Report of spring support inspection at Sakhalin Energy LNG Plant

Week Commencing 01-06-2015

Purpose of visit
The original intent was to assist with the installation of 20 no. new spring units and to set to the
correct load conditions however due to the late arrival of the shipment the work scope was limited
to inspection of the original damaged spring units & walk down of the plant to observe other areas
of concerns.
Inspection of damaged springs
Each of the damaged spring units were inspected the possible reasons for failure was considered
and categorised into 3 possible root causes considering the as installed conditions.
1.) Coil corrosion
2.) Spring overload due to transverse loads
3.) Defect material /excessive vertical loading
1.) Coil corrosion
It was observed that the plastic coating to spring coils had been damaged during either
construction or at commissioning stage, as the spring units had not previously been inspected since
start up then how long ago the damage was inflicted was not known. (Possibly 6-7 years ago)
undercoating corrosion once started would very quickly result in failure.
2.) Spring units overloaded due to transverse loads
1 no. variable spring unit was observed to have suffered damage to the casing due to excessive
transverse load.
Note for base mounted units PSL recommends a max. allowable transverse load of 25 % of the max.
operating load. For loads in excess of 25 % PSL recommends using low friction slide units at the
load pads. The damage to the casing could have been as a result of upset condition loading either at
commissioning or start up (cool down)
It was not known when or how long ago the casing was damaged.
It was noted that certain base mounted units were installed with the intended low friction slide units
missing.

3.) Defective material/excessive vertical loading

The damaged spring unit at the jetty loading arm was observed to be in perfect condition (excepting
the broken coil) showing no damage to the coil coating and no signs of corrosion.
This unit is one of a pair supporting a large filter in the pipe system the failure of the unit was
considered to be as a result of overload during construction /commissioning or possible defective
material.
PSL requested the return of this damaged spring to factory for metallurgical examination.
No evidence of upset operating loading as the spring unit showed no other damage other than the
broken spring coil.
General observation during walk-down
1.) Revised supporting arrangements at unit 1000.
2.) Inoperable spring units at guided restraint.
3.) Condition of hydraulic snubbers.
1.) Revise supporting arrangement unit 1000
It was observed that spring units installed at unit 1000 had been modified such as to disable the
spring effort/effect and convert to ridged supports. The locknut at both sides of the load plates. Have
been tack welded as a permanent modification. It appears that the revision to the support
arrangement was as a result of a attempt to reduce the vibration in the structure & pipe system.
No other modification to the support system was seen i.e. No additional supports or guide/hold
down was seen.
It is advised to replace the redundant spring units with new ringed supports and to confirm that the
modification is in accordance with any stress analysis provided at the time of the modification.
2.) Inoperable spring units at guided restraint
A pipe support arrangement consisting vertical trunnion, base mounted spring unit & all round
guide restraint was observed to have been poorly installed.
3 such arrangement had been provided the intent being to allow vertical movement but to control
lateral displacement.
Of the 3 no. seen 2 of the arrangements were jammed at the guide plate, preventing the pipework
from moving vertically such that the base mounted spring was effectively not working.
It is recommended to review the special pipe support drawing to determine the design intent and to
adjust the guide gaps in the 2 defective supports to allow pipe/spring movement.

Condition of hydraulic snubbers

Approx 12 no. hydraulic snubbers are installed at the Sakhlin Energy LNG Plant, located at the
Flare Pipe Rack and platform.
4 of the units were accessible for inspection 2 of which showed signs of leaking oil from the piston
seal.
It was not possible to determine the level of the oil in the units.
The units will require to be rocked back and forth to check if full or empty. Loosening the locknut at
the extension tube will allow the units to be moved.
Note: If units are completely empty they must be returned to the factory for servicing. It is not
possible to service the units on site.
If however oil is still present in the unit, top up using the recommended grade of oil and take note of
quantity required to top up.
Compare the quantity used in filling with the capacity chart provided (attached).

C. M. Godbeer