Introduction
We developed a steady-state hydraulic model reflecting real-world pipeline conditions and simulated critical surge scenarios using PIPENET Vision. Pressure transients were evaluated against design limits, and where required, mitigation strategies like optimized valve operations and surge protection devices were recommended, ensuring all solutions were practical, compliant, and aligned with site conditions
Key Observations Across Projects
- Pipeline Integrity: Most pipelines demonstrated resilience against surge pressures under normal and upset operating conditions, with minor operational adjustments required in some cases.
- Minimal Cavitation Risk: Vapor cavitation volumes were found to be negligible relative to system volumes, mitigating concerns around vapor collapse damage.
- Surge Mitigation Adequacy: In cases where mitigation was necessary, simple operational changes such as increased valve closure times or immediate pump tripping were sufficient to bring surge pressures within safe limits.
- Design Robustness: The initial design philosophies adopted at these terminals contributed significantly to the systems’ ability to withstand transient surges without extensive retrofitting.
These findings reinforced the importance of early surge analysis during design and the value of periodic reassessment during operational life cycles.
Conclusion
At iFluids Engineering, we believe that proactive surge analysis is not merely a regulatory requirement, it is a critical element of operational excellence, asset longevity, and environmental stewardship. Our experience across diverse pipeline systems positions us uniquely to support clients in safeguarding their infrastructure while optimizing performance.
Partner with iFluids Engineering to ensure your pipeline systems are surge resilient, safe, and future-ready.
Project-Specific Insights
Surge Analysis at IOCL Rajahmundry Terminal – Petroleum Product Pipelines
At Rajahmundry Terminal, the focus was on the Motor Spirit (MS) and High-Speed Diesel (HSD) pipelines responsible for product receipt into the terminal. The surge analysis revealed that, under sudden closure scenarios involving critical valves such as the Receipt Tank inlet DBBV and the IOCL Exchange Pit inlet Manually operated valve (MOV), transient pressures exceeded 110% of Maximum Allowable Operating Pressure (MAOP) thresholds.
To address these surge risks, we recommended operational strategies including extending valve closure times to 40 seconds for specific MOVs and Double Block and Bleed Valve (DBBV) and initiating immediate pump trips aligned with valve closure sequences. The implementation of these measures effectively controlled surge pressures, ensuring that pipeline operating pressures remained within the allowable limits. This project highlighted the importance of precise coordination between valve actuation and pump operations in managing surge phenomena within complex Petroleum product pipeline.
Surge Analysis at HPCL Irumpanam Terminal – BPCL to HPCL Transfer Pipelines as per ASME B31.4
The Irumpanam Terminal project involved surge analysis for product receipt pipelines transferring Motor Spirit and High-Speed Diesel from BPCL to HPCL tanks over a distance of approximately 2.4 km. Simulation of multiple transient scenarios indicated that all observed peak surge pressures remained within the piping design pressure of 15 kg/cm²G, thereby eliminating the need for additional surge mitigation hardware.
Complementing the surge analysis, a detailed mechanical stress assessment was carried out to validate the pipelines compliance with ASME B31.4 standards. The analysis confirmed that sustained, occasional, and displacement stresses under surge loading conditions were within permissible limits, affirming the mechanical robustness of the pipelines. The Irumpanam project demonstrated the effectiveness of well-engineered initial designs in mitigating surge risks even under worst-case operational transients.
Surge Analysis at IOCL Navagam Terminal – Station Piping for WRPL
The Navagam Terminal presented a more dynamic environment, where station piping associated with the IOCL Western Region Pipeline (WRPL) system required detailed surge assessment. The study found that for standard operational flow rates (up to 490 m³/hr), surge pressures following valve closures and emergency shutdown events remained within allowable design margins.
However, as flow rates approached and exceeded the Maximum Allowable Operating Pressure (MAOP) the downstream transient pressures occasionally exceeded 110% of the MAOP following sudden closures of Remotely Operated Shutoff Valves (ROSOV). Recognizing this operational vulnerability, we proposed mitigation strategies including flow rate management, evaluation of larger line sizes, and enhancement of surge protection infrastructure through additional SRVs or surge accumulators.
This project underscored the critical importance of dynamic surge evaluations based on variable operating conditions and the proactive adjustment of operational practices to maintain safe pipeline performance.