Vibration Induced Failure Avoidance
and Management Around Vendor
Packages
Brisbane April 2014
Why The Concern?
FIV (flow induced vibration) failures have lead to fatalities,
fires and lost production many of these around vendor
packages
Vibration related failures in 2000 2010 represented on
average deferment costs of A$1.5M per incident
Vibration typically not addressed comprehensively during
project phase
Vibration Mechanisms
Steady State
Flow induced turbulence (FIT):
Mechanical excitation
High frequency acoustic excitation (HFAE):
Pulsation
reciprocating machinery or rotating stall
flow induced excitation
Cavitation and Flashing
Transient Issues
Fast acting valves
Vibration Mechanisms
Assessment Process Energy Inst. Guidelines
Approach relevant
to all stages of
project life.
Should be
addressed at
FEED
Particularly
important for
process or plant
changes (MoC)
Assessment Approach (Energy Inst. Guidelines)
Identify main lines
and key process
conditions
Identify rotating
and reciprocating
pumps
Locate deadlegs
Locate RVs
FIV Screening - Technical Approach
Main Pipework Assessment
34 Lines Typical Outcome
for LNG Train
3 Lines
Screening Survey Outputs
Small Bore Connection Assessment
Small Bore Connection Bracing
Examples of Good and the Less Good
Case Study 1: Compressor Pipework
Background:
Project to increase throughput as
consequence of new tie-in
Increased duty planned for
compressor
Increased plant capacity >100%
of design
Objective to understand integrity
impact
Actual Configuration
Suction
Dead Leg A Line
Recycle
Line Dead Leg B
Discharge
Line
Analysis of Deadlegs
Quarter Wave
d
Acoustic Frequencies Side Branch
L
Vortex Shedding
Frequencies
Vortices
Flow Flow
140
Quarter Wave Vortex Shedding
Acoustic Frequencies Frequencies
120
f5/4
Natural Frequency (Hz)
100
80
f3/4 1,3 Solution: modified
60
2,1
location of valve
40
20 f1/4 1,1
0
0 50000 100000 150000 200000 250000 300000 350000 400000 450000 500000
Flow Rate (kg/hr)
Case Study 2: RV Piping
Situation: New flare tie-ins as part
of plant expansion Valves closed no flow
Valve closed no flow
Main Pipe OD is 48 Flow
Vibration of Flare Take-offs Observed
Wachel and Bates Criteria
10
Vibrational Amplitude (mm) - Peak to Peak
Danger
0.1
Correction
Marginal
Design
Perception Level
0.01
1 10 100 1000
Frequency (Hz)
Detailed Analysis: Vortex Shedding Frequency
Spectral densities of flow kinetic energy and pressure traces at the RV take-off
mouths are used to estimate dominant vortex shedding frequencies at each
mouth. Examples are shown below.
Dominant shedding
frequency is 10.5 Hz
for this 18 inch take-off
Flow
Root Cause of Vibration
Field data and analysis indicate that the root cause of vibrations is due to
lock-in of RV take-off mouth vortex shedding frequency and RV take-off
piping (standing wave) acoustic resonant frequency.
Piping vibration frequencies (measured): 6.25 Hz, 12.5 Hz
RV piping first acoustic resonant frequency range (computed):
6.0 Hz 10.5 Hz
RV take-off mouth vortex shedding frequency range (computed):
6.0 Hz 30.0 Hz
Vortex Shedding Frequency
Closely spaced 18 inch take-offs show high
energy content at a frequency of 6.4 Hz
Shedding frequency can easily lock-in to a first
acoustic resonant frequency (e.g. f1 ~ 6.0 Hz) , at
which point pulsations and energy content will
start to amplify.
Flow
Analysis Summary
Vortex shedding frequencies and first acoustic natural frequencies of RV piping
are too close!
Based on flow & acoustic analyses a response curve (for the 18 inch take-offs)
which predicts the onset of pulsations can be constructed:
Principal shedding Strouhal curves (blue,
red, green), are identified from CFD analysis.
First mode (red) is associated with highest
pulsation amplification potential.
First acoustic resonance
frequency range of 18 inch RV
piping
Onset of significant pulsation happens when
flow ~ 8 m/s (slightly above 10,000 tons
/day).
True onset of pulsation occurs at ~ 5 m/s,
but is most likely very weak (blue curve is a
high mode of shedding)
Lock-out may occur for flow > 18 m/s. Not
practical solution to avoid pulsations.
Vibration Mitigation Solutions
Vibration mitigation is achieved by de-tuning the vortex shedding frequency
and the RV piping first acoustic resonant frequency. Candidate action
items are:
Move the relief valves closer to the take-off points. This will have the effect of
increasing the acoustic resonant frequencies of the RV piping.
Modify the RV take-off mouths to minimize / weaken vortex shedding. Example:
Forge entrance pieces to provide a 45-deg funnel into the RV piping. Minimize
flow-tripping weld protrusions when welding the piece in place. Some
simulation work is recommended to ensure that a design would work.
Install orifice plates just upstream of the take-off points. The plates will
suppress vortex shedding and increase the acoustic resonant frequencies of the
RV piping. The plates would have to be carefully designed to retain original
relief capacity.
Detailed Analysis Potential Approaches
Conclusions
Address vibration Issues holistically at the plant level and ensure
provision is in place for projects Energy Inst. Guidelines
Ensure vibration management process is in place for new and existing
assets to allow impact of plant or process changes on integrity to be
quantified
Ensure vibration management processes are in place around grey
area equipment where responsibilities are potentially not well defined or
coordinated
Ensure flow induced vibration is considered as part of MoC process.
Ensure awareness of FIV issues amongst integrity stakeholders
