> Process System Integrity (PSI)

Piping Vibration Management

Helping you reduce the risk of vibration induced fatigue failure of
process piping systems

BUSINESS CHALLENGE
Recently published statistics show that approximately 20% of process
pipework failures are due to vibration induced fatigue. The resultant loss of RELATED SERVICES
containment carries potentially serious safety, environmental and cost
implications. Identifying potential areas at risk from vibration induced fatigue is Piping vibration risk assessment
fast becoming a necessity. Piping vibration measurement and
investigation
Primary contributing factors to this include: Detailed simulation and prediction
(including API618/API674
Increasing flow rates due to debottlenecking; pulsation analysis and pressure
Increasing flow rates due to relaxation of erosion velocity limits; surge simulation)
Increasing use of duplex alloys for erosion and weight considerations;
Little or no structured means of addressing the potential problems during HAZOP or QRA studies.

SOLUTION
What is PSI?
Bureau Veritas has worked closely with the oil and gas industry and regulatory authorities to develop a risk assessment
methodology (PSI) that can be applied to combat the problem.

For new facilities, these techniques can be used to identify pipework at risk from vibration fatigue during design, allowing
appropriate modifications to be implemented.

The techniques are equally applicable to operational assets,

particularly where debottlenecking is being undertaken. Here, the
results of a formal risk assessment, supported by field measurement
studies, can often be utilised to eliminate potential fatigue failures
completely. For residual areas of identified high risk, they form a
rational basis from which to formulate suitable mitigating inspection
programmes.

What are the benefits?

Reduction in unplanned downtime (1 failure can typically cause 1-
3 days process outage).
Targeting modifications to only high risk pipework and small bore
connections (typically 90% reduction in workscope compared to a
brace everything approach).
The targeting of inspection and vibration monitoring activities on
areas of high risk instead of a measure everything approach.
The ability to update the assessment with any proposed process
or operational changes so that potential problems can be
identified and solved prior to the plant changes being implemented in practice
WHY CHOOSE BUREAU VERITAS?
Bureau Veritas has been at the leading edge of developing industry-standard risk based methodologies to address
the issue of vibration induced fatigue of process pipework.
We have successfully applied the methodology to over 40 production
plants (onshore and offshore).
We have many years experience of solving complicated vibration
issues on process plants worldwide.
We have the resources available to support you throughout a project
anywhere in the world from design studies through to short notice
call-outs in response to problems on operational plant.

OUR APPROACH
The risk based methodology is based on the results of a Joint Industry
Project published in 2000 (Guidelines for the Avoidance of Vibration
Induced Fatigue in Process Pipework MTD document 99/100) which was
jointly authored by Bureau Veritas, and sponsored by a number of oil
majors, government bodies and large engineering contractors.

Our approach is based around a formal risk assessment process linked to

inspection and survey tasks to identify problem areas, identify solutions
and manage the timely close-out of any modifications to ensure that the plant is fit for service.

The approach can be imbedded in an existing plant inspection management programme and forms a logical extension to
risk-based inspection techniques which often concentrate only on corrosion related degradation mechanisms.

FAQ
Q. What is a piping vibration risk assessment?
A. It is a risk-based assessment procedure which identifies where
piping fatigue failure might occur. It can be augmented with
targeted measurement surveys and detailed simulation techniques
to quantify fatigue life.
Q. When can a risk assessment be done?
A. At the design and construction phases of a new project, or at
any point during plant operation for an existing installation.
CASE STUDY
A new offshore installation was experiencing severe
piping vibration at production rates of above 120,000
barrels per day (bpd). The original design case of
150,000 bpd could not be achieved, so Bureau
Veritas recommended an emergency short term fix
that was put in place and which enabled operation at
the design flowrate.

Q. Isnt a vibration survey alone sufficient?
A. Piping vibration varies with changes to process and operational
conditions, and therefore a vibration survey while providing useful
information is only a snapshot of the piping vibration at the time of
the survey. In contrast the risk assessment approach takes into
account the full operational and process envelope of the plant.
Q. Can the process be integrated into my piping integrity
management system?
A. Yes the procedures, tools and techniques that are used have
been successfully imbedded in clients integrity management
systems to provide an on-going assurance process with respect to
vibration induced fatigue.
However, the client had a stated goal of pushing
production to 180,000 bpd. A PSI risk assessment
screened the complete hydrocarbon system (200
main lines) for potential vibration problems at
180,000 bpd.
The results of the risk assessment showed that 5
main lines needed changes to supports and 28 small
bore connections needed bracing or modification.
Following the proposed modifications, the asset
successfully achieved 180,000 bpd. A vibration
survey undertaken offshore verified the findings of
the study.

CONTACT
about this service, please feel free to contact us:
Jonathan Baker at +44 (0) 23 8038 1440
By e-mail, through oil&gas@bureauveritas.com please
mention "to Jonathan Baker' s attention"
FOR MORE INFORMATION
about other Bureau Veritas services, please visit:
http://energyprocess.bureauveritas.com