Controlling Surges in Pipelines HRL

Controlling Surges In Liquid Pipelines
Date: 05-12-2010
By: Clay Carroll
Company Confidential
Surge Overview
What is Surge?
Surge Overview
Sudden, rapid flow rate changes in a pipeline generate pressure waves Pressure waves travel both upstream and downstream from the point of origin Pressure increases and decreases rapidly Wave speed propagation velocities range from 1100 ft/sec (334 m/sec) for water to 3300 ft/sec (1000 m/sec) for a typical oil pipeline
Surge Overview
Pipeline surges are created by:

Slamming of non-return (check) valve Closure of ESD valves Starting and stopping of pumps Closure of MOV valves (at < 5 seconds per valve diameter inch)
Note: Most surges are created by operator error.
Surge Overview
All liquid piping systems are susceptible to surge effects

Mainline systems Loading/unloading Process Households
Surge Overview
Problems from inadequate surge protection:

Axial separation of flanges Pipe fatigue failure of welds Longitudinal pipe splits Pumps knocked out of alignment Severe damage to piping and supports Damage to specialized components such as loading arms, hoses, filters, bellows, etc.
Surge Overview
Example of a pipeline without surge protection

Surge Overview
Y Split
Surge Overview
Un accidente en la central hidroelctrica de Sajano-Shushenskaya por la explosin de un transformador, La explosin ha generado una onda expansiva que afecto a la rotura de algunas conducciones y causo la inundacin de varias salas.
Terminology
Design Pressure MAOP/MAWP Over Pressure Set Pressure Wave Speed Effective Valve Closure Surge Pressure
Terminology
Design Pressure
Highest pressure, at the maximum temperature, expected during the most severe plant or pipeline operating conditions. This pressure is always equal to or less than the MAOP/MAWP
Terminology
MAOP / MAWP
Maximum gauge pressure permissible in the piping system at the designated temperature. Note: Pipelines are cover by ANSI B33.4. Plant piping is covered by ANSI B31.3.
Terminology
Over Pressure
Pressure increase over the set pressure of the surge relief device expressed in units of pressure or percent of set pressure.
Terminology
Set Pressure
The gauge pressure where the surge relief valve starts to open.
Terminology
Wave Speed of the Fluid

Velocity of sound in the fluid flowing in the pipeline.
This is the speed at which surge pressures are transmitted along a pipeline.
Range from 1100 ft/sec (334 m/sec) for water to 3300 fps (1000 m/sec) for a typical crude oil pipeline.
Terminology
Effective Valve Closure

Period over which the MOV or ESD valve reduces the flow from approx 90% of steady state to zero. Butterfly valve: Ball valve: Plug valve: Last 15% Last 25% Last 30%
Terminology
Surge Pressure
The rapid change in pressure as a result of change in pipeline flow rates. Conversion of kinetic energy (velocity) into potential energy (pressure).
Equations Joukowski Equation

h= C V/ g
Legend: h = head change (pressure) C = wave speed V = fluid velocity change g = gravitational constant
Only variable and key to surge control is to keep the V down in steps to stay within pressure rating of the pipe and flanges.
Equations
Simplified Surge Formula

From Pipeline Rules of Thumb Handbook:
P = 0.8 wV
Legend:
P = pressure rise (psi) w = liquid density (lbs/ft3) V = velocity change (ft/sec)
Equations
Example
Pipeline operating pressure: 600 Psig (41.3 Barg) Pipeline fluid velocity: 10 ft/sec (3.03 m/sec) Media: Crude Oil, density = 50 lbs/ft3 ESD valve trips and closes down the pipeline (velocity = 0) Using P = 0.8 wV, calculated pressure rise = 400 Psi (27.59 Bar) If this was a ANSI 300# rated system (785 Psig / 54.14 Barg), Surge pressure would be above MAWP.
Equations Surge Formulas Rule of Thumb

Pressure will rise about 50 PSI for each one (1) foot per second of fluid velocity change
(Metric) Pressure will rise about 10 Bar for each one (1) meter per second of fluid velocity change.
DOT U.S. Dept of Transportation (DOT) Pipeline Regulations 49 CFR Part 195.406
Pipeline operators must protect their pipelines to within 110% of the maximum allowable operating pressure (MAOP) (ASME/ANSI B31.4 Piping Code)
Design
Design Approaches to Alleviating Surge Pressure in Pipelines
Computer modeling of pipeline hydraulics during the initial stages of project Staged ship to shore telecommunications Staged pump shut-down sequence(s) Staged emergency shut-down (ESD) or motor operated (MOV) actuators to control valve closure times
Rule of thumb is; <5 secs per inch of NPS valve size will likely cause a surge event (e.g. 24 NPS valve needs at least 120 seconds)
Selection and installation of proper surge pressure relief equipment at or near source of surge event.
Design
Typical surge pressure wave propagates at 1000 m/sec (3600 km/h) This translates into a minimal amount of response time Surge control measures must be fully automatic and incredibly fast
Solutions to Pipeline Surges
Heavy wall pipe (i.e. over design system) Rupture Disk Spring loaded relief valves Hydraulic accumulators Nitrogen or pilot operated surge relief valves
Heavy Wall Pipe
Disadvantage is weight and cost.
Rupture Discs
Costly to maintain due to single use Costly loss of product due to non-automatic reset
Spring loaded relief valves

Relatively low flow capacity makes this impractical Slam shut device

Spring loaded relief valves

Pilot Operated Relief valves
Surge Relief valves 660.000 BPD @ 1700 PSI
12 = 660.000 BPD
Cantidad : 1
Spring loaded relief valves 660.000 BPD @ 1700 PSI
3 X K X 4 = 73.000 BPD
Cantidad : 9

Pilot Operated Relief valves
660.000 BPD @ 1700 PSI
3 X K X 4 = 90.000 BPD
Cantidad : 8
Hydraulic Accumulators
Requires accurate sizing due to limited capacity Internal bladder is an elastomer Small size usually requires multiple accumulators to relieve pipeline pressure
Nitrogen or pilot operated surge relief valves

Best solution
Automatic reset Very fast response time less than 100 msec (1/10 sec.) Doesnt slam shut High capacity
N2 Loaded Surge Valve
Nitrogen Panel
Total System
Pilot Operated Surge Valve

Principle of operation Pilot Operated
Typical Pilot Operated P&ID
Surge Event
Typical surge event is over in a few seconds
DOT Regulations
49CFR195.428
PRESENTATION TITLE
Useful Design Information

Date
Speaker Information
Nitrogen Loaded Pop Test - Inline
Pilot Operated Pop Test - Inline
Surge Valve Design Codes
Surge relief valves are designed to ASME B16.34, ASME B16.5. Seat leakage per FCI 70.2 Valve sizing (Cv) is done per ISA 75.01 Do not apply API or ASME VIII codes to these types of valves as they do not apply.
N2 Loaded Valves
Pros Opens at the speed of the surge wave No process media enters the plug cavity (only Nitrogen) Very few parts to maintain in the valve (simple design) Valve of choice for any dirty or viscous service Cons Does required periodic N2 cylinder replacement.
Pilot Operated Valves

Pros Self operated (does require a upstream line tap) Valve of choice for clean refined products in valve sizes 4 and below
Cons Filter on valve will plug in dirty services (crude oil, etc.) Valve full open time is slowed due to limited pilot capacity.
Surge Detection
Use thermal dispersion type flow switches. Install downstream of surge valve. ***Do not use flow meters or paddle type flow switches.
Highly recommend Fluid Components FLT93S or Magnetrol (TD2) for this application.
Information required for Hydraulic Analysis
Process flow diagrams P&IDs Isometrics or piping routing Pipe specifications Equipment datasheets Operating procedures Flow utility diagrams Young's Modulus Pump head/flow/efficiency and power/characteristics
Valve information Design & normal operating conditions Operating temps Fluid viscosity Fluid density Vapor Pressure Critical pressure
Information Required for Valve Sizing

Set Pressure Back pressure Process media Name Desired relief flow rate Specific gravity Viscosity Vapor & Critical pressure Flowing & design temps Design pressure Allowable overpressure (10% is typical) Inlet/outlet pipe sizes & schedules
Typical Applications
Pump Station
MOV
MOV
INLET Pumping Station
OUTLET
SRV
SRV
Surge Tank
Pump
Ship Loading
Loading Arm / Hose
Hose Disconnect
MOV
Storage Tank Pump SRV
ESD
TANKER
Main Line Block Valve
MOV Inlet
Outlet
SRV
What is the difference between pressure relief valve and surge relief valve?
The pressure relief valve start to open at a set pressure and que flow capacity and lift increase as increase the pressure in the system, usually the overpressure rise a 10% above the set pressure. In a Surge relief valve the valve open 100% when the system rise the set pressure and the accumulation on the system it is less than 2%, ussually that valves do not change the fluid direction to handle hight flow capacity. That valves prevent a liquid hammer, the standard PSV did not.
Questions

Controlling Surges in Pipelines HRL

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Controlling Surges in Pipelines HRL

Uploaded by

Copyright:

Available Formats

Controlling Surges In Liquid Pipelines

By: Clay Carroll

Pipeline surges are created by:

Note: Most surges are created by operator error.

All liquid piping systems are susceptible to surge effects

Problems from inadequate surge protection:

Example of a pipeline without surge protection

Wave Speed of the Fluid

Effective Valve Closure

Equations Joukowski Equation

Simplified Surge Formula

Equations Surge Formulas Rule of Thumb

Solutions to Pipeline Surges

Solutions to Pipeline Surges

Heavy Wall Pipe

Disadvantage is weight and cost.

Solutions to Pipeline Surges

Solutions to Pipeline Surges

Spring loaded relief valves

Solutions to Pipeline Surges

Solutions to Pipeline Surges

Solutions to Pipeline Surges

Surge Relief valves 660.000 BPD @ 1700 PSI

Solutions to Pipeline Surges

Spring loaded relief valves 660.000 BPD @ 1700 PSI

Solutions to Pipeline Surges

660.000 BPD @ 1700 PSI

Solutions to Pipeline Surges

Solutions to Pipeline Surges

Nitrogen or pilot operated surge relief valves

N2 Loaded Surge Valve

Pilot Operated Surge Valve

Typical Pilot Operated P&ID

Useful Design Information

Nitrogen Loaded Pop Test - Inline

Pilot Operated Pop Test - Inline

Surge Valve Design Codes

Pilot Operated Valves

Information required for Hydraulic Analysis

Information Required for Valve Sizing

INLET Pumping Station

Storage Tank Pump SRV

You might also like