A recent analysis of pipeline incidents from 2005 to the present, based on data from the US Pipeline and Hazardous Materials Safety Administration, revealed that equipment failure, accounting for 33.15% of all incidents, was the most common cause. These statistics underscore the importance of surge analysis in identifying potential points of failure and implementing preventive measures to enhance pipeline safety and reliability.

As a leading CFD, FEA, piping, and acoustic analysis organization, Mechartes considers surge analysis critical to ensuring pipeline systems’ safety, efficiency, and longevity. Our expert Pipe stress analysis consultants extensively use Surge analysis to identify potential pressure surges, ensure the safety of network components, and improve the network’s reliability and effectiveness.

Therefore, understanding surge analysis is essential for comprehending fluid flow behavior in a pipeline system under transient conditions. In this blog post, we will explore all about surge analysis and how it can be an effective remedial measure.

Demystifying Surge Analysis

As noted above, surge analysis is a process that involves studying the behavior of fluid flow in a pipeline system under transient conditions.

For our pipe stress analysis consultants, the primary goal of using surge analysis is to predict and analyze the effects of these transients on the pipeline system. It helps identify potential pressure surges that can occur in the system and predict their impact.

This is essential in designing a robust pipeline system that can withstand transient conditions and continue to deliver fluid effectively.

The Importance of Surge Analysis

The importance of surge analysis in pipeline management is multi-faceted:

1. Safety of Components

Pressure surges can cause significant damage to pipes, pumps, valves, and other components, leading to costly repairs and downtime. Our pipe stress analysis consultants utilize surge analysis to identify potential damage points and help implement mitigation measures to reduce the risk of damage.

2. System Efficiency

Pipe stress analysis consultants of Mechartes also leverage surge analysis to identify bottlenecks and inefficiencies in the system and implement corrective measures to improve the system’s performance.

3. Reliability

The ability to deliver fluid quickly and efficiently is critical in many operations. Surge analysis helps ensure the pipeline system’s reliability by identifying potential issues and suggesting solutions.

Conducting Surge Analysis

Mechartes’ pipe stress analysis consultants conduct surge analysis using specialized software that simulates fluid flow behavior in the pipeline system under transient conditions. The software employs mathematical models to predict the pressure and flow changes that occur in the system due to transients. The results of the analysis are used to identify potential problems and develop mitigation measures.

Here’s a table illustrating a typical surge analysis process:

Surge Analysis in Different Industries

As pipe stress analysis consultants, we confirm that the application of surge analysis is not limited to a specific industry. It plays a key role in the design and optimization of the pipe network across verticals, including:

• Oil, water, and gas pipelines

• Water distribution and treatment plants

• Refining & Petrochemical Industries

• Industries where fluid is transported over long pipelines

• Fueling and filling stations

Surge Analysis and Regulatory Compliance

In the United States, the Pipeline and Hazardous Materials Safety Administration (PHMSA) oversees the safety of the nation’s pipelines. PHMSA’s Office of Pipeline Safety (OPS) provides data about federally-regulated and state-regulated natural gas pipelines, hazardous liquid pipelines, and liquefied natural gas (LNG) plants. The operators of these pipeline facilities report this data in accordance with Part 191 and Part 195 of PHMSA’s pipeline safety regulations.

According to our pipe stress analysis consultants, surge analysis plays a crucial role in ensuring compliance with these safety regulations and reducing the risk of pipeline failures.

Understanding the Causes of Pipeline Incidents

An integral part of pipeline surge analysis is understanding the potential factors that can lead to pipeline incidents. Recognizing these factors can help in the design and operation phases to take preventive measures and mitigate risks.

The graph below represents the primary causes of pipeline incidents reported in 2022, as per the data from the Pipeline and Hazardous Materials Safety Administration (PHMSA)​​.

As of June 19, 2023, a total of 10,346 pipeline incidents have been reported. The breakdown of these incidents by cause is as follows:

• Equipment Failure is the most common cause, accounting for 33.15% of all incidents. This category includes failures of the physical components of the pipeline, such as pumps, valves, and other equipment.

• Corrosion is the second most common cause, accounting for 19.31% of incidents. This includes internal and external corrosion, which can deteriorate the pipeline material due to chemical, and environmental reactions.

• Excavation Damage and Incorrect Operation are also significant causes, accounting for 12.18% and 11.47% of incidents, respectively. Excavation damage occurs due to external physical damage to the pipeline, often due to excavation activities in the vicinity of the pipeline. Incorrect operation refers to operational errors, such as incorrect valve operation or pump handling.

• Material Failure of Pipe or Weld accounts for 11.16% of incidents. This category includes failures due to defects in the pipe material or welding processes.

• Other Outside Force Damage and Natural Force Damage account for 9.66% and 7.32% of incidents, respectively. Other outside force damage includes various external factors, while natural force damage refers to damage caused by natural disasters and severe weather conditions.

• All Other Causes account for the remaining 5.42% of incidents.

These data highlight the importance of regular inspections, maintenance, proper operation, and the use of high-quality materials.

Mechartés: Global Leaders in Surge Analysis

With over 17 years of experience as a pipe stress analysis consultant and more than 10,000 projects completed across more than 30 countries, Mechartés has been at the forefront of providing accurate simulation results to solve complex engineering problems, including surge analysis.

With offices in Dubai, India, Saudi Arabia, and the USA, Mechartés has a global presence, which allows them to provide comprehensive and tailored solutions to a diverse set of clients around the world.

Experience the unrivaled surge analysis capabilities of Mechartés, your trusted pipe stress analysis consultants, and unlock the potential to optimize your fluid transportation systems’ safety, efficiency, and reliability. Mechartés can meet your surge analysis requirements, and our advanced analysis services can propel your engineering projects to new heights.

Get in Touch with Mechartés and harness the power of surge analysis for your engineering endeavors.