ISH - HYDRO 2014 INTERNATIONAL

Surge Protection Design for Water Conveyance System for the Case of
Power Failure to Pumps in Lift Irrigation Scheme Using SAP2

Ruben Nerella1 E.Venkata Rathnam2 P. Raghuveer Rao3

1
Research Scholar, Department of Civil Engineering, National Institute of Technology, Warangal.
(Email: ruben.ciet@gmail.com)
2
Associate Professor, Department of Civil Engineering, National Institute of Technology, Warangal.
(Email: evr@nitw.ac.in)
3
Senior Scientific Officer, Department of Civil Engineering, Indian Institute of Science, Bangalore
(Email: prvrao@civil.iisc.ernet.in)

ABSTRACT
The paper presents the results of hydraulic transient (surge) analysis of a water pumping system.The study
include formulation of problem with relevant boundary conditions viz., upstream and downstream reservoir,
pump, pipe junction, air vessel, surge tank, air valve, stand pipe etc. The surge equations are generally
solved by Method of Characteristics (MOC) approach. The main assumption in the analysis is that formulas
for computing the steady state friction losses in conduits are valid during the transient state also. A case
study of water pumping main of JCR Devaduala Lift Irrigation project of Telangana State is presented.
Surge analysis is carried out for the case of tripping of power to pumps. The results for pump trip condition
show that there is pressure rise above working pressure and down surge throughout the alignment. The
maximum pressure observed is 291 m as against the pump head of 131 m. Surge protection devices for the
pumping main are designed using software Surge Analysis Program Version 2 (SAP2).
Keywords:hydraulic transients, pressure main, pump failure, air vessel, surge tanks.

1.0 INTRODUCTION

Many researchers including Wylie and Streeter (1993) and Chaudhry (1987) referred pressure
surges as water hammer pressures or hydraulic transients in conduits which may occur due to
change in flow conditions. Liggettt et al. (1992) mentioned that most hydraulic transient analysis
in pipe networks have been done in feed-water system in power plants. Soares et al. (2013)
stressed the need for hydraulic transient analysis in the operation stage of any existing pumping
mains for the diagnosis of malfunction problems or the cause of pipe bursts. In a pumping mains,
changes in flow may be caused by i) starting or stopping of pumps, ii) opening or closing of
valves, iii) Power failure (Pump trip), and iv) single pump failure. The first two conditions (i, ii)
fall under planned conditions where as the other two conditions (iii, iv) fall under unplanned
conditions which form the most critical surge condition in pumping main. The prediction of
maximum transient pressures is used to verify whether pipe materials, pressure classes, and wall
thicknesses are sufficient to with stand predicted pressure loads to avoid pipe rupture or system
damage. Verification of minimum transient pressures is important to prevent air release, cavitation,
and water column separation and consequently, to avoid pipe collapse or pathogenic intrusion into
the system. When severe transients cannot be avoided, either the pipe characteristics are changed,
or surge-protection devices are specified (e.g., air vessels, surge tank etc.) so as to reduce the
extreme pressures to within acceptable limits. Usually, the decision is the most economical and
reliable surge protection devices that yield an acceptable transient pressure response. Stephenson
(2002) simplified the process of sizing of air vessel with nomographs. Both air volume and total
vessel size are calculated.

Hydraulic transients in pumppipe line system can be solved by widely accepted

numerical method called Method of characteristics (MOC) which involves the solving of two non-
linear, first order partial differential equations in two unknowns piezometric head (H) and flow
velocity (V) in two independent variables like time (t) and distance (x) along the pipe line. Wylie
& Streeter (1993) developed the theory and computational methodology for solution by MOC and
are available in standard references. In this paper, transient pressures generated in pipe flows
caused by pump trip are analyzed. Raghuveer Rao (2012) applied the MOC based computer

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program called Surge Analysis Program Version 2 (SAP2) developed at the Indian institute of
Science, Bangalore (IISC) in more than 500 projects. The same has been used for analyzing
transient pressures in the present study. Field data of steady state flow rate were collected at Intake
pump house of JCR Devadula Lift irrigation scheme located in Telangana state, India. Results
obtained with provision of protection devices such as air vessel, one way surge tank, stand pipes
and air valves are presented.

2.0 METHODOLOGY AND DESIGN CONSIDERATION

2.1 Dynamic and continuity equations

Analyses of most hydraulic transients in pressurized systems are carried out assuming one
dimensional flow and are based on the continuity and momentum equations describing the
general behavior of fluids in a closed duct in terms of two variables, namely piezometric
head (H), and fluid velocity (V), in two independent variables time and distance along pipe line.
Hanif Chaudary (1987) derived the continuity and momentum equation for hydraulic transient
conditions which constitute a system of partial differential equations of first order that can be
written as
2 (1)
H a V
+ =0
t g x
V H fV V (2)
+g + g sin + =0
t x 2D

Where, H is piezometric head, V is mean velocity, x is the coordinate along the pipe axis, t is
time, a is celerity (or pressure wave velocity), D is diameter of pipe, g is acceleration due to
gravity, f is Darcy Weisbach friction factor and sin is the slope of the pipeline. Wylie & Streeter
(1993) confirms that method of characteristics (MOC) can successfully replace by a pair of partial
differential equations (Eq.1) and (Eq.2) by an equivalent set of ordinary differential equations.

The new set of characteristic equations can be written as

dV g dH fV V
C +
: + + = 0 where (3)
dt a dt 2D
dx
= a (4)
dt
dV g dH fV V
C : + = 0 where (5)
dt a dt 2D
dx
= a (6)
dt

(Eq 3 Eq 6) are the basis for the finite-difference solution of the water hammer problem. A finite
difference approximation for the velocity and head (Vp, Hp), at point P is expressed as
V p Vi 1 g ( H p H i 1) fVi 1 Vi 1
C+ : + + =0 (7)
t a t 2D
V p Vi +1 g ( H p H i +1) fVi +1 Vi +1
C : + + =0 (8)
t a t 2D

The subscripts i-1 and i+1 in (Eq.7) and(Eq.8) refers to the sample points to the left and right of P
and one time interval t in the past. By combining known variables, We may write Eqns. (7&8) as
C + : Vp = C1 C2 H p (9)

C : Vp = C3 + C4 H p (10)

 ISH - HYDRO 2014 INTERNATIONAL

where
g f t (11)
C1 = Vi 1 + H i 1 Vi 1 Vi 1
a 2D
g (12)
C2 , C4 =
a
g f t (13)
C3 = Vi +1 H i +1 + Vi +1 Vi +1
a 2D
(Eq.9) and (Eq.10) can be referred as compatibility equations and are valid for interior points of
solution space (2 i N) as shown in Figure 1. At any interior grid intersection point (P at section
i), the two compatibility equations (Eq.9) and (Eq.10) are solved simultaneously for the unknowns
Vp and Hp.
t
t
P t
t0+t
a+ a
t
A
t0 B
t
x x
i1 i i+1 1 2 3 ... N N+1
x x x x x
InteriorsectionsUpstreamboundaryconditions
Initialcondition Downstreamboundarycondition

Figure 1. Method of characteristics - characteristic lines in plane (x, t)

2.2 Design of surge protection system

The design of surge protection system is an iterative process in which protection is proposed,
analysis is made, results are evaluated, based on evaluation modification, and process is repeated
until an economic protection system is arrived at. The surge protection devices used for pumping
mains and their role in surge protection system is shown in (Table 1).

Table 1. Surge Protection Devices and its functions

Surge Protection Devices Functions

Air vessel Controls upsurge & down surge

Surge tank, Air valves Controls down surge directly and upsurge indirectly

Stand pipe Controls down surge only

Zero velocity valves and Controls Up surge only

Surge relief valves

2.2.1 Air vessel

It is a closed vessel with water in the lower part of the vessel and compressed air at working
pressure in the upper part Figure 2. The compressed air functions as stored energy cushioning the
rate of velocity reduction in the transmission main.

3
 Q
N
pu =
+
Q
c A
p

=
C
Q
c (utoc
2
H
g
A
H
p

=
cQ 1
50
.5 C C
4
1

=
2
C
6 +inc2
gC A
H

=
V
A
K

Figure 2. Schematic diagram of Air vessel

When pump fails, pump head reduces, pressure in the air vessel reduces by expansion of air. As
result water is supplied to transmission main which reduces the rate of velocity reduction in
transmission mains. The air chamber contribution to the upstream boundary condition must be
incorporated with that of pumps. Assume that there are Npu pumps in parallel and the power fails
simultaneously. The equations for these situations are

Upstream: (13)

Conservation of Mass: (14)

Pump Work Energy: (15)

Chamber Work Energy: (16)

Pump Head Increase: (17)

Where Hc is the head in the chamber, Cout is the out flow coefficient, Aout is the out flow cross
sectional area, and, Qc is the discharge from the chamber.

(18)

(19)

(20)

Raghuveer Rao (2012) used a non-dimensional size parameter (KAV) instead of actual size of air
vessel to specify the volume of the air vessel.

(21)

 C
A
V

:
A
P +
=
1Q
BC
sP
A H
A
V
C
2pP
B

=
Q
s A
C
out 2(
sgH +

Z
B
A H
p

.
0=
sQ
51
+
C 5

ISH - HYDRO 2014 INTERNATIONAL

Where, C0 is air volume under working condition, Q0 is design discharge, L is the length of
transmission main, and a is celerity or pressure wave velocity. After repeated analysis is
determined with different size parameters, volume of air vessel is determined based on results of
surge analysis.

2.2.2 One way surge tank

It is a RCC or feed tank placed at locations where the pipe line undergoes severe down surge
pressures Figure 3. When pressure in rising main drops below the water level in OST due to power
failure, water from OST starts draining into the rising main, controlling further down surge.
Control of down surge avoids column separation and resulting upsurge.

Figure 3. Schematic diagram of one way surge tank

The following equations form the internal boundary Conditions.

Upstream: (22)
Downstream: (23)
Conservation of mass: (24)
Work-Energy: (25)

Where, Cout is loss coefficient for the connecting pipe (0.60-0.98), A, As are cross sectional areas of
pipe and surge tank, Hs is height of tank liquid surface above centre line of the pipe and ZAB is
elevation of centre line of the pipe.

Tank discharge Qs is given by

(26)

(27)

(28)

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2.2.3 Air Valves

Figure 4. Schematic diagram of Air valves

Air valves are intended for control of down surge in view of their function as vacuum breaker
Figure 4. The primary role of air valves is to release/allow air at summits during filling/emptying
the pipeline. This can be used as supplement surge control device at locations where there is severe
sub-atmospheric pressure is expected. Air valves at proper locations make pipeline free of air
pockets. For a cross country pipe line, air valves need to be located at all local peaks and at every
500 to 600 m. Analysis of air valves focuses on a) air inlet capacity of air valve b) air exhaust
characteristic of the air valve.

2.2.4 Stand pipe:

Stand pipe may be considered only at a location along the alignment where the hydraulic grade
line is within a few meters (usually 3 to 4 m) of ground elevation. Also, the downsurge at the
location must be severe enough to require a local protection. Such locations are usually likely to
occur towards the delivery Reservoir. Figure 5 gives a schematic diagram of the stand pipe. The
design variables for the stand pipe are: a) location of the stand pipe, b) diameter of the stand pipe,
c) elevation of the top of the stand pipe. The top of the stand pipe should be fixed 1 to 2 m above
the maximum elevation of hydraulic grade line at the location.

Figure 5. Schematic diagram of stand pipe

3.0 SURGE ANALYSIS

3.1 Case Study : Devadula Lift irrigation Project

The Devadula lift irrigation scheme involves seven reaches (approximately 200 km length) to lift
water from river Godavari to upper parts of Telangana region. Out of seven reaches, reach 1 which
is about 38 km, whose longitudinal alignment and steady state hydraulic grade line is shown in
Figure 6. Two pumps were installed at intake Pumping station (RL 71m) to lift water to
6

1
eD + 1(
)2 K
E

ISH - HYDRO 2014 INTERNATIONAL

Bhimganapuram irrigation tank (RL 166.94 m) with a static lift about 96 m. The design discharge
in the 3000 mm size MS pipe line with 16 mm thick wall is 14 m3/s and rated head is 131 m. The
system parameters/ field data is given as input and simulated the steady state condition as well as
transient condition (Pump trip condition).

210

200 Alignment
HGL
190

180

170

160
Elevation, RL, m

150

140

130

120

110

100

90

80

70
0 4000 8000 12000 16000 20000 24000 28000 32000 36000
Chainage, m

Figure 6. Longitudinal alignment and steady state HGL of pipeline

Two pumps of 7 m3/sec discharge at head of 131m are installed whose speed is 500rpm,
efficiency is 91%. The GD2 values of pump and motor are 14920 and 44000 kg-m2. The power of
motor is 9.9 MW. Length of transmission main is 38252 m long, mild steel pipeline diameter of 3
m, pipe wall thickness is 16 mm with external cement mortar guiniting of 25 mm thick. The pump
characteristics curve is shown in Table 1.

Table 1: Pump characteristics

Discharge (m3/s) 0 1 2 3 4 5 6 7 8 9 9.6

Head (m) 154 152 149 147 145 142.5 139 131 120 103.5 91
Efficiency (%) 0 26.2 45.7 60.3 75.9 84.2 87.97 90.86 90.12 85.4 78.96

When pump trip occurs, discharge and head in the transmission main reduces to zero. In order to
prevent reverse flow trough pumps, a hydraulically operated discharge valve (HOPDV) is
provided. The closure time, on power failure, for HOPDV valve is 20 sec, with 90% closure in 10
sec and remaining 10% closure in 10 sec.

Wave speed estimation: The Elastic wave speed (a) can be estimated by theoretical formulas with
the modulus of elasticity provided by manufacturer of the pipes (Wylie & Streeter, 1993). The
wave speed was estimated as 868 m/s, given by (Eq.29).

(29)

Where, K is bulk modulus of elasticity of water (2.19 GPa), E is modulus of elasticity of pipe (200
GPa), e is pipe wall thickness (16 mm), D is diameter of pipe (3000 mm), is Poisons ratio (0.29)
and is density of water (999 kg/m3).

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3.2 Overview of SAP2

The design of surge protection system is an iterative process. Surge or water hammer analysis is
made for each option by numerical analysis using the method of characteristics. A software is
required for such an analysis, as it involves simultaneous solution of two non-linear, first order
partial differential equations. The present Surge Analysis Program Version 2 (SAP2) is an offshoot
of a software developed in-house at the Indian Institute of Science and used for the design of surge
protection system for more than 500 projects. The principal limitations of SAP2 are: (a) The
software requires that the steady state flow direction in each pipe is known. (b) It is not applicable
for looped networks such as street level pipes in an urban water supply network. (c) The scope of
the software is limited to flow shutdown such as power failure, one or more pumps failure and
closure of the delivery end valve in gravity main.

4.0 RESULTS

4.1 Steady state analysis

The hydraulic parameters mentioned above were given as input to SAP2 and simulated the steady
state analysis i.e., both pumps working as shown in Figure 7.
210
Alignment
200
Minimum Head
190 Maximum Head
HGL
180

170

160
Elevation, RL, m

150

140

130

120

110

100

90

80

70
0 4000 8000 12000 16000 20000 24000 28000 32000 36000
Chainage, m

Figure7. Steady state analysis

4.2 Surge analysis with out protection
The results for pump trip show that there is rise in upsurge and vapour pressure throughout the
stretch as shown in Figure 8. This figure presents the pipeline alignment, the HGL and the
minimum and maximum piezometric heads obtained from surge analysis. The maximum and
minimum pressures at any location in the figure are obtained by deducting the pipe alignment
elevation from the corresponding piezometric head. The alignment levels in the figure correspond
to pipe invert level. The maximum pressure is 291 m which results in a hoop stress exceeding the
yield stress of steel and vapour pressure throughout the alignment. Spurious minimum pressures
with negative values in excess of -10 m should be interpreted only qualitatively not quantitatively.
Also as the pipeline cannot take full vacuum as per AWWA M11 which specifies minimum
thickness of 6 mm for every 1000 mm. As the pipeline is vulnerable to upsurge or pressure rise
and down surge or pressure drop and hence need protection.

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390

340

290 Alignment
Minimum Head
Maximum Head
240 HGL

Elevation, RL, m
190

140

90

40

-10
0 4000 8000 12000 16000 20000 24000 28000 32000 36000
Chainage, m

Figure 8. Minimum and maximum piezometric heads for no protection

4.3 Surge analysis with protection

The analysis carried out by incorporating surge protection devices viz., Air vessel, surge tank,
Stand pipes, Air valves etc. at appropriate locations. After several iterations, the following
protection devices are proposed.

a. Four air vessels of 99 m3 each with 27 m3 of initial air volume with connecting pipe of 900 mm
size with orifice of 500 mm size. The air vessels are connected to the transmission main
through a manifold of 1800 mm size with an orifice of 1000 mm size.
b. One way surge tank of 20 m diameter with storage height of 5 m and staging height of 5 m at
Ch. 5971 m. The twin connecting pipe size is 1400 mm with filling pipe size of 600 mm.
c. Stand pipes of 300 mm size at Ch. 26337 m and 27742 m with top level extending to RL 181
m.
d. Air valves of 200 mm size at Ch. 2687 m and 7035 m.

Figure 9 shows maximum pressure head and minimum pressure head variation along the pumping
main with proposed surge protection on power failure. It can be observed that the maximum
pressure is the maximum working pressure only and practically no sub-atmospheric pressure.
210
Alignment
200 Minimum Head
Maximum Head
190
HGL
180

170

160
Elevation, RL, m

150

140

130

120

110

100

90

80

70
0 4000 8000 12000 16000 20000 24000 28000 32000 36000
Chainage, m

Figure 9. Minimum and maximum piezometric heads with protection

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5. CONCLUSIONS

Surge analysis and design of surge protection system is very important for safe and reliable
functioning of water conveyance systems. The paper presents numerical analysis of surge
pressures in water transmission main using SAP2. The analysis shows power failure results in
maximum pressures in excess of pipe capacity and vapour pressure throughout which the pipeline
cannot withstand. The proposed combination of protection devices the maximum pressure is the
maximum working pressure and practically no sub-atmospheric pressure any where on the
alignment.

6. ACKNOWLEDGEMENTS

Authors gratefully acknowledge the help received from Chief Engineer, JCR Devadula Lift
Irrigation Project, Hanamkonda, Warangal district, Telangana State in providing data for the
analysis.

7. REFERENCES

AWWA M11 (2004), Steel Pipe A Guide for Design and Installation, Fourth Edition, American Water
Works Association, Denver, USA

Hanif Chaudary, M. (1987) Applied Hydraulic Transients,Van Nostrand Reinhold, New York.

Liggettt J A, Li-Chung C. (1992) Inverse Transient Analysis In Pipe Networks. Journal of Hydraulic
Enggineering 120 (8):1014-1024.

Raghuveer Rao, P. (2012) Surge Analysis and Design of Surge Protection System - Case Studies,Water
Hammer Surge Analysis of Piping System (WHSAPS), (pp. 1-42). Trichur, India.

Soares A K, Covas C. I, & Ramos H. M. (2013). Damping Analysis of Hydraulic Transients in Pump -
Rising Main system, Journal of Hydraulic Engineering, 139 (2): 233-242.

Stephenson, D. (2002) Simple guide for design of Air vessels for Water Hammer protection of Pumping
mains, Journal of Hydraulic Engineering, 128 (8):792-797.

Wylie E B, & Streeter V L. (1993) Fluid transient in systems,Englewood Cliffs, N.J: Prentice-Hall.

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