Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 1 of 8

FUNCTIONAL SPECIFICATION
FOR HIGH INTEGRITY PRESSURE PROTECTION SYSTEM

PREPARED / REVISED BY

REVIEWED BY

APPROVED BY

TOTAL No. OF PAGES

DATE

REV. No.

VS VS
FORMAT No. DD/SOF/004A/B

SSK SSK
Ref. PROCEDURE No. DD/SOP/008 TO 015

GRP GRP
ISSUE No. 02

9 9

28.05.08 20.05.09
REV. No. 01

0 1
REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 2 of 8

CONTENTS Clause No. 1.0 2.0 3.0 ITEM Scope of This Document Scope of Supply High Integrity Pressure Protection System 3.1 Design Basis 3.2 Logic Solver 3.3 HIPPS Valves 3.4 Actuators 3.5 Pressure Sensors Special conditions to be fulfilled by the vendor Warranty Factory Acceptance Test Spares Tools Documentation Page No. 3 3 4 4 4 6 6 7 7 7 8 8 8 8

4.0 5.0 6.0 7.0 8.0 9.0

FORMAT No. DD/SOF/004A/B

Ref. PROCEDURE No. DD/SOP/008 TO 015

ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 3 of 8

1.0

SCOPE OF THIS DOCUMENT: Introduction High Integrity Pressure Protection System (HIPPS) is a Safety Instrumented System (SIS) designed to prevent over-pressurization of downstream pipeline system and thereby protect platform equipment by quick isolation at the source. HIPPS, while ensuring highest level of safety of platform and personnel, also conforms to environmental considerations / requirements. This functional specification describes the essential design considerations for the selection of HIPPS, logic solvers, valves, Actuators and sensors for HIPPS application for the intended service.

2.0 2.1 2.2

SCOPE OF SUPPLY: The quantity to be supplied and installed shall be as per the requirements indicated in the Basic Bid Work, Process Design Criteria and P & IDs. The vendor shall be responsible for the selection of the HIPPS logic solver, valves, actuators & sensors suitable for its intended application, its procurement, tagging, packing, testing & calibration, preparation for shipment, along with accessories, spares, and assistance where required for its installation & commissioning at site. This FS shall be read in conjunction with the: Instrumentation Design Criteria Basic Bid Work Project P & IDs Process Design Criteria Electrical Design Criteria Piping Design Criteria / Piping Material Specifications Mechanical Design Criteria Environmental condition of the project.

2.3

Latest editions of the codes enlisted below shall be followed as applicable: Sl.No. 1 2 3 4
FORMAT No. DD/SOF/004A/B

Number IEC61508 IEC61511

Description Functional safety of electrical /electronic /programmable electronic safety related systems Functional safety: Safety Instrumented Systems for the process industry sector

ANSI / ISA Application of Safety Instrumented System for Process Industry) S84.1 1996 DIN 3381 Safety devices for gas supply installations, pressure relief governors and safety shut-off devices
ISSUE No. 02 REV. No. 01 REV. DATE: 01/08/2006

Ref. PROCEDURE No. DD/SOP/008 TO 015

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 4 of 8

3.0 3.1 3.1.1 3.1.2

HIGH INTEGRITY PRESSSURE PROTECTION SYSTEM (HIPPS): DESGIN BASIS HIPPS shall be designed to meet SIL-3 (Safety Integrity Level-3) requirements in accordance with the international Standards as mentioned above. HIPPS shall use as a minimum 02 shutdown valves [primary HIPPs & secondary HIPPs valves]. Valve locations shall be as described in the process description / P&ID / Process Design Criteria. Reliability / Failure data for HIPP System (valves, actuators etc.) shall be ensured to meet SIL 3 requirement, as per IEC 61511 & 61508. The HIPPS valves shall be quick closing shut down valves; typically the closing time shall be up to 5 sec, unless otherwise described in the process description of work of the bid. HIPPS requirements shall be thoroughly documented through a hazard analysis and a Safety Requirement Specifications (SRS) needs to be developed identifying all potential overpressure scenarios by the main LSTK contractor and recommendations of the Hazard Report shall be implemented by the HIPPS vendor. HIPPS vendor may be required to participate in the Hazard study under the scope. HIPPS system shall be designed for shut-in conditions as described in the process description of work of the bid. Each HIPPS loop shall be dedicated loops independent of all the process loops and all other loops within the HIPP system. HIPPS shall be designed for Fail Safe condition (live 0 Signal / loss of Power resulting in safe state). Safe state shall be as described in Process documents. HIPPS shall be independent of well shut down system, though, HIPPS panel shall be suitably integrated with well shut down panel such that in case of HIPPS activation, the SSVs and SSSV shall also get closed. The system shall also comprise of pressure sensors fitted upstream of primary HIPPS valve. Activation of the HIPPS valves shall be based on voting logic derived from the signals from the above pressure sensors. For Pneumatic back up (nitrogen cylinders bank for four strokes/each valve) for HIPP system shall be supplied with recharge facility through instrument air supply. Actuators shall be hydraulic / pneumatic as per process requirement. It shall be independent of the other field instrumentation and not connected to any other system which may reduce the safety & reliability of the HIPP system. HIPP system shall be supplied for a design life of minimum 25 years.

3.1.3 3.1.4

3.1.5

3.1.6 3.1.7 3.1.8 3.1.9

3.1.10

3.1.11

3.1.12 3.1.13 3.1.14 3.2

LOGIC SOLVER: This specification describes the essential considerations in the design and construction of systems to be used as logic solver in safety related systems, for HIPPS application.

3.2.1 Programmable Electronic safety-related System used as logic solver in accordance with the IEC 61508 &61511
FORMAT No. DD/SOF/004A/B Ref. PROCEDURE No. DD/SOP/008 TO 015 ISSUE No. 02 REV. No. 01 REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 5 of 8

Voting logic shall be 2oo3, to meet minimum SIL-3 implementation based on IEC 61508 & 61511 standards. The logic solver equipment constituting the basic components from which the safety applications are built shall be as follows as a minimum: Processor/memory boards Communication boards I/O boards Termination units Power supplies System software & Application programming tools Communication protocols Human / System Interfaces Racks & Cabinet

Vendor to note that: (a) In case of availability of electrical power on the platform, programmable logic solver or electronic solid state based HIPPS is preferred. (b) In case of power constraints on the well platform etc, non- programmable HIPP systems [pneumatic/mechanical] are to be considered. 3.2.2 PNEUMATIC LOGIC SOLVER. Voting logic shall be selected so as to meet SIL-3 implementation based on IEC 61508 & 61511 standards and requisite Certification. The system will be based on pneumatic components, like relays, timers, logic ports, lamps, pneumatic horn, pneumatic spool valves, push button, etc. 3.2.2.1 FUNCTIONALITIES The pneumatic logic solver shall have the following functionalities: Voting logic to meet SIL-3 requirements / Certification. Partial stroke test. Indication of the presence of the inlet gas pressure. Indication of the status (open, intermediate, close) of the HIPPS valves with Limit switches / Position transmitter. Auxiliary pneumatic command to valves actuators. Local reset / Manual override with hydraulic pump.

3.2.2.2 COMPONENTS & MATERIALS The choice of the components and materials shall be for aggressive atmosphere. Components made in stainless steel SS 316.

FORMAT No. DD/SOF/004A/B

Ref. PROCEDURE No. DD/SOP/008 TO 015

ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 6 of 8

The panel will be free standing type, made up of 2 mm thick (min) stainless steel SS316 (Rittal make or equivalent) if located in safe area, and 4 mm thick (min) stainless steel SS316 if it is field mounted. The panel should be Weather proof to IP 65 minimum and also suitable for continuous trouble free operation in harsh corrosive environment (ambient temperature: 16 0C to 50 0C: 95% RH). All the main components (valves, lamps, pressure transmitters etc.) will be suitable to operate with the particular condition (temperature, pressure, aggressive atmosphere, hazardous area, gases, etc, etc). The internal panel pneumatic connection will be made by stainless steel SS 316 tubing and twin ferrule tube fittings, all made in stainless steel. The system will be made with a stainless steel SS316. 3.2.2.3 CONSTRUCTION FEATURES 3.3 3.3.1 Main features: Installing to floor level. Canopy / shade shall be provided. In-coming/Out-coming tubes and cables on the bottom and/or from the side. The external fitting (tube/tube fitting) will be in stainless steel. The external cable-glands shall be in stainless steel.

HIPPS VALVES The valves shall be ANSI class VI leakage. Metal to metal seats are desirable for its inherent fire proof design. The valve seat material shall be suitable for 25 years of life and material conformance test shall be submitted along with prequalification documents. For other type of design, the Company approval must be taken in advance. Refer Piping Functional Specifications of SDVs. Valve body shall be forged or cast and internals / wetted parts shall be selected to suit the process / service conditions (sour services as well as non sour services). Refer Piping Material Specifications for details and process scope of work. Valves shall be provided with anti-blow-out and anti-static device. The valves shall have proven reliability data in compliance with the required Safety Integrity Level (SIL-3) of the HIPPS. Power efficient SOVs (compliant to SIL 3) with characteristics of direct acting high flow, NAMUR, quick exhaust etc. shall be considered. SIL certification for complete valve assembly is required from a reputed SIL certifying agency. ACTUATORS

3.3.2

3.3.3 3.3.4 3.3.5 3.3.6 3.4

3.4.1 HIPPS valve actuator shall be of spring return, quarter turn, compact type. 3.4.2 The actuators, pneumatic or hydraulic shall be designed for Fail Safe condition.
FORMAT No. DD/SOF/004A/B Ref. PROCEDURE No. DD/SOP/008 TO 015 ISSUE No. 02 REV. No. 01 REV. DATE: 01/08/2006

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 7 of 8

3.4.3 Safety factor shall be 1.5 times [min.] of the valve maximum torque. 3.4.4 Manual override (3 way valve) along with manual hydraulic pump with removable lever etc shall be considered. 3.4.5 Antistatic devices are required. 3.4.6 The actuator shall be totally enclosed and rated IP-65. 3.4.7 The actuators shall be provided with Partial Stroke Testing functionality, without overriding the safety function in any time and preventing the full closing of the valve by mistake. 3.4.8 Actuators shall be provided with 3 limit switches (open, close and intermediate)/position transmitters. 3.4.9 The actuators shall have proven reliability data in compliance with the required Safety Integrity Level (SIL-3) of the HIPPS in accordance with IEC 61508 & 61511. 3.5 PRESSURE SENSORS 3.5.1 No of pressure sensors for each HIPPS loop shall be considered as indicated in specifications of logic solver / HIPPS Loop Diagram. 3.5.2 Field mounted pressure transmitters if used shall be of proven type for offshore safety functions. 3.5.3 Pressure sensors shall be suitable for systems requiring SIL-3 level integrity in accordance with IEC- 61508. 3.5.4 All required accessories shall be provided. 4.0 4.1 4.2 SPECIAL CONDITONS TO BE FULLFILLED BY HIPPS VENDOR All the major components / sub components of HIPP system shall have reliability data to meet SIL -3 certification requiremnts. Vendor shall provide the SIL-3 certification for the entire system from reputed SIL-3 certification approval agency along with the SIL analysis report and all references. The vendor shall commission the HIPPS at each offshore platform and demonstrate successful operation of the same. HIPPS shall be supplied as a package on single point responsibility basis. The HIIPS vendor shall have Proven Track Record for supplies of similar HIPP Systems which are in operation on Offshore Installations for a minimum period of two years. WARRANTY Vendor shall have total responsibility for the design and performance of complete HIPP System.Vendor shall warrant the equipment furnished by him and the performance of the said equipment in accordance with this specification. Also refer to Warranty clause as given in bidding documents (Volume I). 6.0 6.1 FACTORY ACCEPTANCE TEST
Factory Acceptance Test procedure for acceptance of HIPP System shall be submitted for Companys / TPI approval 8 weeks before the scheduled
Ref. PROCEDURE No. DD/SOP/008 TO 015 ISSUE No. 02 REV. No. 01 REV. DATE: 01/08/2006

4.3 4.4

5.0

FORMAT No. DD/SOF/004A/B

Design Division Engineering Services 11 - High, Mumbai ISO 9001: 2000

Functional Specifications HIPPS

Spec # Rev # Discipline Page #

C-104 1 Instt. 8 of 8

6.2

6.3

commencement of testing. FAT procedure shall be prepared as per the requirements outlined in the bid documents and applicable standards. Before the system is delivered to the site, satisfactory performance of the entire HIPP System shall be demonstrated. During FAT, HIPPS vendor shall simulate the final onsite configuration as closely as possible. The tests undertaken shall demonstrate each of the following responsibilities has been fulfilled. The system has been tested as an integrated system The hardware and software responsibilities have been fulfilled (as applicable) All tests have been documented in a checklist fashion The system is fully proven and ready for service The system satisfies the requirements of this specification and the particular project application.

7.0 7.1

SPARES Vendor shall provide spare parts needed for startup and commissioning, a list of these items shall be furnished as a part of purchase specification; 10% mandatory spares for supplied system shall be considered in the scope of supply of HIPPS package. In addition, vendor shall furnish a separate itemized priced list of recommended spares for one (1) year post-warranty operation and maintenance. Also refer Instrument design criteria clause number 3.6.4.8 Provision shall be made in HIPPS Panel to operate and control future facilities wherever shown in P&ID and / or indicated in the Basic Bid Work. HIPPS panel / cabinet mounted instruments and accessories required for this purpose shall be supplied and installed by Contractor. TOOLS Vendor shall provide two sets of special tools, if not stated elsewhere, for operation and maintenance of the furnished equipment.

7.2

8.0

9.0

DOCUMENTATION HIPPS Schematic showing all the components shall be submitted for Companys approval before review of PS for HIPPS. SIL Analysis Report shall be prepared for complete HIPP System (Loop), and submitted for Company / TPI review Installation and commissioning procedures for HIPPS shall be submitted to the Company for review and approval before the start of said activities.

FORMAT No. DD/SOF/004A/B

Ref. PROCEDURE No. DD/SOP/008 TO 015

ISSUE No. 02

REV. No. 01

REV. DATE: 01/08/2006