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SURGES IN PIPELINES

Raghuveer Rao Pallepati


Department of Civil Engineering
Indian Institute of Science
Bangalore – 560012 India

Water supply pumping mains

Lift irrigation schemes

Cooling water systems for thermal


and nuclear power plants

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Water supply schemes
• Diamter of pipe – 0.4 m to 2.5 m
• Length 5 km to 150 km
• Discharge – 20 to 270 MLD
• Head – 30 m to 250 m

Lift irrigation schemes


• Diamter of pipe – 1.5 m to 3 m
• Length 0.2 km to 50 km
• Discharge – 2 to 14 m3/sec
• Head – 10 m to 140 m

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Cooling water systems
• Diamter of pipe – 2 m to 3.2 m
• Length 1-2 km
• Discharge – 6 to 16 m3/sec
• Head – 10 m to 20 m

Source Reservoir – water level - min & max


Delivery Reservoir – ground level
Ground level profile
Quantity of water required
MLD - Million liters / day
Number of hours of pumping Delivery
Velocity – 1 m/sec – fix diameter

Source

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Design parameters
Discharge required - Diameter of pipe
Pipe material – Steel/PSC/DI/CI/BWSC/GRP
Thickness / pressure rating
Calculation of pump head
Static head + Frictional loss + Minor losses +
Pump house loss

Delivery
Static Lift

Source

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Friction loss in pipe
Darcy-Weisbach L v2
Hf = f
D 2g

10.67 L Q1.852
Hazen-Williams Hf =
C1.852 D 4.87
Minor losses bends, valves etc.
Pump house loss
Valves, bends etc

Hydraulic gradient line


At pump = Minimum water level in sump + Pump Head
At delivery end = Delivery level
Uniformly varies with length

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Non-return valve
Butterfly valve
Isolation valve
Uniform clousure / dual speed closure
Single door / multi door

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Dual Plate Check Valve

The “Simple & Simplistic” Formula for Surge

a = pressure wave velocity


V = flow velocity
∆H = Surge pressure
g = gravitational acceleration

aV
ΔH =
g
Focus on upsurge only, no attention to down surge

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Anomaly of the simple formula –
An example
Pressure wave velocity, a (approx.) =
981 m/sec
Flow velocity, V = 1 m/sec
∆H = (981 x 1)/9.81 = 100 m
This pressure rise is independent of static lift, pipe
length & pump head !
Same pressure rise for two schemes with 100 m
pump head, one 200 m long with 96 m static lift &
another 60 km long with 10 m static lift !!!

Pressure Wave Velocity

a = pressure wave velocity


K = bulk modulus of elasticity of water
ρ = density of water
E = Young’s modulus of elasticity of pipe material
D = diameter of pipe
t = wall thickness of pipe

K ρ
a=
KD
1+
Et

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Surge – The Phenomenon
Rapid Change in Discharge (Velocity) &
Associated Change in Pressure
Surge – The Causes
Operation of Valves (Closure & Opening)
Starting of Pumps
Stopping of Pumps
Power Failure
Single Pump Failure

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Phenomenon of Power Failure
• Power supply cut; Pump speed starts dropping
from rated speed
• Discharge & pressure (head) starts reducing
• Pressure wave (down surge) transmits through
the rising main
• At delivery reservoir, down surge wave gets
reflected as upsurge wave and moves towards
pump end
• At some reduced pump speed, flow starts
reversing at pump
• NRV at pump closes due to flow reversal
causing a pressure rise or upsurge

Power Failure (contd.)

• These waves (upsurge & down surge) move along


the rising main, reflected at the delivery reservoir
& at the closed NRV at pump end
• Speed of wave movement approx. 1 km/sec
• Reflection at delivery reservoir (+) wave becomes
(–) wave
• Reflection at closed NRV (+/-) wave doubles up,
that is reflected wave same sign as direct wave
• Final result: Low & high pressures all along the
rising main

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Surge – The Problems
¾Pressure rise due to NRV closure too high
(depends on type of NRV & closure pattern)
¾Pressure drop due to down surge immediately
following power failure causes negative pressure,
which may go down to vapour pressure
¾Column separation due to occurrence of vapour
pressure
¾Rejoining of separated columns causing pressure
rise (indirect upsurge)

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Column Separation

Local Peak Cavity development


Pipe alignment
at a local peak cavity Cavity volume with time

Inflow Outflow

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Effect of Column Separation
• At a peak location, pressure goes down to vapour pressure
• This location becomes a pressure control, that is
temporarily like a pseudo-reservoir
• Upstream & downstream water columns separate with
different flow velocities
• Initially outflow velocity more increasing vapour pocket
or cavity size
• Later inflow velocity becomes more (outflow velocity
changes direction – reverse flow) shrinking the cavity
• When cavity volume becomes zero, sudden pressure rise
due to column rejoining occurs
• Pressure rise travels on both sides of rising main
increasing pressure all through

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Surge Analysis Program Version 2 Software Developed at department has been
acquired by 44 organizations through Technology Transfer and also used for analysis
and design of surge protection systems for over 400 Consultancy Projects

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Phenomenon of Single Pump Failure
• Two or more pumps working in parallel;
• One pump suddenly trips due to a fault;
• The pressure in the manifold drops slightly, but the running
pumps control the drop (more the running pumps, less the drop
in pressure at manifold);
• Running pumps get slightly over-loaded;
• Water from running pumps flows through the failing pump;
• NRV on failing pump closes with associated pressure rise;
• Pressure rise depends on type of NRV, delivery pipe size, and
extent of pressure drop at manifold;
• Pressure rise local to pump house, endangering NRV and BFV
or sluice valve.

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N/Nr

Q/Qr

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Parameters Influencing Surge Picture

• Pipeline constant, B = (aVo)/(gHo)


• Friction loss parameter, Hf/Ho
• Pump inertia parameter which is inversely
proportional to combined GD2 of motor and pump
• Longitudinal alignment of the pipeline
• Type of NRV in the pump house
• Number of working pumps (for effect of single
pump failure)
• Delivery pipe size from individual pumps (for
effect of single pump failure)

General Trends

• Larger the value of B, surge relatively more;


• Larger the friction loss, upsurge less critical &
down surge more critical;
• Larger GD2 value, surge less critical;
• Alignment effects are very important and quite
varied;
• Choice of NRVs in pump house and their closure
characteristics may be adjusted to suit
requirements of surge control;

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Non-return Valves - Types

• Swing check valve (small size valves)


• Swing check valve (large size valves)
• NRVs with dash pot arrangement
• Multi-door NRVs
• Dual plate check valves
• Pump discharge valves (NRV cum isolation valve)
• Zero velocity valves (special type upsurge control
valve to be used at intermediate locations along
the rising main)

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Interpretation of Surge Results
The Pipe Material Aspect
• Pipe material
(MS,DI,CI,PSC,BWSC,AC,GRP,PVC)
• Pressure class or wall thickness
• Vulnerability to upsurge or pressure rise
(PSC,AC,PVC,CI)
• Vulnerability to down surge or pressure drop
(large size MS pipe,GRP,PVC)
• D/t issue for MS pipes (6 mm for 1000 mm dia
thumb rule)

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Interpretation of Surge Results
(contd.)
Pump House & Rising Main
• Use more conservative design criteria for pump house pipes
• Manifold design to be atleast as conservative as rising main
design
Valves
• Pressure rating of valves in the pump house
• Type of NRVs
• Pressure rating of valves along rising main
HP & LP Reaches
• Pros & cons

Design Criteria for Surge Protection


Upsurge
• Max. pressure not to exceed 1.5 times (or 1.25 times) working
pressure or pump head
• Low head schemes, particularly with MS pipe, max. pressure
upto twice pump head may be quite safe (criterion: check
against hoop stress)

Down surge
• No sub-atmospheric pressure
• Sub-atmospheric pressure upto (-) 5 m
• Vapour pressure allowed, but upsurge due to column
separation to meet upsurge limit (criterion: check pipe strength
to withstand full vacuum)

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Control of Surge - Principles

• Primary surge immediately following power


failure is down surge or pressure drop,
which occurs due to reduction of flow
velocity;
• If some stored water can be supplied into
the rising main immediately after power
failure, the down surge intensity will
reduce;
• This is the concept used in air vessel & one
way surge tank (OST) protection devices.

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Control of Surge (contd.)

• Upsurge or pressure rise is essentially associated


with the development of return flow after power
failure;
• Hence, if return flow is controlled, upsurge
reduces;
• This is the concept used in air vessel (for control
of upsurge) and Zero velocity valve;
• Alternately, if safe passage is allowed for return
flow, upsurge is again controlled;
• This is the concept used in Surge anticipating
valves (Surge relief valves)

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Zero Velocity Valve

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Surge Protection Devices
• Controls upsurge and down
• Air vessel surge
• Controls down surge directly,
• One way surge tank upsurge indirectly

• ZVV and Surge relief • Controls upsurge only


valve • Control down surge directly,
• Air valves/ACVs upsurge indirectly

• Stand pipe • Controls down surge

Cost of Surge Protection Devices – In


ascending order (general trend)

• Air Valves/ ACVs


• Stand Pipe
• Surge Relief (Anticipating) Valves
• Zero Velocity Valves
• One Way Surge Tanks
• Air Vessel
Except for Air valves/ACVs, this general cost trend
may be changed in specific cases.

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