PIPING VIBRATION IN PROCESS INDUSTRY

CONTENTS
1. Company introduction
2. Piping vibration issues
3. Classifications of pipe vibrations
4. Consequences of pipe vibrations
5. Vibration measurement
6. Causes
7. Reduction / elimination of vibration
8. Sample case studies and solutions



Vibrations are unwelcome ?

1. Create noise, fatigue, physical as well as psychological un-
comfort to operators.
2. Vibrations can loosen threaded connections, break pipe
supports, cause a crack at joints.
3. Can make equipment to nozzle piping connects leak
4. Under worst circumstances it can even become a source of
catastrophic accident.



VIBRATIONS are caused by

1. Constant excitation by external or internal
forces
2. Excitation frequency close to natural frequency
of the system





TYPE OF VIBRATIONS
1. STAEDY SATE
2. TRANSIENT


STEADY STATE VIBRATIONS
Excitation sources
a. Machine unbalanced forces ( compressors / turbines)
b. Cavitation in a pump
c. Two phase flow / Flashing in the system
d. Operation of control valves / orifice plates
e. Faulty equipment foundation



STEADY STATE VIBRATIONS
1. Vibration is forced
2. Repetitive / cyclic
3. Continues for long period of time
4. Such vibration excitation origin may be a
a. Machine
b. Process flow
c. 2 phase flow,
d. Slug flow
e. Catalyst flow in Reactor Regenerator



Transient vibration
Occur for a short period but due to large
exciting forces like :
Rapid opening and closing of valves, causing
water hammer.
Vapor pocket collapse causes two side
liquids to collide with each other.
Safety valve discharges
contd.



Transient vibration
Exciting forces :
Slug flow ( 2 phase flows in oil and gas lines
or heater transfer lines)
Wind induced vortex shedding .
Loads due to earth quake.



Vibration measurement
Vibrations measured by vibration sensors
Dominating frequencies determined by
filtering vibration signals by Fast Fourier
Transformation.
Assessment of measured value is difficult.
Standards per VDI 2056 & ISO 10816 can not
apply to piping.
NEN 7-4-1 manufacturer directive is used for
Reciprocating machines.




acceptable vibrations limits for machines




Acceptable vibrations limits for process piping
1. It is not mandatory or possible to have a pipe system with
zero vibration.
2. Vibration needs to be minimized to acceptable limits.
3. Final achieved vibration if necessary, the line need to be
checked for fatigue for designed life period ( where the
number of cycles are high) .
4. Additionally supported piping must be re- analyzed for
flexibility and nozzle loads.




Allowable vibration velocities




General screening criteria for allowable vibration




Magnification factor for allowable vibration




Analysis for pipe vibration
1. Static Analysis
2. Quasi static analysis
3. Dynamic analysis
a. Model analysis
b. Harmonic analysis
c. Response spectrum analysis
d. Time history analysis



Software for Stress analysis calculations
1. AUTOPIPE
2. CAE PIPE
3. CAESER II
4. PIPE PAK
5. TRIFLEX
6. ANASYS
7. Customized individually company developed



Check list for vibration analysis
i. Identify the source of exciting force.
ii. Can it be reduced or eliminated ?
iii. Is the vibration with in acceptable limits ?
iv. Calculate the natural 1
st
and 2
nd
frequency of pipe
geometry
v. Determine the exciting force frequency
vi. Change pipe supporting system, change location of
control valves, orifice plates et.
vii. Provide dampeners/ snubbers
viii. calculate fatigue life cycle
ix. Increase pipe thickness
x. Recheck the flexibility of piping system




Some of case Histories



Problem Solution
Glycol pump vibration in GDU Provided spring supports near
dampeners
Vortex shedding due to wind effect Provided additional guide support with
adjoining column
Vibration in Refinery Vacuum Heater
transfer line
Changed type of transfer line support,
added a spring support
Reboiler pump feed line in Vacuum
unit of refinery
Pump cavitation identified, NPSH was
increased by lowering the pump
elevation
Gas flow pipe line : slug formation Additional support inserted in the gas
line
Air Fin Cooler inlet piping AFC supports modified, soft paddings
inserted.

Discipline wise involvement



Department Role & responsibility
Process Indication of type of service ( 2 Phase
flow, slug flow etc.), pulsation frequency,
Mechanical Determination of possible excitation
sources ( machines & equipment)
causing piping vibration problems.
Civil Design foundation for the given dynamic
loadings of the machine
Piping Calculation of pipe system 1
st
and 2
nd

natural frequencies, pipe analysis for
vibration , vibration induced stresses,
deflection, fatigue analysis, flexibility
analysis
Inspection Vibration and noise measurement,
physical measurement & inspection of
components for any tell tale signs of
failures