Surge analysis study for crude oil pipeline - A case study

Nandini Pandey, Rajeev Bansal, Simant Hazarika, Adnan Z Ansari, C.P.Singhal

pandey_nandini@ongc.co.in

This paper discuss Surge analysis of stabilized crude oil dispatch pipeline network and
investigates the condition at which pressure is likely to occur. A dynamic model cover field
pipeline geometry, pressure safety devise, pressure relief system and operating pumps was
established for transient simulations of different operating variants to analyse the influence on
system and find simulation results for secure operation of pipeline.

There are mainly two types of failure of the pipeline system or equipment from surge events
i.e. catastrophic failure of the pipeline system or equipment and fatigue failure of the pipeline,
valves, instrumentation, equipment and components. In the catastrophic failure a pipe burst
or a pipeline collapse from buckling and fatigue failure occurs due to derating of pipeline
material.

The pipeline Surge analysis studies require the simulation of transient instantaneous events
like pump shutdown, pump startup, power loss, sudden valve closure , stuck pig and water
column separation. Pressure surge can dispute significant damage to pipelines producing
leaks, cracked pump casings, environmental damage, personal injury, increase maintenance
costs, OH&S, production losses and crude oil revenue loss.

This paper presents Surge analysis study for 14trunk pipeline from Mehsana - CTF to
Navagam CTF. Mehsana Asset lies in North Gujarat about 56Km of Ahmedabad in India.
The stabilized crude oil is being dispatched from Mehsana- CTF to Navagam- CTF via a14 x
77Km trunk pipeline. The current operating pipeline specification is API-5LGrX46 and 8.3mm
thickness. Reciprocating type pumps with design capacity of 3240 BPD each and pressure
range of 40-44 Kg/cm2 was continuously pumping during peak production rates.
For controlled & safe hydraulic operation, the operational philosophy constitutes pumps trip
pressure switch & pump pressure safety valve switch being set at 47.5 Kg/cm2 & 49 Kg/cm2
respectively & Pressure Safety Valves (PSV) nearby Mehsana CTF and Navagam - CTF
are set at 52Kg/cm2 and 71Kg/cm2 respectively. One Motor Operated Valve (MOV) is located
at 100m from Mehsana CTF and seven sectionalizing ball valves are located in 14x 77Km
trunk pipeline from Mehsana- CTF to Navagam CTF. Under normal operating conditions
when three pumps are running for the maximum flow rate case of 7680 BOPD, pump
discharge pressure range is 40-44Kg/cm2 with a pump trip at 47.5Kg/cm2 and pump PSVs trip
at 49Kg/cm2.

As per Hydrocarbon and other liquid ASME B31.4 definition Surge pressures in a liquid
pipeline are produced by sudden change in the velocity of the moving stream that results from
shutting down of a pump station (due to pump power failure) or pumping unit, pump start-up,
valve movements or closing of a valve, or blockage of the moving stream. These surge
pressures are the highest and lowest in the pipeline systems. If surge pressure excess the
maximum allowable pipeline pressure, result in damage the pipeline, relief system valves and
pumps. If surge pressure below the minimum allowable operating pressure, result in cavitation
and pipeline collapse. The standards often allow overpressure condition above Maximum
Allowable Operating Pressure (MAOP) for a short period. The pipeline may operate for short
time above MAOP and still be within the permissible limits defined by the code. The Safe
Operating limit above which the pipeline may be allowed to operate is typically 10% to 15%
above the MAOP limit, depending upon prevailing regulations.

Surge analysis studies for different operating variants were carried out through a simulation
model developed in dynamic multiphase flow simulator OLGA. The model consisted of pipeline
as per geometry, pumps, valves, controls and pressure safety devise. Each pipeline will be
unique in this respect; however the following is a sample of scenarios which should be
considered:
1) What if one pump trips and another keeps running?
2) What if a pump is restarted within a given number of seconds after being tripped?
3) What if a control or emergency shut-down valve is closed rapidly?
4) What if an operator opens/closes a valve too quickly?
5) What if a given pipeline component malfunctions?
6) What if power fails to the motors driving the pumps?
7) What if the power fails to the motors driving the pumps?
8) What if the pump delivery valve closes in a given number of seconds?
9) What if the demand on the system is increased?

The complete pipeline valuation requires simulation and examination of different operating
conditions for each valve closure, pump trip and fluid parameters. The dynamic model was
used to simulate surge pressure condition within the pipeline system for valve operation,
sudden blockage, pump trip, if pump does not trip etc. Simulation runs were carried out for
several variants like, Closure of sectionalizing motor operated valve (MOV) on the mainline,
Closure of inlet MOV of the storage Tanks during receipt, Stoppage of Pump (s) at originating
/ intermediate pump station, Closure of valves during emergency shutdown, farthest valve
closure, mid valve closure and nearest valve closure. For each variants predicted maximum
surge pressure and its location in the pipeline.

This paper presents the pipeline surge analysis study through dynamic simulations covering
the OISD STD-141- clause no 5.1.9 & clause no 6.2.2 for 14 x 77Km trunk line from Mehsana-
CTF to Navagam CTF.