II

Spec. No. C -104

Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR Discipline Instrumentation
ISO- 9001:2008 HIPPS Paae: 1 OF 9

FUNCTIONAL SPECIFICATION

FOR

HIGH INTEGRITY PRESSURE PROTECTION

SYSTEM

Rev 3a Addendum to Rev 3 Paqe 9/9

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 Spec. No. C - 104
Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 2 OF 9

CONTENTS

Clause Page
ITEM
No. No.
1.0 Scope of This Document 3
2.0 Scope of Supply 3
3.0 High Integrity Pressure Protection System 3
3.1 Design Basis 3
3.2 Logic Solver 5
3.3 HIPPS Valves 6
3.4 Actuators 6
3.5 Pressure Sensors 7
4.0 Special conditions to be fulfilled by the vendor 7
5.0 Factory Acceptance Test 8
6.0 Spares 8
7.0 Tools 9
8.0 Pre-Qualification criteria 9
9.0 Documentation 9

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 Spec. No. C - 104
Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 3 OF 9

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/ GGS equipment by quick isolation at the source. HIPPS, while ensuring highest
level of safety of platform/ GGS and personnel, also conforms to environmental
considerations / requirements.
This functional specification describes the essential design considerations for the selection of
HIPPS consisting of logic solvers, valves, Actuators and sensors for HIPPS application for
the intended service.
In general HIPPS Logic Solver shall be electronic type, unless otherwise specified in Basic
Bid work.
2.0 SCOPE OF SUPPLY:
2.1 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.
2.2 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 for its
installation & commissioning at site. This FS shall be read in conjunction with the:-
• Instrumentation Design Criteria (IDC)
• Basic Bid Work
• Project P & IDs
• Process Design Criteria
• Electrical Design Criteria
• Piping Design Criteria / Piping Material Specifications
• Mechanical/ Pipeline Design Criteria

2.3 Latest editions of the codes enlisted below shall be followed as applicable in addition to the
codes mentioned in the IDC:

Sl. No. Number Description

1 DIN 3381 Safety devices for gas supply installations, pressure relief
governors and safety shut-off devices

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) requirements in accordance
with the international Standards IEC 61511 & IEC 61508.
3.1.2 HIPPS shall use as a minimum 02 shutdown valves (primary HIPPS & secondary HIPPS
valves) of SIL 3. Valve locations shall be as described in the process description / P&ID /

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 Spec. No. C - 104
Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 4 OF 9

Process Design Criteria. Refer Clause 11.4 (Requirement of Hardware Fault Tolerance) and
Table 5b of IEC 61511-1

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

3.1.4 The HIPPS valves shall be quick closing shut down valves. Primarily closing time of the
valve shall be based on Dynamic Simulation of over pressure scenario of the process.
However, processing time (includes sensing to 100% closing of valve) of the loop actuation
shall not be more than 5 sec. Also refer Process Design Criteria for closing time of valves.

3.1.5 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 Safety
Study Report shall be implemented by the HIPPS vendor. HIPPS vendor may be required to
participate in the HAZOP/HAZID study under the scope.

3.1.6 HIPPS system shall be designed for Shut-in Tube Head Pressure (STHP) and flowing well
fluid Temperature conditions as described in the process description of work of the bid.

3.1.7 Each HIPPS loop shall be dedicated loop and independent of all the process loops as well as
all other HIPPS loops within the HIPP system to increase safety and reliability of the HIPPS.

3.1.8 HIPPS shall be designed for Fail Safe condition. Safe state shall be as described in Process
documents.

3.1.9 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 sequence of
events shall follow approved SAFE Chart.

3.1.10 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.

3.1.11 Actuators shall be mechanical/ hydraulic / pneumatic as per process requirement.

3.1.12 HIPP system shall be supplied for a design life of minimum 25 years.

3.1.13 The HIPPS supplier shall be responsible for recertification of the System to maintain the
intended SIL for the entire life of the HIPPS.
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.

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 Spec. No. C - 104
Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 5 OF 9

In general, programmable logic solver based HIPPS is preferred. In case of severe power
constraints on the well platform etc, Pneumatic logic solver based HIPP systems are to be
considered.

3.2.1 PROGRAMMABLE ELECTRONIC LOGIC SOLVER:

Minimum requirement is SIL-3 Programmable Electronic safety-related system used as logic
solver in accordance with the IEC 61508 & 61511. However, voting logic shall be 2oo3.
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 shall be based on pneumatic components, like relays, timers, logic ports, flag
indicators, pneumatic horn, pneumatic spool valves, push button, etc.

3.2.3 The 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
Proximity switches / Position transmitter.
• Auxiliary command to valves actuators.
• Local reset
3.2.4 COMPONENTS & MATERIALS
The Electronic Logic-Solver Panel shall be free standing type, made up of 2 mm thick (min)
stainless steel SS316 if located in safe area, and 4 mm thick (min) stainless steel SS316 if it is
field mounted.
The Pneumatic Logic-Solver Panel shall be free standing type made up of 4 mm thick (min)
stainless steel SS316. The choice of the components and materials shall be for aggressive
atmosphere and made in stainless steel SS 316.

The Logic-Solver Panel shall be Weather proof to IP 65 minimum and also suitable for
continuous trouble free operation in harsh corrosive environment (ambient temperature: 16
ºC to 50 ºC: 95% RH).
All the main components (valves, lamps, pressure transmitters etc.) of the HIPP System shall
be suitable to operate with the particular condition (temperature, pressure, aggressive
atmosphere, hazardous area, gases, etc, etc).

3.2.5 CONSTRUCTION FEATURES

• Installing to floor level.
• In-coming/Out-going 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.

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 Spec. No. C - 104
Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 6 OF 9

3.3 HIPPS VALVES:

3.3.1 The valves shall be tight shut off (ANSI class VI leakage). Vendor shall propose suitable seat
materials capable of meeting the specified design pressure and temperature. Design and
testing requirement of valves shall be as indicated in Piping functional specification 2004A.
3.3.2 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). MOC of valve shall
comply with the process requirements and functional specification Piping Design 2007A.

3.3.3 The HIPPS shutdown valve shall be in accordance with functional specification
Piping Specialty 2004D provided with this FS, with specific requirements for the HIPPS
application in accordance with this specification and the Project Data Sheets.

3.3.4 All surface preparation, painting and protective coatings shall be in accordance with Spec
No. 2005, latest edition.

3.3.5 Valves shall be provided with anti-blow-out and anti-static device.

3.3.6 The valves shall have proven reliability data in compliance with the required Safety Integrity
Level (SIL-3) of the HIPPS.

3.3.7 Power efficient SOVs (SIL Certified) with characteristics of direct acting high flow, quick
exhaust etc. shall be considered.

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.

3.4.3 Safety factor will be 1.25 times of the valve maximum torque (under STHP).

3.4.4 Manual override either by providing manual hydraulic pump with removable lever or heavy-
duty hand wheels shall be provided. Hand wheels shall be normally in disengaged position
and locked during normal platform operation. Unlocking/engaging of lever/manual override
shall generate alarm and logged in the Logic Solver PLC.
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.

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Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 7 OF 9

3.4.8 Actuators shall be provided with proximity limit switches (open, close and intermediate) /
smart 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.

3.4.10 Material of construction of actuators shall be selected to prevent galvanic corrosion with the
valve and accessories.
3.5 PRESSURE SENSORS:
3.5.1 Field mounted pressure transmitters if used shall be of proven type for offshore safety
functions with SIL certification.

3.5.2 Pressure sensors shall be suitable for systems requiring SIL-3 level integrity in accordance
with IEC- 61508.

3.5.3 Three different make for the three different pressure transmitters shall be preferable.

3.5.4 SIL 3 certified High integrity Manifold (Astava interlocking manifold) shall be provided.

3.5.5 All required accessories shall be provided.

4.0 SPECIAL CONDITONS TO BE FULLFILLED BY HIPPS VENDOR:

4.1 Vendor shall provide the SIL-3 certification for the entire HIPPS Loop / system from reputed
SIL-3 certification agency along with the SIL analysis report and all references.

4.2 The single point responsibility for the supply of HIPPS shall be ensured in following ways:
a) In case the HIPPS supplier is the manufacture of either HIPPS valve or HIPPS Logic
Solver, in that case manufacture of either HIPPS valve or HIPPS Logic Solver
respectively shall have single point responsibility of complete HIPPS package. To ensure
this the HIPPS valve manufacturer or HIPPS Logic Solver manufacturer shall carry out
an agreement between them for after sales service support for the design life of HIPPS.
This agreement will be submitted to the company for review.
b) In case the HIPPS supplier is not the manufacturer of HIPPS valve, the single point
responsibility will be with HIPPS supplier only and to ensure this HIPPS supplier shall
carry out an agreement among him, the HIPPS valve manufacturer and the HIPPS logic
solver manufacturer for after sales service support for the design life of the HIPPS.
c) In both the above cases, the HIPPS supplier shall have Proven Track Record for supplies of
similar HIIP Systems which are in operation on Offshore/ remote Onshore Installations for a
minimum period of two years

5.0 FACTORY ACCEPTANCE TEST:

5.1 Factory Acceptance Test procedures for acceptance of HIPP System shall be submitted for
Company’s / TPI approval 8 weeks before the scheduled commencement of testing. FAT

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Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 8 OF 9

procedure shall be prepared as per the requirements outlined in the bid documents and
applicable standards.

5.2 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 final onsite
configuration as closely as possible.
5.3 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.

6.0 SPARES:
6.1 Vendor shall provide normal commissioning spare parts as apart of the HIPP System
supplied and mandatory spares shall be 10% minimum or 1 (one), whichever is more of each
type and range for Pressure Transmitters/Pneumatic Pressure switches, SOVs, Limit
Switches/Position Transmitters and I/O cards for Electronic Logic Solver or all type of panel
components for Pneumatic Logic Solver. In addition, vendor shall furnish a separate list of
recommended spares for one (1) year (post-warranty) trouble free operation along with the
prices for purchaser’s review. Also refer Instrument design criteria clause number 3.6.4.8.

6.2 Provision shall be made in HIPPS Panel to operate and control present as well as future wells
wherever shown in P&ID and / or indicated in the Basic Bid Work. Vendor shall provide
minimum one extra complete loop components in the Logic Solver Panel and cable right up
to the field Junction Box (terminated at both end) as installed spare. HIPPS panel / cabinet
mounted instruments and accessories required for this purpose shall be supplied and installed
by Contractor.

7.0 TOOLS:
Vendor shall provide one set of Hand-held communicator, PLC Programmer and any special
tool required for valve actuator for each platform, for operation and maintenance of the
furnished equipment.

8.0 PRE-QUALIFICATION CRITERIA

HIPPS being a critical system involved in the safety of the platforms requires special skill
w.r.t. Design, Selection, Integration and Installation. The new HIPPS supplier shall be
evaluated based on one of the following criteria.
Further, the HIPPS supplier in each of the following case shall have single point
responsibility for the supplied HIPPS.

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 Spec. No. C - 104
Offshore Design Section FUNCTIONAL
Rev. No. 3a
Engineering Services SPECIFICATION FOR
Discipline Instrumentation
ISO – 9001:2008 HIPPS Page: 9 OF 9

a) One of the major components i.e. either the HIPPS valve (meeting Piping functional
specification) or the LOGIC SOLVER should be in the regular manufacturing range of the
HIPPS system supplier. In case, the logic solver is the HIPPS supplier then HIPPS valves
should be from ONGC suggested vendor list. The HIPPS supplier must possess a valid
certificate as an organization having Functional Safety Management capability (Certification
by TUV Rhineland / EXIDA / SIRA) and having Proven Track Record for HIPPS supplied
in offshore/ onshore remote application.
In the above case, if the HIPPS supplier does not possess a valid certificate as an
organization having Functional safety management capability then the HIPPS supplier
should have SIL certified engineer (valid certificate holder from TUV Rhineland / EXIDA /
SIRA) in its strength capable of carrying out SIS analysis and designing SIFs. The SIL
certified engineer shall have the responsibility as a project manager or the Lead engineer.
Further, the HIPPS supplier shall have single point responsibility for the supplied HIPPS and
shall produce an agreement carried out between HIPPS valve manufacturer and HIPPS
Logic Solver for after sales support for the design life of HIPPS.
b) If the HIPPS supplier is an organization possessing certification for Functional Safety
Management capability from TUV Rhineland / EXIDA / SIRA and is not the manufacturer
of HIPPS valve or Logic solver but possesses experience for supply of HIPPS for
offshore/ onshore remote application , in that case the HIPPS supplier shall select HIPPS
valves and Logic solvers from ONGC suggested vendor list and selected HIPPS Valves and
Logic solver shall be SIL 3 certified (from TUV Rhineland / EXIDA / SIRA) and must
have proven track record for use in HIPPS for offshore application.
Further, the HIPPS supplier shall have single point responsibility and shall produce an
agreement made between the HIPPS supplier and the supplier of HIPPS Valve and Logic
Solver supplier for providing after sales service support to the HIPPS supplier for the design
life of HIPPS.
The HIPPS supplier in all the above cases shall produce SIL 3 certification for each of the
components of HIPP system and SIL 3 certificate for the entire loop of the HIPP system given
by TUV Rhineland / EXIDA / SIRA.
The HIPPS supplier has to ensure that the after sales service support base is available in India
and the details for the same has to be furnished along with Pre-qualification document.

9.0 DOCUMENTATION:
HIPPS Schematic showing all the components shall be submitted for Company’s approval
before review of PS for HIPPS. SIL Analysis Report shall be prepared for complete HIPP
System (Loop), and submitted for Company / TPI review.

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