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Hydraulic surges are created when the velocity of a fluid suddenly changes and becomes
unsteady or transient. Fluctuations in the fluid’s velocity are generated by restrictions like a
pump starting/stopping, a valve opening/closing, or a reduction in line size. Hydraulic surges
can be generated within a matter of seconds anywhere that the fluid velocity changes and
can travel through a pipeline at very high rate of speed, damaging equipment or causing
piping failures from overpressurizing. Surge relief systems absorb and limit high-pressure
surges, preventing the pressure surge from traveling through the hydraulic system. Methods
for controlling hydraulic surges include utilizing a gas-loaded surge relief valve, spring-
loaded pressure safety valves, pilot-operated valves, surge suppressors, and rupture disks.
Typical applications
Surge control products have been used in many industries to protect the maximum working
pressure of hydraulic system for decades. Typical applications for surge relief equipment is
in pipelines at pump stations, receiving manifolds at storage facilities, back pressure control,
marine loading/off loading, site specific applications where pressure surges are generated
by the automation system, or any location deemed critical by an engineering firm
performing a surge analysis.
Surge suppressors
Surge suppressors perform surge relief by acting as a pulsation dampener. Most suppressors
have a metal tank with an internal elastic bladder in it. Within the tank they pressurize the
top of the bladder with a compressed gas while the product comes in the bottom of the
pressure vessel. The gas in the bladder is supplying the system with its set point. During
normal operation, as the process conditions begins to build pressure; the internal bladder
contracts from the pressure gain allowing liquid to move into the surge suppressor pressure
vessel adding volume to the location. This increase in physical volume prevents the pressure
from rising to dangerous levels.
Advantages:
Rupture discs
A rupture disc, also known as a burst disc, bursting disc, or burst diaphragm, is a onetime
use, non-reclosing pressure relief device that, in most uses, protects a pressure vessel,
equipment or system from over pressurization or potentially damaging vacuum conditions.
A rupture disc is a sacrificial part because it has a one-time-use membrane that fails at a
predetermined differential pressure, either positive or vacuum. The membrane is usually
made out of metal, but nearly any material can be used to suit a particular application.
Rupture discs provide instant response (within milliseconds) to an increase or decrease in
system pressure, but once the disc has ruptured it will not reseal. Due to the one time usage
of this disc it requires someone to replace the plate once it has ruptured. One time usage
devices are initially cost effective, but can become time consuming and labor-intensive to
repeatedly change out.
Advantages:
1) Isolates equipment from the process conditions, protecting the equipment until it is
needed for a surge relief event.
2) Cost effective installation.
3) Very fast response time.
Disadvantages:
1) Fast speed of response with soft closure to prevent generating a second surge event.
2) Can be used on high viscosity products such as crude oil.
3) Good flow characteristics (Cv)
4) No blowdown, reseats at the set point.
Disadvantages:
1) There are many types of rubber elastomers for many different types of products.
2) Fast speed of response when the rubber boot isn’t cold.
3) Achieves positive seal even when there is minor particulate in the line.
Disadvantages:
1) Rubber boot is greatly affected by temperature, the lower the temperature the less
repeatable the relief valve set point.
2) Poor flow characteristics (Low Cv) require larger valves to achieve the desired flow
rates.
3) Replacing the rubber boot requires the valve be removed from the line to be
disassembled.
4) Current generation valves have metal internals and do not use older generation
Rubber Boot.