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  • Vibration Induced Fatigue Safety Moment

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    Anthony Barnes
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    The document summarizes a gas plant failure that occurred during commissioning in Algeria. Two gas treatment trains were brought online, but problems with the CO2 plant caused gas to be diverted to the flare. The increased flow through the flare system exposed deficiencies in the design that allowed gas velocities to exceed code levels. Within hours, a 6-inch line connecting to the flare header failed catastrophically due to excessive vibration and fatigue. Around 80 tonnes of gas was released but did not ignite due to wind direction. An investigation found the blowdown system was underdesigned and quality checks of critical safety systems like the flare header were not properly conducted. Lessons included ensuring personnel competencies, demonstrating compliance to codes and standards, and

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    The document summarizes a gas plant failure that occurred during commissioning in Algeria. Two gas treatment trains were brought online, but problems with the CO2 plant caused gas to be diverted to the flare. The increased flow through the flare system exposed deficiencies in the design that allowed gas velocities to exceed code levels. Within hours, a 6-inch line connecting to the flare header failed catastrophically due to excessive vibration and fatigue. Around 80 tonnes of gas was released but did not ignite due to wind direction. An investigation found the blowdown system was underdesigned and quality checks of critical safety systems like the flare header were not properly conducted. Lessons included ensuring personnel competencies, demonstrating compliance to codes and standards, and

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as ppt, pdf, or txt
    238 views9 pages

    Vibration Induced Fatigue Safety Moment

    Uploaded by

    Anthony Barnes
    The document summarizes a gas plant failure that occurred during commissioning in Algeria. Two gas treatment trains were brought online, but problems with the CO2 plant caused gas to be diverted to the flare. The increased flow through the flare system exposed deficiencies in the design that allowed gas velocities to exceed code levels. Within hours, a 6-inch line connecting to the flare header failed catastrophically due to excessive vibration and fatigue. Around 80 tonnes of gas was released but did not ignite due to wind direction. An investigation found the blowdown system was underdesigned and quality checks of critical safety systems like the flare header were not properly conducted. Lessons included ensuring personnel competencies, demonstrating compliance to codes and standards, and

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as ppt, pdf, or txt
    of 9

    Safety Moment

    Jan 2010

    Algerian Gas Plant Failure - Background

    A gas treatment plant was in the final stages of commissioning.

    Train 1 had been flowing gas for a couple of weeks then Train 2 was
    brought on stream

    Within a matter of hours of start-up of Train 2 problems with the CO2


    plant resulted in gas being diverted to flare.

    During the start-up of Train 1, it had been noted that the flare system
    seemed excessively noisy and vibration in some of the pipe work
    resulted in bolts holding pipe clamps becoming loose.

    Background (Continued)

    As Train 2 started to send gas to flare the situation became worse.

    Within hours the 6" line taking gas off the top of the glycol contactor
    to the flare header failed catastrophically at the header.

    The plant then went into automatic emergency shutdown resulting


    in a large proportion of the gas inventory (approx. 80 tonnes)
    venting through the hole left by the failed 6 pipe in the flare header.

    Luckily the wind was blowing away from the plant and the gas did
    not ignite.

    Schematic

    Photos

    Initial Investigation Findings

    The 6" dia line connecting the glycol contactor to the


    flare header was under designed. The under-design
    caused sonic velocities resulting in excessive vibration
    and rapid turbulence induced fatigue failure.

    A complete engineering check of the entire blowdown


    system revealed numerous instances where gas
    velocities exceeded code levels.

    Root Cause Findings


    Root Cause Findings of the Engineering Authority Investigation
    Multiple breakdowns of the Project systems including:

    Failure to appreciate the importance of the blowdown system to the safety of


    operations

    Failure to apply what should have been a good Quality System.

    The Contractor QC system required independent checks of critical safety


    systems. These checks were not carried out for this line.

    Failure to follow through on HAZOP findings. The HAZOP commented on


    the unusual configuration of pipe work entering the header. These
    comments were not followed up

    Failure of the commissioning team to adequately respond to excessive noise


    and vibration in the blow-down system. Bolts that fell out of pipe clamps
    were replaced and re-torqued without reference back to the designer.

    Lessons from Incident

    Ensure personnel competencies are specified and applied at all


    levels

    Demonstrate compliance with codes, standards and procedures,


    verify and retain calculations and documents

    Ensure special attention is given to piping systems handling slugs,


    2-phase fluids and turbulent flow.

    Demonstrate closure of all design reviews and HAZOP actions

    Train operators and commissioning personnel to understand


    significance of unusual situations and to respond correctly during
    commissioning and start up.

    THOUGHTS

    SHORT DISCUSSION MOMENT Best Practice

    Maximum velocities

    WP EMS Process Design specifies 0.5 Mach Max at Vent/Flare Discharge

    Others ?
    Specify flow regimes in line lists?
    More attention to flow induced vibration in process
    systems as a result of debottlenecking?

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