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Surge and Stress Analysis of Product Pipeline and Storage Tanks at HPCL, Kolkata Terminal

Railway siding completed at Kolkata Terminal-II, Budge Budge unloads the products (ATF, HSD, MS) at Kolkata Terminal-II, HPCL. The products are then pumped to Kolkata Terminal-I via 14” diameter pipelines (3 nos.) through the KoPT jetty area and stored in the respective storage tanks.

The scope of the project consists of performing Surge and stress analysis of HSD, MS & ATF Product pipeline between Terminal-II and Storage tanks of Terminal-I.

The study objectives were as follows:

  1. Study Basis for the project:

Basis for the simulations and analysis such as Battery limit, Fluid properties, valve properties, pipeline material data, pump details etc. were recorded in the Study basis document. The assumptions and basis were confirmed with the client prior to modelling.

  1. Steady state simulation:

Steady state modeling and simulation of the pipeline system (HSD, MS & ATF) was performed to estimate the pressure profile across the pipeline length and confirm the operating flow rate.

  1. Transient state simulation:

Transient state modeling and simulation of the pipeline system (HSD, MS & ATF) was performed to estimate the Surge pressure in product pipelines occurring during transportation of product from terminal-I in the case of sudden valve closure and pump trip.

  1. Surge Analysis:

Based on peak surge pressure and low pressure, mitigating measures were recommended wherever required to reduce the peak surge pressure and its effect on the facility.

  1. Stress modeling:

Stress modelling of the pipeline was performed to confirm pipe support integrity and to ensure that the piping system is flexible and the pipe stresses are within the allowable limits for assumed loading cases (Hydro, Operation, Occasional, Sustain and Thermal).

  1. Stress Analysis:

Based on calculated stress and maximum frequency generated, the requirement of supports for the aboveground portion and requirement of thrust blocks for the underground portions to place the anchors were recommended wherever required.

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