High Integrity Pipeline Protection System (HIPPS) Mokveld

These systems have been utilised in Germany for over 30 years and are proven to be extremely reliable in very rapid isolation of pipelines.

They are so reliable that the need for other safety related devices such as Safety Relief Valves can be minimised. They have the following advantages:

Negating the need for flare systems to be sized for the case of a well failing to close.

Production piping downrating, giving potential cost benefits of more than 25%

Fast inventory isolation within two seconds

Huge capital cost savings

For an HIPPS system the following components are required:

An extremely reliable tight shut-off isolation valve which closes within 2 seconds

Robust triplicated pressure sensing utilising switches or transmitters which are in a 2003 voting configuration

A Programmable Electronic Safety System or Electronic Safety System which is “Stand Alone” and meets IEC 61508 SIL requirements appropriate to the application

The Whole System Certified by an International Approval Body such as TUV

Completely independent of “human intervention”

Low Maintenance Requirement

The principal of operation is that the 2003 voted redundant pressure instrumentation trips on high pressure and isolates the pipeline very rapidly (typically within two seconds) by rapidly closing the valve. Dependant on the level of reliability required sometimes two HIPPS systems are installed in series. The need for this is determined by reliability analysis against a required facility reliability figure. These figures are determined by factors such as safety, environmental, public perception of a prescribed event and cost of an event.

TYPICAL APPLICATIONS

Onshore Gas Pipelines

Offshore and Onshore Gas Well Pipelines

Offshore Subsea Applications

HIPPS Papers and Applications

The following technical papers, articles and application examples are from our sponsor Mokveld

What is HIPPS? - HIPPS is an abbreviation of “High Integrity Pressure Protection System”. HIPPS systems are applied to prevent over-pressurisation of a plant by shutting-off the source of the high pressure. In traditional systems over-pressure is dealt with through relief systems. Relief systems have obvious disadvantages such as release of (flammable and toxic) process fluids in the environment and often a large footprint of the installation. With the increasing environmental awareness relief systems are no longer an acceptable solution. HIPPS provides a technically sound and economically attractive solution to protect equipment in cases where High-pressures and / or flow rates are processed, the environment is to be protected, the economic viability of a development needs improvement and the risk profile of the plant must be reduced. HIPPS is an instrumented safety system that is designed and built in accordance with the IEC 61508 and IEC 61511 standards. This useful paper describes the technology well.

12.09 Shutoff Valves - This paper highlights the HIPPS applications.

5.10 Considerations in Designing HIPPS - Willem-Jan Nuis / Rens Wolters - HIPPS is an abbreviation for High Integrity (Pressure) Protection System, which is a specific application of a Safety Instrumented System (SIS) designed in accordance with IEC 61508. The function of a HIPPS is to protect the downstream equipment against overpressure by closing the source. Usually this is done by timely closing one or more dedicated safety shut off valves to prevent further pressurisation of the piping downstream of those valves.

5.10 Axial excellence in China's Gas Transmission Network - Chris Charles and Machiel Bosma - Since the early 1900's an exceptional valve concept was used in hydro-power plants: the axial flow valve. Axial flow refers to the streamlined symmetrical and unrestricted flow path between the valve inner and outer body. In the 1950's Mokveld acknowledged the advantages and adopted the concept into their control valves designs. Over the last decades, this axial control valve has captured a strong position across the full range of gas and oil segments; production, processing, transmission, storage and distribution. In this article, Mokveld presents some benefits of the use of axial control valves and provides some specific project application examples of their engineered valve solutions in China.

5.10 Partial Stroking on Fast Acting Applications - Willem-Jan Nuis / Rens Wolters - A proof test is a periodic test of the safety instrumented system, IEC 61508 adds that the target should be to detect 100% of all dangerous failures and all safety functions should be checked. Based on this we feel that partial stroking should not be considered a proof test. Partial stroking is born out of and focused on the breakaway torque of a ball valve. Partial stroking does not verify if the final element performs its safety function that is of course closing within a certain time. Therefore partial stroking should be considered on its best a diagnostic test. In some respect this could be contradicted while most partial stroke devices do not perform the test automated and do not shut-down the safety system when a fault is detected. We will however consider it a diagnostic test.

5.10 Application Examples

Full Electronic HIPPS in the Netherlands - Compressor station with underground High Integrity Pressure Protection System.

Integral Mechanical HIPPS in Argentina - Stand-alone HIPPS in remote area

Other Useful Links to Technical Papers and Articles

5.10 High Integrity Pressure Protection System - A High Integrity Pressure Protection System (HIPPS) is a type of safety instrumented system (SIS) designed to prevent over-pressurisation of a plant, such as a chemical plant or oil refinery. The HIPPS will shut-off the source of the high pressure before the design pressure of the system is exceeded, thus preventing loss of containment through rupture (explosion) of a line or vessel. Therefore, the HIPPS is considered as a barrier between a high-pressure and a low-pressure section of an installation. Covers Traditional systems, Advantages of HIPPS, Components of HIPPS, HIPPS Diagram, Standards and Design Practices -from Wikipedia, the free encyclopedia.

5.10 High Integrity Pressure Protection Systems - The connection of new gas production sources to a gas plant facility have often required mechanical relief devices for protection of the gas production facility and / or pipeline. New production sources connected to existing pipelines require that the pipeline is protected against potential overpressure which may result in the release of the hydrocarbons to the atmosphere or undesirable burning of these hydrocarbons via a flare system. International standards - API 521, Code Case 2211 of the ASME Section VIII, Division 1 and 2, ANSI/ISA 84.01-2004, IEC 61511 - are now in place to allow for the application of high reliability safety instrumented systems to replace traditional mechanical relief devices and to remove the need for flaring. The evolution of High Integrity Pressure Protection System (HIPPS) has therefore radically reduced the need for traditional mechanicalrelief devices and the level of flaring in oil and gas applications - from ICS Triplex Silvertech.

5.10 HIPPS Design - In general, the HIPPS design should satisfy the required SIL by calculation, based on component reliability and fault tolerance requirements. It should be noted also that in the UK, ALARP ( as low as reasonably practicable ) plays an important role when considering risk in the derivation of the safety case associated with any HIPPS application. Reference to, and conformance with, safety standard IEC 61508 will be an essential requirement of the HIPPS design process - from MCE International.

5.10 Safety Instrumented Systems for the Overpressure Protection of Pipeline Risers - This provides guidance on pipeline riser system pressure containment, and on the overpressure protection of riser systems by means of instrumented systems which are remotely located on a normally unattended installation (NUI) or subsea- from the HSE UK.

5.10 High Integrity Pressure Protection Lowers Subsea Costs - Ian Ramsay-Connell - Several North Sea examples illustrate the advantages of install ing high-integrity pressure protection systems (HIPPS) on subsea wells. Many published papers discuss the benefi ts of subsea HIPPS and many studies show the potential cost-benefi t analysis of this technology in deepwa ter applications - from Yokogawa.

4.10 HIPPS-High Integrity Pressure Protection Systems - By now if you have been working in the process industries (like chemicals, oil & gas, petrochemicals and so on) for some time, you must have come across the term HIPPS. What is it? It is an acronym for High Integrity Pressure Protection Systems. These protection systems can be considered to a special subset of Safety Instrumented Systems, that are meant to provide protection to pressurized equipment (tanks, pipelines and so on) against overpressure and consequent rupture. Thanks to our sponsor Abhisam Software.

12.09 Instrumented Protection Systems – HIPPS, High Integrity Pressure Protection Systems - High Integrity Pressure Protection Systems (HIPPS) are used to reduce the risk that a system can exceed its design pressure to a tolerable level. Conventional design standards applied in the oil and gas industry stipulate that final protection of piping and pressure vessels against over-pressurisation shall be provided by means of mechanical relief devices. Sometimes the use of these devices, like relief valves, is undesirable or impossible. Instrumented protection systems provide a technically sound and economically more attractive solution to this problem in situations where:
- Extremely high-pressures, or flow rates are processed.
- Environmental constraints or restrictions limit the use of conventional relief systems.
- The economic viability of a development needs improvement.
- The risk profile of the plant must be further reduced.

3.10 HIPPS solutions - Safe Operation and Nonstop Availability - The main reasons for using HIPPS (high-integrity pressure protection systems) are safety, environmental and economic. Safety to ensure that you can confidently operate close to design limits. Environmental to avoid unnecessary flaring and thereby limiting air emissions. And economic to reduce costs, because it is always cheaper to use HIPPS than to install full-flaring capacity and full-schedule piping and equipment. The continuous operation of equipment is a prerequisite. Nonstop operation – this is the advantage offered by HIMA HIPPS solutions. All applicable standards up to SIL 3 and even SIL 4 are also met.

HIPPS protects subsea production in HP/HT conditions - Lars Bak - Lilleaker Consulting AS - Roald Sirevaag and Halvor Stokke -The subsea production system for the high pressure/high temperature (HP/HT) Kristin field was developed to accommodate its shut-in wellhead pressure of 740 bar (74 MPa) and flowing temperature of 157° C (315° F). This required protecting the flowlines and risers from overpressure. The Kristin field began production in Nov. 2005, and in Aug. 2006, five of six subsea high integrity pressure protection system (HIPPS) were working. During the initial year of operation, the Kristin subsea HIPPS proved reliable, operations friendly, and efficient, causing no unplanned production loss. This performance can be attributed to the extensive qualification process, the design effort, and quality control throughout development. Thanks to offshore-mag.com

Subsea HIPPS offers high-pressure field development option - Sandeep Patni and Janardhan Davalath - A major challenge in developing a deepwater project is recovering reserves at a reasonable capex investment for flowline and riser installation. A high-integrity pressure protection system (HIPPS) is a step toward improving recoverability. HIPPS provides a pressure break between subsea systems that are rated to full shut-in pressure and the flowline and riser, rated to a lower pressure. Thanks to offshore-mag.com

High Integrity Pressure Protection Systems [HIPPS] for the Overpressure Protection Of Pipeline Risers - This document is to provide guidance for Inspectors in respect of the provision of remotely located HIPPS, including those located subsea, for the protection of pipelines, pipeline risers and some associated topsides process pressure systems. From the HSE (UK)

High Integrity Protection Systems (HIPPS) – Making SIL Calculations Effective - Jean-Pierre Signoret - In the oil industry, traditional protection systems as defined in American Petroleum Institute (API) 14C are more and more often replaced by high integrity protection systems (HIPS). In particular, this encompasses the well-known high integrity pressure protectionsystems (HIPPS) used to protect specifically against overpressure. As safety instrumented systems (SIS) they have to be analysed through the formal processes described in the International Electrotechnical Commission (IEC) 61508 and IEC 61511 Standards in order to assess which Safety Integrity Levels (SIL) they are able to claim. Thanks to Touchoilandgas.com

5.10 Wellhead Flowline Pressure Protection Using High Integrity Protective Systems - Angela E. Summers, Ph.D., P.E., President, SIS-Tech Solutions, LP Bryan A. Zachary, Director, Product & Application Engineering, SIS-TECH Solutions, LP - For many years, owner/operator pipe specification practices have required that wellhead downstream piping be adequate to sustain a full wellhead shut-in. This inherently safer design practice ensured that flowline pipe was specified with a maximum allowable working pressure (MAWP) equal to or greater than the maximum pressure expected to be produced by the well. This practice has been proven to provide adequate protection in thousands of wellhead installations throughout the world. Inherently safer practice has been challenged recently with the introduction of electric submersible pumps (ESPs) in new and existing wells. The maximum discharge pressure under block-in conditions is greater than the MAWP of existing flowline pipe. A safe alternative to replacing the pipe is the use of a high integrity protective system (HIPS) designed and managed as a safety instrumented system (SIS). While the HIPS protects the flowline, the implementation of the HIPS introduces a new cause for blocked ESP discharge, which can result in significant ESP damage and production losses. This new hazard scenario must be addressed in the overall risk reduction strategy for the ESP and pipeline. This presentation explains how HIPS can be applied as a layer of protection against flowline overpressure in single and multiple wellhead installations. It also discusses how HIPS implementationaffects the necessary ESP protection.

High Integrity Pressure Protection Systems (HIPPS) - Angela E. Summers, Ph.D., P.E., President, SIS-TECH Solutions, LLC - Fortunately, API 521 and Code Case 2211 of ASME Section VIII, Division 1 and 2, provide an alternative to pressure relief devices – the use of an instrumented system to protect against overpressure. When used, this instrumented system must meet or exceed the protection provided by the pressure relief device. These instrumented systems are safety instrumented systems (SIS), since their failure can result in the release of hazardous chemicals and/or the creation of unsafe working conditions. As SISs, they must be designed according to the United States standard ANSI/ISA S84.01-1996 or the international standard IEC 61511. The risk typically involved with overpressure protection results in the need for high SIS integrity; therefore, these systems are often called High Integrity Pressure Protection Systems (HIPPS) or High Integrity Protection Shutdowns (HIPS). Thanks to SIPI

High Integrity Protection Systems For New And Existing Vessels - Bryan A. Zachary and Angela E. Summers, Ph.D., P.E. - High Integrity Protection Systems (HIPS) are Safety Instrumented Systems (SIS) implemented to address overpressure scenarios in lieu of a pressure relief valve (PRV). HIPS essentially replaces the PRV for those scenarios that the SIS is designed to prevent. HIPS applications are generally pipeline and pressure vessel overpressure protection. Thanks to SIS-TECH Solutions

Preventing overpressure: A safety system success story - using failsafe systems to prevent overpressure - David K. Thomas -From the ISA

Flare Load Mitigation Using HIPS

12.09 High Integrity Protection Systems (HIPS) for Flare Load Mitigation - Angela E. Summers, Ph.D., P.E., President, SIS-TECH Solutions, LLC - The American Petroleum Institute (API) and American Society of Mechanical Engineers (ASME) provide criteria for the protection of vessels and pipelines from excess pressure. In conventional design, a Pressure Relief Valve (PRV) is used as the primary means of protection, and a flare is used to safely combust the gases relieved during an overpressure event. Although conventional, the use of a PRV is sometimes an unattractive proposition, particularly where the pressure relief involves a large flare load. API 521 and Code Case 2211 of ASME Section VIII, Division 1 and 2 allow the use of an SIS in lieu of a PRV as long as the SIS meets or exceeds the protection that would have been provided by the PRV. As an SIS, the design must follow the safety lifecycle provided in the United States standard ANSI/ISA 84.01-1996 or the international standard IEC 61511. The required risk reduction results in the need for high SIS safety availability; therefore, these systems are often called High Integrity Protection Systems (HIPS)

12.09 Flare Header Over-pressure Protective System using HIPS - In the chemical process industry, a key safety consideration is the control and response to over-pressure situations. Traditionally, pressure relief valves and flares were used to handle the relieving of vessels from over-pressure in the worst case scenario. When units are expanded, modified, or when a new unit is being integrated into a plant, existing flare capacity may be inadequate. Flare capacity, an essential safety design feature, is normally sized on the basis of handling the largest release resulting from a single contingency for a unit. Conventional design of over-pressure protection systems require additional flare capacity either by installing another flare system or reducing contingencies of existing flare systems. An alternative is to apply High Integrity Protective System (HIPS) to reduce some single contingencies to double contingencies, thereby allowing continued operation without compromising safety, or requiring additional expansion or investment in the flare system. A properly designed and applied High Integrity Protective Systems (HIPS) may be used to reduce loads to existing flare systems or provide additional safeguards where conventional pressure relief devices have proven to be unreliable. The use of HIPS also conforms to ISA S84 "Application of Safety Instrumented Systems for the Process Industries" and the Draft International Electrotechnical Commission (IEC) 61508 Standard "Functional Safety: safety-related systems", Parts 1 through 7 - from processoperations.com .

5.10 Maximize the Use of Your Existing Flare Structures - Due to the design vintage of many petroleum refineries and petrochemical plants, existing pressure relief and flare systems may be overloaded because of prior unit expansions/upgrades have increased the load on the flare for combined flaring scenarios beyond the original design intentions, the desire to connect atmospheric relief valves to the flare for environmental and safety consideration and to eliminate blow down drums, addition of new process units that need access to flaring capacity. As a result, many petroleum companies are engaged in comprehensive flare systems evaluation and upgrading projects to ensure continuing safe operations, to MAXIMIZE the use of their exiting flare systems, and to MINIMIZE the need for modifying existing flare structures or building new ones. This excellent paper provides a general framework for evaluating and maximizing available flare systems capacity, and investigates criteria and approaches for determining a tolerable risk event for flare systems. It also details how to implement a HIPS design - from ioMosaic Corporation.

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