many septuplex pumps are in use. The more
typical simplex, duplex and triplex pumps require pulsation dampeners to bring their
pulsation problems under control.
Smooth Strokes
Pulsation dampeners are devices attached to the pump output that moderate the
pumps pressure and volume fluctuations. They can be attached on a nipple off the outlet
line, or they can sit inline. There are numerous designs available, but the basic elements
consist of a sphere containing a diaphragm or a cylinder containing a bladder. With the
first design, the diaphragm is held in place by the two halves of the sphere. The
diaphragm splits the interior of the sphere into two halves - one contains nitrogen and the
other the fluid being pumped. A charging valve and pressure meter sits on the gas side of
the sphere, and the other side connects to the plumbing. The cylindrical design is similar
in operation, but a bladder is attached to the charging valve, and the fluid flows in around
the bladder.

In both cases, the gas side of the dampener is pre-charged to about 70-80% of the
minimum allowable system pressure, so there will always be some liquid within the
dampener. Then, when the fluid is pressurized, since the nitrogen is more compressible
than the hydraulic fluid, most of the fluid above the average system flow goes into the
pulsation dampener, rather than creating a compression wave. Then, during the low
pressure portion of the piston stroke, the gas expands to force the fluid back out of the
dampener into the system, maintaining the mean flow and pressure.

Pressure Drop
The elasticity of the rubber and the compressibility of the gas work together to
eliminate greater than 95 percent of the flow and pressure variations, prolonging the life
of the equipment. This does require, however, that the system be properly designed,
installed and maintained. To begin with, the right materials must be selected for the
diaphragm/bladder and the vessel. The diaphragm or bladder is typically made using
Buna-N, however other materials such as Neoprene, EPR, Butyl, Viton, Hypalon, Silicon
and Teflon are also available depending on the material being pumped. 304 or 316
stainless steel is normally used for the vessel, though other materials - including Alloy
20, Hastelloy C, polypropylene, PVDF, Teflon and Nylon - can also be used as
appropriate.
Next is properly sizing the dampener. On a piston pump, the formula is to
multiply together four factors: the area of the plunger face in square inches (A), the stroke
length of the piston in inches (L), the K Factor of the pump as discussed earlier (K), and
the pressure factor (e.g. a pressure factor of 50 would give approximately a 5%
pulsation control). AxLxKx50 = size of dampener in cubic inches. So if you have a
simplex pump (K Factor = 0.60) with a 3 diameter piston (A= 7) and a five inch stroke
(L=6), then your minimum size for a dampener is 1050 cubic inches. You would then
select the next larger size dampener a 5-gallon (1155 cu. in.) model.
Next is installation. The dampener should be placed as close to the pump outlet as
possible. Depending on design constrictions, the dampener can either sit in line, or off to
the side, connected by a nipple. If using a nipple, be sure to select the shortest possible
nipple diameter and the dampener inlet should be no smaller than the pump outlet pipe
diameter or they will restrict the flow into and out of the dampener, reducing its
effectiveness. The dampener should be pre-charged with nitrogen to 70-80% of the
system mean operating pressure.
Finally, be sure to check the nitrogen pressure on a regular basis to ensure it is
still at the pressure needed. Shut off the pump before checking the pressure, otherwise
you will a fluctuating reading closer to the mean operating pressure of the system, rather
than the pre-charge pressure.
With these steps in place, you can rest assured that the fluid will flow smoothly,
reducing vibration, extending pump and plumbing life, and eliminating costly downtime.
At least that is one less thing you will have to worry about, though you will still have to
watch your blood pressure in the morning commute.
About the Author: Joe Cheema is a Senior Project Engineer for accumulator
manufacturer at Fluid Energy Controls Inc. in Los, Angeles, Cal. For more information
call 323-721-0588 ext 3267 (email: [email protected]) or visit www.fecintl.com.