Integrating an RBI Approach for Vibration-Induced Fatigue into a Mechanical Integrity Programme

Abstract

Abstract Vibration-induced fatigue accounts for more than 20% of process piping failures. This integrity threat is often not addressed as part of traditional mechanical integrity programs. Most vibration-induced fatigue failures can be prevented using a proactive, risk-based inspection (RBI) and assessment approach. The goal of this paper is to show how such an approach can be synergistic and integrated within existing mechanical integrity programs. Facilities typically rely on plant operators to identify and report vibration problems. However, vibration issues can be hard to identify with visual inspection alone. Vibration risks can be assessed using the Energy Institute's "Guideline for the Avoidance of Vibration Induced Fatigue Failure in Process Piping". The guideline can be adapted to streamline inspection programs and utilize the results during commissioning and operations. This paper will illustrate how this guideline can be practically applied and integrated within conventional mechanical integrity programs, such as RBI programs used by corrosion engineers. There is a gap between vibration studies carried out at the design stage and mechanical integrity programs of an operational plant. Due to perceived difficulties in the early detection of vibration problems, issues are often managed with a reactive approach. For example, in most cases, NDT does not discover vibration issues before they become critical. To close this gap, a proactive, risk-based approach can be used to reduce vibration risks to acceptable levels before damage occurs. This is achieved through targeted screening and risk-ranking of critical locations, based on process and design considerations. This approach allows for a cost-effective utilization of existing data from the design stage in order to support mechanical integrity programs during operations. The resulting vibration management database helps operators ensure vibration integrity throughout the asset lifecycle, eg, when changing process conditions or extending the lifetime of facilities. Case studies will be used to illustrate how operators can effectively manage piping vibration risks for offshore assets, and how a risk-based approach can significantly reduce the time and costs spent on traditional vibration management. The paper will illustrate how an effective screening process combined with innovative vibration data management can support operators throughout the facility lifecycle while reducing costs for integrity teams. The proposed process can lead to significant risk mitigations by providing actionable recommendations such as retro-fitting of supports, vibration-specific operating windows, design changes, and inspection plans targeted at high-risk areas. Integrity inspectors, engineers and facility managers will benefit from this paper and learn how to manage vibration- induced fatigue failure risks more effectively.