Advanced solutions key to reliable HIPPS Integrated system helps ensure safety integrity levels Carsten Thoegersen Emerson Process Management, Valve Automation igh integrity pressure protection systems (HIPPS) are be- Ing employed extensively by otishore operators to create the best solution for personnel and asset protection in high: pressure environments, In addition to providing pressure protection, HIPPS are widely considered the most viable solution for required regulatory reductions, including lower flaring and decreased fugitive gas emissions ‘Compared with conventional pressure protection systems such as relief valves or rupture disks, HIPPS address many different chal lenges. One side ofthe challenge is relate tothe reliable equipment needed to perform the safe shutdown ofthe process, while another sides the procedures driving verification, validation, and proof test ‘These procedures are very important to ensure the required safety integnty level (SIL) is addressed and maintained throughout the en- tire safety lifecycle ofthe HIPPS, Defining HIPPS HIPS are part of the safety instrumented system (SIS) and de- signed to prevent overpressure by shutting off the source and cap turing the pressure inthe upstream side ofthe system, thus provid ing a barrier between the high pressure and low pressure sides ofan offshore topsides production facility. The tight shutoff will prevent loss of the containment and eliminate fugitive emissions. In this re- «gard, HIPPS are seen asthe “las ine of defense.” ‘Atypical HIPS will include two or three inal elements in series, ‘often required to shut down within 23 seconds for gas and 68 sec: HIPPS challenges. 82 Offshore February 2014 + wrxorshreag com LMIPPS operational schematic. ‘nds for liquids, depending on the pipeline pressure flow rate, and the diameter and class ofthe pipeline, ‘The initiator of the shut down sequence (peak pressure surge) will be detected by a pressure sensing system. In the associated diagram, three sensors are connected to the logic solve, which is configured to vote with a 2003 logic system (2 out of). Ifthe pre- defined parameters for pressure are exceeded, the logic solver will shut down the final elements and the process. The 2008 configuration is usually preferred for HIPPS, since it provides availabilty as well as reliability forthe system, Challenges From an engineering point of view, the challenges faced by HIPS can be split into three phases: analyzing, designing, and operating (performance) ofthe HIPPS. These phases are described below. ‘The analyze phase is critical, and will require the end user/op- erator to perform a hazard and operating study (HAZOP) and risk assessment to identify potential process risk. Once the risk is identi fied, a risk reduction factor (RRF) will be selected to ensure that the potential risk is reduced to an acceptable level. The RF will define the SIL for which the HIPPS will need to be designed (1/RRF - SIL) Designers are challenged by the lack of standards outlining the design parameters of HIPS. Whereas conventional pressure relict valves are designed using prescriptive standards ike ASME and BS, HIPS are designed as another safety instrumented function (SIF) tied into the safety instrumented system (SIS) In designing HIPS, ‘engineering contractors will instead have to use performance-based ‘standards ike IBC 61508 and TEC 61511, Tnassessing the equipment available on the market today itis not dificult to source the right components needed to build the HIPPS and verify the system to the required SIL level. The validation is ‘often more critical since the operator will need to ensure that the HIPPS fully meets the requirements outlined in the Safety Require :ments Specification (SRS). If discrepancies are found late in the pro- cess, the date of “first oil” could potentially be extended, ‘A welkinown analysis of incidents, performed by the UK HSE.MMMM © Pcvines & FLOWLINES 7 incidents is related to poor specifica ‘Whereas SIL will protect against random fil: lures, systematic failures due to poor specif cations can only be addressed through the use of IEC 61511 in the design phase Operating a HIPPS also presents diferent allenges compared with conventional pres: sure relie systems. Among end users and ‘operators, there is often seen a fear of losing ‘Complete HIPPS packages are tasted and prepared for shipment for an on- and ofshore reduction fcity. control during scheduled test This can result intests being incomplete or not carried out at all, impacting the required safety level. The safety lifecycle depends on the frequent test ing and diagnostic ofall components in the shutdoven circuit, so rigid procedures orauto- mated tests wil be key to safe performance, Advantages and pitfalls ‘The design of a HIPS is often more com: plex in that the system requires the success ful functioning of multiple devices to achieve the same performance as a single pressure relief valve. This means that the calculated reliability of multiple devices: initiator, logic solver and the final element Ginchuding valve, actuator and controls) wil need to meet oF ‘exceed the reliability ofa conventional pres: sure relief valve To ensure thatthe HIPS system has the correct relabiy,enganeers need to pay close attention tothe basis forthe calculated failure IPLOCAS mission isto provide value to mefhbers through forum for sharing ideas, _engaging the industry and its stakeholders, faciitting business opportunities and promoting the highest standards in the pipline industry. + Unique Business Networking + HSE Monitoring & Awards Construction Innovation & Awards ‘+ Industry-speciti Training NOL rec ROE aR)sates given by the manufacturer when they select control components. Despite current safety standards that have been known to the industry for more than 10 years, there is alot of confusion in the marketplace regard- ing the difference between calculated data (FMEDA), laboratory test results, and field reported failure data. For example, using data without knowing its origination could be 1 potential pitfall. A case in point would be taking failure data taken from a high cycle ‘test and using it in the calculation of a HIPPS application, which could have years between fullvalve strokes, However, there are clearly more advan- tages than pitfalls. One of the main adva tages isthe reduction of fugitive emissions, Although a HIPS will not be able to fully replace existing systems for pressure relict, it will reduce the number of relief systems required and thereby minimize the need for annual test and its verification, Its a sound and safe way to help operators and end us- ers to reduce fugitive emissions and comply with legislation, Another clear advantage is that the auto- mated test of the control components of the HIPS will eliminate the need for personnel onsite to verify pressure reli systems. A fully automated test such as partial stroke _& FLOWLINES test (PST) can be used to run diagnostics ‘on the critical control components in the shutdown circuit and thereby increase the istic coverage (DC) ofthe system. For LHIPPS with requirements for fast closing < 23 seconds, solenoids and pllotoperated boosters ean be configured to ensure rel- able testing and avoid costly and time con suming spurious trips. While diagnostics are used to uncover a very high percentage of potential dangerous failures with the system sill in service, they could also potentially force the operator to shut down the process ia critical falure is de- tected. Depending on how critical the HIPPS is for the availabilty of the plant, a redundant HIPPS canbe installed in parallel and used ina “by-pass” configuration during repai. Addressing all phases To ensure that all of the challenges in designing, constructing, and operating a HIPS are addressed correctly, consider: able coordination is required among all of the involved parties and component sup- pliers. Alternatively, an integrated solution with a single source of responsibilty is pre- ferred, Not only does that approach address all ofthe issues faced, but it also provides the operator with a proof test and inspection plan to support the safety lfecyele.Itfurther ensures that the required SIL is maintained throughout the lifetime ofthe installation. On the component level, control equipment needs to be supplied with adequate certified failure data to meet SIL3 requirement for HIPS. These feldproven or verified compo- nents include actuators, digital valve control ler, valves, solenoids, logic solvers, and pres- sure transmitters, The main advantage to be found with the Emerson solution is the safety consultancy’ provided, making sure there isa holistic view Of the process from frontend engineering ‘over SRS to the validation of the system. © The author Canton There has 25 ers of experience wth xb oi and gos operation At ‘Bmenon Proce Management/ Valve Atomation, he has hel. rile ostion ning ranch manager and abs (iret Hee caren ose fon basins deelpmet os an ‘indy special oro and ausase, Carton hae tears dec en sabe ried oeclnel aae Profesional (CPSP. high temperatures? 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