File Reference

Page

1007-DISQ-0-P-SS-48078-Rev.2

1 of 23

Contract
Number: 1007

RWE Dea

Disouq Field Development

FEED

Specification for
High Integrity Pressure Protection System
HIPPS

Document number
1007-DISQ-0-P-SS-48078

07.02.12 Issued for design

1
0
Rev

A Saleh /
A Khamisy

A Fawzi

A Hamdan

RWE

01.02.12 Issued for Client comment

A Saleh /
A Khamisy

A Fawzi

A Hamdan

RWE

18.01.12 Issued for Client comment

A Saleh /
A Khamisy

A Fawzi

A Hamdan

RWE

Approved
By

Client
Approval

Date

Description

Issued By Checked By

Onspec Engineering Solutions

Disouq Field Development Project
Specification for
High Integrity Pressure Protection System

Changes List
Rev.

Date
prepared

Prepared by

Description

(DD.MM.YYYY)

01

01.02.2012

02

07.02.2012

A Saleh /
A Khamisy
A Saleh /
A Khamisy

Client Comments incorporated.

Client Comments incorporated.

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for
High Integrity Pressure Protection System
Table of Contents
1

Introduction ...................................................................................................................... 5

1.1

Background .................................................................................................................. 5

1.2

Purpose of Document................................................................................................... 5

1.3

Definition ...................................................................................................................... 6

1.4

Units of Measurements ................................................................................................ 6

Referenced Documents ................................................................................................... 7

2.1

Project Documentation ................................................................................................. 7

2.2

International Codes and Standards .............................................................................. 7

2.3

Order of Precedence .................................................................................................. 10

System Description ........................................................................................................ 11

Extent of Supply ............................................................................................................. 13

4.1

Inclusions ................................................................................................................... 13

4.2

Exclusions .................................................................................................................. 14

Design Requirements .................................................................................................... 15

5.1

HIPPS Safety Loop .................................................................................................... 15

5.1.1

Initiator .................................................................................................................... 16

5.1.2

Logic Solver ............................................................................................................ 16

5.1.3

Actuator .................................................................................................................. 16

5.1.4

Final Element .......................................................................................................... 17

5.2

Utilities ........................................................................................................................ 18

5.3

Reliability .................................................................................................................... 18

5.4

Piping, Flanges, Gaskets and Bolts ........................................................................... 18

5.5

Painting ...................................................................................................................... 18

5.6

Noise Limitations ........................................................................................................ 18

5.7

Material Certification & Traceability ............................................................................ 19

5.8

Nameplates ................................................................................................................ 19

5.9

Climate Condition ....................................................................................................... 19

Installation, Operation and Maintenance ....................................................................... 20

6.1

Installation and Commissioning.................................................................................. 20

6.2

Maintainability............................................................................................................. 20

6.3

Special Tools .............................................................................................................. 20

6.4

Spare Parts ................................................................................................................ 20

6.5

Training ...................................................................................................................... 20
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Specification for
High Integrity Pressure Protection System
7

Preparation for Shipment ............................................................................................... 21

Quality Management ...................................................................................................... 21

8.1

Testing and Inspection ............................................................................................... 21

8.1.1

Factory Acceptance Test (FAT) .............................................................................. 21

8.1.2

Site Acceptance Test (SAT) ................................................................................... 22

8.2

Vendor Data Requirements ........................................................................................ 22

Abbreviations List .................................................................................................................. 23

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O
Onspec
Eng
gineering Solutions
S
Dis
souq Field Developme
ent Projectt
cification fo
or
Spec
High In
ntegrity Pre
essure Prottection Sys
stem

Introd
duction

1.1

Background
d

ed seven na
atural gas reserves
r
in the Disouq
q Concessio
on within
RWE Dea Egypt has discovere
ng in 2008, as shown on the co
oncession map
m
below. Further
the onshore Nile Delta, startin
on in the co
oncession is ongoing. RWE Dea Egypt is th
he operatorr of the Con
ncession
exploratio
with EGA
AS as a parttner.

The seleccted develo

opment com
mprises a ce
entral gas treatment site near NSG
G-1x, where
e the gas
is collecte
ed, treated by means of
o Low Tem
mperature Se
eparation utilizing the Joule
J
Thom
mson
effect to a
achieve gass quality, an
nd compresssed for exp
port. Treated
d gas is tran
nsferred via
a a 16
pipeline directly
d
into the GASCO
O NTS pipe
eline.
The well fluids are gathered and
d fed to a common inle
et separatorr at the central plant. All
A gases
and liquid
ds will be se
eparated an
nd processe
ed on the ce
entral treatm
ment site intto sales gass,
stabilized
d condensatte, and free
e production
n water.
Treatmen
nt of gas is carried out in two trains, while trea
atment of condensate
c
is in a singlle train.
Three tra
ains of saless gas compression are installed. Fuel
F
gas forr the gas en
ngine drivess is
taken from
m the suctio
on of the sa
ales gas com
mpressors.
1.2

Pu
urpose of Document
D

This Spe
ecification defines
d
the general re
equirementss for the design, man
nufacturing, supply,
installatio
on and testing of a num
mber of Hig
gh Integrity Pressure P
Protection Systems
S
(HIPPS) to
be utilised
d for the Disouq develo
opment pro
oject.

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for
High Integrity Pressure Protection System
The present specification is primarily to define Company minimum requirements and does not
relieve the Vendor from his responsibility for design, performance and safe operation of the
whole system.
The Vendor shall provide the work defined herein complete in every respect and in
accordance with good engineering practice, ready to operate in the manner indicated,
regardless of whether full details of such completeness, or practice is given.
HIPPS shall be certified in accordance to International Regulations as stipulated in API 521.
1.3
Definition
DESCRIPTION
DEFINITION
Company
RWE Dea Egypt, in a later project stage, a JV formed between RWE Dea
Egypt and EGAS
Vendor
Vendor is the party, which designs, manufactures or supplies equipment
3rd party
Independent Verification Service The party(s) which carry(s) out all or parts
of verification services of the design, fabrication, installation and testing of
the System(s)
1.4

Units of Measurements

Units of Measurements shall be in accordance with Environmental Data and Units of

Measurement document no. 1007-DISQ-0-M-RT-42015.

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for
High Integrity Pressure Protection System

Referenced Documents

The design, construction, testing and general requirements shall comply with the latest edition
of the following specifications, data sheets, codes and standards.
2.1

Project Documentation

NUMBER
1007-SSSE1-1-P-DW-48031
1007-DISQ-0-L-SS-39004

DESCRIPTION
P&ID Wellhead SSSE 1-1
Protective Coating Specification

1007-DISQ-0-F-SS-10018

Noise Control Specification

1007-DISQ-0-L-SS-39010
1007-DISQ-0-M-RT-42015

Specifications for Piping Material

Environmental Data and Units of Measurement

2.2

International Codes and Standards

DESCRIPTION
NUMBER
American National Standards Institute (ANSI)
ANSI 6 1.20.1
Pipe Threads
ANSI 816.34
Valve Standard
ANSI 616.5
Steel pipe flanges and flanges fittings
ANSI 616.10
Flange Ends
ANSI 646.1
Surface texture
ANSI/ FCI 70.2
Seat leakage standard
ANSI B 1.20.1
Standard for Pipe Threads, General Purpose
ANSI B2.1
Pipe Threads (Except Dryseal) Specifications, Dimensions, and Gauging
for Taper and Straight Pipe Threads Including Certain Special
Applications
ANSI B16.20
Ring-Joint Gaskets and Grooves for Steel Pipe Flanges
ANSI B 16.47
Large Diameter Steel Flanges NPS 26 Thru NPS 60
ANSI B16.5
Pipe Flanges and Flanged Fittings
ANSI B 16.9
Factory Made Wrought Steel Buttwelding Fittings
ANSI B 16.11
Forged Steel Fittings, Socket Welding and Threaded
ANSI B 31.1
ANSI B 31.3
ANSI B 31.4
ANSI B 31.8
ANSI B16.34

ANSI B16.104
ANSI B 36.10M

Power Piping Code

Chemical Plant and Petroleum Refinery Piping
Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,
Anhydrous Ammonia, and Alcohols
Gas Transmission and Distribution Piping Systems
Valves - Flanged and Buttwelding End Steel, Nickel Alloy and Other
Special
Alloys
Valve Leakage Classifications
Welded and Seamless Wrought Steel Pipe

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Disouq Field Development Project
Specification for
High Integrity Pressure Protection System
American Petroleum Institute (API)
API 1104
Standard for Welding of Pipelines and Related Facilities
API 2B
Specification for Fabricated Structural Steel Pipes
API 500
Recommended practice for classification of locations for electrical
installations at petroleum facilities classified as Class 1, Division 1 and
Division 2.
API 5L
Specification for Line Pipe
API RP 14C
Recommended Practice for Analysis, Design, Installation and Testing of
Basic Surface Safety Systems on Offshore Production Platforms
API SPEC 6D
Specifications for Pipeline Valves, End Closures, Connectors and Swivels
API SPEC 14D
Specifications for Wellhead Surface Safety Valves and Underwater Safety
Valves for Offshore Service
API SPEC. 6F
Fire test for valves
API 60
Specification for pipe line valves
API 521
Pressure relieving and depressurization systems
API STD 598
Valve Inspection and test
API STD 607
Fire Test for Soft Seated Ball Valves
API RP 550
Manual on Installation of Refinery Instruments and Control Systems, Part
1 - Process Instrumentation and Control, Section 6 - Control Valves and
Accessories
API 554
Process Control and Instrumentation
API SPEC 6D
Specifications for Pipeline Valves, End Closures, Connectors and Swivels
American Society for Testing and Materials (ASTM)
ASTM A193 / 193M Specification for Alloy Steel and Stainless Steel Bolting Materials for
High Temperature Service
ASTM A194
Standard Specification for Carbon and Alloy Steel Nuts for Bolts for HighPressure/ High-Temperature Service
ASTM A234
Standard Specification for Piping fittings of Wrought Carbon Steel and
Alloy Steel for Moderate and Elevated Temperatures
ASTM A269
Standard Specification for Seamless and Welded Austenitic Stainless
Steel Tubing for General Service
ASTM A269
Specification for Seamless and Welded Austenitic Stainless Steel Tubing
for General Service
ASTM A320
Specification for Alloy Steel Bolting Materials for Low Temperature
Service
ASTM A325
High Strength Bolts for Structural Joints, including Suitable
Nuts and Plain Hardened Washers
ASTM A370
Methods and Definitions for Mechanical Testing of Steel
Products.
ASTM A403
Standard Specification for Wrought Austenitic Stainless Steel
Piping Fittings
ASTM 450/450M
Standard Specification for General Requirements for Carbon
Steel, Ferritic Alloy, and Austenitic Alloy Steel Tubes.

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Specification for
High Integrity Pressure Protection System
ASTM-E 94

Standard recommended practice for radiographic testing

ASTM-E 142

Standard method for controlling quality of radiographic testing

American Society of Mechanical Engineers (ASME)

ASME Section II
Material Specifications
ASME Section VIII Pressure Vessels
ASME Section IX Welding and Brazing Qualifications
National Electrical Manufacturers Association (NEMA)
NEMA ICS-2

Industrial Control Devices, Controllers and Assemblies

National Fire Protection Association (NFPA)

NFPA 70
National Electrical Code
NFPA 493
Intrinsically Safe Apparatus
International Electro-technical Commission (IEC)
IEC 664
Insulation co-ordination within low-voltage systems including
clearances and creep age distances for equipment
IEC 60059
IEC Standards Current Ratings
IEC 60079
Electrical Apparatus for Explosive Gas Atmospheres
IEC 60085
Thermal Evaluation and Classification of Electrical Insulation
IEC 60228
Specification for conductors in insulated cables.
Fire Resisting Characteristics of Electrical Cables
IEC 60331
Test on Electrical Cables under Fire Conditions
I EC-60332
Low-voltage
electrical installations
IEC 60364-1
IEC 60529
Degrees of protection provided by enclosures (IP Code)
IEC 60534
Industrial Process Control Valves Inspection & Routine Testing
IEC-61508
Functional Safety Electrical /Electronic/ Programmable Electronic Safety
Related Systems
IEC-61511
Functional Safety - Safety Instrumented Systems for the process industry
sector

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)

MSS-SP-25
MSS-SP-54
MSS-SP-55
MSS-SP 61

Standard marking system for valves, fittings, flanges and unions.

Quality standards for steel casting radiographic examination method
Quality standards for steel casting visual method
Pressures Testing of Steel Valves

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for
High Integrity Pressure Protection System
National Association of Corrosion Engineers (NACE)
MR-01-75
Sulphide Stress Cracking Resistant Metallic Material for Oil Field
Equipment

Instrument Society of America (ISA)

ISA-TR84.00.022002 -

Part 3: Safety Instrumented Functions (SIF)-Safety Integrity Level (SIL)

Evaluation Techniques Part 3: Determining the SIL of a SIF
via Fault Tree Analysis

German Institute for Standardisation (Deutsches Institute fr Normung) (DIN)

DIN 3381

Safety devices for gas supply installations operating at working pressures

British Standard (BS)

BS EN 14382

Safety devices for gas pressure regulating stations and installations

BS 6755-2

Testing of valves. Specification for fire type-testing requirements

Euro Norms (EN)

EN 13463-1
EN 13463-2

Basic Methods & Requirements for non-electrical equipment for explosive

atmospheres
Flow Restricting enclosure, fr

EN 13364-3

Flame proof enclosure, d

EN 13364-5

Constructional safety, c

EN 13364-6

Control of ignition sources, b

EN 13364-7

Pressurisation, p

EN 13364-8

Liquid immersion, k

2.3 Order of Precedence

In case of discrepancies among the various documents, the following order of precedence shall
be applied:
1. Purchase Order and amendments thereto
2. Data Sheets and drawings
3. This Specification
4. Other Referenced Project Specifications
5. Egyptian National/Local Codes and Standards
6. International Codes and Standards

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for
High Integrity Pressure Protection System

System Description

High Integrity Pressure Protection System (HIPPS) is a specific application of a Shutdown

System (ESD). The function of a HIPPS is to protect the downstream equipment (vessel or
pipeline) against over-pressure by closing the source. Usually this is done by timely closing the
dedicated safety shut-off valve to prevent further pressurization of the piping downstream of
this valve.
The installation of the HIPPS at the Disouq Development Project shall reduce the pipeline
design pressure to be 100 barg. This shall realise the following advantages:

Reduced cost of pipeline - can constitute a significant portion of field development cost
Reduced pressure rating of downstream equipment separators, process plant, etc.
Increased safety by ensuring reduced pressure.

The entire system, consist of final element, being a safety shut-off valve and its switching
units, actuator, and mechanical pressure measuring devices able to initiate activation of safety
shut-off valve. These elements shall be all integrated into a single system.
In accordance to lEC 61508, IEC 61511 and ISA TR84.00.02, the HIPPS, consisting of the
elements defined above, shall be viewed as a Safety Integrity Function (SIF) and shall be
treated as a dedicated safety loop. The loop shall meet the defined Safety Integrity Level. The

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Onspec Engineering Solutions

Disouq Field Development Project
Specification for
High Integrity Pressure Protection System
assessed SIL level shall be calculated and confirmed by Vendor and audited by a certified 3rd
party. The following shall be considered when calculating the SIL level:

Device integrity determined by documented and supportable failure rates

Redundancy and voting using multiple devices to ensure fault tolerance
Functional testing at specific intervals to determine that the device can achieve the fail
safe condition
Diagnostic coverage using automatic or on-line methods to detect component or device
failure
Other common causes including those related to the device, design, systematic faults,
installation, and human error

The HIPPS system shall be capable of standalone operation without reliance on external
power supply or other DCS or ESD equipment.
The HIPPS system shall be separated from the wellhead control system, and it shall act
independently from the wellhead control system, and is configured so that it cannot be overridden by the normal control system.
The HIPPS control system must be configured so that the shut off valve closes in the event of
a safety function failure: that is, the system is to fail safe.
The HIPPS Vendor shall prove that the supplied system PFD meets the specified SIL level.
The HIPPS design shall be based on hydraulic actuator with accumulator and hand pump for
pressurisation.

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Specification for
High Integrity Pressure Protection System

Extent of Supply

The Vendor shall furnish all system hardware, tubing, parts and materials for a fully functional
system.
The Vendor shall prepare system specifications, and test procedures for Factory Acceptance
Testing (FAT), Site Installation, and Site Acceptance Testing (SAT) for the system. The
Vendor shall then perform the above testing, and maintain a system log with any corrections
made.
The Vendor shall obtain 3rd party auditing of the system design, including the SIL level
calculations and provide all results and conclusions to Company for approval.
Any modifications made to the system design after completion of the 3rd party audit shall be
subject to a re-audit of the system.
The Vendor will perform the scope of services stated above in accordance with the provisions
of IEC 61508 and IEC 61511.
4.1

Inclusions

The scope of supply shall include but not be limited to the following:

Voting System:
o Two or three mechanical pressure switches (Initiators)
o Logic solver
Hydraulic actuator
Final element (HIPPS shut off valve)
Cabinet architecture and design.
Foundation details if required
Detailed Specification of the final element (shut off valve) describing material, design
standards, valve and actuator sizing and integration.
Detailed specification of the instrumentation such as actuator, initiators, logic solver,
tubing, reset button etc.
Specific safety aspects in accordance to DIN 3381 & EN 14382.
Detailed of all the services, supports, installation and post-installation support services.
Implementation of all functions.
Instrumentation, valves, fittings and tubing.
Special tools
Fabrication and assembly
Lubrication and consumables such as hydraulic oil (first filling), etc.
Inspection & testing (including factory and site acceptance tests)
Painting and protective coating
3rd party certification (where specified in the material requisition)
Supervision of installation
Commissioning and start-up spare parts
List of two years operational spare parts
List of capital spares
Packing, marking and preservation
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Specification for
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4.2

Test equipment required for SAT

Documentation as detailed within VDRF and minimum quality surveillance (including
installation, operation and maintenance manuals)
Performance and mechanical guarantees
Warranty.
Spare parts.
Training.
Providing all documentation required for continuous & reliable operation.
Exclusions
Civil works including foundations

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Specification for
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Design Requirements

HIPPS vendor shall be responsible for the complete design, fabrication, testing, supply and
guarantee of the HIPPS.
Mechanical HIPPS shall have its own sensing, logic solver and final element loop and shall be
totally self-contained.
The mechanical system shall be standalone without requirement for external power source
and therefore suitable for locations in remote areas.
Considering the consequences relating to escape of gas, injury to personnel, economical
losses caused by damage to capital equipment, loss of production, the required Safety
Integrity Level has been determined to be SIL 3 system certified according to IEC 61508 and
IEC 61511complete with all required hardware configuration, accessories, hydraulic tubing to
shut off valve, documentation & drawing requirements and test & inspection requirements.
The required SIL level shall be met over the full lifecycle of the HIPPS. The design life of the
HIPPS system shall be 25 years.
HIPPS shall be certified according to IEC 61511 with respect to mechanical actuating and
additional requirements over & above IEC 61508 to achieve fast acting valve.
The system shall be designed to include facilities to allow periodic testing of the HIPPS to
prove integrity including:

The reaction speed of the safety shutoff valve.

Determination of leakage rate of the safety shutoff valve.

The interval for periodic testing may be one or two times per year, the vendor shall include in
its offer the periodic testing as per above statement.
The HIPPS design package shall be fully based on mechanical instrumentation in order to
achieve the saving on power, installation cost and ease of use.
The HIPPS shall be designed so that no consumption or external power sources of any kinds
are required (fully self-contained).
The HIPPS shall be supplied fully tested with all elements of the safety loop integrated.
HIPPS to be provided with substantiated reliability data of the elements in the safety loop
based on actual field data of previously supplied HIPPS systems.
The HIPPS shall automatically close, by means of multiple springs in the actuator to the safe
position (valve closed) upon detection of high pressure.
System speed of response (instrumentation and final control element) shall be selected such
that overpressure in the protected pipeline is avoided, and pressure surges in the upstream
section of the wells, caused by the closing of the valves, remain acceptable. The Vendor shall
provide Company with recommended pressure setting and speed of response to ensure
pipeline protection and accepted pressure surge at well site upstream. Vendor shall support
the recommendation with detailed study or dynamic modelling.
5.1

HIPPS Safety Loop

The safety loop is a functional unit, consisting of input (initiator), logic solver and output (final
element).
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Specification for
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The logic solver shall be fully integrated with the valve actuator and shall be fully independent.
5.1.1

Initiator

The initiators are the elements measuring the process variables (PV) to sense pressure
increase. The initiators shall be mechanical pressure switches. A safety loop shall consist of 2
or 3 pressure switches (1oo2 voting or 2oo3 voting) to achieve the required SIL level.
Operating Pressure: 65 to 90 barg

Design Pressure: 100 barg

Operating Temperature: 10 to 60 C

Design Temperature: -20 to 80 C

Mechanical pressure switches shall be provided with test units.

All mechanical pressure switches to be tropic proof by proper design & construction by
material selection.
Pressure switches voting act as Pressure Measuring & Triggering Device (PMTD), it shall
have set point accuracy suitable to satisfy HIPPS accuracy.
Pressure Switches shall be mounted directly onto the switching device (actuator).
Pressure Switches Voting shall be the only device that directly or indirectly triggers the HIPPS.
No other elements of the HIPPS may interfere with the trip command generated by the
Pressure Switches Voting.
5.1.2

Logic Solver

Logic solver shall receive the pneumatic signals from the initiators, performs the required
voting and drives the final elements. Logic Solver hardware shall be designed and certified in
compliance with SIL3 performance requirements.
5.1.3

Actuator

The actuator and valve shall be designed, manufactured and assembled by the same Vendor.
The actuator is a vital component between the pressure sensing element and the final
element. It shall be specifically designed for fast reliable stroking over an extended service life.
On failure, they are to close the final element.
Actuator shall be of the multiple parallel springs - return piston type. Fail action, by means of
spring force only, shall be fail-close.
Actuator shall be designed to operate the valves against full rated system design pressure at
the specified minimum supply pressure.
Spring force of the actuator for the safety shut off valves in the open position shall be 500%
oversized based on the "break away" force requirements in the open position. Available spring
force at the closed position shall be at least 150% of the required valve shut off force in the
closed position based on the most unfavourable valve condition.
Opening the valve shall be by means of hydraulic pump installed directly on the actuator.
Actuators shall have a hydraulic end of stroke damping to avoid slamming.
Actuator shall be of the linear stem movement with easy access to shut-off valves / actuator
stem connection. Actuator / shut-off valve stem connection shall be fully enclosed to eliminate
damage of stem by sandstorms or other adverse environmental conditions.

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Specification for
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Actuator shall ensure valve speed to close shall be in accordance to system requirements as
per previous points.
Vendor shall supply all accessories to obtain stroke as specified for the valves full stroke.
Actuator shall be mounted directly on the valve.
Yoke, brackets and / or pedestals shall be an integral part of the actuator (and should be
accounted for in the reliability data).
Actuator shall have a dedicated hydraulic tank and a return line .
5.1.4

Final Element

The shut-off valve must meet the requirements of high safety standards in critical applications.
The final element shall be designed to be a highly reliable valve and maintain tight shut-off
capabilities under all encountered conditions maintaining the integrity of the elements function.
Long periods of inactivity (valve remains fully open for a long period) shall not influence the
response time of the valve, nor the stroking speed (to close).
The body of the safety shut-off valve shall be of a single piece eliminating leakage paths to
atmosphere.
Valve with a flow tendency to open is not allowed.
While valve is in the open position, the sealing mechanism shall exclude any possibility of
direct erosive action by flow on the seal.
In closed position the valve must ensure bi-directional tightness in accordance to ANSI
816.104/ FC170.2 Class VI.
HIPPS valve shall be certified fire safe to API 6FA, API 607 or BS 6755.
Valves shall have zero leakage in accordance with API 598.
The safety shutoff valves must ensure seat tightness for more than 10 cycles under full rated
design pressure.
The safety shut-off valves shall be supplied with all required accessories.
The safety shut-off valves shall be metal to metal seat due to sand content in the fluid.
HIPPS shut off valve shall comply with the following:
Valve Rating

API 5000

Fluid

Hydrocarbon gas, water and condensate.

Operating pressure

65-90 barg

Pressure Rating

API 5000

Flow Rates, maxima

10, 15 and 20 MMSCFD

Operating Temperature

10 to 60 C

Maximum Temperature

-20 to 80 C

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Specification for
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Type of Protection, Ingress EEx (d) IIB T3, IP 65

Protection
Travel time

Fast Acting (to be recommended by Vendor)

Manual Reset Hydraulic

connection

NPT for HIPPS valve

5.2

Utilities

The following utilities are available at well site:

5.3

Hydraulic Supply: HIPPS Vendor is responsible to provide HIPPS System with

Hydraulic Power Supply. HIPPS system shall include, but not limited to the following:
o Hydraulic Pump
o Hydraulic Tank.
o Local Instruments to indicate the hydraulic pressure, tank level, rest button, etc.
Reliability

Reliability analysis should be performed on the HIPPS to establish the Probability of Failure on
Demand (PFD). The loop PFD shall meet stated SIL requirements.
The HIPPS shall maintain the stated minimum level of reliability based on maintenance regime
(minimum of annual or six month proof test).
5.4

Piping, Flanges, Gaskets and Bolts

All piping shall be designed in accordance with ASME B31.3.

All Piping, Flanges, Gaskets and Bolts shall be designed in accordance to document no. 1007DISQ-0-L-SS-39010 Specifications for Piping Material.
The pipe work arrangement and connections to all equipment shall follow the manufacturers
recommendations.
5.5

Painting

All equipment shall be finish painted or coated in accordance with Protective Coating
Specification 1007-DISQ-0-L-SS-39004.
A sufficient quantity of touch-up paint (10%) shall be supplied with the equipment to repair
minor damage to the paint finish after site installation.
5.6

Noise Limitations

The overall Sound Pressure Level form the package shall not exceed 80 dBA at 1 metre from
the skid edge. If necessary noise control measures shall be applied to the equipment by the
Vendor to ensure that these limits are adhered to. Where noise control measures such as
acoustic insulation or acoustic enclosures are required, these shall be provided by the Vendor.
These enclosures shall be easily removable without the need to dismantle any part of the
equipment or otherwise shall not obstruct operational or routine maintenance activities.

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The VDRF will require the vendor to confirm the predicted sound power level and maximum
overall sound pressure level in accordance with document no. 1007-DISQ-0-F-SS-10018,
Noise Control Specification.
5.7

Material Certification & Traceability

All field instrumentation shall be supplied with calibration certificates.

The Vendor shall ensure appropriate manufacturing systems and procedures are used to
ensure full traceability of materials. During manufacture each assembled component shall be
clearly and permanently marked in order that it can be traced back to the originally supplied
material certificate and its origin determined.
5.8

Nameplates

The HIPPS System and field instrumentations shall be equipped with a manufacturers
nameplate of 316 stainless steel permanently attached with stainless steel screws or rivets
indicating the specified data. In addition to specified data the following data shall be provided
which is a minimum:

5.9

Tag number.
Serial number
Model number
Range
Purchase Order Number
Manufacturers Name
Year of Manufacture
Valve Inlet and outlet connection sizes and rating
Pressure and temperature rating of the internal pressure retaining components.
Operating ranges and materials of the parts exposed to the process fluid.
And other important design parameters
Climate Condition

The High Integrity Pressure Protection System shall be suitable to operate in the north delta
climate conditions as per Environmental Data and Units of Measurement, document no. 1007DISQ-0-M-RT-42015

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Installation, Operation and Maintenance

6.1

Installation and Commissioning

Special installation or commissioning requirements are to be identified by the vendor.

6.2

Maintainability

The system equipment shall be arranged to allow sufficient access for maintenance and
operation. The layout of the system equipment shall reflect a compact ergonomic design with
adequate spacing between adjacent equipment and pipe work. Adequate withdrawal space,
and/or removable pipe spools shall be provided, where necessary, to permit removal and
replacement of major components of the system.
Piping shall be arranged and supported so that the identified equipment maintenance items
can be removed without dismantling surrounding equipment other than removing spool pieces
adjacent to equipment connections.
The Vendor shall supply necessary special tools to enable periodic testing and maintenance.
Instrumentation supplied with the equipment shall be located to permit easy access for
operation, testing and maintenance.
6.3

Special Tools

All special tools that are required for the installation, adjustment, commissioning, operation,
testing and maintenance of the HIPPS shall be included in the Vendors scope of supply. This
shall include any special lifting devices required for site installation of the equipment.
6.4

Spare Parts

The spare parts necessary during the construction, commissioning and start-up shall be
provided by the Vendor with the package, unless otherwise specified in the purchase order.
The spare parts for two years operation may be purchased separately from the main
equipment unless otherwise specified in the purchase order. They shall be listed (as per
Vendor recommendation) and quoted separately from the main equipment as optional item.
6.5

Training

Special training requirements for operators and maintainers are to be identified and
recommended by the vendor.

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Specification for
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Preparation for Shipment

All equipment shall (where practical) be supplied fully assembled. In order to minimise the
installation and pre-commissioning time at site, the equipment shall be suitably packed ready
for shipment. The Vendor shall also include adequate protection and preservation for a
minimum of six months outdoor storage from delivery to site. All necessary temporary supports
and other facilities shall also be provided to enable the equipment to be securely anchored
during transport.
Each equipment item shall be clearly identified on the outside of the packing with a description
and tag number so that any packaging need not be removed until such time as the equipment
is ready to be installed.
Spare parts shall be individually packed for long term storage. All exposed or loose parts shall
be completely boxed with identification tag. Gaskets supplied by the fabricator shall be new;
gaskets used for shop hydrostatic test are not acceptable.

Quality Management

The Vendor and his Sub-Suppliers shall maintain Quality Management Systems in accordance
with BS EN ISO 9001, Quality Management Systems Requirements and in accordance
with Company approved Quality Plan document 1007-DISQ-0-A-QP-10090 rev 00 and the
Minimum Quality Surveillance Requirements document 1007-DSQ-0-FO-10091.
These Quality Management Systems shall be adopted by the Vendor throughout the various
phases of the project (Engineering, fabrication, assembly, testing, Inspection, installation and
commissioning).
The Vendor shall manage and implement the work in accordance with an acceptable certified
management system, covering engineering, purchasing, expediting, fabrication, testing,
installation and commissioning in respect of the applicable regulations, Codes and Standards.
8.1
8.1.1

Testing and Inspection

Factory Acceptance Test (FAT)

The Vendor shall perform inspection and testing at his shop in the presence of Company
and/or its representative prior to shipment. Vendor shall be fully responsible for the complete
design, fabrication, inspection, testing, installation and commissioning of all the system
components.
The Vendor shall perform a complete functional test of all the High Integrity Pressure
Protection System components before making the equipment available for the witnessed
Factory Acceptance Test (FAT).
All testing will be conducted in accordance with test procedures. The vendor shall furnish the
test procedures to the Company for review at least 2 months prior to the FAT.
The vendor shall make available, at his cost, all necessary test equipment, tools, cables and
personnel for the duration of the tests.
The FAT shall be performed at the Vendors facilities with a comfortable work environment and
easy access to all equipment.
A test log shall be maintained by the vendor to keep record of the tests carried out, any fault,
rectification work done, etc.

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Specification for
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Deficiencies noted during FAT shall be corrected and fully retested to Company satisfaction.
Certification of completion of FAT including a list of outstanding deficiencies shall require
signature by the Company.
Company reserves the right to inspect all stages of manufacturing/assembling/testing of the
equipment package at Vendor/Sub-Vendor shop.
Company shall have the right to reject any equipment non-conforming to the purchase order
and referenced specifications.
The Vendor shall carry out all specified testing and inspection required by contractual
documentation, specifications, applicable codes & standards and the manufacturers quality
control system. The Vendor shall retain all required records and documentation pertinent to
these activities.
Acceptance criteria of tests, when not defined by the applicable codes, shall be specified by
the Vendor in the Vendor Quality Control Plan and/or test procedures and shall be sent to
Company for review.
8.1.2 Site Acceptance Test (SAT)
As minimum the SAT shall include the following:
Site Integration Test for mechanical and instrument integration
Commissioning: initial operation test prior to opening of well and at the first
opening of well
Performance Test: multiple operation tests at full flow and pressure
A complete audit of all equipment to verify that it has been received and does not
have any mechanical damage, loose parts, etc.
Verify that agreed outstanding items noted during FAT have been corrected and
tested.
Verification that the installation meets the Company specifications
Verification that all equipment is functional
All Site Acceptance Tests shall be carried out with the Vendors representative in
attendance. All field test instruments to be specified by Vendor and supplied by
Vendor
The SAT shall include testing of all systems and external interfaces which cannot
be tested during the FAT(s)
Vendor shall submit detailed test procedures to be approved by Company
8.2

Vendor Data Requirements

The Vendor data requirements shall be as specified on the Vendor Data Requirements Form
(VDRF) attached to the Material Requisition. The required number of reproducible and copies
shall be as specified.
An installation, operating and maintenance manual (IOM) and manufacturers record book
(MRB) shall be provided as detailed in the material requisition.

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ABBREVIATION
ANSI
API
ASME
ASTM
BS
CCR
CTP
DCS
DIN
ESD
EN
FAT
HIPPS
IEC
lEE
ISA
I/O
MSS
NACE
NEMA
NFPA
NPT
PCS
PFD
PMTD
PV
SIF
SI
SAT
SIL

Abbreviations List
DESCRIPTION
American National Standards Institute
American Petroleum Institute
American Society of Mechanical Engineers
American Standard for Testing Method
British Standard
Central Control Room
Central Treatment Plant
Distributed Control System
Deutsches Institute fr Normung German Institut for Standardisation
Emergency Shut Down
European Norm
Factory Acceptance Test
High Integrity Pressure Protection System
International Electro technical Commission
Institution of Electrical Engineers
Instrument Society of America
Input/output
Manufacturers Standardization Society of the Valve and Fittings Industry
National Association of Corrosion Engineers
National Electrical Manufacturers Association
National Fire Protection Association
National American Standard Taper Pipe Thread
Process Control System
Probability of Failure Demand
Pressure Measuring & Triggering Device
Process Variable
Safety Integrity Function
International Standard
Site Acceptance Test
Safety Integrity Level

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