Engineering Procedure

SAEP-27 19 July 2009

Pipelines/Piping Hydraulic Surge Analysis
Document Responsibility: Process and Control Systems Dept.

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations…………………….... 2
3 Applicable Documents................................... 2
4 Definitions...................................................... 4
5 Instructions.................................................... 5
6 Responsibilities............................................ 11

Exhibits............................................................... 12

Previous Issue: New Next Planned Update: 19 July 2014

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Primary contact: Rasheed, Mahmood Ayish on 966-3-8730674

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

1 Scope

This Saudi Aramco Engineering Procedure (SAEP) provides technical guidance to

define full scope of hydraulic surge analysis during DBSP, Project Proposal, Detailed
Design and throughout the different stages of a project cycle and throughout the
operational life of a pipeline to ensure consistent approach. It provides Saudi Aramco
engineers and engineering design contractors with guidelines describing the
requirements to conduct and review pipelines hydraulic surge analysis studies for
existing and new facilities.

2 Conflicts and Deviations

2.1 Any conflicts between this standard and other applicable Saudi Aramco
Engineering Standards (SAESs) or industry standards, codes, and forms shall be
resolved in writing through the Manager, Process & Control Systems Department
of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this standard in writing to the Company, who
shall follow internal company procedure SAEP-302 and forward such requests to
the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

3 Applicable Documents

To ensure compliance with the appropriate Saudi Aramco and International Standards
and Codes for over pressure protection of pipelines, the following Engineering
Standards shall be reviewed in conjunction with hydraulic surge analysis studies. These
Standards encompass hydraulic analysis, surge analysis, over pressure protection of
pipelines, design pressure, materials, operating conditions, Maximum Allowable
Operating Pressures and Maximum Allowable Surge Pressures.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-12 Project Execution Plan
SAEP-14 Project Proposal
SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering
Requirement
SAEP-303 Engineering Reviews of Project Proposal and
Detail Design Documentation

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

SAEP-354 High Integrity Protective Systems Design

Requirements
SAEP-363 Pipeline Simulation Model Development and
Support

Saudi Aramco Engineering Standards

SAES-B-017 Fire Water System Design
SAES-B-058 Emergency Shutdown, Isolation, and Depressuring
SAES-B-060 Fire Protection for Piers, Wharves and Sea
Islands
SAES-B-064 Onshore and Nearshore Pipeline Safety
SAES-B-070 Fire and Safety Requirements for Bulk Plants
SAES-J-600 Pressure Relief Devices
SAES-J-601 Emergency Shutdown and Isolation Systems
SAES-J-605 Surge Relief Protection Systems
SAES-J-700 Control Valves
SAES-L-100 Applicable Codes and Standards for Pressure
Piping Systems
SAES-L-132 Material Selection of Piping Systems
SAES-L-310 Design of Plant Piping
SAES-L-410 Design of Pipelines

Saudi Aramco Engineering Reports

SAER-5437 Guidelines for Conducting HAZOP Studies
SAER-6043 High Integrity Protection System (HIPS)
Evaluation Team Report

3.2 International Standards and Codes

ANSI/ASME Code “Process Piping” Chemical plant and petroleum refinery

pipeline for in-plant piping

ANSI/ASME B16.5 Pipe Flanges and Flanged Fittings

ANSI/ASME B31.1 Power Piping
ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Pipeline
or In-Plant Piping

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

ANSI/ASME B31.4 Liquid Petroleum Transportation Piping Systems

for Cross-Country Liquid Pipelines
ANSI/ASME B31.8 Gas Transmission and Distribution Piping
Systems

American Petroleum Institute

API STD 521 Pressure-Relieving and Depressuring Systems

American Water Works Association

AWWA M45 American Water Works Association, Fiberglass
Pipe Design

National Fire Protection Association

NFPA 24 Installation of Private Fire Services Mains and
their Appurtenances
NFPA 25 Inspection, Testing and Maintenance of Water
based Fire Protection Systems

4 Definitions

Hydraulic Surge: Also referred to as “water hammer.” This is a phenomenon in

pipeline operations characterized by a sudden increase in internal pressure. Hydraulic
surge is often caused by the transformation of kinetic energy to potential energy as a
stream of fluid is suddenly stopped.

Surge Analysis: An engineering study that is undertaken to perform a hydraulic transient

analysis of a specific system through the use of specialized simulation software which
models the system, fluid and operating conditions. The transient analysis will predict the
time history of pressures and flows throughout a system as a result of potentially
applicable transient events. From the results, an experienced engineer/specialist can
determine whether additional surge protection is required, what form of surge protection
is most suitable, its capacity and where it should be located. The surge/transient analysis
referred to in this Standard is specific to pipelines/piping systems.

HAZOP (Hazard and Operability): A systematic, detailed analysis technique applied

to identify hazards and operability issues which have the potential to place the process
plant, environment or personnel at risk. The HAZOP study identifies abnormal process
deviations that may require additional protective functions. The HAZOP analysis shall
follow the guidelines of SAER-5437, Saudi Aramco HAZOP Engineering Report.

PHA (Preliminary Hazards Analysis): An initial screening exercise that can be used
to identify, describe, and rank major hazards. This technique can also be used to

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

identify possible consequences and likelihood of occurrence and provide

recommendations for hazard mitigation.

5 Instructions

5.1 General Requirements

5.1.1 PMT shall provide a copy of this Engineering Procedure to the

Engineering design contractor involved in conducting the hydraulic and
surge analysis study and a full comply to this procedure shall be notified
to the contractor.

5.1.2 Risk assessment studies such as PHA or HAZOP, if available, shall be

used as a basis for the surge analysis. The whole risk assessment (PHA
and HAZOP) shall be an exercise in which all concerned parties
(stakeholder organizations) are involved in sharing awareness and
responsibility for the decisions and assumptions made to commence the
surge analysis study. The risk assessment shall be conducted as defined
in SAEP-12, SAEP-14 and SAEP-303.

5.1.3 The engineering design contractor shall use the approved pipeline
simulation software that is defined in the Saudi Aramco Recommended
Simulation Software Vendor List. The approved list can be obtained
from P&CSD/Pipelines & Simulation Unit.

5.1.4 At the completion of the hydraulic surge studies, the engineering design
contractor shall submit an electronic copy of complete simulation models
and supporting documents to P&CSD/Pipelines & Simulation Unit, the
Proponent and FPD for review and approval.

5.2 Surge Analysis Preparation Procedures

The hydraulic surge analysis study shall be undertaken if over pressure or

transient risks to piping or pipelines are identified in the following phases of a
project or where changes to operating conditions are made including:
1) Conceptual and Feasibility studies have been completed, detailed engineering
design such as DBSP, Project Proposal and Detailed Design is in progress.
2) Prior to any change in existing pipeline operation or modification to the
pipeline system. If the maximum flow rates or maximum operating
pressures increased from the previous operation, a new surge analysis at the
new conditions to ensure that the pipeline system is protected.
3) Any change or equipment data update in the detailed design, final pipeline
design, at the last minute, or during construction works.

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

4) During commissioning and start up activities, especially for testing sections

of the pipeline system or if the tested system is different from the standard
design configuration.

The study shall not be limited to the mentioned transient risk situations and
P&CSD shall endorse the hydraulic surge analysis study timing.

Before the surge analysis commences, a technical specification for the surge
analysis study shall be prepared and approved by Proponent or SAPMT’s
engineering contractor to acknowledge the problem for further assessment,
scope development, and possible surge protection solution. The following list
shall be completed to define full scope of the surge analysis for pipelines to
ensure a consistent approach for all projects.

5.2.1 Analysis Objective

The objective of the analysis will determine the extent of the pipeline
system to be modeled and the accuracy of data required during pipeline
model development and evaluation. A clear surge analysis objective
shall be prepared and agreed with the pipeline hydraulic and surge
analysis specialist of P&CSD prior to conducting the analysis.

5.2.2 Pipeline System Scope

Hydraulic surge analysis shall not be limited by project scope of work.

The whole pipeline system needs to be analyzed and the model built for
hydraulic surge analysis shall include all the possible causes from within
or beyond project scope boundaries and interfaces with other related
facilities.

5.2.3 Possible Scenarios of Surge Analysis

The transient/surge flow conditions that are expected to occur shall be

defined. The analysis shall look at various possible causes, identify the
critical cases, specify and design the necessary surge protection system
as identified during the PHA, HAZOP and surge analysis studies.

Exhibit II shall be used as a checklist to identify potential causes of

transient pressure. As a minimum the following potential causes of
liquid piping overpressure shall be investigated:
a) Inadvertent closure of a pipeline Class-1 or Class-2 valve.
b) Closure of a downstream plant ESD valve.
c) Trip of intermediate pump.

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

d) Closure of one looped pipeline.

e) Closure of more than one looped pipeline.
f) Closure of isolation valves, inside interfacing, upstream and
downstream.
g) Closure or control failure of a pipeline or downstream control valve.
h) Inadvertent start of a standby pump, in addition to existing pump(s)
operation
i) Impact of new pipeline interfacing with existing pipeline

5.2.4 Data Requirements

The following list identifies data that shall be gathered before a surge
analysis study is conducted:
a) Pipeline system data: General description of the pipeline system,
function and a summary of the likely hazard scenarios as identified
in the PHA and HAZOP studies. Pipeline data including length,
elevation profile, diameter, wall thickness, roughness or friction
factor, elastic (Young’s) modulus, pressure rating, maximum
permissible pressure (pipes, components, joints, support), minimum
acceptable pressure (pipes, components, joints, supports).
b) Operating conditions: pipeline inlet pressure and temperature,
arrival pressure, maximum and minimum flow rates.
c) Fluid data: The key data required are the physical properties at the
relevant operating pressure and temperature for the evaluated
pipeline system. Physical properties include: density, viscosity, true
vapor pressure, bulk modulus, working temperature. Alternatively,
for compositional analysis, the fluid composition shall be defined.
d) Ambient conditions (summer/winter temperatures), thermal
conductivities for pipelines and soil and/or the overall heat transfer
coefficient between the pipeline and soil.
e) Pumps: Type, number, location, performance characteristics, with
operating curves and the following rated conditions: (head, flow,
speed, power and efficiency), Inertia of rotating elements (impeller,
motor and coupling)
f) Valves: Type, number, location, dynamic performance characteristic
(Cv curve), open/close time, pressure rating and maximum
permissible pressure. Additional data for pressure relief valves: set

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

pressures for opening and closing, time needed to open and close,
discharge pressure.
g) Tanks: Location, general layout, dimensions, maximum, minimum
and normal levels of the liquid surface, elevation relative to the
main pipeline, length and diameter of the connecting piping.
h) Bypass piping: Location, length, diameter, head loss.
i) Surge and transient event data: Time scale of valve and pumps
operation (Control Logic) and sequence of events to be investigated.
j) Units of measurements must be consistent.

5.2.5 Surge Analysis Methodology

1) The analysis shall be performed first without assuming the
intervention of any overpressure protection devices or equipments.
Refer to Exhibit II for a list of potential causes of a transient
pressure in a pipeline/piping system.
2) Additional analysis shall be performed where the introduction of
modifications to the system design are made to mitigate identified
overpressure conditions, e.g., trimming pump impellers, increasing
pipe wall thickness, removing or modifying the device causing the
excessive transient pressures, adding overpressure protection
equipment such as relief systems as specified in SAES-J-600 and
SAES-J-605 or HIPS as per Saudi Aramco Engineering Procedure
& Report SAEP-354 & SAER-6043.

Surge analysis shall ensure compliance with the appropriate Saudi

Aramco and International Standards and Codes ANSI/ASME B31.1,
ANSI/ASME B31.3, ANSI/ASME B31.4, ANSI/ASME B31.8, or
ANSI/ASME B16.5 for over pressure protection of pipelines and process
piping. For fire water and safety related systems, surge analysis shall
ensure compliance with the appropriate International Standards Codes
API STD 521, AWWA M45, NFPA 24 and NFPA 25.

Surge analysis studies shall be conducted assuming that process initiated

shutdown signals triggering pump trips, due to low suction and high
discharge pressure, successfully stop pumps. This is provided that such
signals originate from an ESD system and the signal loops and ESD
system meet the required Safety Integrity Level (SIL) assessment and
design requirements of SAES-J-601.

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

5.2.6 Pipeline Model Validation

When plant and pipeline operating data is available, the model shall be
validated against a set of operating data within the known constraints of,
1) accuracy of plant measurements, 2) tolerance and convergence
limitations within the simulator, and 3) the errors associated with
simplifying assumptions made during model development. Models shall
be validated also during project proposal and/or detailed design by
SAPMT’s engineering contractor.

Before the data can be applied to the model, it shall be necessary to

evaluate the quality of the measurements caused by faulty instruments.
If available, a software package shall be used to evaluate all elements of
the data. The software package shall reconcile the data to identify faulty
instruments and to eliminate or reduce measurements errors.

Following model validation, if it is determined that the model results are

not within acceptable limits, tuning of specific parameters may be
required to improve accuracy. Model parameters may only be changed,
following discussion and agreement with P&CSD. Typically, the
difference between pipeline model results and operating data can be less
than 2%. If the discrepancies are greater than 2%, the design contractor
shall submit explanations for the discrepancies to P&CSD and seek
approval to use the model for studies. This is covered by SAEP-363.

5.3 Documentation Requirements

A surge analysis specific sheet shall be developed per Exhibit I and submitted
for approval prior to performing surge analysis.

At the completion of the transient analysis studies, documentation shall be

developed containing, as a minimum requirement, the following sections:
a) An executive summary that shall include a brief description of the problem
under investigation, background, objective, proposed solution, tool used
and concluding remarks.
b) A system description of the pipeline and study objectives.
c) A description of the model including a detailed description of the
simulation software components being used.
d) A description of each scenario adopted for the study.
e) Operation Control Philosophy/Logic implemented in the simulation.
f) The methodology used to extract, reconcile, and filter the operating data.
g) Model drawings.

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

h) Tabulated results for each scenario.

i) Graphical results representing time plots and/or profile plots of critical
variables to support conclusions established for each scenario.

The following sections provide a detailed description of requirements for the

documentation.

5.3.1 Study Objective

Describe the purpose of the study and the role that simulation plays in
addressing that purpose. The objective of the simulation must be clearly
stated. The model shall be represented as a tool to help solve specific
problems or answer specific questions rather than as an end product. The
simulation package and version used to build the model shall be defined.

5.3.2 Work Scope

Describe the system under investigation. The level of detail, model

boundaries, sources of feed…etc. This can be accomplished by
referencing available documents. Major relevant system characteristics
should be summarized in the report that describes the simulation.

5.3.3 Study Assumptions

In order to understand the model and its limitations, all assumptions shall
be identified. Discuss the limitations of the model’s representation of the
actual system and the impact those limitations have on the results and
conclusions presented.

5.3.4 Property Package

Describe the thermodynamics packages that were utilized to define the

fluid properties. Flow, heat transfer and pressure drop correlations must
also be described.

5.3.5 System Drawings (PFD’s, P&ID’s and Model Sketches)

Provide the modeled system Process Flow Diagrams and Process

Instrumentation Diagrams. Also, provide the simulation schematic used
to build the model and compare the simulation model with the overview
and actual pipelines/process to highlight differences.

5.3.6 Model Results Analysis

Present the calibration criteria, procedure, and results. Describe the

source of the observed data to which model results are compared.

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Document Responsibility: Process and Control Systems Dept. SAEP-27
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Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

Explain the appropriateness of using these data for model comparisons

and the basis for any adjustments made to actual observations when
making the comparisons. It is important to report and use as many types
of data as possible for successful calibration of the model.

5.3.7 Results Analysis Profile and Trends

Provide results analysis in profiles (specific variables vs. length of

pipeline) and trends (specific variables vs. time) for all the evaluated
cases.

All the prepared document shall be submitted to P&CSD for review and
approval.

6 Responsibilities

P&CSD provides technical guidance for all hydraulic and surge analysis, or pipeline
control system studies during DBSP, Project Proposal, and Detailed Design phases of a
project. P&CSD proactively works with Proponent and SAPMT on pipeline design;
reviews all related pipelines studies and models; and provide guidance during each
design stage. It is P&CSD responsibility to approve and endorse the pipeline studies
and models.

SAPMT or proponent shall be responsible for obtaining approval for the surge analysis
technical specification (Exhibit I) from the appropriate organizations prior to
performing the analysis. If any changes are made to the system or its operating
conditions or procedures, the technical specification shall be revised.

It is the responsibility of Proponent and SAPMT to consider the implications of pipeline

transient risk assessment, if the project scope is changed or it is part of a phased
development.

Suppliers for pipeline and related components such as surge relief, rotating equipments
shall provide Saudi Aramco and the design contractor the required equation data for
conducting detailed surge analysis studies.

Revision Summary
19 July 2014 New Saudi Aramco Engineering Procedure.

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Document Responsibility: Process and Control Systems Dept. SAEP-27
Issue Date: 19 July 2014
Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

EXHIBITS

TABLE OF CONTENTS

EXHIBIT I Surge Analysis Technical Specification – Summary Sheet

EXHIBIT II List of Potential Causes of Transient Pressure in a Pipeline/Piping

System – Checklist

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Document Responsibility: Process and Control Systems Dept. SAEP-27
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Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

EXHIBIT I – Surge Analysis Technical Specification – Summary Sheet

The following sheet summarizes minimum surge analysis requirements for the pipeline system
specified. The analysis report that follows from this is only valid for the pipeline system as
defined. If any changes are made to the system or its operating conditions or procedures, the
report shall be reviewed.
____________________________________________________________________________
Project Name:

Scope:

Data Requirements: Data requirements as listed in Section 4.2 of the Procedure

Design and Operating Criteria:
Pipelines & Piping Design as per Saudi Aramco Engineering
Standards (SAES-L-100, SAES-L-132, SAES-L-310 and
SAES-L-410)
Fire and Safety related system design as per Saudi Aramco
Engineering Standards (SAES-B-017, SAES-B-060,
SAES-B-064 and SAES-B-070)

Design Constrains:
Maximum operating Pressure
Minimum operating Pressure
Maximum Flow Rate
Minimum Flow Rate
Other Parameters

Pipeline Transient Criteria:

Maximum Transient Pressure
Minimum permitted pressure
Other Parameters

Transient Pressure Causes and scenarios List of the causes to be investigated

Study Basic Assumptions

Recommended Surge Protection Systems This should be modified as required.

Operational Requirements Constrains that should be included in the operation

instruction manual

Date:
Specification completed by: ______________________

*Approved by:

Proponent Representative ______________________

P&CSD Representative ______________________

* P&CSD shall decide on the approval level

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Document Responsibility: Process and Control Systems Dept. SAEP-27
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Next Planned Update: 19 July 2014 Pipelines/Piping Hydraulic Surge Analysis

EXHIBIT II – List of Potential Causes of Transient Pressure in a Pipeline/Piping System

– Checklist
____________________________________________________________________________
Item No. Possible Causes
____________________________________________________________________________
1. Inadvertent closure of a pipeline Class-1 or Class-2 valve as per SAES-B-058.
2. Closure of a downstream plant ESD valve.
3. Trip of intermediate pump.
4. Closure of one looped pipeline.
5. Closure of more than one looped pipeline.
6. Closure of isolation valves, inside interfacing, upstream and downstream.
7. Closure or control failure of a pipeline or downstream control valve as per SAES-J-700.
8. Impact of new pipeline interfacing with existing pipeline.
9. Inadvertent start of a standby pump, in addition to existing pump(s) operation
10. The pipeline system start up and shutdown
11. The lineup of the pipeline is changed
12. The flow rate or capacity of the pipeline system increases/decreases
13. Changes are made to the original design of the system
14. Component (e.g., flow/pressure control valve, surge relief valve, etc.) malfunctions
15. Basic design data (flow rates, fluid properties, materials spec., etc,) are inaccurate
16. The surge protection system and control fail
17. Any other potential causes that a risk assessment (PHA & HAZOP) identifies

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