High Integrity Pressure Protection System

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Janis Weaver
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1 High Integrity Pressure Protection System _CCI_HIPPS.indd 1

A CCI HIPPS offering is unique in its: Innovative custom engineered system approach Variety of actuator and valve solutions for an optimized process Dedicated valve and control experts focused on

2 A CCI HIPPS offering is unique in its: Innovative custom engineered system approach Variety of actuator and valve solutions for an optimized process Dedicated valve and control experts focused on risk and cost Protection Layer HIPPS Human Operator Basic Process Control Risk Factor CRITICAL EMERGENCY Low Protection Type ISOLATION PROCESS The World Leader in Severe Service Applications For over 50 years, CCI has developed products and services for the unique needs of the power, nuclear and oil and gas industry s. Our team of experienced engineers have elevated their skills to the point of becoming industry experts; known as Valve Doctors. These experts focus on solving the newest challenges in control valve, actuation and safety system applications. HIPPS Safety Considerations about Over-Pressure and Safety Protection An important safety consideration in the process industry is the prevention of containment loss due to vessel or pipeline overpressure situations. Accidental loss of containment can have catastrophic effects to both humans and the environment; as well have an economic impact from production loss and maintenance costs. Conventional plant designs utilize pressure safety-relief valves as a primary means of pressure protection. In today s new plant designs, with increased flow rates and increased environmental constraints, the utilization of conventional pressure relief devices become impractical from an economic standpoint. The new designs call for a dramatic increase in pipe diameters and vent systems, as well as the safety relief valves. As such, the utilization of HIPPS methodology is widely becoming accepted as the process industry s preferred pressure protection system. HIPPS systems are a series of components, specifically engineered to isolate the source of dangerous high pressure instead of relieving the excess flow, in the case of an overpressure event. HIPPS is an independent and reliable Safety Instrumented System that is designed with high integrity as per established ANSI/ISA and IEC standards, in order to equal or exceed the safety performance of conventional safety valves. Safety As a Safety Instrumented System (SIS), HIPPS requires each specific applications to be investigated thoroughly. The main metric of the SIS is the safety integrity level (SIL). The SIL represents the necessary risk reduction to obtain the desired tolerable risk, as recognized in a user s risk analysis. Every HIPPS subsystem (sensors, logic solver, final elements) are designed in order that all together are capable of achieving the overall SIL of the complete loop _CCI_HIPPS.indd 2

The international standards IEC 61508 establishes a framework for the design of instrumented systems that are used to mitigate safety-related risks, while IEC 61511 and the ANSI/ISA S84.00.

3 The international standards IEC establishes a framework for the design of instrumented systems that are used to mitigate safety-related risks, while IEC and the ANSI/ISA S are intended to address the application of SIS in the process industry. Precision and performance When the process industry has a severe duty application, like HIPPS, where product integrity are focal, CCI has the engineering and products to meet the challenge. Our custom designed solution will have the industry leading analytics applied to ensure that the overall integrity level of the system will be achieved; which is supported by a third party SIL certification. Safety requirements are exceeded using the specific equipment to maximize operation time. Standard diagnostics include input signal monitoring, logic solver diagnostics and automatic partial stroke testing, when applicable, of the final element sub-system. The equipment consists of: Initiators / Process Sensors Initiators are either electronic or electro-mechanical pressure switches or transmitters which measure the process variables (PV) to sense an event. Logic Solver The Programmable Electronic System (PES) receives the signals from the initiators, performs the required logics (voting, diagnostics, and partial stroke test routine) and engages the final elements. Final Element The final elements are the physical units that are called upon to isolate the exposure and are typically fail safe valves, open or closed using spring Logic Solver loaded, hydraulic or pneumatic actuators and solenoids. The final configuration is prescribed by SIL for the desired fail safe level. PT PT PT The CCI HIPPS design may utilize dual devices in a 1oo2 configuration (two valves in OPEN OPEN Initiator series), where each valve has 1 or 2 solenoids (in 1oo2 logic) INTERMEDIATE INTERMEDIATE powered by two independent CLOSE CLOSE Final Elements outputs from the redundant SIL 3 certified Logic Solver _CCI_HIPPS.indd 3

Final Element Valve/Actuator options Once the engineering is done, the full advantage of working with CCI will become clear as the breadth of products we offer will be evaluated to meet your

The actuator with quarter turn movement with a very quick closing time. Damper free valve design, due to the absence of mechanical shocks at the stroke end.

The full bore valve has nearly no pressure loss when open Measurement of process variables Pressure is the process variable (PV) most commonly measured in a HIPPS system.

An advantage of the analog transmitters is that they can be continuously monitored and the operability of the transmitters readily observed, thus reducing the potential for initiator related

4 Final Element Valve/Actuator options Once the engineering is done, the full advantage of working with CCI will become clear as the breadth of products we offer will be evaluated to meet your integrity level. The product advantage extends beyond the valve size and design to include the technology embodied in other options. The actuator with quarter turn movement with a very quick closing time. Damper free valve design, due to the absence of mechanical shocks at the stroke end. The valve construction intrinsically permits the pipeline to be pig inspected. The full bore valve has nearly no pressure loss when open Measurement of process variables Pressure is the process variable (PV) most commonly measured in a HIPPS system. The evolution of the electronics has made the use of analog transmitters more suitable than the traditional discrete switches which have been used as input sensors to Logic Solver s in the past. An advantage of the analog transmitters is that they can be continuously monitored and the operability of the transmitters readily observed, thus reducing the potential for initiator related failure events. Most HIPPS applications require 2 or 3 transmitters (1 out of 2 or 2 out of 3 voting logic) as field devices. The use of redundant inputs enables system designers to incorporate diagnostics into the HIPPS, which significantly reduces the probability to fail on field input demand. Other options like independent process connections and diversity in pressure instruments, when practicable, are also recommended _CCI_HIPPS.indd 4

The Logic Solver All HIPPS logic solver hardware is designed and certified to be in compliance with SIL3 or SIL4 performance requirements, as provided in IEC 61508. Additionally, ANSI/ISA S84.00.

5 The Logic Solver All HIPPS logic solver hardware is designed and certified to be in compliance with SIL3 or SIL4 performance requirements, as provided in IEC Additionally, ANSI/ISA S and IEC recommend the HIPPS safety logic to be independent from the basic process control and lower layer protection systems. Although the logic solver can be provided with fully pneumatic logic solver (requiring no power consumption), solid state, or programmable electronic systems (PES); the preferred IMI solution utilizes the PES to provid a high level of self diagnostics, enhanced availability and fault tolerance. Diagnostics CCI provides, on demand, advanced diagnostic systems (hardware + software) that enable on line testes to be performed which may detect a possible failure occurrence in the safety loop. The main characteristics of the automatic test are: Performs without any production loss and check the state of the final element loop Doesn t inhibit the safety function at any time Enables an extension to the full stroke test interval Reduces the probability of valve sticking Provides a comparison between final element signature and the profile acquired during each test _CCI_HIPPS.indd 5

6 Throughout the world, companies rely on CCI to solve their severe service control valve problems. CCI has provided custom solutions for these and other industry applications for nearly half a century, and when it comes to safety related valve equipment and processes no one has the engineering capability like CCI CCI /11 Contact us: info@ccivalve.com _CCI_HIPPS.indd 6

Safety Instrumented Systems

Safety Instrumented Systems What is a Safety Instrumented System? A Safety Instrumented System SIS is a new term used in standards like IEC 61511 or IEC 61508 for what used to be called Emergency Shutdown