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PVM Training

Module 1 - Pipework Vibration

Objectives & Outcomes

Gain knowledge of vibration and


specifically piping vibration.
Learn how to identify potential
risks & failure mechanisms.
Learn how to measure and
quantify vibration risk.

Contents Module 1

General Vibration

What is Vibration / Fatigue


Amplitude and Frequency
Natural Frequency
Vibration Excitation
Vibration Measurement

Pipework Vibration
Risks
Main Pipe
Excitation Mechanisms
Fretting
Small Bore
Poor Geometry Examples
SBC Supports
Pipework Vibration Criteria

General Vibration

What is Vibration ? Video

An oscillating motion about a reference position


Frequency is a measure of the number of cycles of this motion during a
period of 1 second SI unit: Hertz (Hz)
Vibration occurs due to dynamic effects of tolerances, clearances,
rolling/rubbing contact and out of balance forces in mechanical systems
Vibration is often destructive, but is sometimes generated intentionally to
perform a task
X
Mass, M

Damping,

Stiffness, K

What is Vibration ?

Peak to Peak

Mass (kg)

Peak

Max Positive +

RMS

AMPLITUDE

mass

Stiffness
(k)

Time

mass

Max Negative Root Mean Square useful unit of amplitude in a sine wave -

RMS 2 / 2 * Peak

Frequency

A vibrating systems motion can consist of:


a single component occurring at a single frequency, e.g. a tuning fork, or
Several components occurring at different frequencies simultaneously,
e.g. a car, engine, exhaust, road noise, suspension etc
In practice the second case is correct for the majority of vibrating systems
When looking at the different frequency components in a vibrating system,
frequency analysis is required.

Time & Frequency Domains Single Frequency

1.5

0
0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

-0.5

-1

-1.5

1.2

Tim e (sec)
1

Period

0.8
Amplitude

Amplitude

0.5

Frequency = 1 / Period

0.6
0.4
0.2
0
0

25

50

75

100

125

Frequency (Hz)

150

175

200

Time & Frequency Domains Multiple Frequencies


Random Vibration with energy distributed over a wide frequency range
30000

From Disorder (time history)..

20000

Amplitude

10000

0
0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

-10000

-20000

-30000
Time (s)

To Order (frequency domain).

0.9

Important Measurement Units


SI Unit for frequency measurement is number of cycles per second (Hertz).
Other common frequency unit is RPM revolutions per minute.
To be understood, it is essential that units state both the parameter and
amplitude measure being used e.g.:

Velocity - mm/s RMS


Acceleration - g (peak)
Displacement - mm (peak to peak)

Natural Frequency & Resonance

Natural Frequency

1
Natural frequency : f n
2

spring stiffness
mass

Very little energy is required to excite the natural frequency of a system, as


the system wants to respond at this particular frequency. If damping is
present then this will dissipate the dynamic energy and reduce the vibrational
response.

Natural Frequency & Resonance Video Tacoma Narrows

Vibration Excitation - Recap

Excitation can either be tonal i.e. energy is only input at discrete frequencies,
or broadband i.e. energy is input over a wide frequency range.
Tonal Excitation Resonant
Excitation frequency matches a natural frequency then a resonant condition is said to exist. All
excitation energy is available to drive the natural frequency of the system

Tonal Excitation Forced


Excitation frequency does not match a system natural frequency, then vibration will still be
present at the excitation frequency, although at much lower levels than the resonant condition.
High levels of vibration will occur only if the excitation energy levels are high, relative to the
stiffness of the system.

Broadband Excitation
If the excitation is broadband then there is a probability that some energy will be input at the
system natural frequencies. Generally, response levels are lower than for the purely resonant
vibration case described above because the excitation energy is spread over a wide frequency
range.

Measurement Techniques Why Do We Measure Vibration?

Vibration amplitude and frequency data provide good correlation to dynamic strain.
To be able to identify sources of undesirable vibration.
To avoid excitation of resonances in certain parts of the system.
To use for condition monitoring.
To construct or verify computer models of structures & systems.

Fatigue

Progressive and
localized structural
damage that occurs
when a material is
subjected to cyclic
loading

Fatigue Assessment

For an F2 category weld


Stress Range = 35 N/mm2
= 2.3% Probability
17.5N/mm = 0.1%
Probability BS7608

Stress Ratio SR

Classification

Action

SR < 0.5

OK

None

0.5 < SR < 1

CONCERN

NDT. Modify at the earliest


opportunity

SR >= 1

PROBLEM

NDT. Modify immediately

Pipework Vibration

Root Cause of Reported Leaks


30

Percentage of all Incidents

25

20

15

10

0
Degradation
of material
properties

Corrosion /
Erosion

Fatigue / /
Fatigue
Vibration
Vibration

Incorrect
Installation

Operator Error

Inadequate
Procedures

Inadequate
equipment

Inadequate
isolation

Procedural
violation

Line blockage

Main Pipe Vibration Excitation

Excitation
There are a variety of excitation mechanisms which can be present in a
piping system including;

Flow Induced Turbulence


Mechanical Excitation
Pulsation

Flow Induced Turbulence Excitation


Turbulence will exist in most piping systems. The dominant sources are
found at major flow discontinuities, such as: partially closed valve, short
radius or mitred bends, tees or reducers. This in turn generates potentially
high levels of Broadband Energy, which is typically concentrated at lower
frequencies (below 100 Hz)

Fluid Velocity Profile

Kinetic Energy

Mechanical Excitation

Most of the problems encountered have been with reciprocating


compressors & pumps. Dynamic forces load the pipework connected or
cause vibration of the supports which in turn excites the pipework
connected. Normally high levels of vibration and failures only occur when
the natural frequency of the pipework system coincides with the running
speed (or harmonics) of the machine.

Transmission
Problems can also occur on pipework which shares supports with either the
machinery or associated pipework, but is not part of the system which involves
the excitation.

Pulsation Excitation
Fluids within piping systems also exhibit natural frequencies Acoustic.
Pressure pulsation is a tonal form of excitation whereby dynamic pressure
fluctuations are generated in the process fluid at discrete frequencies.
If these frequencies coincide with a structural natural frequency of the
pipework system high vibration can occur.
Typical sources of Pulsation are:
Reciprocating Pumps &
Compressors
Centrifugal Compressors
(Rotating Stall)
Flow over bodies within
flow (thermowells)
Dead Leg Branches

Potential Failure Mode: Identifying Fretting Issues

Typical locations to be considered include:

U-bolt pipe clamps, particularly where there is no resilient layer (e.g. tico pad)
Resting supports
Deck penetrations
Loose insulation cladding
Contact between pipes (partial clash)
Pipework in contact with other equipment items (e.g. cable racks, handrails,
other fittings, etc)
Temporary supports (e.g. scaffold poles, chain blocks etc.)
Where fretting is identified, the items in contact should be separated and
appropriate inspection performed to quantify any damage which has been
sustained.

Examples of Fretting

The screw and nut used to mount a temp gauge


in contact with pipe, resulting in penetration of
sch. 160 pipe

Pipeline contact to cable rack


resulting in fretting damage

U-bolt is attached to the connection on a


reducer section and is not lined and susceptible
to fretting damage

Pipework Vibration
Small Bore

Small Bore

Excitation generally from the main pipe as previously


described
Geometry significantly effects the response

Length
Diameter
Type of fitting
Number & size of valves
Parent pipe schedule
Location

Example of High Risk Geometry

Necked down connection


and large cantilevered mass

Large cantilevered mass with


poor geometry

Example of High Risk Geometry

Support to first flange,


however, large mass
assembly overhang

Large cantilevered mass with


poor geometry

Example of High Risk Geometry

Example of High Risk Geometry

Clamp Inadequate Supports

Brace only protects welded


connection to parent pipe. Down
stream elbow welded connection
unprotected

Connection braced at small bore


pipe using flat bar, no support
provided to the valve and potential
punch through threat.

Clamp Inadequate Supports

Connection braced to deck.


Combination of static (axial)
loading and vibration leading
to failure

Connection handcuffed to
adjacent pipe rather than parent
pipe

Clamp Adequate Support

Clamp provides restraint in both the horizontal and vertical


direction.
No overhanging mass of the valve

Clamp Maintenance & Inspection

Example of critical
clamp not been
re-instated correctly
after intervention work
on line

Disadvantage of Bracing Everything

High cost
Risk of corrosion
Risk of loosening resulting in ineffectiveness
On-going maintenance is required

Welded Web Supports

Example of SBC fully


supported using
welded webs

Thin-wall Pipework
Potential failure location when high
frequency vibration present

Piping Vibration Criteria

Industry standard curves based


on 25 years experience in the
petrochemical industry
Frequency Weighted

Pipework Vibration - Experience

Piping Vibration Criteria

Doosan Power Systems application of the


pipework vibration curves is to calculate
the overall RMS value over the entire
frequency range, acting at the lowest
dominant frequency, and compare it to the
curves to determine the classification.

ACTION

OK

No action required, vibration levels are


acceptable

CONCERN

The level of vibration, above which, further


analysis is required to determine if
modifications must be undertaken to
prevent possible high cycle fatigue failure

PROBLEM

The level of vibration, above which,


modifications must be undertaken
immediately to prevent high cycle fatigue
failures

Solutions What Role Can you Play

Keep your eyes and ears open


Pipework vibrating
Leaks / drips
Noise, especially tonal
Changes from yesterday / last trip

Dont assume someone else is dealing


with the concern!

Questions

Any Questions

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