Water hammer Can it happen in my plant?

Stuart C. Ord

Consequences

Do we need to protect against it?

YES !
How to predict it and prevent it damaging pipelines and equipment

What is it?
Shock
A

waves caused by rapid

deceleration of liquid flow mechanism for loss:

Rupture of pipes and vessels
Cost, personal safety

Destruction of pipe supports, pipe bridges

Domino effect

Contamination of fluid and/or environment Chronic effects

Where does it occur?

In

any pipe carrying fluid subject to rapid changes in flow rate

Any length Any diameter Any fluid contents Any pipe material

Where is it a problem?
Where flowrate changes rapidly Obvious causes e.g. valves, pumps Less obvious causes e.g. cavitation, ROs Where Where

pipes are long

there are significant elevation changes

Why does it occur?

A) Valve open

Liquid flowing steadily

Pipe support

Why does it occur?

B) Valve closes suddenly

Shock wave Liquid flowing steadily

E-15

Liquid stationary

Valve experiences a large force

Why does it occur?

C) A time later

Shock wave Liquid flowing steadily

E-23

Liquid stationary

Pipe support experiences large force

Consequences: High pressure

Joukowski equation:

Limiting

closure time:

dP = v * c * r

t=2*L c
L = length of pipe, m t = pipeline period, s

c = speed of the sound wave in the pipe, known as the wave celeric, m/s V = initial flow velocity of the liquid, m/s r = fluid density

Consequences: High force

Simple

equation for force caused by passing pressure wave:

F = A * dP
A = pipe cross-sectional area F = force, N dP = Joukowski pressure rise

Flexible structures
Dynamic load factor Force reduced to zero for flexible structures Force doubled for rigid structures

F = A * dP * DLF

Wave celeric
C0 C Kd 1 Ee

Downstream of valves
Liquid is slowed by pressure falling Limited scope before cavitation occurs Often the fluid can return to collapse the cavity If so, severe water hammer can be expected
High pressure Low pressure Liquid flowing steadily

Liquid stationary Closed valve (or tripped pump)

Cavity growing (vacuum)

High points
More

problems from cavities

Cavities can form without the help of water hammer Decelerating fluid makes them more likely

Barometric leg

Vapour cavity

Pump tripped

Venting gases
Unstable

flow as gas is flushed out Unusual case of restrictor orifice A) Just before the strike

Liquid flowing quickly

Air

E-39

Restrictor - orifice

Non-return valves
Uncontrolled,

positive feedback closure!

Reverse flow after pump trip Slams shut

E-48

Valve characteristics
Valves

do not change flow in proportion to their position!

Some
Exact

valves are very non-linear

behaviour depends on system as well as valve characteristics

Valve characteristics

Danger signs
Long Long

pipes with isolation valves pipes with pumps changes in elevation

Large

How to avoid water hammer

velocities Elastic pipes Good valve performance

Low

Slow operation Good characteristics

Pump

inertia - flywheels

Minimisation and mitigation

Control

devices

Surge tanks / accumulators Correctly designed non-return valves Pressure relief valves

Stronger

pipes

Surge tank

Medium and large bladder dampers

Non-return valves good and poor

A wider range of types, classified by suitability for application in different deceleration environments.

Complex spring loaded ones give the most reliable closure at minimum flow whilst giving reasonable forward flow resistance

Non-return valves

Flywheels
Flywheels can be highly reliable Weak link between flywheel and motor Less expensive than large accumulator Especially if expensive material of construction

Flywheels

Flywheels

Analysis of surge problems

Complex

situations

Flowmaster Wanda Hammer Fathom Pipenet

Analysis of surge problems

Simpler

situations
(Istec Ingenieria, Uruguay)

Hytrans Hytran

(Hytran Solutions, New Zealand)

Spreadsheet

(www.CEDCS.com)

Flowmaster - setup

Flowmaster - results

Hytrans - setup

Hytrans results

Spreadsheet

Results
Flowmaster

Excellent graphics of max / min values Hytrans Graphs of values vs time, mix & match Simpler graphics of max / min values Cavity formation (requires care) Graphs of pressure & flow vs time, animated

Warns of cavities

Spreadsheet

Indicative only

Interpretation of results
Pressure limits Examination of max / min values

Force limits Examination of pressure / time history

Sudden changes High rates of change

Processing by spreadsheet

COMAH

Criterion 5.2.1.6 The safety report should show that all foreseeable direct causes of major accidents have been taken into account in the design of the installation Vibration Vibration generated .... may be caused by changes in phase, water hammer, high pressure drop or cavitation....., poor piping design, etc.. .... may induce fatigue failure of the containment. The safety report should show how vibration has been assessed, and any potential problems addressed.

COMAH

Update the safety report every five years or after significant changes or new knowledge about safety matters The safety report needs to be kept up to date. If there are any modifications to the plant or the way it is operated or if new facts or information become available, the safety report must be reviewed and, if necessary, revised at the time. It must be reviewed after five years even if there have not been any changes.

Conclusions
It

is necessary to know enough to spot the danger signs Solutions to problems can be simple Ignoring the problem can lead to disaster Analysing for potential problems and correct solutions can be legally mandatory Complex high risk situations need expert modelling and design solutions

Data requirements

Can it happen in my plant? Do I need to protect against it?

We

YES !

know what causes it We can predict it We can prevent it damaging pipelines and equipment
Stuart Ord www.CEDCS.com

Demonstration links

Link to simple calculator

(Has useful demo problem)

Link to force analysis demo data Link to force analysis real data

Link to HiTrans >>>

(Doesnt operate from Slideshow)

Demo model

Valve Closing time varies

100m level Water 20C

500m long 0.2m dia Steel Celeric=1000m/s

500m long 0.2m dia Steel Celeric=1000m/s

20m level