Upload
informa-australia
View
356
Download
59
Tags:
Embed Size (px)
DESCRIPTION
Andy Saunders Tack delivered the presentation at 2014 Gas Compressor Stations Conference. The Gas Compressor Stations Conference is the only conference specifically dedicated to the design, build and maintenance of gas compressor stations. For more information about the event, please visit: http://www.informa.com.au/gascompressors14
Citation preview
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
3 Lines
Typical Outcome
for LNG Train
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
Suction
Line
Discharge
Line
Recycle
Line
Dead Leg A
Dead Leg B
Actual Configuration
Flow FlowVortices
Side Branch
d
L
0
20
40
60
80
100
120
140
0 50000 100000 150000 200000 250000 300000 350000 400000 450000 500000
Flow Rate (kg/hr)
Natu
ral
Fre
qu
en
cy (
Hz)
f5/4
f3/4
f1/4
Quarter Wave
Acoustic Frequencies
Vortex Shedding
Frequencies
1,3
2,1
1,1
Quarter Wave
Acoustic Frequencies
Vortex Shedding
Frequencies
Solution: modified
location of valve
Analysis of Deadlegs
Case Study 2: RV Piping
Valves closed – no flow
Flow Valve closed – no flow
Main Pipe OD is 48”
Situation: New flare tie-ins as part
of plant expansion
Design
Marginal
Correction
Danger
Perception Level0.01
0.1
1
10
1 10 100 1000
Frequency (Hz)
Vib
rati
on
al
Am
pli
tud
e (
mm
) -
Pe
ak
to
Pe
ak
Wachel and Bates Criteria
Vibration of Flare Take-offs Observed
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:
First acoustic resonance
frequency range of 18 inch RV
piping
Principal shedding Strouhal curves (blue,
red, green), are identified from CFD analysis.
First mode (red) is associated with highest
pulsation amplification potential.
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
• 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.
Vibration mitigation is achieved by de-tuning the vortex shedding frequency
and the RV piping first acoustic resonant frequency. Candidate action
items are:
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