Why HIPPS ?? We have 600# (high pressure bearing) pipeline from well pads till production header. After that, we have 150# (low pressure bearing) pipeline due to economy & usage purpose. Due to some abnormality, if high pressure reaches 150# pipeline, then it may cause explosion to pipeline & hence vessels in trains area.

High pressure Bearing PipelineLow pressure Bearing Pipeline FLOW 107 psi Onsite Normal Operation (Without HIPPS):

High pressure Bearing PipelineLow pressure Bearing Pipeline FLOW 136 psi If Pressure Increases High Pressure

WHAT IS HIPPS??? HIGH INTEGRITY PRESSURE PROTECTION SYSTEM

HIGH INTEGRITY  Using 3 transmitters in downstream (works on 2oo3 logic).

PRESSURE PROTECTION  Safety Integrity Level – 3  High pressure from formation  Back pressure from trains  Pipe rating ( 600# to 150# )

Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems IEC 61508IEC and IEC standards for design, implementation and management of safety systems.IEC SIL (Safety Integrity Level ) - is a measurement of performance required. SIL 3 In accordance with IEC61508 and IEC61511 Low demand PFD-Frequency of demand of operation is < 1 per year STANDARD- International Electro Technical Commission (IEC)

1 LOGIC SOLVER 107 PSI Onsite Normal Operation (With HIPPS):

LOGIC SOLVER PSI If pressure increases:

1 LOGIC SOLVER 136 PSI

LIST OF INSTRUMENTS

TRANSMITTERS  PSIT-2011 & 2021 for Upstream  PSIT-2010 A/B/C & 2020 A/B/C for Downstream  PSIT-201 & 202 for Lube Oil (All PSIT’s are of ROSEMOUNT and Model of series 3051S)

PSIT-201 & 202  Set Point – 1800 to 2700 psi  Purpose  To start/stop the pump

PSIT SPEIFICATIONS TypeDiaphragm Seal type Maximum Temperature80ºC Minimum Temperature-40ºC Diaphragm MaterialHasteloy C 276 Fill Fluid MaterialSilicon Output Signal Type4-20mA Digital Communication stdHART Trip SP135psi

Specifications TypeBall Valve (Make- Valve Technologies) Size30” Opening time Upto 30 minutes Closing timeUpto 5 seconds Design Pressure91.7 bar Design Temperature130ºC Failure ActionFail to close Hydraulic Oil usedISOVG46 XSV

TRIPS FOR HIPPS VALVES: 1. Downstream pressure of HIPPS: 2oo3 logic. 2. When the pressure of air purge to HIPPS panel falls below 0.15 mm of water column (gauge available in field). 3. Position feedback of the HIPPS valve (any one) not available when valves are in OPEN condition: After a time delay of 40 min, both the HIPPS valves will close.

START-UP CONDITIONS 1.Pressure difference between upstream & downstream PSIT must not exceed 2.5 bar. 2.Upstream pressure should not exceed 100psi.

LOGIC OF 2oo3

BASIC LADDER LOGIC OF 2oo3

HYDRAULIC DIAGRAM

MOTOR DETAILS MakeCrompton Greaves Voltage415v +/- 6% Type3ɸ AC Squirrel Cage Induction Motor Full Load Current3.25 A Full Load Speed1415 RPM

1300 PSI PRESSURE IS SUFFICIENT FOR KEEPING THE VALVE IN OPEN POSITION. Pump stops at 2700 PSI. If the circuit hydraulic pressure is < 1800 PSI - ONE AMONG THE TWO PUMPS WILL START. < 1400 PSI THEN BOTH THE RUNS WILL START AUTOMATICALLY. CONTINUE:

PLC AIDIDO PSIT-2011/2021Limit switch of XSVXSY 2010 A1-1/2, XSY 2010 B1-1/2, XSY 2010 A1-1/ 2, XSY B2- 1/2 PSIT-2010 A/B/C(ZSO/ZSC- 2010A/2010B)XSY 2020 A1-1/2, XSY 2020 B1-1/2, XSY 2020 A1-1/ 2, XSY B2- 1/2 PSIT-2020 A/B/C(ZSO/ZSC-2020A/2020B)Trip lamp, Fault lamp PSIT-201/202Trip RESET, Fault RESET We have S7 400 PLC for HIPPS package & S7 200 PLC for hydraulic circuit. We are using two PLC’s. One for each stream for production redundancy. PLC I/O’s

Specifications of S7 400 PLC: 1. Modular PLC. 2. Handle large module. 3. Used where high processing speed & deterministic response time is required. 4. Used for data intensive tasks (data parallelism). 5. Have additional line monitoring diagnostic feature- generates alarm when wire breaks or short circuit.

Specifications of S7 200 PLC: 1. Shoebox PLC 2. Less Memory. 3. Handle small module 4. Cost effective.

ARCHITECTURE

PLC PURGING SYSTEM DETAILS MakePepperl + Fuchs Model3003-LPS-C1-YZ-VM SupplyInstrument Air Overpressure ProtectionBreather Range bar Temp. Range-29 to 50°C PurposeTo remove & prevent flammable gas or vapor accumulation. Note: Before opening the HIPPS panel, the purge pressure low trip logic should be BYPASSED by making the trip BYPASS switch “ON”. (switch available near HIPPS panel).

Cause & Effect

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