Pressure Transient Analysis & Surge Protection

systems for Liquid HC Pipelines

Basics & Familiarization Module

08-Jun-2020

AHMED SHAFIK
Process Engineering & Operations Expert
professionalche@gmail.com
Module Overview / Agenda

 Surge definition

 Why Surge Could Happen?

 Challenges

 Famous Incidents

 Manual calculation - Joukowski formula

 Pressure Tansient Modelling Software

 Design Considerations

 Surge Relief Solutions / Devices

 Resources

 Questions

 Back up
Surge Definition

 Its commonly called “Water Hammer”, and is defined as a sudden increase in pressure due to an
instantaneous conversion of momentum to pressure when flowing liquid stopped quickly.
 Hydraulic surge is often caused by the transformation of kinetic energy to potential energy
as a stream of fluid is suddenly stopped
 Once pump tripped, you will observe that the pressure in the immediate discharge is decreasing
because the flow still going forward with no current supply and a strong wave will rush back
towards the pump discharge coming all the way from the close end point creating the pressure
spike.
 As noticed in the below graph, pressure spike will continue hitting the pipe / pipeline trying to
release the generated excessive energy and therefore your system will be under risk.

 ASME B31.3 defined that the pressure rise due to surge and other normal operation variations
shall not exceed the internal design pressure at any point in the piping system and equipment by
more than 33%.
Here you have to ask yourself, Do I Have Safe & Reliable System to Operate?!!!
Why Surge could happen?

 Pumps stoppage / trip / Priming.

 Spurious Closure of manual valves, MOVs (Motor Operated Valves) or an automatic emergency

shutdown device – ESD.

 Black outs / Power failure.

 Slamming shut of a non-return (check)valve.

All of the above will generate pressure waves travel both upstream and downstream from point of origin.

 Please note that some pipelines are in transient operations over 75% of the time.

 Surge (pressure rise) increases as much as the pipeline portion increases since the contained momentum will be
higher (more volume).

 A pressure surge can consist of multiple events, resulting in up to ten times the normal pipeline pressure. When a
surge relief valve opens, it vents the pressure to a safety system.

 Also, it worth to mention that Surge pressure is created during the last 20% of valve closure.
Other notes about surge

 The rapid closure of a valve can result in an initial reduced pressure in the downstream which may be

sufficient to reduce the absolute pressure below the vapor pressure and generates a cavitation

scenario. The cavitation might lead to a higher transient pressures and unbalanced forces.

 Also Fast pressurization of a closed system, can double the pressure rise at the far end of the system as

the pressure wave is reflected from the closed end. This can arise either from the fast opening of a

valve at the system inlet or due to pump start up with pump discharge valve open.

 Surge may result in the creation of huge unbalanced forces within the piping system which may

damage the supports, collapse pipe bridges or even line rupture and displacement from its original

location.

 Experiences indicate that the failure of pipework supports as a result of pressure surge is more likely

than pipeline rupture due to over pressure.

Challenges

 Surge can significantly exceeds the Maximum Allowable Operating Pressure (MAOP) plus any
additional overpressure allowance, typically 33% above MAOP.

 Sudden transition from momentum force (flow) to pressure force will lead to shaking / vibration
of pipeline / piping and might lead to sever damage in pipeline/piping if the system design is not
adequate.

 Your system could be equipped with surge relief valve, however, missing calibration and regular
checks could lead to failure of valve to act as required and accordingly lead to destructive failure
of the system.
Surge protection System is healthy
• Ensure Pipeline / piping Integrity in light of ASME B31.3 code for pipeline / piping over
pressure protection.
• Meet Regulatory Requirement & Environmental protection.
• Maximize pipeline/piping capacity & decrease cost.
Surge protection System is unhealthy
• Unplanned shutdown S/D and interrupted operations.
• Exposed risk to People, Property & Environment.
• Resolution & Mitigation associated cost including maintenance activities.
• Project Delays.
• Decreased Operating pressure and capacity.
Serious Industrial Incidents due to Lack of Proper Surge Protection

 In 1999, a pressure relief valve failed on a 16-inch gasoline pipeline operated by the Olympic
Pipe Line Company in Bellingham, Wash., spilling 277,000 gallons of gasoline into the river. The
gasoline exploded, killing three young boys. The incident resulted in five felony convictions for
Olympic employees and a $75 million wrongful death settlement.

 In 2009, at the Sayano-Shushenskaya hydroelectric plant in Siberia, severe water hammer

ruptured a piping segment going to a turbine due to improper surge relief system design. A
transformer exploded, killing 69 people.
Important Terminology

MASP is the maximum gauge pressure permissible in the piping system under abnormal
operating conditions & shall not exceed 133% of the rated MAOP.

MAWP ≥ Design Pressure

Design Pressure The design pressure is the highest pressure, at the maximum temperature expected
during most severe plant operating conditions. This pressure is always equal to or less than
the MAOP.

MAOP The maximum allowable operating pressure is the maximum gauge pressure at which the
piping system may be operated for a designated temperature.

Operating Pressure 75% - 90% of Design Pressure

Effective Valve Closure Time The period over which a Valve reduces the flow from 90% of its steady state to zero. In
relation to Total Valve Closure Time, this is typically the last 15% opening for butterfly
valves, 25% opening for ball valves and 30% opening for plug valves. This can be used as a
role o thumb at the initial assessment phases.

Sonic velocity Is the velocity at which a small disturbance will propagate through the medium, its also
known as Acoustic Velocity . It is related to the change in pressure and density of the
substance and can be expressed with Hook's Law as
Surge Calculation
A- Manual calculation - Joukowski formula

 Role of Thumb used in the past to estimate the surge pressure, considering that that the only
variable is the velocity, P is equal to
0.8 * Weight of liquid per cubic foot * Velocity Change
 Another old way to estimate is to consider 50 Psi change in pressure with the velocity change of
every 10 ft/sec

Can you still use these formulas?

Yes BUT ONLY while you are standing for quick and rough estimation .

 The Joukowsky equation is a simplified method for calculating the peak transient pressure
experienced when a valve is closed against a fluid in motion and may be represented as follows:

ΔP=ρ a Δv

Density Pressure wave velocity Change in liquid velocity

 The Joukowsky equation takes into consideration the elasticity of the pipe wall and the
compressibility of the fluid itself through the calculation of the speed of sound (a), however
assumes instant closure of the valve.
Manual calculation - Joukowski formula
Required Inputs for Joukowsky Equation

Inputs required for calculation:

1. Fluid Properties:
• Density
• Viscosity
• Vapor pressure
• Bulk modulus
• Temperature

2. Pipe Properties:
• Roughness
• Young Modulus
• Poisson ratio
Definition of Inputs

Bulk modulus : is the property characterizing the compressibility of a fluid , i.e. how easy a unit
volume of a fluid can be changed when changing the pressure working upon it.

The Bulk Modulus Elasticity can be expressed as:

Some fluids have ready calculated Bulk Modulus Elasticity:

Definition of Inputs

Relative roughness : Is the ratio between absolute roughness and pipe diameter

Relative roughness can be expressed as:

Some pipe material Roughness are available :

Definition of Inputs

Young Modulus: is a measure of stiffness of an elastic material. M ate r ial

Young's Modulus, Modulus of Elasticity
()
- E -
(10 6 psi ,
(GPa )
M psi )
ABS plastics 1.4 - 3.1

It is used to describe the elastic properties of pipeline / piping. A luminum Bronze

Aluminum 10
120
69
A luminum Alloys 10.2
Carbon Fiber Reinf orced
150
Plastic

Young's modulus can be expressed as

Carbon nanotube, single-
1000+
w alled
Chlorinated polyether 1.1

Chlorinated PV C (CPV C) 2.9

Concrete 17
Concrete, High Strength
30
(compression)
Epoxy resins 2-Mar
Fiberboard, Medium
4
Density
Flax f iber 58

Glass 50 - 90

Glass reinf orced

17
polyester matrix
Gold 10.8 74
Granite 52
Graphene 1000
Grey Cast Iron 130
Hemp f iber 35
Inconel 31
Iridium 75
Iron 30.5 210
MDF - Medium-density
4
f iberboard
Mercury
Molybdenum (Mo) 48 329
Monel Metal 26

Some pipe material Young Modulus are available :

Nylon-6 4-Feb
Polyethylene HDPE (high
0.8
density)
Polyethylene
2 - 2.7
Terephthalate, PET
Polyamide 2.5
Polymethylmethacrylate
2.4 - 3.4
(PMMA)
Polyimide aromatics 3.1
Polypropylene, PP 1.5 - 2
Polyethylene, LDPE (low
0.11 - 0.45
density)
Polytetraf luoroethylene
0.4
(PTFE)
Polyvinylchloride (PV C) 2.4 - 4.1
Silicon 19 - 27 130 - 185
Silicon Carbide 450
Silver 10.5

Steel, stainless A ISI 302 180

Steel, Structural A STM-

29 200
A36
Titanium Alloy 105 - 120
Tungsten (W) 400 - 410
Tungsten Carbide (WC) 450 - 650
Definition of Inputs

Poisson ratio: the ratio of the relative contraction strain (transverse, lateral or radial strain) normal
to the applied load - to the relative extension strain (or axial strain) in the direction of the applied
load
Poisson's Ratio can be expressed as

Some pipe material Poisson’ s ratio are available :

Calculation sheet
Sudden closure
T= 0 Seconds

No Sudden closure
T= x Seconds
Limitations - Joukowsky formula

 Although, Joukowsky formula is far better and more precious than the past rough estimation formulas, still it
can be only applicable to a limited sub set of fluid systems. It application should be limited to situations
matching the following criteria:
1. Simple 'linear' piping systems i.e. there are no branches by which pressure waves can be reflected back
and cause constructive interference in the main line.
2. Valve closure time is significantly shorter than the pressure wave communication time.
3. System frictional losses are similar to that of a water transport system.

 Additionally the Joukowsky equation does not consider column separation in its analysis of fluid hammer.
Column separation can often result in surge pressures exceeding those predicted by the Joukowsky equation
and therefore the Joukowsky equation should not be applied when analyzing system in which the pipeline
pressure can rapidly drop below the fluid vapor pressure.

 As a process engineer, you can use it to verify vendor document or to identify the healthiness of your system,
however, for an accurate and precise data you need to run PipeNet or similar software to estimate accurately
the pressure rise. Then you will be translating this data into generated forces.

 Once you have the generated forces, pick up the phone and call the piping engineer to run CEASAR software
which will verify whether the piping / pipeline is granted well designed supports and structure to make sure
that it will not go anywhere else after the surge event occurs.
Pressure Transient Modelling Software

 There are currently various software packages that can be used for analysis
• HyTran
• Flowmaster
• WANDA
• Hammer
• AFT Impulse
• PIPENET
• PTRAN
PIPENET – Example
Design Considerations
Designing a surge relief system (1 – 2)

 The design of a complete surge relief system is dependent upon a complex range of factors, including

the potential for pressure increases, the volumes which must be passed by the surge relief equipment in

operation, and the capacity of the system to contain pressures.

 Control or ESD valve closure times can also affect surge pressures in a pipeline. By extending valve

closure time, a more gradual flow decay can be achieved.

 Control narrative and system interlocks to ensure Staged pump shutdown sequence and linked

ship/shore ESDs when your facility is linked to loading berths / jetties.

 Carry out transient / surge analysis using a detailed computer modeling to simulate the complex

interactions of equipment, pipelines, and fluid to normal, fault, and emergency events.

 Design piping to withstand maximum surge pressure – MSP.

Designing a surge relief system (2 – 2)

 Although many design approaches can help reduce surge pressures in pipelines, go for a higher pipe

rating or massive support arrangements aren’t recommended for associated significant cost, and a

surge relief valve found to be the most feasible option to protect the system.

 A correctly designed surge relief system will include components to dampen or slow the relief valve on

closing, and this often requires sophisticated reverse flow plots.

 In nitrogen-loaded Surge Relief valves, attention must be paid to the nitrogen gas system. The nitrogen

system must supply a constant pressure (set point) to the modulating valve, even under conditions of

varying ambient temperatures. Normally, the system is designed to use standard gas bottles and has its

own control system to regulate the nitrogen supply pressure.

Surge Relief Solutions / Devices
Surge Effects Reduction Methods

 Ensure Proper design applied considering the worst case scenario with its respective
control narrative for valve interlocking and proper mitigating means are in place.
 MOVs / ESD Closing time are enough to absorb the wave velocity created by Surge. This
can be assured by having proper Equipment strategy in place which will ensure that Surge
relief valves’ set points are verified and the valves are being calibrated on regular basis to
ensure that it will operated whenever required.
 Ensure that operating procedures are in place and operations are well trained and
competent to operate.
 Line design pressure / rating.
 Supports are well designed to withstand the shaking / vibration resulted from Surge.
 Surge relief valve and associated relief Drum.
Surge Effects Reduction Methods

Active Protection
By using devices to actively protect the systems against the effects of pressure surge during
pipeline normal operation like:
 Variable speed pumping
 Soft starters
 Slow closing and opening valves

Passive Equipments for Surge Protection

 Surge Vessels
 Surge Shafts
 Air Valves
 Vacuum Breakers
 Pressure Relief Valves
 Surge Anticipation Valves
 Intermediate Check valves
Selection of System for Surge Protection
Surge Relief Devices

 Modulating Relief Valves

 Direct Acting
 Accumulators

Gain in system due to proper surge protection device

Modulating relief valves

 Can detect and absorb pressure spikes before over pressure scenario takes place.

 Excellent for low viscosity fluids, refined products.

 Excellent fast response.

Commercial types:

• Pilot Operated

• N2 over Oil loaded

Direct Acting Relief Valves

 Pressure applied to the inlet nozzle must overcome spring force in order for valve to open.

 Spring operated relief valves can open and close rapidly during operation, causing reduced

capacity and secondary surge waves.

Disadvantages:

1. Non modulating valve.

2. Use a full rated spring in their design, it can slam open and close during relief operations.

3. Slam open/close cause chattering, thus causing secondary surge waves to occur.

4. Relief capacities are limited.

Accumulators

 Act as shock absorber.

 Quickly absorbs and expels the product back into the system.

 Ready for immediate reuse after a pressure surge takes place.

 Best location for installation is at the pressure transient location.

 Suitable for both positive and negative surge events, equipped with P/V RVs.

Disadvantages:

1. Single accumulator can absorb a small amount of fluid.

2. Higher CAPEX due to the possible requirement of large size accumulator.

3. Not effective for line pack.

Resources

 ASME B31.4 Pressure Piping Code prescribes requirements for the design, materials, construction, assembly, inspection, and testing of

piping transporting liquids such as crude oil, condensate, natural gasoline, natural gas liquids, liquefied petroleum gas, liquid alcohol, liquid

anhydrous ammonia, and liquid petroleum products between producers’ lease facilities, tank farms, natural-gas processing plants, refineries,

stations, ammonia plants, terminals, and other delivery and receiving points.

 API RP 520, 'Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries, Part 1 - Sizing and Selection', Seventh Edition,

January 2000.

 API RP 521, 'Guide for Pressure-Relieving and Depressuring Systems' Fourth Edition, March 1997.

 CRR 136/1998, Workbook for Chemical Reactor Relief Sizing, HSE.

 DIERs Manual " A perspective on Emergency relief system" by DIER Technical Committee. Guide to Pressure Relief (PSG 8), Part

C:Section 5, 1999.

 Chemical Engineer's Handbook - Perry, Seventh Edition

 "Investigation Report: Refinery Explosion and Fire," U.S. Chemical Safety and Hazard Investigation Board, March 2007.

 "Olympic Pipe Line accident in Bellingham kills three youths on June 10, 1999," History.org

 "Lessons from Russian Hydroelectric Plant Accident," Engineering Ethics Blog

 "An Introduction to Liquid Pipeline Surge Relief," Emerson Process Management, April 2007, page 2.
Back Up
Water Hammer – Steam System

 As soon as steam leaves the boiler, it starts losing heat. As a result, steam starts condensing inside the pipe work.

 The rate of condensate formation is high particularly during the start ups when the system is cold. As a result of

the condensation, the droplets of water are formed. After condensate is formed, the flow inside the pipe has

two components, steam and condensate.

 The flow velocity of steam is much higher than that of the condensate. During such dual phase flow, the heavy

condensate which flows at the bottom of the pipe is pulled by high speed steam and this creates ripples. If the

level of condensate is high enough, the ripples may fill the entire pipe cross section.

 Under pressure, and with nowhere else to go, the ripples are transformed into a mass of water (often

referred as slug) which is much denser than steam and travelling with the velocity of steam. When this slug is

stopped by any obstacle like a bend or equipment, the kinetic energy of the slug will be suddenly

converted into pressure energy which will create a shock wave in the entire pipework.

 The pipework will keep on vibrating until this energy is dissipated in the structure.
The Impact of Water Hammer

 One might wonder why water hammers are thought to be a serious problem. The destructive nature of water

hammer can be realized through the following illustration:

 Recommended velocity of saturated steam in pipe network = 20-35 m/s

 Recommended velocity of water in pipe network= 2-3 m/s

 In case of water hammers, condensate is dragged by steam and hence, the water slug travels with velocity equal

to that of steam which is around ten times more than the ideal water velocity. As a result, the total

pressure impact exerted by water hammer is very high.

Best Practices to Avoid Water Hammer

 There are certain best practices, which when followed, ensure least chances of occurrence of water hammer.

Some of these practices are:

1. Steam lines should always be installed with a gradual slope (gradient) in direction of flow.

2. Installing steam traps at regular intervals and also at the low points ahead of any risers. This ensures removal of condensate from the

steam system as soon as it is formed.

3. Movement / sagging of pipes should be avoided by providing proper support. Sagging pipes can form pool of condensate in the

pipework, increasing the chances of water hammer.

4. Standard start up procedures are required for cold start of the plant. Operators should be trained to open isolation valve slowly

during the start-up modes.

5. Do not allow steam into any line filled with subcooled condensate or into any cold steam line suspected of containing condensate.

6. Drain pockets should be properly sized to ensure that condensate just not jumps over it. Instead, the drain pockets should be sized

enough so that all the condensate reaches the trap.

How do you calculate flow from a pressure measurement?

 For fluid flow measurements, orifice plates, Venturi tubes and nozzles simplify the use of differential pressure

(ΔP) sensors to determine the flow rate. In these cases, the flow is related to ΔP (P1-P2) by the equation: