12/21/2017 Vibration Monitoring and Risk Analysis System for Process Piping - Case Study 613

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Vibration Monitoring and Risk Analysis System for Process

Piping
Case Study

by Ángela Angulo

Summary

TWI conducted an exploratory project investigating the use of vibration analysis for condition monitoring of process
piping. The project led to the development of an advanced standalone system, capable of monitoring the main line of
a piping system for vibration-induced fatigue failure. The vibration assessment reveals the operating condition of the
piping system, before a likelihood-of-failure (LOF) assessment provides further analysis using a risk matrix.

The assessment methods and procedures follow the standards from the ‘Guidelines for the avoidance of vibration-
induced fatigue failure in process pipework’, published by the Energy Institute (EI) in 2008.

Background

Vibration-induced fatigue is one of the most common causes of failure in process piping systems. The resulting
unexpected hydrocarbon release may lead to financial losses and impact both health and safety and the
environment. Data published by the UK’s Health and Safety Executive (HSE) for the offshore industry has shown that
in the UK sector of the North Sea, fatigue and vibration failures account for 21% of all hydrocarbon releases.

The likelihood of failure of a piping system when flow-induced turbulence is the excitation mechanism is governed by
two conditions: flow-induced vibration factor (Fv) and dynamic pressure (ρv2).

The flow-induced vibration factor is calculated from the geometric properties of the pipe being inspected. The
external pipe diameter (Dext) and the wall thickness of main pipe (T) are used to calculate the and for a particular
piping support arrangement, as specified in the aforementioned EI guidelines.

The dynamic pressure is determined from the flow properties of the fluid system. It depends on parameters such as
density or fluid velocity.

The likelihood of failure for flow-induced turbulence is then calculated using the following equation:

The calculated LOF for the respective piping system is then integrated with online measurement data to determine
the effective LOF. This is done by measuring the vibration level against the predefined natural frequency, as in the
following equation:

Objectives

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12/21/2017 Vibration Monitoring and Risk Analysis System for Process Piping - Case Study 613

The objectives of this project were as follows:

identify the excitation mechanisms

provide detailed screening of main pipework (and possibly small-bore connections)
assess the likelihood of fatigue crack initiation using vibration analysis.

Innovations

The condition monitoring system developed for the project is capable of incorporating vibration analysis (Figure 1).
This is in contrast to existing systems, which are unable to link vibration analysis of pipework to the likelihood of
fatigue crack occurrence.

[ Zoom ]

Figure 1 VA-RA Condition Monitoring

System

The market-dominating piping vibration management system relies on a desktop assessment by specialist engineers.
However, the system developed by TWI offers operators a portable device that screens the vibration signal into
either of two options:

an acceptable vibration signal that passes the first stage of assessment/screening described in the EI guidelines
an unacceptable vibration signal that then requires a risk-based assessment by specialist engineers.

Therefore, the present system achieves the following for plant owners/operators:

easy operation: the first screening method can be undertaken by a non‑specialist engineer/inspector
low cost: the first screening method can achieve cost savings since specialist vibration management vendors are
only required to investigate piping sections that failed the first level of screening.

Developments

The resulting LOF is combined with a consequence of failure (COF) value to quantitatively determine the risk
associated with the pipeline’s condition. This provides quantitative risk management, calculating asset integrity and
informing maintenance activities.

The system strategy is described in Figure 2:

[ Zoom ]

Figure 2 The different modules of the

system including the user interface
and the MEMS Accelerometer
ADXL325

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12/21/2017 Vibration Monitoring and Risk Analysis System for Process Piping - Case Study 613

The testing environment, as defined by the operator, will determine which parameters are used. These could include
the external pipe diameter, support span length, wall thickness of main pipe, fluid velocity, gas dynamic viscosity
and fluid density.

The system prototype comprises a vibration signal sensor and an assessment module. A touchscreen interface allows
the operator to enter the pipe and fluid details. Once the vibration data is acquired, the functions can be calculated
either in real-time or using offline advanced data processing.

The system is able to plot both the acceleration and the frequency spectrum, enabling the detection of dominant
peak frequencies. This allows the initial vibration assessment to be determined and the LOF for flow-induced
turbulence to be calculated and plotted on the risk-based inspection matrix (Figure 3).

[ Zoom ]

Figure 3 Display of the LOF in the risk

matrix for vibration induced by
rotating motor with embedded
unbalance

Applications

The developed system can be used for fluid-carrying pipework deployed in the following environments:

oil and gas upstream production/processing offshore plants

oil and gas downstream chemical processing plants
power generation plants
water/waste water plants
pharmaceutical plants

Research leading to these results has received funding by TWI’s Core Reach Programme. For further information,
please contact us.

Ángela Angulo
Senior Project Leader – Condition and Structural
Monitoring
Ángela Angulo is a senior project leader at TWI specialising in condition
monitoring. Ángela has an MEng degree in industrial engineering from the
University of Navarra in Spain and an MSc in structural integrity from
Brunel University.

Ángela joined TWI in January 2013, in the Integrity Management Group,

which provides cost savings and reliability assurance through the
development and application of advanced innovative inspection,
assessment and risk management solutions for industry sectors including
oil and gas. Within the condition monitoring section, Ángela works on the
following areas of expertise: strategic health monitoring using vibration
analysis, acoustic emission, modal analysis and guided ultrasonic waves.

Ángela has experience in forecasting for economic and societal impacts of

project results, exploitation strategy and plan, and market route and
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12/21/2017 Vibration Monitoring and Risk Analysis System for Process Piping - Case Study 613
opportunity identification.

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