GUIDELINES FOR THE AVOIDANCE OF VIBRATION INDUCED FATIGUE FAILURE IN PROCESS PIPE

(DNV-RP-D101 Reference)
PRINCIPAL PUMP SYSTEM (IMO) CASTILLA

Item

Aspect

What is the Maximum value of kinetic

energy (pv^2) of process within the
sysrtem Under Consideration

Is Choked flow possible or are sonic flow

velocities likely to be encontered

3
4

Applic.
Fluid(s)

EXCITATION FACTORS
Likehood Classification
Low
Medium

All

pv^2<5000
kg/m*s^2

between 5000 and

20000 kg/m*s^2

Gas

No

Is there any Rotating or reciprocating

machinery

All

No

Are There any Positive Displacement

pumps or compressors

All

No

Rotating Equipment
Only
Screw/Gear type
Positive displacement
machine

No

Compressor has Stall

characteristics but
operational restraints in
place to ensure that
rotating stall is not
encountered

Are They any Systems which may exhibit Liquid /

flashing or cavitation
Multiphase

No

Are There any Systems with fast acting

opening or closing Valves

All

No

Are There Intrusive Elements in the

process Stream

Gas / Liquid

No

Is There a possibility of Slug Flow

Multiphase

No

No

Yes: However, suitable

corrective action in
place validated for the
complete operating
envelope

Are There any Centrifugal compressors

which have potential to operate under
rotating stall conditions

10

Is There a History of Pipework vibration

Issues, or are there any Systems which
are similar to those on another plant
which have a known history of pipework
vibration issues

Gas

All

CONDITION AND OPERATIONAL FACTORS - QUALITATIVE ASSESMENT

Likehood Classification
Applic.
Item
Aspect
Fluid(s)
Low
Medium
Better than
A
What is the quality of construction?
All
industry
At industry standard
standards
B

What is effectiveness of the plant

manteinance programme (including
corrosin management)?

All

Better than
industry
standards

At industry standard

Are there any cyclical operations (e.g.

Batch operation)?

All

No

What is the number of unplanned

process interruptions in an average
year? (on normal continuous operations)

All

0-1

2-8

FAILURE IN PROCESS PIPEWORK

QUALITATIVE SCORE

ILLA

TORS
ood Classification

HIGH
MEDIUM
LOW

2
3
6

QUALITATIVE ASSESSMENT
High

pv^2>20000 kg/m*s^2

Yes
Reciprocating Equipment
Reciprocating Type Positive
Displacement Machine

Potential Excitation
Mechanism

Value / Comment

T2.2 Flow Induced Turbulence

T2.6 Flow Induced Pulsation
(Gas Only)

4153 kg/m*s^2

T2.7 High frequency Acoustic

Excitation (Gas Only)

Not Apply - Liquid

Low

Low

T2.3 Mechanical Excitation

Positive Displacement
Pump

T2.4. Pulsation - Reciprocating

Positive Displacement
Pump

Stall rotating Condition

Unknown. Compressor has
rotating stall characteristics
T2.5. Pulsation - Rotating Stall
and may operate at
conditions that will give rise
to stall conditions
Yes

T2.9. Cavitation and Flashing

Yes

T2.8. Surge / Momentum

Changes

Selection

Medium

Medium

Not Apply - Liquid

Low
No
Low

Yes
Yes

Yes

TM-04. Vortex Shedding from

Intrusive Elements
Slug Flow - Seek Specialist
Advise

Chapter 4 Review

PSV
No
No

High
Low
Low

Yes
High

- QUALITATIVE ASSESMENT
ood Classification
High
Below industry standars

Contributory Factor
Build Quality

Score

Medium

Value / Comment

Selection

ASME B31.4 Code Used

Low

Below industry standars

Yes

Corrosion / Manteinance
Management

Cyclical Loading

Low
Low

9 or more

Process upsets

2 Contention Fails
reported on last year
Medium

QUANTITATIVE ASSESSMENT
Value / Comment

LOF

Go to T2.3 Sheet

0.90

Go to T2.4 Sheet

1.00

Go to T2.8 Sheet

0.63

T2.2 - FLOW INDUCED TURBULENCE

Input
Symbol
Units
External Pipe Diameter
Dext
mm
Maximum Span Lenght Between supports on
Lspan
m
line of interest
Wall Thickness of Main Pipe
T
mm
Fluid Velocity
v
m/s
Fluid Density

kg/m^3
Phase
Select
Calculations
Single Phase fluid pv^2
v^2
kg/m^2
Fluid Viscosity Factor
FVF
Stiff Arrangement (less than)
Lspan(1)
Lspan(1)
Medium Stiff Arrangement (between)
Lspan(3)
Lspan(3)
Medium (between)
Lspan(4)
Flexible (greater than)
Lspan(4)
Support Arrangement Classification
Select
Outside Diam
Fv
Stiff
60 to 762
52334.734
Medium Stiff
60 to 762
26073.970
Medium
273 to 762
11315.656
Medium
60 to 219
13592.219
Flexible
273 to 762
3713.909
Flexible
60 to 219
3943.531
Fv=
52334.733505
LOF=
0.08

Value
219.1
4
11.8618
2.08
960
Liquid - Multiphase
4153.344
1.00
5.85
5.85
8.32
8.32
11.02
11.02
Stiff

597370.472
364988.000
150621.000
12.736
58426.111
11.885

Comments
8"
Acc to field survey
Acc to thk measurements
for 250 KBPD
0,96 SG
Crude Oil

-0.835
-0.905
-0.888
-0.100
-0.945
-0.124

MECHANICAL EXCITATION
Pipework Connected or adjacent to
Reciprocating / Positive Displacement Compressor / Pump
Diesel Engine / Gas Engine
Screw Compressor / Pump
Centrifugal Pump
Electric Motor / Alternator (15 kW or greater)
Electric Motor / Alternator (Below 15 kW)
Centrifugal Compressor
Gas Turbine
Selection of LOF
Reciprocating / Positive Displacement Compressor / Pump

LOF
0.9
0.8
0.6
0.4
0.4
0.2
0.2
0.2

0.9

PULSATION: RECIPROCATING / POSITIVE DISPLACEMENT PUMPS &

COMPRESSORS

1
0.4

Selection of LOF
1.0

Equipment
Power (HP/kW)
Discharge Pressure (psi/bar)

IMO Pump
550
1350

404.52445
93.07926

PULSATION: ROTATING STALL

1
0.2
0.4

Selection of LOF
0.2

T2.6 PULSATION: FLOW INDUCED EXCITATION - GAS ONLY

Input
Symbol
Units
Value
Internal diameter of branch
dint
mm
49.000
Internal diameter of main line
Dint
mm
195.376
Lenght of Sidebranch
Lbranch
m
2.000
Mean fluid velocity in main pipe
v
m/s
2.080
Gas density

kg/m^3
960.000
Dynamic viscosity

Pa*s
2.40E-05
Calculations
Critical Diameter
dcrit
mm
175.088
Does the deadleg branch have an
Select
No
internal diameter >=dcrit
Reynolds Number
Re
16255316.480
Speed of sound in gas
c
454.127
ratio of specific heat capacities (Cp/Cv)
Universal Gas Constant
Gas temperature
Molecular weight of gas
Is Re > 1,6e7
Strouhal Number
S1 (Strouhal Number)
2S1 (Strouhal Number)
S (Strouhal Number) value selection
Fundamental Excitation Frequency
Fundamental Acoustic Natural Frequency
of side branch
is Fv/Fs>=1,0
Calculated LOF
LOF=

R
Te
Mw

1.700
J/K*kmol
K
grams/mol

S
S1
2S1
S
Fv

8314.000
423.150
29.000
No
0.302
0.354
0.708
0.302
12.805

Fs

46.775
No

0.290
0.200

Commments
2" SCH 80 pipe
8" 0,467" WT
Deadleg lenght (till PSV)
for 33299 BPD
0,9SG
Air @ 150C
6.893

Air @ 150 bar

150 C
App. B Table B4

in

T2.7 HIGH FREQUENCY ACOUSTIC EXCITATION - GAS ONLY

Input
Symbol
Units
Value
External diameter of branch
dext
mm
60.300
External diameter of main line
Dext
mm
219.100
Internal diameter of main line
Dint
mm
195.376
Distance between source and welded
Ldis
m
5.452
discontinuity
Molecular weight of gas
Mw
grams/mol
29.000
Pressure upstream of pressure reducing
P1
Pa (absolute)
13789500.000
device
Pressure downstream of pressure
P2
Pa (absolute)
689476.000
reducing device
Wall Thickness of the main line
T
mm
11.862
Wall Thickness of the branch
t
mm
5.537
Upstream Temperature
Te
K
339.000
Mass Flow Rate
W
kg/s
58.822
Sonic Flow corection Factor (if Sonic
SFF
0.000
Flow Exist =6, otherwise =0)
Calculations
Sound Power level (source)
PWL
dB
173.502
PWL is greater than or equal to 155 dB?
PWL (discontinuity)
Factor
Factor
Factor
Factor
Number of Cycles to Failure
Factor
Dext/dext is lesser than 10
FLM1
N=N*FLM1
Is the connection a Weldolet?
FLM2
N=N*FLM2
Is the piping Material Duplex?
FLM3
N=N*FLM3

Yes
dB
a
s
B
LOG10(N)
N
Dext/dext

N(1)
Select
N(2)
Select

Calculated LOF
LOF=

N(3)
Lf
Lf<=0?
Lf<=0?
Lf>=1?
Lf>=1?
0.823
0.823

Max Cycles to Failure

1.11E+07

171.828
0.938
73.429
161.831
7.589
38816499.393
3.633
Yes
1.133
43994692.104
Yes
0.285
11050017.450
No

0.823
No
No

Commments
2"
8"
8"
From Discharge nozzle Till PSV
Branch
App. B Table B4
2000 psi (Upstream PSV)
100 psi (Downstream PSV)
0,467" WT
SCH 80
150F
971,2 GPM @ 0,96SG

PSV

T2.8 SURGE MOMENTUM CHANGES DUE TO VALVE OPERATION

Input
Symbol
Units
Value
Fluid Density

kg/m^3
960
External diameter of main line
Dext
mm
219.100
Internal diameter of main line
Dint
mm
195.376
Upstream Static Pressure
P1
Pa (absolute)
13789500.000
Downstream Static Pressure
P2
Pa (absolute)
689476.000
P
Static Pressure Drop
Pa
13100024.000
Wall Thickness of the main line
T
mm
11.862
Mass Flow Rate

kg/s

Pipe Support Type

Select

Correction for Support Type

Main line Wall thickness for SCH 40 Piping
mm
Calculations

Relation T/SCH 40 Pipe WT

Peak Force
Fmax
Limit Force
Flim
LOF
Fmax/Flim

58.822
Stiff
4.000
8.179
1.450
13.753
21.917
0.627

Commments
0,96 SG
8"
8" 0,467" WT
2000 psi (Upstream PSV)
100 psi (Downstream PSV)
0,467" WT
Considering 100% Flow Rate throw the PSV
(971,2 GPM @ 0,96SG)
According to Evaluation on T2.2
8" SCH 40 THK

T2.9 CAVITATION AND FLASHING

Input
Symbol
Units
Upstream Static Pressure
P1
Pa (absolute)
Downstream Static Pressure
P2
Pa (absolute)
Liquid Vapor Pressure at Upstream
Pv
Pa(absolute)
Temperature
Select Valve Type or None
Fl
Select
Liquid Pressure Recovery Factor

Calculations
(P1-P2)/
P2>=Pv
LOF

Value
13789500.000
689476.000
152926.000
Globe
0.900
11050579.742
1.185
Yes
0.000

Commments
2000 psi (Upstream PSV)
100 psi (Downstream PSV)
7,48 psia
PSV Assumed as Globe type Valve

Input
Thermowell Type
Outside Diameter of Straight
Thermowell
Outside diameter at base
Outside diameter at Tip
Average Outside Diameter
Internal Bore
Factor
Factor
Factor

T4. THERMOWELL ASSESSMENT

Symbol
Units
Select

Value
Straight

Dtw

mm

21.300

D1
D2
DA
dtw

A
k

mm
mm
mm
mm

21.300
21.300
21.300
6.365
0.299
0.299
1.000

Youngs Modulus of thermowell material

Etw

Pa

200000000000.000

Second moment of area

Cross sectional Area
Lenght from the support point to the
tip
Lenght of largest diameter section on
stepped thermowell
Lenght of smaller diameter section on
stepped thermowell
Density of thermowell material
Parent Pipe Schedule
4-Way gussets?
Wall thickness Modifier
Straight Thermowell Structural Natural
frequency
Tapered Thermowell Structural Natural
frequency
Stepped Thermowell Structural Natural
frequency
Selected fn
Strouhal Number
Reynolds Number
Fluid Density

I
A

m^4
m^2

0.000
0.000

Ltw

0.300

Mean Fluid Velocity

Characteristic Dimension
Dynamic Viscosity
Vortex Excitation Frequency
LOF=

L1

0.300

L2

0.300
kg/m^3
Select
Select

7833.410
SCH 80 to less than SCH 160
No
0.930

fn

Hz

174.605

fn

Hz

58991.976

fn

Hz

174.734

fn
S
Re

Hz

kg/m^3

174.605
0.237
27891.356
901.000

m/s

10.900

Dchar

Fv

mm
Pa*s
Hz

21.300
0.008
121.459
0.29

FM

Commments
1/2" Pipe

1/2" Pipe 0,294" WT

0.28300 lb/in^3

0,901SG
for 10" Sch 0,812" Header at 250
KBPD
7,5 cP

SBC
Geometric LOF
Type of SBC
1
ANSI Rating
>=900#
Type of Fitting
Weldolet
Overall Lenght
>600mm
Number of Valves
>=2
Parent Pipe SCH
40
SBC Min Diameter
2"
Geometric LOF
Location LOF
Main Line LOF
Location of SBC
Bend
Parent Pipe SCH
40
Location LOF (Mean A-B)
Location LOF

Cantilever
0.9
0.9
0.9
0.7
0.5
0.78

1.00
0.9
0.7
0.80
1.00

Selection of SBC LOF

Main Line LOF x 1,42

Minimum of Geometric and Location
LOF

1.42

SBC LOF

0.78

0.78

Note: FBW Fully Backwelded

PBW Partially Backwekded

See Note

ACTIONS FOR MAIN LINE

ACTIONS FOR SBC (S

ACTIONS FOR SBC (SMALL BORE CONNECTION)

Type Of Fitting
Short Contoured Body
Contoured Body
Forged Red Tee
Welded Tee
Weldolet
Threadolet (FBW)
Screwed (FBW)
Threadolet
Screwed
Sockolet
Threadolet (PBW)
Screwed (PBW)
Set-On
Set-In
Set-Thru

SCH 160 or Greater

SCH 80 to less than SCH 160
SCH 40 to less than SCH 80
Less than SCH 40

Number and Size of Valves

>=2
1
0

Overall Lenght of Branch

>600mm
0.9
<600mm
0.7
<400mm
0.3
<200mm
0.1

0.4
0.6
0.6
0.6
0.9
0.9
0.9
0.95
0.95
1
1.1
1.1
1.3
1.3
1.3
FM
No
0.96
0.93
0.85
0.42

<900#
0.9
0.5
0.2

Straight
Tapered
Stepped

FM (4-Way Gussets)
Yes
0.98
0.96
0.93
0.85
Rating
>=900#
0.9
0.9
0.5

Parent Pipe Sch

10S
20
40
80
160
>160

0.9
0.8
0.7
0.5
0.3
0.3

None
Ball
Butterfly
Globe
Gate

SBC Min Diameter

0,5"
0.9
0,75"
0.8
1"
0.7
1,5"
0.6
2"
0.5
Low
Medium
High

Score A
Valve
Reducer
Bend
Tee
Mid Span
Partial Support
Fixed Support

Gas
Liquid - Multiphase
Stiff
Medium Stiff
Medium
Flexible

Fl
NA
0.6
0.62
0.9
0.6

No
Yes

A
B
C
D

4
2
1
0.5

0.9
0.9
0.9
0.9
0.7
0.6
0.1

Score B
10S
20
40
80
160
>160

0.9
0.8
0.7
0.5
0.3
0.3

1
1
1
2
2