SURGE ANALYSIS OF

PUMPING SYSTEMS
Thomas C
Th Crowley,
l PE & Weston
W Engel,
E l PE - Carollo
C ll
Stewart Noland, PE Crist Engineers
Scott Foster, PE Flow Science
October 14, 2014
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Oklahoma
Okl h City,
Cit OK
Central Arkansas Water Little Rock, AR
SUA Stillwater, OK
Recommendations
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Okl
Oklahoma
h City,
Cit OK
Central Arkansas Water
Stillwater, OK
Recommendations
 Factors Causing Surge

Primary Surge Transients

Pump Startup
Pump Shutdown
Power Loss
Valve Shutdown
Secondary Surge Transients
Air Valve
Water Column Separation
 Factors Causing Surge

Primary Surge Transients

Pump Startup
Pump Shutdown
Power Loss
Valve Shutdown
Secondary Surge Transients
Air Valve
Water Column Separation
 Factors Causing Surge

Primary Surge Transients

Pump Startup
Pump Shutdown
Power Loss
Valve Shutdown
Secondary Surge Transients
Air Valve
 Factors Causing Surge

Primary Surge Transients

Pump Startup
Pump Shutdown
Power Loss
Valve Shutdown
Secondary Surge Transients
Air Valve
Water Column Separation
 Factors Causing Surge

Primary Surge Transients

Pump Startup
Pump Shutdown
Power Loss
Valve Shutdown
Secondary Surge Transients
Air Valve
Water Column Separation
Factors Causing Surge
Air Valve Caused Surge
Air Valve Caused Surge
 Factors Causing Surge

Primary Surge Transients

Pump Startup
Pump Shutdown
Power Loss
Valve Shutdown
Secondary Surge Transients
Air Valve
Water Column Separation @ High Spots
Water Column Separation
Water Column Separation
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Okl
Oklahoma
h City,
Cit OK
Central Arkansas Water
Stillwater, OK
Recommendations
 Factors Influencing Surge
F
Formation
ti
Pipeline Properties
Pipeline profile (particularly high points)
Pipeline and lining Material
Configuration (Storage locations)
Pipe Appurtenances
Air valve Location and Types
Valve Types and opening/Closing
Type of Check Valves
Pump
P Features
F t
Pump performance curves and operating speeds
Rotational moment of inertias for pump/motor
p p/
assemblies
Common Surge Misconceptions
Pipeline velocities must be low to reduce the
effects of water hammer
Surges only occur in long pipelines
The noise and knock in a system
y is an indicator of
the magnitude of a surge
Surge protection devices should be installed on an
experimental basis because it is not possible to
accurately determine the magnitude of surges
g p
The use of surge protection devices are not
economically viable
Pressures in a system must be high before
dangerous surges can occur
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Okl
Oklahoma
h City,
Cit OK
Central Arkansas Water
Stillwater, OK
Recommendations
How can you determine if Surge is
an Issue?
I ?
Banging
g g Noises and Vibration
Pressure waves bouncing from piping
Check valve slamming
F
Frequentt pipe
i breaks
b k in
i the
th Same
S
places especially near pump station or
low/high
o / g po points
ts in the
t e system.
syste
System Measurements (transients
occur too quickly for normal PTs)
Difficult to observe due to infrequent
occurrence and difficulty in monitoring.
Why Should You Care About Water
Hammer.
H
Catastrophic Service Breaks
Pipe Materials Behave Differently:
Plastic: Lower p
propagation
p g but more
susceptible to fatigue from cyclic loading.
Steel, Concrete: Higher pressure rise but
less susceptible to cyclic loading.
loading
Contamination Potential
Damage to system instrumentation
(Gauges, Flowmeters, etc.)
Control and Alarm Issues
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Okl
Oklahoma
h City,
Cit OK
Central Arkansas Water
Stillwater, OK
Recommendations
 Types of Surge Suppression
E i
Equipment t - Passive
P i
Pump Control Valves Characteristics:
 Types of Surge Suppression
E i
Equipment-t Passive
P i
Pump Check Valve Characteristics:
 Types of Surge Suppression
E i
Equipment-t Passive
P i
Controlled Pump
p Startup/Shutdown
p
Provide wirth S-curve feature to Time
with Valves
Not all Soft Starts Created Equal
Voltage/Torque
g / q Control More Important
p
than Current.
 Types of Surge Suppression
E i
Equipmentt
Pump Design Features:
Pump Curve
Pump Impeller Moment of Inertia
Anti Reverse - Ratchet
 Types of Surge Suppression
E i
Equipment t - Active
A ti
Air/Vacuum Relief Valves (Size and
Location)
 Types of Surge Suppression
E i
Equipment t - Active
A ti
Air/Vacuum Relief Valves (Size and
Location)
AVV Surge Check Devices
 Types of Surge Suppression
D i
Devices - Active
A ti
Surge Anticipation Valves
Surge Tanks
Bladder
Bl dd
Hydropneumatic
Surge Towers
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Okl
Oklahoma
h City,
Cit OK
Central Arkansas Water
Stillwater, OK
Recommendations
CAW Maumelle Pump Station
Hi t
History
600

550

500

450

Elevation (fft)
400

350

300

250

200
0 1 2 3 4 5 6 7 8 9
Distance (miles)
Breakson Pipeline Elevation
Breakson
72inch Pipeline Pressure
48 inch
48inch
Protect,ReplaceorBypassAreaof
HighestPressures
 ARV

48 60 30

12 ARV
30mgd
48 60 30

12
30mgd
36 24

12
48 30mgd
ARV 24
36
24
60
12
30mgd
ARV
15 mgd
15mgd 30
30
24 48 Pumps14
36
ARV
14
15mgd 48
24

E
30mgd 48
72
Pumps57 Figure
g 1 Existing
g Schematic Maumelle Pump p Station
Lake Maumelle Pump Station and Transmission Main
Preliminary Design Technical Memorandum
Central Arkansas Water
 Surge Analysis Assumptions
All Air/Vacuum Relief Valves equipped with controlled
venting/slow
g/ closing.
g
All seven pumps are operating (174 mgd at 333-341
TDH)
One of the river crossings is out of service (highest
velocity)
l )
Pump Control Valves Close within 60 seconds of power
loss.
All fi
five S
Surge A ti i t V
Anticipator l
Valves (SAV ) ffully
(SAVs) ll open
following activation (Pressure below 75 psig).
SAVs Remain in operation for 30 seconds and close
within 260 seconds.
seconds
Both the 72-inch and 48-inch Transmission Mains are
hydraulically connected.
 AtalltimesMaxHGL<1.33xPressure
Rating

ProperOperationofCAVsCrucial
toprotectionscheme.

AreasofHigh
PotentialforVapor
CavityFormation
andCollapse

Figure
g 2 Existing
g System
y Lake Maumelle Transmission Mains
Lake Maumelle Pump Station and Transmission Main Preliminary
Design Technical Memorandum
Central Arkansas Water
 AtalltimesMaxHGL<1.33xPressure
Rating

CAVsinadequatetopreventvapor
cavityformation

AreasofHigh
PotentialforVapor
CavityFormation
andCollapse
 Repressurization
andpotentialfor
and potential for
VCcollapse

Potentialcyclingof
eventvery
damagingtoPCCP.

Figure
g 2 Existing
g System
y Lake Maumelle Transmission Mains
RapidDropof Lake Maumelle Pump Station and Transmission Main Preliminary
Design Technical Memorandum
PressureatPS Central Arkansas Water
 Surge Analysis Mitigation
Install Three 12 ft diameter x 60 ft long
g
surge tanks with 45% air.
Install tanks at pump station.
Install
I ll new valves
l to close
l within
i hi 5
seconds of power failure at pump
station.
Retain existing SAVs for increased level
of protection.
Install Surge Checks on CAVs at
stations further down the pipes.
CAVsrequire
controlledventing
CAVsrequire
controlled venting
controlledventing
 ARV

30
DualDiscCheckValve LugType 48 48 60
VFD
12
12 ARV
DismantlingJoint
30mgd
DMJ
30
60
ARV VFD
12

DM
24

MJ
30mgd

36
ARV
15mgd
24 48 24
12
12
14 48 30mgd
ARV 36
15mgd 24 60 24
12
VFD 30mgd
30
30mgd

36
J
DM
J
DM

30 48
M

30
30
J
DM

30

H
48
60
60 60
60 72
72 Figure
g 5Proposed
p Schematic Surgeg Tanks Option
p 1
Lake Maumelle Pump Station and Transmission Main
Preliminary Design Technical Memorandum
AirCompressor(Typ of4) Central Arkansas Water
CAW Surge Suppression System
CAW Surge Suppression System
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Okl
Oklahoma
h City,
Cit OK
Central Arkansas Water
Stillwater, OK
Recommendations
 M
36

42
42
48
FM M
Existing Ka

20

Kaw 36 36 36
36
Reservoir 9mgd,173psigVTPump
1,000HP(typ of2)
aw Raw Wate

LargePumps
Legend 24 M

F Flowmeter
M
M
Strainer
er Pipeline S

ElectricActuatedControlValve M

GlobeStyleCheckValve
M
4mgd,78psigVTPump
ConstantSpeedPump 200HP(typ of3)
Schematic

36
S ll P
SmallPumps
VariableSpeedPump
V

24 24
4MG RawWater
ButterflyIsolationValve StorageTank
ToStillwater
To Stillwater 24
24
24
WTP
12
24 42
FIGURE 1.1

FromStillwater ToOSUWTP
36
WTP
New Water Treatment Plant and Capacities Study Update
Draft Report August 2012
 2inchcombination
AirValve(typ)
Sta.633+48
Manway
Existing Kaw Raw Water Pipeline

Sta.1931+68 Sta.1307+92
(TankFarm) Manway
e Profile

HorizontalScale:
0.5inch=2miles
FIGURE 2.3

New Water Treatment Plant and Capacities Study Update

Draft Report August 2012
 Surge Analysis Results

Potentially Damaging Surge Waves

were occurring due to:
Large Pump Startup/Shutdown
Lack of Proper Air/Vacuum Relief Valves
 Sta.633+48 Sta.525+00 Sta.117+43
4inchCAV 4inchCAV 4 inch CAV
4inchCAV

Sta.1307+92
Recom

4inchCAV
mmended Lo
ocations for CAVs

HorizontalScale:
0.5inch=2miles
Sta.1677+51 Sta.756+05 Sta.368+75
2inchCAV (relocated) 2inchCAV (relocated) 2inchCAV (relocated)
Sta.00+00
2inchCAV (relocated)
FIGURE 4.1

Sta.190+29
2inchCAV (relocated)

New Water Treatment Plant and Capacities Study Update

Final Report October 20122
 Agenda

Factors Causingg Surge

g in Pumping
p g Systems
y
Factors Influencing Surge Severity
Why Should I Care about Surge?
Types of Surge Suppression Systems
Case Studies:
Okl
Oklahoma
h City,
Cit OK
Central Arkansas Water
Stillwater, OK
Recommendations
 Conclusions and
R
Recommendations
d ti
Do not assume that low velocities = No
Surge
Always
y perform
p a surge
g hydraulic
y
analysis:
On new systems
On existing systems to change conditions
To determine timing of pump/valve startup.
System
S t conditions
diti will
ill dictate
di t t solution:
l ti
Active or Passive
Type of Active
Questions

55