Asset Management Services

Plant Integrity Management Services

Germanischer Lloyd Service/Product Description

Germanischer Lloyd Service/Product Description

Plant Integrity Management

Services
Service Title:

Asset Management Services

Lead Practice:

GL Asset Management (UK)

Contents
Page 3 Service Description and Values Generated
Pages 4 - 12 Detailed Method Statement
a: Plant Integrity Management System Audits
b: Corrosion Management
c: Material Defect and Component Failure
Investigation
d: Fitness for Service Assessment
e: Written Schemes of Examination
f: Coatings Services
g: Welding Services
h: Risk Based Inspection
i: Pipework Vibration Services

Pages 12 - 22 Case Studies and Examples

a: Corrosion Management of LNG Storage Facilities
b: Integrity Management Review
c: Fracture of Thermowell
d: Failure of Impulse Pipework Compression Fitting
e: Fitness-for-Purpose Assessment of Pressure Vessels
f: Fracture Mechanics Assessment of a Defective Pig Trap
g: Defect Assessment of Corroded Pipework
h: Review of Integrity Management Framework
i: Safety Management Audit
j: Fitness for Service Assessment
k: Repair of Amine Stripper
l: Investigation of Coating Failure on Oil Storage Tank

SERVICE DESCRIPTION

Service Description
and Values Generated:
Pages 23 - 32 Case Studies and Examples
m: Corrosion Management Study
n: Weldability Testing of 48 Diameter X80
Europipe Production
o: Design and Qualification of Repair
Procedures for Bellows Attachment Welding
p: Evaluation of RBI Software

Germanischer Lloyd (GL) provides a range of Plant Integrity

Management services to assist Operators in managing their assets in
a safe and efficient manner, as well as complying with all prevailing
regulations and legislation.
GL are able to tailor their services to meet client needs and can
generally provide support & solutions to a range of Integrity
Management problems.
Supporting each of the core services are experts with many years
experience in integrity management.

q: T-OCR Risk Based Inspection

r: Investigation of Double Block and Bleed
Valve Vibration at a Gas Processing Facility
s: Long Term Monitoring of Pipework
Vibration at Gas Compressor Stations
t: Assessment of Risk of Pipework Failure Due
to Vibration During Offshore Plant Uprating
u: Vibration Screening at an Onshore Gas
Terminal

DETAILED METHOD STATEMENT

a. Plant Integrity Management System Audits

b. Corrosion Management

In general, an audit or review of an Integrity Management System will

begin with a Gap Analysis. This entails a thorough review of the
Operators activities from corporate policy and organisation through
to company procedures and work instructions, including the
following:

GLs approach to corrosion management is to consider the process,

materials and safety aspects as an integrated whole. In most respects
the process dictates the materials and corrosion control methods used
on plant while occasionally the materials technology available will
shape the feasible process solutions. Ultimately, the objective is to
produce a system that assures the safety of plant operations. Thus, all
have to be addressed when considering corrosion management.

Compliance with
requirements

Integrity threats and mitigations in place

-

national

legislation

and

local

Onshore mechanical damage, corrosion, ground

movement etc
Offshore mechanical damage, stress/fatigue type
material failures, internal and external corrosion etc

1. Gather process data e.g. temperatures, pressures and

fluid compositions during both normal operation and
upset conditions

Quantitative risk assessments undertaken

Engineering documentation

Identify pressurised systems

Plant records and fault data

Identify major hazards

Quality, health, safety and environmental issues

Identify HAZOP actions related to corrosion and

materials

Plant Operations and Maintenance

-

Work scheduling
Record keeping
Routine and non routine activities

2. Consider the safety risk assessment in order to:

3. Conduct corrosion risk assessment including:



Calculation of internal corrosion rates

Plant Inspection

Assessment of stress corrosion cracking threat

Modification and repair process

Assessment of erosion threat

Emergency management

Assessment of external corrosion including under

insulation

Defect assessment and repair methods

Training and competency of staff

Safe control of operations

Continuous improvement processes in place

The Integrity Management System under review can then be assessed

for compliance with prevailing regulations and compared to
international best practice. Recommendations can be made to the
Operator as to how they can improve their processes and systems.
Generally in such a project there will be a Phase 2 which comprises
gap closure actions. Depending on the results from the gap analysis
this might entail a complete overhaul of an Operators Engineering
Documentation System or it may involve some rationalisation and
repackaging to ensure that the IMS is clear and coherent.

The production of a corrosion management system would

generally involve the following stages:

DETAILED METHOD STATEMENT

4. Produce corrosion management scheme



Select materials (corrosion resistant alloys or carbon

steel with corrosion allowance)

Select corrosion control methods (e.g. inhibition,

coatings, cathodic protection)

Select corrosion monitoring methods and locations

Produce corrosion data management strategy and

select tools

Devise suitable key performance indicators (KPI) for

corrosion management

c. Material Defect and Component Failure Investigation

GLs approach to failure investigations is not only to use state of the
art methods to determine the immediate cause of the failure, but also
to identify the root cause and propose solutions for eliminating the
problem in future.
There are many reasons why a material defect or failure may arise; for
example:

Incorrect materials selection,

Materials quality issues,

Fabrication issues,

Document change procedure for revising scheme if

process parameters are altered (e.g. after
debottlenecking)

Operating conditions outside original design parameters,

Environmental factors,

Produce plant/field corrosion management guide/

manual

Maintenance and protection issues,

Human and procedural factors,

Third party damage.

5. Feed back the corrosion management activities into the

field safety case and risk assessment as mitigating factors

The scope of a failure investigation depends upon the nature of the

failure and also upon the results obtained as the investigation
proceeds.
An important first step is to ensure the failure is preserved for future
examination, particularly where this may be used as evidence for
litigation purposes. This may involve visits to site to assist in
identifying, examining and collecting all relevant material, and
stabilising and protecting as necessary for transport to the laboratory.
In the event of a dynamic failure, such as an explosion resulting in
extensive damage, this may be a difficult and arduous task as the
majority of the failures evident will be effect and not necessarily
directly relevant to identifying the cause. In these circumstances
detailed photography is essential before any material is removed from
the site of the failure. It is also important to talk to site personnel to
establish the circumstances surrounding the failure and operating
conditions at the time.
Where the failure involves a defect in a component or structure it is
important that NDT (Non Destructive Testing) is carried out to
determine the extent of the failure and any associated damage prior
to extraction for detailed analysis. GL NDT experts offer a range of
techniques, both on-site and in the laboratory, including: magnetic
particle inspection (MPI), dye penetrant testing (DP), manual
ultrasonic testing (MUT), alternating current potential drop (ACPD),
and mechanical measurements.
For characterising the defect or failure a metallurgical examination
and materials testing programme is carried out.

DETAILED METHOD STATEMENT

A metallurgical examination of a defect or failure would typically

include:

Visual examination by eye and using a stereo optical

microscope

Detailed fractography using a scanning electron

microsope (SEM)

Surface compositional analysis by semi-quantitative X-ray

energy dispersive micro-analysis (EDX) in the SEM

Preparation of weld sections for macro-examination and

hardness surveys

Preparation of mounted and polished sections for

microstructural analysis and to confirm crack path

Materials testing, to establish compliance with relevant standards and

to generate mechanical property data for supporting engineering
analysis assessments, would typically involve:

Chemical composition

Tensile testing (e.g. yield strength, ultimate tensile strength,

elongation etc, and specific tests for threaded fasteners)

Hardness testing

Charpy impact testing

Fracture mechanics testing (such as CTOD and J-integral)

The output from the metallurgical analysis and materials testing

programme would offer the customer an opinion on the mode and likely
cause of failure, and an understanding of the contribution of material
related factors. It is usual to complement the metallurgical examination
and materials testing programmes with an engineering analysis to
identify and understand the contribution of mechanical factors.
Depending upon the nature and scope of the investigation further
analysis may be carried out to understand the wider implications of
the failure and to ensure that recommendations for preventing further
failures are implemented, for example:-

Detailed fracture mechanics analysis to determine safe

operating parameters

Fitness for purpose assessments

Remaining life analysis

Review and update of operating procedures

Review of asset integrity and inspection programmes

(such as RBI)

d. Fitness for Service Assessment

GL routinely undertakes assessments of damaged pressure vessels and
pressure systems for an international clientele of asset owners/
operators worldwide. We have in-depth knowledge and experience in
the use of industry recognised assessment methods such as:


API 579

RSTRENG

DNV RPF101

BS7910

ASME VIII

PD5500

BS EN13445

GL therefore have the capability to assess the integrity of pipework

and pressure vessels and routinely use advanced numerical techniques
such as the finite element (FE) method and pipe stress analysis to
undertake fitness for service assessments. We have excellent
knowledge of the UK Pressure Systems Safety Regulations, 2000
(PSSR) and relevant US Code of Federal Regulations (e.g. CFR 192 and
195).
For any fitness-for-purpose assessment, assumptions are required on
the input parameters. These assumptions include:


Original equipment design data

Operational and maintenance history

Expected future service

Information specific to the assessment such as defect

sizes, stress state, location of flaws, and material
properties such as tensile strength and fracture
toughness.

Fitness for Service can be demonstrated using methods such as stress

analysis, defects assessment and fracture mechanics approaches.
These are described as follows:

DETAILED METHOD STATEMENT

Stress Analysis

Defect Assessment

Fitness for service can be demonstrated using higher level assessment

methods such as FE (Finite Element Analysis). GL can undertake work
ranging from the stress analysis of individual structural components
such as pressure vessel nozzles, full pressure vessel models to
complete piping systems. GL consultants have the capabilities to
undertake advanced non-linear, static/dynamic analysis, vibration,
thermal and fatigue analyses. We use these capabilities to undertake
fitness-for-service assessments of pressure systems and in conjunction
with full scale testing facilities to develop defect assessment methods
for pipelines and pressure vessels. GL uses an extensive range of FE
and associated software tools that are mounted on both SUN Unix
network and PC based Windows system. The software tools we use
include:

Defect assessment is a deterministic approach used to assess the

integrity and fitness for service of defects found on pressure vessels or
piping. Defects are features that affect the structural integrity of
vessels, pipelines or piping, and may be located on the surface of the
pipe wall or actually inside the material of the pipe or shell. There are
numerous codes that can be used to assess defects and are
summarised in documents such as the Pipeline Defect Assessment
Manual used for pipelines, which our consultants understand the best
methods to use. In addition, GL has experience in conducting
assessments to API 579 and BS 7910 used for pressure vessels and
piping.

ABAQUS (Standard and Explicit) FE analysis program

MSC/PATRAN and ABAQUS CAE FE pre and post

processor programs

PC based software such as MathCad and MATLAB

In addition to the above, our consultants can write customised

programs, user subroutines, etc. in order to overcome the limitations
in proprietary software. Areas of expertise include;


Linear and non-linear analysis. Where necessary,

non-linear effects can be included in the analysis; this can
be through the modelling of non-linear material
behaviour, geometric non-linearity and contact

Buckling, postbuckling and collapse analysis of pipelines

Soil structure interaction

Steady state and transient heat transfer analysis

Fatigue and fracture mechanics; cracked body analysis

Design by analysis

Sources for defect data include NDT methods. Using in-house

expertise, appropriate assessment methods can then be chosen and
applied to demonstrate fitness-for-service in order to satisfy regulatory
requirements and operators integrity management strategy.
Damage assessment capabilities include the following;
i) Manufacturing Damage, Manufacturing features are
often a discontinuity in the geometry of the pipe or shell
such as a reduction in wall thickness or in the material
itself.
ii) Construction Damage, Construction defects may
include girth weld defects or seam weld defects caused by
lack of fill or misalignment, and in the most severe case,
cracking. Also, other forms of damage may occur such as
indentation damage, corrosion at the girth weld, or even
damage to the external coating.
iii) 3rd party interference, 3rd party damage is often the
most severe form of damage resulting in failure of the
pipe or requiring immediate repair. Often this involves
mechanical damage such as a gouge resulting in metal
loss of the pipe wall, or distortion of the pipe wall such as
a dent.
iv) Operational damage. Defects arising from operational
usage include external corrosion caused by damaged or
disbonded coating where the Cathodic Protection System
is not effective. Also internal corrosion caused by water in
the product, and even other forms of corrosion namely
Sweet Corrosion and Sour Corrosion may occur in
pipelines.

Windows is a trademark of MicrosoftTM corporation

DETAILED METHOD STATEMENT

Fracture Mechanics

e. Written Schemes of Examination

BS7910 and similar codes such as the UK nuclear industry code R6

and API 579, carry out fracture assessments using the Failure
Assessment Diagram (FAD). This provides a graphical method for
assessing the proximity of a loaded structure containing a defect to
failure by fracture and plastic collapse mechanisms. Proximity to
fracture is characterised by the fracture ratio parameter Kr and
proximity to plastic collapse is characterised by the parameter Lr. A
loaded structure can therefore be represented as an assessment point
on the FAD following calculation of Lr and Kr.

The Written Schemes of Examination (WSoEs) will be logically

structured to allow for effective monitoring and control and will show
individual pressure systems within each of the major systems. The
components that require periodic inspection in order to ensure
continued fitness for purpose will be identified.

This diagram is used in levels 1 to 3 of BS7910 to determine the

acceptability of cracks by plotting a point on the diagram. When
deciding which level to use, this depends on the input data available
and conservatism required. These levels can be summarised as;


Level 1 is a simplified assessment method when there is

limited data on material properties

The WSoE will be structured in such a way that will allow the User to
determine the future inspection requirements for at least a 5-year
period, however, it is more likely that future inspection requirements
for circa 10 years will be attained.

Level 2 is the normal assessment route

The items of equipment covered will generally cover the following:

Level 3 is based a ductile tearing resistance analysis

Using the fracture mechanics approach our consultants can determine

whether a defect is SAFE or UNSAFE based on the Failure Assessment
Diagram. Using the fatigue assessment approaches described in
BS7910, we can then determine the remaining fatigue life and future
integrity of the structure if subjected to cyclic loading.

The WSoE will ensure that all components within the plant are
sufficiently inspected to ensure that any defects are detected at an
early stage to prevent inoperability of the asset. Such inspections may
not be limited to pressure containing components, but may also
include access ladders, gantries, foundations, whose failure may limit
the operability of the plant or equipment.

Pressure vessels, drums, tanks etc.

Heat exchangers

Compressors

Filters

Onshore pipelines

Offshore pipelines

Relief valves

Pressure safety valves

Fire systems components

Compressed air and nitrogen systems

DETAILED METHOD STATEMENT

The WSoEs will be developed by:

Reviewing existing documentation pertaining to design,

manufacture, construction, testing, modifications and
repairs, past inspection reports, etc. and plant operation
records.

GL will nominate competent, technical engineers, with long term

experience in compiling WSoEs for major gas transporters, to
undertake this work. The WSoEs will be generated on Microsoft Word
and Excel and be provided on CDs and hard copy. The WSoEs will be
based on UK best practice and will not include any other national
requirements, unless otherwise stated.

Establishing safe operating limits and their protective

devices.

The WSoE will be submitted to the Independent Competent Person

for review and/or approval.

Identifying individual pressure systems.

Developing examination specifications from each

component group.

Identifying examination frequencies on fixed time

intervals for major items of equipment based upon
industry practices, GL experience and information as
supplied from the Client.

Liaising with the system User.

The WSoEs will typically include :

Safe Operating Limits.

Equipment to be inspected.

Identification references of each item of equipment.

Nature and type of inspection required (visual, NDT etc.)

Functional testing requirements for protective devices.

Preparatory work required prior to inspection.

Frequency of inspection.

Detailed written inspection procedures for each item of

equipment, based on current inspection methodologies,
based upon the generic examination specifications.

Competencies/qualifications required by inspectors.

Standard report formats for recording examinations.

Identification of applicable international / national codes,

specs, procedures etc.

Applicability and adaptability to utilise the most up to

date inspection techniques for the examination of plant in
the most cost effective manner.

DETAILED METHOD STATEMENT

f. Coatings Services

g. Welding Services

Many factors dictate the protection being afforded to plant and

equipment and these must be considered when selecting paint and
coating systems for providing corrosion, erosion and chemical
resistance. Long term corrosion protection will generally require:

GL staff have been involved, in many cases, in the development and

qualification testing of procedures and consumables for the
construction of pipelines, process plant and ancillary high pressure
equipment. GL carries out weldability studies on all candidate linepipe
and components used in the UK National Transmission system in
accordance with the requirements of National Grid specification
T/SP/MPQ/1. For line pipe this involves the production of a full scale
girth weld under simulated field conditions, to an approved
procedure and including such factors as lifting and manipulation to
simulate movement of the line-up clamps following deposition of the
hot pass.

1. Identification of appropriate coating systems



Identify substrate type, method of preparation,

operating temperature, requirements for insulation,
contents being processed or stored etc

2. Small-scale performance evaluation to ensure long-term

protection at the new construction and maintenance
stage


Application,
accelerated
performance assessment

corrosion

testing,

3. Development of coating application specifications for

new construction and maintenance


Surface preparation, application, inspection and

testing

4. Coating survey and technical audits to ensure successful

application and compatibility with existing systems

GL has been involved in material selection, testing, specification

development and quality control issues to ensure long term protection
of plant and equipment.
Where inappropriate coating systems have been specified, or coatings
have been applied incorrectly, GL offer a consultancy service to help
confirm the cause of failure. Laboratory test programmes help
establish the mechanism of failure, and to apportion blame where
litigation is a likely outcome.

Additionally, repair special procedures are tested and qualified before

being putting into service.
Welding consultancy services are also required when new or difficult
materials are involved, such as those employed for high temperature
or sour service environments and include materials such as Inconel,
duplex stainless steels or linepipe clad with these materials. In these
cases very specific welding procedure specifications are drawn up and
initial production welding is carried out under the supervision of
GL expert staff.
GL also carries out welding prequalification of high pressure
components produced by new suppliers, and an investigation of the
welding procedures and consumables employed by candidate
companies is an integral part of this. Site visits are carried out and
supervision of component production ensures that they meet the
relevant requirements for specific companies and individual projects
and can be welded into the system without problems.
GL also supplies expert assistance in the selection and application of
methods for weld repair of pipelines, process plant and high pressure
equipment. This is supplemented by expertise in inspection which
ensures that defective areas are professionally repaired and returned
to service in fully reliable condition.

h. Risk Based Inspection

The main objectives of the RBI is to derive an inspection strategy that
ensures the maintenance of integrity of the plant.

10

To establish a minimised vessel inspection programme in

accordance with regulations

To optimise the inspection strategy for equipment

including the testing and maintenance of relief valves

To establish integrity management procedures for LNG

pipework

To reduce, and where possible, eliminate the need for full

vessel isolation and entry by utilising borescopic
inspection techniques

DETAILED METHOD STATEMENT

The RBI methodology combines expert judgement and probabilistic

modelling. RBI software is used for the execution of criticality
assessments and generation of inspection plans.
The methodology includes procedures to define process fluids and
systemise process streams. Within any process stream there may be
changes in pressure and/or temperature of the contained fluid. A
system is defined as being that part of a process stream at similar
temperature and pressure; such changes may give rise to different
corrosion regimes, or a different fluid state. Systemisation of sites is
carried out using the latest version hard copies of the piping &
instrumentation diagrams (P&IDs).

A Plant Integrity Review (PIR) is then undertaken. The PIR re-evaluates

criticality assessments by examining process history, operating
conditions and past inspection results. The initial risk assessment is
reviewed and verified against actual plant experience. This is an
essential step as it provides an opportunity for the degradation
mechanisms calculated by the software to be verified, by the expert
panel and any additional failure mechanisms to be added. Changes
to equipment criticality and confidence factors arising from the PIR
will produce changes to the recommended inspection
frequencies/tasks. PIR meetings should be formally recorded, using
the appropriate PIR decision record template, with details of the key
decisions made and persons present.

As part of the RBI process, a qualitative assessment is carried out by

relevant members the RBI Project Team. This procedure uses process
system information, in combination with the materials and contained
fluid properties to allocate specific operational consequence ratings
relating to standby, financial and location impact. This is also used to
highlight any particular areas of concern with respect to equipment
deterioration.

The competent should either be present at the PIR or receive a

detailed report of any changes that are proposed, their reasons and
the effect on periodicity for equipment covered by PSSR. Any changes
that are made to the Written Schemes of Examination (WSoE) should
then be either made by the competent person or certified by the
competent person before they can take effect and job plans can be
altered.

i. Pipework Vibration Servicves

GL offers a broad range of vibration measurement and analysis
services with specialist skills and knowledge in the following areas to
determine and manage the risk of vibration-induced fatigue failure
of process pipework:

Following data entry, an initial criticality (risk) assessment is carried

out using the current equipment design and process information. This
will generate an initial relative risk (or criticality rating) for each item
of equipment in the database, based on the probability and
consequence.
The RBI software includes a module program that can be used
to develop detailed inspection plans. Although the RBI will determine
the recommended frequency of inspection, it cannot assign an
inspection method. This must be manually selected from a list of
methods. The RBI project team is responsible for populating the
database with recommended inspection methods for each interim
inspection task. However, these may be amended by site once the RBI
system is fully operational, depending on the views of site engineers,
inspectors and the competent person.

Troubleshooting service to resolve vibration related

problems

Detailed screening of main pipe and small bore

connections

Vibration measurement and assessment

Provision of advice and design guidance

Identification and development of optimum solutions

Substantial experience has been gained in the investigation of

pipework vibration problems on process plant, including mechanical
and flow-related sources, and structural and acoustic transmission of
vibration. This knowledge, coupled with an extensive range of
experimental and theoretical techniques which can be employed,
enable a thorough investigation to be carried out. Any failure
investigation can also draw on the substantial expertise in the
company regarding integrity issues on pipelines, pipework
components, rotating machinery, pressure vessels and other
structures. In the event of a vibration related failure or identification
of a problem, GL are able to provide a timely response, depending
on the urgency of the request for support.

11

DETAILED METHOD STATEMENT

As part of a plant integrity management programme for onshore and

offshore assets, it is essential to manage the risk of potential vibration
problems on piping systems and small bore tubing. This can be
achieved through a structured screening methodology which aims to
quickly identify pipework at risk, assess the relative risk, and prioritise
effort on plant areas of most concern.
GL have been active in developing strategies for reducing the threat
of vibration related failures in order to target potential problems and
demonstrate legislative compliance, resulting in a significant reduction
in the risk of failure at many sites.
Typically a study of this type would cover the main pipework and small
bore connections through the following:


Visual survey

Basic vibration measurements

Assessment of risk of failure

The screening programme aims to identify issues from the site survey
requiring immediate action, such as ineffective supports, poorly
supported pipework and vulnerable small bore connections.
Subsequent investigations, if required, can then focus on the highest
risk areas which might include assessment of vulnerable connections,
monitoring of transient vibration events, and monitoring of plant over
an extended period to assess the behaviour over a full range of
operating conditions.
This assessment methodology is consistent with the process industry
best practice, and has been used by operators to successfully
demonstrate to the UK HSE that appropriate steps have been taken
to manage the issue of pipework vibration on their assets.
An additional benefit of this type of project is an increased awareness
of vibration issues for operational staff. This helps to avoid these
problems becoming significant in the future, through recognition of
problems at an early stage, and implementation of best practice for
any maintenance and replacement activities.
GL offers extensive experience of vibration surveys and on-site
measurements on operating plant pipework. Methodologies and
assessment methods have been developed for measuring and
assessing dynamic stress and vibration on all aspects of pipework
systems. Intrinsically safe instrumentation has been designed
specifically for these applications, allowing vibration measurements
to be carried out in hazardous areas using a combination of strain
gauges and accelerometers as required. This includes a friction strain
gauge for small bore pipework which was developed and patented by
GL, and which can be easily and rapidly installed to achieve accurate
dynamic strain measurement on most pipe sizes without the need for
significant surface preparation.

12

GL has also developed a measurement, data acquisition and analysis

system that performs long term monitoring of a large number of
sensors over extended periods, for investigation of intermittent but
significant pipework vibration problems associated with compression
facilities and process plant. Subsequent analysis of the data provides
in-depth understanding of the operators specific vibration problems
to enable the implementation of a cost-effective solution.
Following collection of the measurement data from a site, vibration and
fatigue assessment techniques are used, which have been developed
and independently validated to assess dynamic stress and vibration on
all aspects of pipework systems. Acceptance criteria have been derived
from BS 7608 (Fatigue design and assessment of steel structures) for a
range of common welded pipework and instrument stabbing
connections and used extensively in site surveys and assessments.
Finite element modelling is used in support of assessment and analysis
activities, with detailed studies allowing pipe wall vibration modes
and stress concentration effects to be investigated in depth.
To reduce the risk of failures occurring to acceptably low levels,
GL is able to provide advice on all aspects of pipework design related
to dynamic behaviour, building on the experience gained in resolving
vibration related pipeline integrity issues. This advice can be applied
at any stage of a plants design, construction and operation. For
example, specifications can be written for input to the design of an
installation, design reviews can be carried out, and/or an as-built
review of new or existing plant can be undertaken to identify areas of
concern. Guidance can be provided on areas such as the following:


Main pipework configuration

Pipework supports

Small bore connections

Impulse pipework

Valve selection

Thermowells

Subsequent to the identification of pipework vibration problems, and

building on an increased understanding of the cause of the problem
from any on-site investigation, GLs expertise is well placed to make
recommendations on the need for remedial measures to reduce the
risk of failures occurring. A variety of solutions to reduce the risk of
vibration-related failures are typically proposed for the clients
consideration, taking into account issues of cost, effectiveness, ease
of implementation, operational restrictions and safety, depending on
the nature of the problem and site under investigation.
Solutions can range from redesign and modification of pipework and
connections, and improvement of pipework supports, to identification
of preferred operating regimes and recommendations for
investigation of plant performance, and development of design
guidance documentation for future projects.

CASE STUDIES

a. Corrosion Management of LNG Storage Facilities

Date:
Customer:
Savings:

Ongoing
National Grid
Improved corrosion management

GL has provided direct support and guidance for corrosion

management initiatives at five separate sites within the UK. In recent
years, this support has focused on the development of best-practice
corrosion management policies and guidelines.
GL assisted with the initial implementation of these guidelines by
raising the profile of corrosion issues in LNG processes, and by
promoting a corrosion awareness culture across the business.
Specific areas of support have included:


Fabric maintenance Management and interpretation of

site surveys to determine requirements for maintenance
painting and insulation replacement. Definition of
site-specific workscopes for ongoing fabric maintenance.

Corrosion Management Policy Drafting of policy to

reflect best-practice approach to corrosion control and
monitoring. Identification and definition of specific tasks
to enable integration with maintenance management
system.

Cooling Water Treatments Review of cooling water

systems and chemical treatment service provision at all
sites. Identified shortfalls in operational systems,
recommendations for improved monitoring and
opportunities for rationalisation of service contracts.

LNG Vaporiser Life Extension Conducted studies at two

sites to confirm fitness-for-service of direct-fired vaporiser
units and identify operations and maintenance to achieve
required life extension.

13

CASE STUDIES

b. Integrity Management Review

Date:
Customer:
Savings:

2006
UK North Sea Oil Gas Operating Company
Improved systems integrity

GL was requested to carry out a review of integrity management

procedures relating to pressure systems, pipelines and subsea
equipment ahead of an internal audit of the client company
management systems. As part of this review GL was asked to consider
the suitability of the following:


Organisational relationships for delivery of effective

integrity management

Corrosion risk assessments used as a basis for integrity

management planning

The methods and frequency of inspection

Inspection records of lead integrity management

contractor

The interpretation and analysis of inspection data

Review feedback process from inspection findings into

future inspection programmes

The impact of general fabric maintenance procedures on

integrity management

To carry out the review effectively, GL requested access to a number

of client and integrity management contractor documents, including:

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Integrity Management Policy

Pressure Systems Integrity Management System

Subsea and Pipeline Integrity Management (Draft)

Fabric Maintenance Philosophy

Pressure Systems Integrity Review Procedure

Monitoring, Inspection and Mitigation Procedures

Written Schemes of Examination (for relevant assets)

The review of documentation was followed by a number of interviews

with key staff within the client organisation and the lead integrity
management contractor. The objective of the interviews was to
address a series of questions that were developed based on the
relevant
policies/procedures
and
integrity
management
best-practice within the oil and gas industry.
It was found that the integrity management systems for pressure
systems, subsea and pipelines were well structured and were, in
general, providing highly effective services. Although there had been
a number of relatively recent changes in terms of both staff and
supporting guidelines/procedures, it was considered that these were
largely positive and should strengthen the understanding and control
of integrity management issues in the near future.
The most pressing issue to be addressed concerned the fatigue of
topside process plant. It was considered that the existing risk based
inspection (RBI) plan could not be expected to manage this problem.
Although it was felt that the RBI process could assist with, through
criticality assessments, the targeting of equipment a separate strategy
was required to manage the problem effectively.
Further actions were recommended in the following areas:


Management of corrosion under insulation (CUI)

Incorporation of piping systems from vendor skids into

inspection plans

Consideration of performance targets or key performance

indicators for the Integrity Management Policy

Clarification of the terms of engagement between the

client and lead integrity management contractor

Consideration of weld corrosion in risk assessments

CASE STUDIES

c. Fracture of Thermowell

d. Failure of Impulse Pipework Compression Fitting

Date:
Customer:
Savings:

Date:
Customer:
Savings:

2005
Transmission Pipeline Operator
Improved use of thermowells

GL were asked to investigate the failure of a stainless steel thermowell

which had been located in a dry gas transmission pipeline. A
circumferential crack was found at the base of the thermowell. A
metallurgical examination determined that the crack was consistent
with low stress, high cycle fatigue crack propagation. An assessment
of the process conditions indicated that the fracture was caused by
flow induced vibration produced by vortex shedding around the
thermowell.

2005
Compressor Station Operator
Improved installation specifications

GL were asked to investigate the failure of a compression fitting on a

section of impulse pipework at a compressor station. The failure of
the fitting had caused the shutdown of the compressor unit. A
metallurgical examination determined that the failure was due to
three circumferential low stress, high cycle fatigue cracks which had
initiated on the outer surface of the pipe at the point of contact with
the back ferrule of the compression fitting.
The root cause of the problem was identified as inadequate support
provided to the impulse pipework. GL suggested an improved
support arrangement and, as part of a larger programme of work,
GL monitored the vibration of the impulse pipework to ensure that
the new support arrangements were sufficient to prevent any future
failure of this pipework.

Fracture highlighted using dye penetrant

As a result of this failure the customer reviewed the use of
thermowells across its whole network. GL assisted by providing
further guidance on the susceptibility of thermowells to vortex
shedding, and by identifying appropriate alternatives.
Failed impulse pipework

Above scanning electron microscope images of crack surface. Left

low magnification, transgranular separation and feathery
appearance typical of austenitic stainless steel low stress high cycle
fatigue failures. Right high magnification, fine striations, a
characteristic feature of low stress high cycle fatigue crack
propagation.

Circumferential fracture

15

CASE STUDIES

e. Fitness-For-Purpose Assessment of Pressure Vessels

Date:
Customer:
Savings:

2007
Centrica
Cost savings to the client through a reduced frequency
for repair/replacement, reduced system downtime, and
life extension of high-pressure storage assets.

Issue:
Fracture mechanics-based fitness for purpose (FFP) assessment
methods, such as those described in BS 7910, R6 and API 579 have
undergone rapid developments over the past 30 years. The FFS
(Fitness For Service) methodology has developed into a powerful tool
that enables the analyst to assess the significance of flaws in welded
structures.
Although comprehensive and applicable to a wide range of
engineering components, the methods contained within these
guidance documents are conservative. Furthermore, the methods can
be limited by, for example, the availability of stress intensity factor
and reference stress solutions for specific geometries. One such
limiting geometry is the nozzle, in particular the nozzle attachment
welds, which is a common feature on high-pressure gas storage
systems.
In the UK, operators must follow legislation given in the Pressure
Systems Safety Regulations (PSSR), which provides a regime with the
aim of ensuring the safety of pressure systems. One of the regulations
requires that high-pressure gas storage systems must be subject to
periodic inspections followed by a FFS assessment to ensure the
integrity of the system.

Pressure Vessel Nozzle

Methodology & Results:

To ensure compliance with the requirements of the PSSR, GL has
developed an in-house procedure that enables an FFS assessment to
be undertaken for a flaw in a nozzle weld. This procedure was
developed to reduce the conservatism inherent in the assessment
procedures given in BS7910 while still maintaining an acceptable level
of safety. Using a combination of Finite Element analysis and fracture
mechanics techniques, a full FFS of pressure vessels was completed.

Savings:
This has resulted in substantial cost savings to the client through a
reduced frequency for repair/replacement, reduced system downtime,
and life extension of high-pressure storage assets.

16

Finite Element Analysis of Pressure Vessel Nozzles

CASE STUDIES

f. Fracture Mechanics Assessment of a Defective Pig Trap

Date:
Customer:
Savings:

2007
United Utilities
Cost of temporary pig trap and system downtime
due to installation

Issue:
GL were required to conduct a detailed assessment of a reported crack
indication found on the closure casting of a pig trap located at an
AGI facility in the UK. Following defect measurement in February
2007, this was recorded at approximately 3-4 mm. A number of pig
runs were then subsequently conducted. The defect was then
re-measured and reported to have a maximum depth of 5.3 mm.
Measurements suggested that the defect had therefore grown since
the pigging runs were conducted in 2007. The operator of the site
facility intended to conduct further pig runs in February 2008 and
hence required an assessment to determine whether the defect was
safe for the intended pig runs.

Methodology & Results:

The approach that GL used was based on a BS7910 level 2a fracture
mechanics assessment. Using fracture mechanics calculations and use
of the FAD (Failure Assessment Diagram), the aim was to determine
whether the current size of crack was safe under the current design
conditions and safe for the intended pig runs. Finally using a BS7910
fatigue assessment of the crack, fatigue calculations were then
conducted to determine the remaining fatigue life of the reported
defect and whether further pressure cycles can be tolerated due to
the intended pig runs. The fatigue assessment results showed that
the defective area was likely to endure a large number of cycles before
failure. Consequently it was concluded that the defect would endure
sufficient further pressure cycles to conduct the intended pigging
runs.

Savings:
Ultimately, the operator would have had to install a temporary pig
trap to conduct the required pigging runs. Following this, the
temporary trap would have been removed and a new trap installed in
its place resulting in costly delays and system downtime. By
conducting a fracture mechanics assessment, GL have saved the client
costs associated with installing a temporary pig, inspection delays and
system downtime.

17

CASE STUDIES

g. Defect Assessment of Corroded Pipework

Date:
Customer:
Savings:

2004
ADMA-OPCO
Savings due to potential loss of containment and
system shutdown

Issue:
ADMA-OPCO identified areas of general corrosion on the inlet
pipework to separators on one of their platforms. The corrosion had
occurred where clamps were fitted around vertically orientated 12
pipework, just above the girth weld that connects the pipework to
90 elbows. ADMA-OPCO requested that GL undertake an assessment
of the defective area.

Methodology & Results:

Four assessment methodologies were used for the assessment, B31G,
RSTRENG, LPC-1 and API 579 Level 1. Predicted failure pressures and
safe operating pressures were calculated using the B31G, RSTRENG
and LPC-1 assessment methodologies. Results showed that all failure
pressures were well in excess of the design pressure, however the safe
operating pressures calculated using the B31G and RSTRENG
methodologies were considered to be unacceptable. In addition, the
defect area was assessed to the general and local metal loss Level 1
procedures of API 579. The defects had been found to be
unacceptable. These assessment results formed part of an overall
opinion regarding the safety of the reported defect.

Savings:
Savings were made due to potential loss of containment and system
shutdown.

18

CASE STUDIES

h. Review of Integrity Management Framework

i. Safety Management Audit

Date:
Customer:
Savings:

Date:
Customer:
Savings:

2007
Middle East Oil Producer
Improved integrity management

A major operating company in the UAE were keen to ensure that their
recently implemented Integrity Management Framework was
delivering what was intended.
GL undertook a gap analysis of the current operating philosophy
against the IMF, and reported on where we felt the organisation was
in relation to the IMF as well as benchmarking where we determined
the IMF was in relation to international best practice.

2006
UK LNG Terminal Operator
Improved safety management system

A UK LNG Terminal operator were expanding their storage capacity.

Before they were able to commission the new phase, it was imperative
that a complete safety audit was undertaken to ensure that all
processes currently in place were operating correctly.
GL sent in a team of specialists in their field to undertake this review.
Interviews were undertaken with a cross section of staff, documents
were reviewed, and site inspections were undertaken to ensure that
the practice matched the document trail.

This project covered:

Pipelines

Pressure Equipment

Critical Safety Systems

Rotating Equipment

Structure

Civils

Electrical Equipment

Lifting Equipment

Wells

The benefit to the client was that they were able to ensure that all
deficiencies were actioned and lessons learned before the expansion
was commissioned.

Once the gap analysis had been undertaken, a detailed list of

deficiencies was prepared, and suggested improvements identified to
bring the operations up to the desired level.

19

CASE STUDIES

j. Fitness for Service Assessment

Date:
Customer:
Savings:

2007
BG Tunisia
Improved monitoring and compliance

Issue:
Regulatory conditions state that all pressure systems need to be
inspected to ensure they are fit for purpose, and examination
schedules needed to be produced. Therefore the client required an
inspection schedule to be developed to make sure their assets are fit
for purpose and operating within the design specifications.

Methodology & Results:

By working closely with the client and by taking reference from
Pressure Systems Safety Regulations, the contents of the WSoEs were
agreed upon. An up to date inspection scheme was produced,
scheduling inspection work to be carried out during the plant
shutdown period. Inspections were identified with inspection dates
and times organised and a contingency for remedial work allocated.
A list of required inspection qualifications was produced and from
this a list of qualified engineering staff was assembled. A Competent
Person was assigned to define roles under the UK legislation that the
staff would take.

Savings:
From the construction of the WSoEs an extensive inspection of the
clients assets were produced. The inspection identified areas of
remedial work that were required and helped setup monitoring
programmes on assets that were at greatest risk of failure. The
Written Scheme of Examination also provides the client with a means
to demonstrate compliance with the Pressure Systems Safety
Regulations 2004.

20

CASE STUDIES

k. Repair of Amine Stripper

Date:
Customer:
Savings:

2006
BG Hannibal Gas Processing facility
Failure of processing vessel and plant shut down

Issue:
The client had experienced up to 40% loss in wall thickness on an
amine stripper due to corrosion.

Methodology and Results:

The use of a coating system to isolate the vessel wall from the
corrosive environment inside the amine strippers was considered to be
the most cost effective solution. GL reviewed the properties of a range
of different generic coatings systems to identify a material that would
be compatible with the operating conditions within the amine
stripper. Having identified a suitable material, a technical review of
the proposed coating specification was performed and technical
assistance provided during the on-site coating application process.

Savings:
Through wall corrosion failure and the requirement to shutdown the
plant to facilitate a vessel repair. The estimated cost of a shutdown
was 500,000/day.

21

CASE STUDIES

l. Investigation of Coating Failure on Oil Storage Tank

Date:
Customer:
Savings:

2006
Major Exploration and Operating Company
Prevention of large-scale coating failure

Issue:
The customer was experiencing cracking and disbonding of the
coating system applied to the external surfaces of a crude oil storage
tank. The customer required GL to establish the mechanism of
breakdown and to recommend methods of reparation.

Methodology and Results:

GL visited site to investigate the scale and nature of the failure. A
laboratory programme of work was initiated to reproduce the coating
failure under controlled conditions and to establish the failure
mechanism systems for reparation of the failed coating were
recommended and an application procedure prepared.

Savings:
This work identified the mechanism of coating failure and helped to
prevent similar failures occurring in the future.

22

CASE STUDIES

m. Corrosion Management Study

Date:
Customer:
Savings:

2006
National Grid
Development of a robust corrosion management
policy to maximise asset life

Issue:
The client wanted to establish a robust corrosion management plan
for the above ground installations that were an integral part of the
high pressure gas transmission system.

Methodology & Results:

GL performed a review of the customers corrosion management
policy with a view to quantifying how much should be invested on
inspection and maintenance for corrosion control purposes. The
review included:


Inspection and maintenance policy

Future maintenance requirements to reflect best industry

practice

The current inspection frequencies and those frequencies

required to maintain plant and equipment
fit-for-purpose

A series of site visits were conducted to obtain an overview of the

current condition of the corrosion control systems, the general
requirements for maintenance painting and to identify and quantify
areas which would require regular inspection and maintenance.

Savings:


Reduced unscheduled reductions and outages due to

corrosion related issues.

Reduced repair cost.

Maximisation of asset life.

23

CASE STUDIES

n. Weldability Testing of 48 Diameter X80 Europipe

Production

Date:
Customer:
Savings:

2007
National Grid (Milford Haven extension)
Approved procedures of manufacturing

Weldability testing entails the production of a full-scale girth weld

between two 12m pipe joints under field conditions and including
the manipulation of the partially-completed weld to simulate the
removal and movement of the line-up clamp. Following production of
the complete girth weld, the joint is subjected to X-ray inspection and
must pass required codes (T/SP/P/2 or API 1104 requirements) and is
then subjected to a full suite of mechanical tests. Following
satisfactory results from these investigations, the welding procedure
and the linepipe manufacturing route are qualified for supply to
National Grid.

Girth welding of 48 X80 pipe

during weldability testing

Simulation lifting of 48 joint after

hot pass deposition.

Sample welding procedure qualification record from the

48 X80 trials, showing joint design, consumables,
pre-heat requirements, pass sequence and other details.

24

CASE STUDIES

o. Design and Qualification of Repair Procedures for Bellows

Attachment Welding
Date:
Customer:
Savings:

2008
Pipeline Operator
Improved welding procedure

A GL report on the bellows connection concluded that the bellows on

the pipeline required a weld repair to be undertaken on the cracked
fillet welds. The bellows configuration is shown in Figure A of that
report, reproduced below:

Proposed weld procedure for the repair. Qualification of this

procedure is in progress.
Weld Repair instructions:

Consequently, according to British Standard BS 6990, prior to welding

onto the live pipeline, it is necessary to qualify a procedure, simulating
the cooling effect of the gas which complicates the qualification. The
qualification set-up should simulate actual flow conditions.
The weld procedure has been developed to minimise the risk of
lamellar tearing. For weld procedure qualification, plate material
representing the nearest equivalent currently available material is
used.

Weld repairs to cracked fillet welds in bellows unit to be

carried out after qualification of the attached weld repair
procedure and following decommissioning and purging
of pipeline 2.

Ensure all necessary risk assessments and safety checks

have been undertaken and procedures are followed,
including safe control of operations (non routine
operation) and entry into confined spaces.

Prior to repair, determine chemical analysis of carrier pipe

and box material by on-site material sampling of the
carrier pipe and restraining box material in accordance
with T/PM/Q/10 (ref clause 12 and appendix B). Report
results to GL for assessment.

Remove the two fillet weld cracks in bellows 2 by grinding

in accordance with T/PM/P/11 appendix F.

Confirm defect removal by visual inspection and MPI.

Check carrier pipe for defects by UT & MPI below

intended area of weld repair prior to welding.

Perform weld repair in accordance with attached

procedure: WPS/A/Tinsley/01FR (subject to qualification).

Completed repair welds to be subjected to visual

inspection and MPI.

Cracking located in bellows attachment fillet welds.

25

CASE STUDIES

p. Evaluation of RBI Softaware

Date:
Customer:
Savings:

2007
Major Gas Operator
Company time understanding the issues with
different RBI software packages

Issue:
The client was in the process of evaluating bidders for provision of
integrity management software (IMS) oriented risk based inspection
management of pressure systems, pipelines and structure of the
Miskar Assets. Five software products were evaluated: Tishuk T-OCA,
DNV Orbit, Lloyds Capstone, Aver Kvarner Coabis and Credosoft Credo
Pro. The client required a third party overview of the RBI systems
embedded in the software and to determine the merits of the five
different RBI systems.

Methodology & Results:

From GL experience with RBI systems, an evaluation of the RBI
software was produced. The main factors GLs experienced personnel
believed to be important in determining an effective RBI system are:


Determine whether the RBI is qualitative, quantitative,

semi-quantitative or combination of both

Evaluate how the software derive Probability of Failure

(PoF)

Evaluate how the software derives Consequence of Failure

(CoF) and whether important consequence attributes
have been captured

Degradation mechanisms in the assessment and

comparison with degradation mechanism in country

Post RBI analysis activities (e.g. Inspection planning)

Savings:
An impartial third party review of software was obtained, denoting
the merits and drawbacks to each system. Allows GLs experienced
personnel to put forward the best system that meets the requirements
of the client, so that the investment into the system produces the best
result. Also saves personnel time in trialling all the software and
producing an evaluation of each.

26

CASE STUDIES

q. T-OCR Risk Based Inspection

Date:
Customer:
Savings:

2005
Major Natural Gas Company
Reduced equipment downtime and
costs due to failures

Issue:

Savings:

The client expressed an interest in adopting a risk based inspection

(RBI) scheme for integrity management of its offshore and onshore
process plant. A feasibility study was required to determine the
practicalities, outline implementation costs and potential benefits of
applying RBI.

Main saving is on the company time and finances on determining the

benefits and viability of implementing an RBI approach. Also identifies
to the client the long term benefits of a RBI approach, as shown
below:

Methodology & Results:

The initial part of the study included a review of the current integrity
management systems. This was followed by an assessment of the
feasibility and requirements for the application of RBI. The final part
of the study comprised two RBI pilot studies centring on known areas
of concern on the specific plants. The key results from this study were
as follows:


A feasibility of applying (risk based inspection) RBI to the

facilities produced

A review of existing approaches to integrity management,

and any modification required to accommodate the RBI
approach were identified

Potential benefits of applying RBI to its facilities identified,

including improvements in equipment reliability and cost
reductions from optimisation of inspection planning and
deployment

Reduced equipment downtime and costs due to failures

Reduced requirement for items to be taken offline to be

inspected

Focusing of inspection resources on key corrosion and

materials degradation issues

The report also includes recommendations for implementation of RBI,

including support required and a breakdown of likely resources
requirements.

27

CASE STUDIES

r. Investigation of Double Block and Bleed Valve Vibration at

a Gas Processing Facility
Date:
Customer:
Savings:

2004
Onshore Operator, Kazakhstan
Management of the risk of failures reduce the
occurrence of failures and the associated costs of
plant shutdown and remedial work

Issue:
During the commissioning and early operational life of a large gas
processing facility, failures were experienced of a significant number
of small bore connections across the plant. This was determined to
be due to the poor design of these connections. Replacing all these
fittings would have been extremely costly, and a programme of
bracing of the large double block and bleed valves was therefore
undertaken. However, it was not known how effective this bracing
was in reducing the dynamic stresses to acceptable levels.

Methodology & Results:

GL undertook a study across the processing plant to
characterise the vibration of the small bore connections with large
mass double block and bleed valves. Dynamic stress measurements
were taken on a selection of connections, including a range of
different designs and bracing arrangements. This knowledge was
used to develop a screening method which could be used by Client
staff to assess all the connections on the plant to implement a
prioritised replacement plan.

Savings:
Management of the risk of failure of these connections reduced the
occurrence of failures, and the associated costs of plant shutdown
and remedial work.

28

CASE STUDIES

s. Long Term Monitoring of Pipework Vibration at Gas

Compressor Stations
Date:
Customer:
Savings:

2003 to 2008
UK Onshore Operator
Detailed understanding of the risk of pipework
vibration problems across operating range of
compression plant

Issue:
Earlier work programmes had carried out an initial assessment of
small bore connections at compressor stations, from which a large
programme of replacement and removal had been instigated.
However, some pipework vibration problems were known to occur at
operating conditions that were experienced only occasionally and had
not been assessed.

Methodology & Results:

GL developed a data acquisition and analysis system that would perform long term monitoring of a large number of sensors over extended periods. To date this has been installed on nine of the
twenty-six UK compressor stations for a period of at least three
months in each case, and has provided a comprehensive assessment
of the pipework vibration over the full station operating range. For
example, at several stations, pipework vibration problems were
identified which were a result of the interaction of the gas flow from
adjacent units, phenomena that would not have been picked up by
carrying out measurements on each unit separately. This equipment
has also been used to investigate vibration problems following specific
incidents on compressor stations and on seal and lubrication oil
system pipework.

Savings:
Detailed understanding of the occurrence of pipework vibration
problems across the operating range of the plant ensures that full
consideration is given to the causes, directing any remedial action and
confirming safe operating ranges.

29

CASE STUDIES

t. Assessment of risk of pipework failure due to vibration during offshore plant uprating
Date:
Customer:
Savings:

2007
UK Offshore Operator
Eliminated need for major changes to main
pipework, and allowed uprating to be achieved
within available timescales

Issue:
Upgrade of two offshore compressor trains was planned to increase
gas flow rates. A preliminary study by the Client suggested that the
risk of vibration related failure of the main pipework was already
unacceptable and would be increased by uprating. The available
outage period was insufficient for significant design changes to the
pipework to be implemented.

Methodology & Results:

GL undertook a study to assess the dynamic stresses
experienced by the main pipework and small bore connections during
operation of the compressor units in their original configuration.
Assessment of the dynamic behaviour was carried out over a range of
operating conditions on both compressor trains. Knowledge gained
of the relationship between vibration and gas flow was subsequently
used to predict the likely behaviour of the pipework at the current
maximum and uprated conditions.
The study concluded that there was no need for major changes to
the main pipework prior to the uprating, allowing effort to be
concentrated on issues related to small bore connections.

Savings:
The findings of this work eliminated the need for major changes to
the main pipework, achieving significant cost savings for the project
and allowing the uprating to be achieved within the available
timescales.

30

CASE STUDIES

u. Vibration screening at an onshore gas terminal

Date:
Customer:
Savings:

2005 to 2008
UK Operator
Demonstrated management of risk of vibration
related failure of pipework to regulatory bodies

Issue:
To manage the risk of vibration related pipework fatigue failures a
structured vibration screening and assessment methodology was
required by the Client, to identify problem areas and define
subsequent actions.

Methodology & Results:

A phased approach was employed by GL to identify potential problem
areas on the main pipework and small bore connections. The initial
site survey consisted of a walk-round visual review of the site
processes and pipework, basic vibration measurements, and
assessment of the likelihood of failure of any connections. This
exercise identified key problem areas for immediate remedial action
and further investigation, allowing effort to be focused on the highest
risk areas in subsequent stages.
Recommendations included identification of pipework support design
and maintenance issues, changes to the design of small bore
connections that were identified to be at risk of failure, and
identification of areas of the plant to be assessed in greater detail to
develop an understanding of any problems identified and to develop
solutions. This subsequent detailed assessment work has included
installation of monitoring equipment to assess the behaviour of the
plant over its full operating range.
This methodology is now being deployed for the Clients offshore
facilities.

Savings:
This project successfully demonstrated to the UK Health and Safety
Executive that the issue is being adequately managed across the
Clients facilities.

31

Asset Management Services



Plant Integrity Management Services

Germanischer Lloyd
Industrial Services GmbH

Pipeline Integrity Management Services

Production Optimisation (Includes RAM
and Gas Processing)
Dynamic and Steady State Simulation
Rotating Equipment Performance &
Condition Monitoring including
Emissions Reporting
Gas Quality and Interchangeability

Oil and Gas

Steinhft 9
20459 Hamburg, Germany
Phone +49 40 36149-7700
Fax +49 40 36149-1781
glis@gl-group.com

www.gl-group.com/glis

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Issue no.001 15.05.2008