Protecting force mains with valves
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![Page 1: Protecting force mains with valves](https://reader033.fdocuments.us/reader033/viewer/2022052621/558506ded8b42ae71b8b53d5/html5/thumbnails/1.jpg)
HOW TO USE VALVES TOPROTECT FORCE MAINS
Brian GongolDJ Gongol & Associates, Inc.
January 28, 2015
Nebraska Snowball Conference
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Let's start with a beer keg
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If you pump a few times, you add pressure
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Pumping too much creates foamy beer
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Beer is relatively incompressible
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Releasing a little volume eases lots of pressure
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Water in a pressurized system: Same behavior
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Not zero like a solid (steel or concrete)
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But close
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Squirt guns and belly flops prove it
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Water is not like air in a storm door cushion
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But also unlike pushing on a pool cue
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Energy is transmitted quickly but not instantly
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Energy is conducted as a wave
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Surge is like a train starting or stopping
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Energy transmits through couplers
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Slam is the train sliding back downhill
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Blood pressure is a surge event
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Everyone with a dishwasher knows surge
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Driving while hauling tank of liquid
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Don't jam on gas or brake
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Operate smoothly
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Sudden starts/stops could drop a transmission
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Momentum/inertia matters
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Centrifugal pump from stop to 100%
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Like hitting gas pedal to floor
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Shock demand is hard on transmission
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Rotative speed isn't 100% instantaneously
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Pipe friction
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Fire hose/garden hose/flexible hose
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PVC pipe
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Ductile iron, copper, and other metal pipe
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More friction means more surge dissipation
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But also more headloss and energy use
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High efficiency trade-off with surge potential
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Magic number: 10 critical periods
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Cross-cancellation of wave action
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Surge moves at the speed of sound in water...
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...modified by pipe characteristics
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Published tables of surge wave speed ("a")
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"a" for plastic pipe is 900 fps (615 mph)
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"a" for ductile iron is 5,000 fps (3400 mph)
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Plastic expands and absorbs the wave energy
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Metal disspates less wave energy
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Surge mitigation techniques
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VFDs might help
But what part of the scaleis actually effective on surge?
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Depends upon static head
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Soft starters might help
But what about pump shutdown?
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What about power failure?
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Automatic pressure-control valves
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Air is also a problem
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Air release upon pipeline fill
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Dynamic operation to release air
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Vacuum-breaking upon pressure drop
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Air in solution in water: About 2%
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Air valves
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Air restricts pipe diameter
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Can be significant
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Air pockets will build
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Imagine trapping a tough balloon in the pipe
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Lots of compression possible...
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...but dangerous high pressure results
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Weight of a column of water
4" diameter, 500' long 43.55 cubic feet 325.75 gallons
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At 8.3 lbs per gallon: 2700 lbs. (a Honda Civic)
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You have to break that vacuum
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Pipe is not like a drinking straw
Something has to give eventually
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How it's harmful
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Long-term wear on pipes
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Main breaks
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Valve failures
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Backspinning pumps
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Pipe swings inside plant
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Leaks
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Contamination by negative-pressure events
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We've covered hydraulic problems (air/water)
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Upsurge and downsurge are hydraulic
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Slam is mechanical
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Slam comes from column reversal
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Slam and surge are independent
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Check valves are used for protection
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Prevent simple column reversal
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Ball check valves
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Weighted-flapper check valves
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Cushioned check valves
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Non-slam check valves
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Close fast enough to prevent slam
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Don't close too fast for pumps and systems
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Quick self-closure isn't actual slam
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Slam is involuntary seating of the valve
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Some valves can control both surge and slam
Checktronic Overcoming high head after bringing pump up to speed
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Illustrations
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Tank to closed valve
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Pump to closed valve
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Demo: Surge valve
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Demo: Sewage air-release valve
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Demo: Water air-release valve
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Demo: Wide-body air-release valve
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To recap
Pipes, valves, and equipment are endangered by three problems:
Hydraulic upsurge and downsurge
Hydraulic consequences of air
Mechanical slam
These problems can be resolved through multiple means Automatic valves are often the best choice
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You don't have to figure it out alone
Free surge analysis available Call: 515-223-4144
Email: [email protected]
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Questions?
Thank you for coming!
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Thank you for your attention!
Contact us anytime with questions
Brian Gongol DJ Gongol & Associates 515-223-4144 [email protected]
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References
Catalog photos of valves are courtesy GA Industries All other photos are original work by Brian Gongol. All rights
reserved.