Understanding vibration induced pipework failure

Vibration induced fatigue of process piping systems is an important and fundamental failure mechanism. Data published by the UKs Health & Safety Executive (HSE) for the offshore industry has shown that in the UK Sector of the North Sea, fatigue/vibration failures account for 21 % of all hydrocarbon releases. Although overall statistics are not available for onshore facilities, available data for individual plants indicates that in Western Europe, between 10 % and 15 % of pipe work failures are caused by vibration induced fatigue.

Leading industrial consultants AV Technology Ltd (AVT) are already carrying out pipe-work vibration assessment tests for a number of major UK companies in line with the requirements of the latest updated guidelines, published by the Energy Institute in 2008 (ISBN 978 0 85293 453 1). AVT engineers are fully conversant with the necessary test procedures and all-important analysis and presentation of data.

Understanding vibration induced pipework failure

Vibration induced fatigue of process piping systems is an important and fundamental failure mechanism. Data published by the UKs Health & Safety Executive (HSE) for the offshore industry has shown that in the UK Sector of the North Sea, fatigue/vibration failures account for 21 % of all hydrocarbon releases. Although overall statistics are not available for onshore facilities, available data for individual plants indicates that in Western Europe, between 10 % and 15 % of pipe work failures are caused by vibration induced fatigue.
The latest guidelines, published by the Energy Institute in 2008 (ISBN 978 0 85293 453 1), are aimed at minimising the risk of incurring loss of containment from vibration induced fatigue failures of process plant pipe-work. The document is an enhanced and expanded version of the former MTD Guidelines (Marine Technology Directorate) first issued in 1999, which has been a key element in maintaining integrity in the design and maintenance of process pipe-work within the oil, gas and petro-chemical industries. Key benefits of following good practice include: Compliance with statutory duty Improved safety and reliability Reduced liabilities from product leakage Minimised plant down time

The Energy Institute guidelines are broken down into two main scenarios: Proactive Assessments, which can be used to routinely assess all pipework (existing or proposed) on a site to ensure that good practice has been adopted and to try to identify possible areas of concern Reactive assessments, used to further investigate and assess known vibration issues or to trouble shoot actual failures. Some of the sections within the guidelines are further divided into the two main categories of

Main Lines and Small Bore Connections (SBC)

AV Technology Ltd are already carrying out pipe-work vibration assessment tests for a number of major UK companies in line with the updated requirements. Their engineers are fully conversant with the necessary test procedures and allimportant analysis and presentation of data.

The Energy Institute guidelines propose very logical phased approaches and include various Technical Modules, detailing procedural flowcharts and good/bad practice guidelines for each phase. Key phases include: Qualitative Assessment Visual Assessment Basic Vibration Monitoring Specialist Measurement Techniques Specialist Predictive Techniques Corrective Actions

The Qualitative Assessment phase is possibly the most difficult to implement and involves various calculations for assessing the likelihood of having a vibration induced fatigue problem on existing or proposed new plant. This assessment takes into account many relevant factors, including: fluid

energy, flow velocities, process machinery, types of valves, chances of flashing or cavitation, construction quality and cyclic operation. The assessment includes a calculation process
for scoring likely excitation factors and conditional and

operational factors, which are then combined to predict the

Likelihood of Failure (LOF) for each pipe branch.

The Visual Inspection phase is a quick yet powerful way to spot many obvious potential areas of concern. It is a fact that many pipework vibration problems are simply the result of operators not following recommended good practice. These include installing effective pipe supports, bracing SBCs properly, avoiding fretting, repairing poor condition or damaged supports, avoiding poor geometry and allowing for thermal expansion of tubing, The Energy Institute guidelines give many good quality photographic examples of good and bad practice.

The Basic Piping Vibration Measurement phase provides a simple method of identifying areas of concern based solely upon measured values of pipework vibration. This is an area which falls within AVTs mains areas of expertise and involves experienced engineers visiting sites with suitable instrumentation to

measure and analyse vibration data. Initial vibration levels are typically recorded using a single axis accelerometer connected to a portable data collector, with required

frequency measurements ranging from 1 Hz up to 300 Hz. The results are presented as vibration amplitude (in units of RMS velocity) versus frequency. By comparing these measurements criteria against presented vibration in the

assessment

guidelines, the vibration is classified into one of three categories: Acceptable, Concern or Problem.

For further assessment of pipework with vibration levels in the Concern or Problem classifications or for pipework with higher frequency vibration (> 300 Hz), the guidelines recommend the implementation of further Specialist Measurement Techniques. These include: Dynamic Strain Measurement and Fatigue Analysis Experimental Modal Analysis Operating Deflection Shape Analysis Dynamic Pressure (pulsation) Measurement

In addition, Specialist Predictive Techniques can be deployed, including: Finite Element Analysis, Computational Fluid Dynamics (CFD) Pulsation and Surge Analysis.

AVT have years of cumulative expertise in many of these Specialist Techniques, specialising in the provision of expertise and resources to apply sophisticated tools and analysis methods in order to provide a more detailed assessment of the dynamics of specific pipelines throughout their life cycles. A high percentage of the work carried out by AVTs Special Projects Division is concerned with the onsite measurements of dynamic strain and vibration data using multi-channel instrumentation systems, together with the analysis and assessment of the measured data, including fatigue life analysis.

The final stage of any pipe work assessment is to recommend Corrective Actions to reduce vibration levels and the likelihood of future vibration induced fatigue failures. Corrective actions can take many forms, including: Improving pipe supports, Implementing more effective SBC bracing, Modifying process conditions to reduce fluid loadings Installing pulsation dampeners and viscous dampers.

The design of practical and appropriate corrective actions is important to achieve cost effective yet practical solutions. Such work is often supported by AVTs in-house FEA capability, which is particularly useful for predicting the effects of remedial repairs. Mechanical design of supports is performed using AVTs SolidWorks 3-D CAD software.

AVTs Technical Director Neil Parkinson is clear on the role his company can play in pipe work fatigue analysis and as he explains:

Our strengths in predictive and condition based maintenance, together with those in structural monitoring and vibration assessment, provide the perfect knowledge base for delivering a comprehensive service for vibration induced fatigue projects. Vibration in pipe-work can be affected by a number of direct and indirect factors relating not just to the pipe-work itself, but also adjacent support structures and buildings. It is therefore vitally important to provide clients with a comprehensive overview of the vibration patterns together with constructive improvement recommendations. Strain gauging and FEA are powerful tools in the analysis process. Although these are often perceived as distinct, alternative technologies for assessing structural integrity, AVT have long recognised the

increased power of combining practical strain gauge work with theoretical Finite Element Analysis (FEA).to give us a distinct competitive edge. Whilst FEA models can produce important predictions of stress, displacement and frequency, often actual in-service loading conditions are unknown and so results can be highly unreliable unless validated using actual in-service data such as strain measurements. Conversely, whilst actual strain gauge data can yield vital accurate information about stress amplitudes and fatigue, they are normally limited to measurements at just a few positions and therefore do not give a complete 3D picture of the modal behaviour of a structure.

Mulit-axis accelerometers assembly fixed to pipework

Examples of good and bad practice in pipework

U-bolt is attached to the connection on a reducer section and is not lined. It is therefore susceptible to fretting damage.

Lining provides protection to line from fretting at the U-bolt.

Fretting damage to main pipe. There is no resilient pad between support and pipe. Note also pipe clash below.

Reinforcement plate on pipe at rest support to resist fretting damage to pipe.

Fretting damage to pipe caused by pipework vibrating relative to deck penetration cover

Resilient pad between support and pipe protects against fretting damage.

Examples of good and bad practice in pipework

Bracing insufficiently stiff; single plane only; only protecting weld to parent pipe.

Bracing stiffness increased; diagonal brace protects in two planes; valve now supported.

Temporary fix of mass loading to detune a structural resonance still in place some time later.

Rope used to support cable tray!

Fretting due to loose cladding and damage caused by knife edge contact at insulation end cap (existing cladding has been removed

Images courtesy of the Energy Institute

AV Technology Ltd is a leading multi-discipled consultancy with over 30 years experience. Our portfolio includes:
Consultancy: Services: Products:

Condition Monitoring Facilities & Assets Maintenance Noise & Vibration Structural Integrity Training Hydraulic Systems

Condition Monitoring Lubrication Management Maintenance Solutions Noise & Vibration Strain Gauging Structural Monitoring Visual Inspection

Acoustic Emission Sensors Condition Monitoring Systems Lubrication & Filtration Silo Weigh Structural Monitoring Systems Vision Systems Spi-VR vibration recorder

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