Analytical and Experimental Study of Flow-Induced Vibration in Industrial Piping Systems at a Refinery in the South South Geopolitical Zone

Flow-induced vibration in refinery piping systems represents a significant structural integrity concern, as sustained high-cycle pipe vibration can rapidly progress from initial fatigue crack initiation to catastrophic failure of welded connections, instrument connections, and pipe support attachments, with severe safety and environmental consequences. This study presents an analytical and experimental investigation of flow-induced vibration in selected high-risk piping circuits at a petroleum refinery in the South South geopolitical zone of Nigeria. Vibration measurements were conducted on 23 piping circuit locations identified as potentially vulnerable based on flow assurance reviews, using triaxial accelerometers and data acquisition systems sampling at 2,048 Hz. Velocity spectra and stress equivalent vibration levels were computed and assessed against the Energy Institute guidelines for process piping vibration. Computational fluid dynamics analysis was applied to three highest-severity locations to identify the hydrodynamic excitation sources, including turbulence-induced fluctuations, vortex shedding at flow discontinuities, and pulsation from reciprocating pumps. Fourteen of twenty-three locations exceeded the Energy Institute screening threshold for potential fatigue concern. Root cause analysis attributed the most severe vibration at two locations to acoustic resonance in pipe branches coinciding with pump pulsation frequencies. Remedial measures including acoustic stub installation and support stiffening were designed, implemented, and their effectiveness confirmed by post-modification vibration surveys. Keywords: flow-induced vibration, piping system, fatigue, acoustic resonance, petroleum refinery.