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Related terms:
Equivalent Mud Weight, Gel Strength, Pressure Loss, Swab Pressure, Drillpipe, Mud
Weight, Operating Pressure, Wellbore
Leaks
Trevor Kletz, in What Went Wrong? (Fifth Edition), 2009
• The steam main went down through a tunnel under a road, rose up on the
other side, and was joined by another supply line (see Figure 34-2).Figure 34-2.
Condensate filled the dip in the steam main and overflowed into the horizontal
section on the right, condensing a steam bubble. The resultant water hammer
ruptured the main.
• Following flooding, someone entered the tunnel to inspect the insulation. As
the steam trap in the tunnel was blowing, it was isolated before entry was
allowed but was not reopened afterward.
• The steam supply valve located before the tunnel was reached, as well as the
valve on the other supply line, were both closed and both were passing. The
leak in the first valve filled the dip in the main with condensate and the leak in
the other valve maintained a steam bubble in the higher part of the main.
•
Ultimately, the cold condensate completely filled the dip and overflowed into
the horizontal part of the main, causing the steam bubble to condense. The
resultant surge pressure ruptured the main at a T-joint, the weakest part.
Afterward, the company trained more than 700 employees on the operation of
steam systems. Consultants surveyed the steam system, including 3,000 traps. More
than 100 were repaired or replaced, and a better system for their inspection and
maintenance was set up. However, many other steam mains have also failed due to
water hammer. The hazard is well known and has often been described, for example,
in the booklet Hazards of Steam, first published by Amoco in 1963 and revised by
BP in 2004 [9]. A similar incident had occurred in the same power station 25 years
earlier. Why did the company not learn from its own and others' experience?
The report [6] does not provide this information, but one can hope that the com-
pany improved its procedures for reinstating equipment after isolation for entry or
maintenance.
Cementing hydraulics
Boyun Guo, in Applied Well Cementing Engineering, 2021
(6.65)
where
ve = the effective annular velocity, ft/s or m/s
vf = fluid velocity, ft/s or m/s
vp = pipe upward velocity, ft/s or m/s
(6.66)
where
(6.67)
For closed-end pipes such as casing string with float shoe, the fluid velocity can be
calculated by
(6.68)
(6.69)
Calculate the surge pressure generated by a 10 ¾ in. casing string under the
following conditions, and predict whether the total borehole pressure will exceed
the formation fracture gradient. Assume that the casing is effectively “closed” with
a float shoe and laminar flow in the annulus.Casing depth:6400 ft (1951 m) TVDFracture
gradient:0.82 psi/ftHole diameter:14 ¾ in.Average fluid weight:15.5 ppgPlastic viscosity:37 cPYield
point:6 lb/100 ft2Pipe velocity:− 110 ft/min (the negative sign denotes downward velocity)
Solution
Therefore the borehole will be safe during downward motion of the casing.
borehole pressure will be lower than the formation pore gradient. Assume that the
casing is fully opened and laminar flow in the annulus.Casing depth:6400 ft (1951 m)Pore
pressure gradient:0.78 psi/ftHole diameter:14 3/4 in.Average fluid weight:15.5 ppgPlastic viscosi-
ty:37 cPYield point:6 lb/100 ft2Pipe velocity:110 ft/min
Solution
Therefore the borehole will be safe during the movement of casing string.
Liquids—Hydraulics
In Pipeline Rules of Thumb Handbook (Eighth Edition), 2014
where:
Example
An 8.625-in. × 0.250-in. w.t. products pipeline transports kerosene at 4.5 fps. The
weight of the kerosene is 51.12 lb./ft3, and the API gravity is 41.1 (rel. density =-
0.8198). K = 171,000 psi.
Using the full equation, P = 178 psi; the difference is approximately 3%.
where
As an example, assume a rapid closing check valve closes at 36 in. (OD = 0.375) in wall
thickness pipe with water velocity of 4 fps (k = 294,000 psi), E = 29,000,000 psi, and
W = 62.4 lb/cu ft. Determine the instantaneous pressure rise above the operating
pressure. Substituting into the equation
The pressure rise acting at the closed valve in the piping system can exert a force
equal to pressure times the cross-sectional area of the pipe or about 175,665 pound,
which can cause an unrestrained pipe to move from its normal position.
Event Descriptions
On–off valve: Quick closure •Quick closure of valve causes pressure
rise that is at least higher than Joukows-
ki’s pressure given by Eq. (5.12) if effective
stroke time of the valve is less than the
pipeline period of 2 · L/c•The pressure
rise is proportional to the initial fluid ve-
locity•Ship loading lines with quick-re-
lease coupler valve is the typical example
for the study
On–off valve: Quick opening •Quick opening of valve causes severe
pressure rise if there is a vapor cavity
downstream of the valve. Sudden open-
ing of the valve pressurizes the vapor
cavity and collapses it leading to severe
pressure rise•Such situations are likely to
occur at the stage of priming and re-start
of plant facilities
Pump station: Power failure •Power failure of motor or turbine dri-
ver causes sudden reduction of discharge
pressure, and causes column separation
if the pressure reduces below the vapor
pressure•Subsequent rejoining pressure
rise due to backpressure occurs when the
vapor column instantly closes or collapses
Pump station: Start-up •Sudden increase of discharge flow and
pressure due to pump start-up some-
times causes collapse of downstream
vapor cavities•Inappropriate air release
from air valves at downstream high point
also causes severe pressure rise
Check valve: Reverse flow •In pump station, power failure induces
sudden closure of discharge check valve
due to reverse flow. This causes a large
shock force on the check valve, pipe sup-
port, and pump nozzle•If pumps are in
parallel operation and one pump trips,
downstream high pressure causes large
reverse flow until the check valve clos-
es•The shock force is proportional to the
reverse flow velocity•Dynamic character-
istics determine the reverse velocity, and
should be considered for the selection of
the check valve
Lift-type safety valve: Blow-down •In liquid systems, long lead line from
branch point to safety valve sometimes
causes large pressure oscillation [131]
and structural vibration when the safety
valve blows•If the valve with long lead line
installed at discharge of the pump having
droopy head-flow characteristics and the
set point of the valve is near the discharge
pressure, such a possibility becomes high
Various design codes and standards specify the limitation on surge pressure in
a piping system. Since pressure surge is categorized as an occasional load, the
allowable surge pressure is normally greater than the design pressure of the system.
For example, ASME/ANSI B31.3 for the chemical and petrochemical plant piping
systems specifies a maximum allowable surge pressure of 1.33 times the design
pressure of the system. For long-distance pipelines, ASME/ANSI B31.4 specifies 1.1
times the design pressure. It should be noted that each code and standard has a
unique definition of the allowable stress, which leads to different definitions of
the allowable surge pressure.
Table 5.14 shows typical data necessary for surge analysis of a piping system. Initial
pressure and flow balance are first determined based on the boundary conditions
before transient analysis can be implemented.
Item Contents
Piping data Configuration of pipe network; pipe lengths;
outside diameter and wall thickness; elevation;
Young’s modulus of pipe material; pipe friction
factor; design pressure
Control valve data Cv-valve opening curve, stroke speed, closing
time
Check valve data Maximum Cv, dynamic characteristics (decelera-
tion versus reverse velocity)
Pump data Head-flow characteristic curve; torque-flow char-
acteristic curve; rated and operation conditions
(flow, head, speed, torque); rotational inertia
(GD2); starting torque curve of driver; design
pressure of case
Tank data Inside diameter, liquid surface level, gas pressure
at liquid surface, gas volume and polytropic ex-
ponent in case of closed-type tank
Fluid properties Bulk modulus, density, viscosity, vapor pressure,
void fraction of dissolving gas
Process data Initial pressure and flow balance
Transportation Pipelines
Alireza Bahadori PhD, CEng, MIChemE, CPEng, MIEAust, RPEQ, in Oil and Gas
Pipelines and Piping Systems, 2017
Fig. 15.10. Key problems and issues that result with a too high or too low equivalent
mud weight (EMW).
Planning Problems
• Inaccurate predrill pore pressure and EMW predictive estimates (Fig. 15.10)
• Unexpected factures/faults
Operational Problems
• Lack of appreciation of all EMW cause and effects
• Barite sag
• Swabbed gas
Planning Problems
Operational Problems
• Faults
• Depleted reservoirs
12.11.1 Requirements
The transfer system shall incorporate a means for rapidly and positively stopping
the flow in an emergency. Transfer systems shall be designed to prevent dangerous
surge pressures when the flow in either direction is stopped.
Transfer pumps may be centrifugal, reciprocating, gear, or another type designed for
handling LPG. The design pressure and construction material of the pumps shall be
capable of safely withstanding the maximum pressure that could be developed by
the product, the transfer equipment, or both.
Compressors used for liquid transfer normally shall take suction from the vapor
space of the container being filled and discharge into the vapor space of the storage
vessel from which the withdrawal is being made.
There are two forms of transient pressures: the generation and transmission of
pressure waves in a closed pipe system due to the compression and elasticity of the
fluid, and mass oscillation where the whole water column moves between two open
surfaces as illustrated by the U-tube experiment in school physics. The first type of
event is potentially the more damaging but the designer needs to be aware of both
possibilities. It must be stressed that the analysis of surge pressures and the design
of remedial works is a specialist area of work and if it is considered that there could
be a problem with surge then expert advice should be sought.
Secondary pressure waves are generated as the initial wave passes any fitting or
change to the pipeline, such as an enlargement or tee, but when a pressure wave
reaches the closed end of a pipeline (such as a shut control valve at entry into a
reservoir) it is reflected as a wave of the same type, that is, a positive wave is reflected
as a positive wave, a negative wave as a negative one. Conversely, a pressure wave
reaching an open end to a pipeline discharging to a reservoir or tank is reflected as a
wave of the opposite type. Even in a relatively simple system, therefore, the pattern of
secondary and reflected waves can become complicated. Wave amplitude is damped
by friction and pipe wall elastic losses so it is often the passage of the initial pressure
wave which gives rise to the most critical pressures. However, this is not always the
case as secondary and reflected waves can interact positively and may cause air or
check valves to shut suddenly, so generating further high pressures. Similarly, if the
pressure falls low enough, vacuum cavities may form, which may also cause high
shock pressures when they subsequently collapse on a rising pressure. The analysis
of transient conditions can thus be very complicated and the results depend not only
on the elements of the system, but also on the profile of the pipelines. Although
methods have been developed in the past for hand or graphical computations,
computer programs are now used almost universally to analyse transient conditions.
The main concern with transient pressures is that they should not be high enough
to cause bursting of the pipes or fittings. To put the potential for damage into
perspective, it is worth noting that the rise in pressure head, known as the Joukowsky
head after the scientist who first developed the theory, on a sudden change of velocity
ΔV in a pipeline, is given by a.ΔV/g, where a is the velocity of wave propagation and
g is the acceleration due to gravity. In a ductile iron pipeline the wave speed may be
as much as 1200 m/s although it is normally between about 900 and 600 m/s as a
result of small quantities of air present in the water. With this high value for the wave
speed, the slamming of a valve in a pipeline operating at a velocity of 1.5 m/s could
lead to a pressure rise of 180 m. Even with a wave speed of 600 m/s the pressure rise
would be 90 m. Such surge pressures undoubtedly occur, but are often not recorded
to the full extent by the ordinary Bourdon pressure gauge which is too ‘sluggish’ in
operation to record the peak transient pressure.
Codes of practice for most pipe materials allow some transient overstressing above
the allowable operating pressure (defined as the internal pressure, exclusive of
surge, that a component can safely withstand in permanent service). However, other
elements of the system including valves and jointing systems and the resistance
of thrust blocks should be considered, particularly if an existing system is being
uprated.
In potable water systems it is normal practice to avoid any negative pressures and
consequent risk of contamination being drawn in through open air valves or through
joints designed primarily to prevent leakage from high internal pressure. In addition,
large diameter, thin-walled, pipes may collapse if negative pressures fall enough
to induce buckling (Section 17.8) and certain plastic materials, particularly PVC-U,
may suffer from fatigue failure if there are repeated excessive transient pressure
fluctuations above a certain magnitude over the life of the system.
In the majority of systems the most likely causes of transient pressures are rapid
valve closure and pump stoppage. Rapid valve closure can be controlled; it is always
advisable to ensure that valves cannot be slammed shut and have a closure time
long enough to limit the pressure rise to acceptable values. The minimum time of
closure should, at least, be greater than the time it takes for the pressure wave to be
reflected back to the valve from the far end of the line, 2L/a, where L is the length
of the pipeline and a is the wave speed as defined above. A longer closure time, or
closure that allows the last 10–20% of the valve open area to be much slower than
over the first 80%, may be required (Fig. 18.1). However, the most critical case for
surge in a system is usually a power failure causing simultaneous stopping of all the
pumps. Most modern low-inertia pumps stop producing forward flow of water in a
few seconds when turned off, so they effectively stop almost instantaneously. Thus
the problem of low pressures being transmitted through the system has become
more severe. One solution is to add a fly wheel to increase the pump inertia but this
goes against the trend for lighter and smaller pumps with reduced motor starting
currents and may give rise to problems with bearings and drive shafts.
Once the potential problems are identified, it is necessary to consider their allevia-
tion. It is rarely economic to increase the strength of a pipeline solely to cope with
surge pressures so it is usually necessary to provide some other form of protection
for the system. There are a number of protective measures that can be adopted as
listed below (Thorley, 2004). An indication of suitable locations for installation of
some of the devices mentioned is shown in Figure 15.10.
Figure 15.10. Pipeline profile with locations for installation of surge protection
devices.
2. Increased pump inertia. Fly-wheels fitted to the pumps reduce the rate of
deceleration of the pump and the corresponding rate of change of flow. In
the right circumstances these can be the most effective and robust form of
protection but there may be issues with modern pumps as noted above. If
proposed, their use must be discussed with the pump manufacturers.
3. Air vessels (also referred to as ‘surge vessels’) which comprise pressure vessels
connected directly to the pipeline, part of their volume being occupied by
compressed air. They are commonly used to feed water into the pipeline when
the pumps stop but they also provide a cushion to absorb high pressures on
the returning wave and on pump start up. Air is gradually absorbed into the
water and compressor facilities are required to provide occasional topping up
of air in the vessel. For this reason they are generally installed only at pumping
stations. The absorbed air can find its way into the pipeline and come out of
solution as pressure falls (Section 15.10).
4. Accumulators are similar to air vessels except that the air is separated from the
water in the vessel by a flexible rubber membrane thus greatly reducing the
loss of air by absorption. This eliminates the need for compressor facilities and
allows the use of a gas such as nitrogen in place of air, topped up periodically
from a portable cylinder.
5. Surge shafts (open-topped shafts connected directly to the line) can be con-
structed, if the topography permits, but they must extend above the hydraulic
grade line. They should only be used on potable water systems where the
ventilation facilities are designed to eliminate the risk of infiltration or airborne
contamination, such as those fitted to potable water storage tanks. Such
ventilation facilities must be designed to cope with the air flow appropriate to6.
the maximum rate of change of volume in the shaft during a transient event.
Feed tanks operate by feeding water into the line to relieve low pressures. They7.
can be located at high points below the hydraulic grade line as they are isolated
by non-return valves which only allow flow into the pipeline. Again the issue
of potential contamination must be addressed. There may also be an issue of
water quality if the feed tank is not called upon to operate regularly and there
is no turnover of the stored water.
Air valves of the large orifice type may be used to prevent low pressures in 8.
the line by opening to admit air when the pressure falls below atmospheric.
Their use for this purpose is not generally permitted on potable water schemes
because of the risk of contamination as mentioned above. There are potential
drawbacks including the generation of high shock pressure on slamming,
unless special non-slam valves are used.
Pressure relief valves can be set to open at a given pressure or operate in 9.
response to an initiating event thus limiting the maximum pressures at their
location.
Bypass pipework can be fitted around the pumps to allow water to be drawn 10.
from the sump provided the pressure on the delivery side falls low enough.
However, this may be insufficient to prevent other low pressure problems
occurring down the line on a simple system, but they may be effective at
booster stations where the pressure on the suction side of the pumps rises
significantly on pump stoppage.
Non-return check valves can be used along a pipeline to reduce the effect of the
returning positive pressure or water column, but they may give rise to adverse
effects themselves so must be analysed carefully and used with care.
Pump delivery non-return valves need to be suitable for the system and its transient
response, especially if a surge vessel is also provided because the flow in the con-
necting pipe to the air vessel may reverse very quickly. Ideally, the non-return valve
should shut at the moment of flow reversal but if it reacts more slowly the reversed
flow may slam the valve shut with the generation of a high shock pressure (Section
18.18). The dynamic response of the non-return valves should thus be matched to
the transient characteristics of the pipeline system.
Surge protection system design must also take account of long-term performance;
operations staff may be aware of the need to maintain surge equipment when the
station is new but after 20 years, and after several changes of staff, the importance of
components such as air valves may be forgotten. The approach should be for robust
solutions in most cases and particularly for systems in remote locations.