High Cycle Fatigue Failure and Damping Solutions for Vibrating Process Piping in Gas Processing Plants: A Review and Industrial Case Study
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Abstract
Vibration‑induced fatigue remains one of the most persistent mechanical‑integrity threats in gas‑processing plants. Complex flow regimes, high‑energy acoustic sources and flexible piping layouts combine to generate dynamic loads that can initiate and propagate fatigue cracks, often with limited or no prior visible damage. This paper has two objectives. First, it synthesizes recent research on flow‑induced vibration (FIV), acoustic‑induced vibration (AIV), and structural resonance in process piping, with emphasis on prediction, evaluation and mitigation in gas‑processing systems. Second, it documents an industrial case study from a large onshore gas facility where capacity‑increase testing revealed excessive vibration on 18″ raw‑gas inlet lines at 430 MMSCFD, leading to a structured campaign of vibration measurements, mitigation design and re‑assessment.
The literature review covers developments in FIV and AIV mechanisms, fatigue‑life prediction methods, high‑fidelity numerical modelling (including combined acoustic–structural and fluid–structure interaction models), and state‑of‑the‑art mitigation technologies such as tuned mass dampers, vibro‑impact systems, viscoelastic treatments and material hardening. While Energy Institute (EI) and ASME screening methods are valuable first‑pass tools, they are shown to be insufficient for complex multiphase flows and transient operation without follow‑up modal or transient analyses.
The industrial case study demonstrates how these principles were applied in practice. Vibration measurements on four process trains initially identified “concern area” or “concern line” conditions at dead‑leg branches, small‑bore connections and bypass bracing supports near an emergency shutdown valve. A dedicated pipe support, added mass, clamp re‑tightening and a new pipe‑to‑pipe support on a MEG injection line were designed and implemented. Subsequent measurements at 430 MMSCFD showed up to ~70% reduction in resultant RMS velocity at the most critical branch, with all points falling within EI acceptance limits. A later survey on a fifth train (Train 6) confirmed acceptable behavior up to 420 MMSCFD, with only a few locations classified as “concern line” and targeted for ongoing optimization.
The results highlight the importance of early screening, targeted high‑fidelity analysis, tailored damping and stiffening solutions, and continuous monitoring. An integrated, data‑driven vibration‑management framework is recommended to support safe throughput increases and long‑term mechanical integrity of gas‑processing piping systems.