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Design DivisionFunctional Specifications

HIPPS

Spec # C-104Engineering Services Rev # 111 - High, Mumbai Discipline Instt.ISO 9001: 2000 Page # 1 of 8

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:

DD/SOF/004A/B DD/SOP/008 TO 015 02 01 01/08/2006

FUNCTIONAL SPECIFICATION

FOR

HIGH INTEGRITY PRESSUREPROTECTION SYSTEM

PREPARED / REVISED BY

REVIEWEDBY APPROVED BY

TOTALNo. OFPAGES

DATE REV.No.

VS SSK GRP 9 28.05.08 0

VS SSK GRP 9 20.05.09 1

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CONTENTS

ClauseNo.

ITEM PageNo.

1.0 Scope of This Document 32.0 Scope of Supply 33.0 High Integrity Pressure Protection System 4

3.1 Design Basis 43.2 Logic Solver 43.3 HIPPS Valves 63.4 Actuators 63.5 Pressure Sensors 7

4.0 Special conditions to be fulfilled by the vendor 75.0 Warranty 76.0 Factory Acceptance Test 87.0 Spares 88.0 Tools 89.0 Documentation 8

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3.0 HIGH INTEGRITY PRESSSURE PROTECTION SYSTEM (HIPPS):

3.1 DESGIN BASIS

3.1.1 HIPPS shall be designed to meet SIL-3 (Safety Integrity Level-3) requirementsin accordance with the international Standards as mentioned above.

3.1.2 HIPPS shall use as a minimum 02 shutdown valves [primary HIPPs &secondary HIPPs valves]. Valve locations shall be as described in the processdescription / P&ID / Process Design Criteria.

3.1.3 Reliability / Failure data for HIPP System (valves, actuators etc.) shall beensured to meet SIL 3 requirement, as per IEC 61511 & 61508.

3.1.4 The HIPPS valves shall be quick closing shut down valves; typically the closingtime shall be up to 5 sec, unless otherwise described in the process descriptionof work of the bid.

3.1.5 HIPPS requirements shall be thoroughly documented through a hazard analysisand a Safety Requirement Specifications (SRS) needs to be developedidentifying all potential overpressure scenarios by the main LSTK contractorand recommendations of the Hazard Report shall be implemented by the HIPPSvendor. HIPPS vendor may be required to participate in the Hazard study underthe scope.

3.1.6 HIPPS system shall be designed for shut-in conditions as described in theprocess description of work of the bid.

3.1.7 Each HIPPS loop shall be dedicated loops independent of all the process loopsand all other loops within the HIPP system.

3.1.8 HIPPS shall be designed for Fail Safe condition (live 0 Signal / loss of Powerresulting in safe state). Safe state shall be as described in Process documents.

3.1.9 HIPPS shall be independent of well shut down system, though, HIPPS panelshall be suitably integrated with well shut down panel such that in case of HIPPS activation, the SSVs and SSSV shall also get closed.

3.1.10 The system shall also comprise of pressure sensors fitted upstream of primaryHIPPS valve. Activation of the HIPPS valves shall be based on voting logicderived from the signals from the above pressure sensors.

3.1.11 For Pneumatic back up (nitrogen cylinders bank for four strokes/each valve) forHIPP system shall be supplied with recharge facility through instrument airsupply.

3.1.12 Actuators shall be hydraulic / pneumatic as per process requirement.3.1.13 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.

3.1.14 HIPP system shall be supplied for a design life of minimum 25 years.3.2 LOGIC SOLVER:

This specification describes the essential considerations in the design andconstruction of systems to be used as logic solver in safety related systems, forHIPPS application .

3.2.1 Programmable Electronic safety-related System used as logic solver inaccordance with the IEC 61508 &61511

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The panel will be free standing type, made up of 2 mm thick (min) stainlesssteel 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 Weatherproof to IP 65 minimum and also suitable for continuous trouble free operationin harsh corrosive environment (ambient temperature: 16 0C to 50 0C: 95%RH).

All the main components (valves, lamps, pressure transmitters etc.) will besuitable 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 316tubing 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

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.

3.3 HIPPS VALVES

3.3.1 The valves shall be ANSI class VI leakage. Metal to metal seats are desirable forits inherent fire proof design. The valve seat material shall be suitable for 25years of life and material conformance test shall be submitted along with pre-qualification documents. For other type of design, the Company approval must betaken in advance. Refer Piping Functional Specifications of SDVs.

3.3.2 Valve body shall be forged or cast and internals / wetted parts shall be selected tosuit the process / service conditions (sour services as well as non sour services).Refer Piping Material Specifications for details and process scope of work.

3.3.3 Valves shall be provided with anti-blow-out and anti-static device.3.3.4 The valves shall have proven reliability data in compliance with the required

Safety Integrity Level (SIL-3) of the HIPPS.3.3.5 Power efficient SOVs (compliant to SIL 3) with characteristics of direct acting

high flow, NAMUR, quick exhaust etc. shall be considered.3.3.6 SIL certification for complete valve assembly is required from a reputed SIL

certifying agency.

3.4 ACTUATORS

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.

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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 thevalve by mistake.

3.4.8 Actuators shall be provided with 3 limit switches (open, close andintermediate)/position transmitters.

3.4.9 The actuators shall have proven reliability data in compliance with the requiredSafety 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 inspecifications of logic solver / HIPPS Loop Diagram.

3.5.2 Field mounted pressure transmitters if used shall be of proven type for offshoresafety functions.

3.5.3 Pressure sensors shall be suitable for systems requiring SIL-3 level integrity inaccordance with IEC- 61508.

3.5.4 All required accessories shall be provided.

4.0 SPECIAL CONDITONS TO BE FULLFILLED BY HIPPS VENDOR

4.1 All the major components / sub components of HIPP system shall have reliabilitydata to meet SIL -3 certification requiremnts.

4.2 Vendor shall provide the SIL-3 certification for the entire system from reputedSIL-3 certification approval agency along with the SIL analysis report and allreferences.

4.3 The vendor shall commission the HIPPS at each offshore platform anddemonstrate successful operation of the same.

4.4 HIPPS shall be supplied as a package on single point responsibility basis. TheHIIPS vendor shall have Proven Track Record for supplies of similar HIPPSystems which are in operation on Offshore Installations for a minimum periodof two years.

5.0 WARRANTY

Vendor shall have total responsibility for the design and performance of completeHIPP System.Vendor shall warrant the equipment furnished by him and theperformance of the said equipment in accordance with this specification. Also referto Warranty clause as given in bidding documents (Volume I).

6.0 FACTORY ACCEPTANCE TEST

6.1 Factory Acceptance Test procedure for acceptance of HIPP System shall besubmitted for Companys / TPI approval 8 weeks before the scheduled

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commencement of testing. FAT procedure shall be prepared as per the requirementsoutlined in the bid documents and applicable standards .

6.2 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 finalonsite configuration as closely as possible .6.3 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 SPARES

7.1 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 supplyof HIPPS package. In addition, vendor shall furnish a separate itemized pricedlist of recommended spares for one (1) year post-warranty operation andmaintenance. Also refer Instrument design criteria clause number 3.6.4.8

7.2 Provision shall be made in HIPPS Panel to operate and control future facilitieswherever shown in P&ID and / or indicated in the Basic Bid Work. HIPPSpanel / cabinet mounted instruments and accessories required for this purpose

shall be supplied and installed by Contractor .

8.0 TOOLS

Vendor shall provide two sets of special tools, if not stated elsewhere, for operationand maintenance of the furnished equipment.

9.0 DOCUMENTATION

HIPPS Schematic showing all the components shall be submitted for Companysapproval before review of PS for HIPPS.

SIL Analysis Report shall be prepared for complete HIPP System (Loop), andsubmitted for Company / TPI review

Installation and commissioning procedures for HIPPS shall be submitted to theCompany for review and approval before the start of said activities.

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