1007-disq-0-p-ss-48078 high integrity pressure protection system (hipps)

8/9/2019 1007-DISQ-0-P-SS-48078 High Integrity Pressure Protection System (HIPPS)

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Onspec Engineering Solut ions

Disouq Field Development Project

Specification for

High Integrity Pressure Protection System

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Changes List

Rev.Date

prepared (DD.MM.YYYY)

Prepared by Description

01

01.02.2012 A Saleh /

A KhamisyClient Comments incorporated.

02 07.02.2012 A Saleh / A Khamisy

Client Comments incorporated.


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Onspec Engineering Solutions


Specification for


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Table of Contents

1 Introduction ...................................................................................................................... 5

1.1

Background .................................................................................................................. 5

1.2 Purpose of Document................................................................................................... 5

1.3 Definition ...................................................................................................................... 6

1.4 Units of Measurements ................................................................................................ 6

2 Referenced Documents ................................................................................................... 7

2.1 Project Documentation ................................................................................................. 7

2.2 International Codes and Standards .............................................................................. 7

2.3 Order of Precedence .................................................................................................. 10

3 System Description ........................................................................................................ 11

4

Extent of Supply ............................................................................................................. 13

4.1 Inclusions ................................................................................................................... 13

4.2 Exclusions .................................................................................................................. 14

5 Design Requirements .................................................................................................... 15

5.1 HIPPS Safety Loop .................................................................................................... 15

5.1.1 Initiator .................................................................................................................... 16

5.1.2 Logic Solver ............................................................................................................ 16

5.1.3 Actuator .................................................................................................................. 16

5.1.4 Final Element .......................................................................................................... 17

5.2 Utilities ........................................................................................................................ 18

5.3 Reliability .................................................................................................................... 18

5.4 Piping, Flanges, Gaskets and Bolts ........................................................................... 18

5.5 Painting ...................................................................................................................... 18

5.6 Noise Limitations ........................................................................................................ 18

5.7 Material Certification & Traceability ............................................................................ 19

5.8 Nameplates ................................................................................................................ 19

5.9 Climate Condition ....................................................................................................... 19

6

Installation, Operation and Maintenance ....................................................................... 20

6.1 Installation and Commissioning .................................................................................. 20

6.2 Maintainability............................................................................................................. 20

6.3 Special Tools .............................................................................................................. 20

6.4 Spare Parts ................................................................................................................ 20

6.5 Training ...................................................................................................................... 20


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7 Preparation for Shipment ............................................................................................... 21

8 Quality Management ...................................................................................................... 21

8.1

Testing and Inspection ............................................................................................... 21

8.1.1 Factory Acceptance Test (FAT) .............................................................................. 21

8.1.2 Site Acceptance Test (SAT) ................................................................................... 22

8.2 Vendor Data Requirements ........................................................................................ 22

Abbreviations List .................................................................................................................. 23


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Page: 5 of 23

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Specification for


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The present specification is primarily to define Company minimum requirements and does notrelieve the Vendor from his responsibility for design, performance and safe operation of thewhole system.

The Vendor shall provide the work defined herein complete in every respect and inaccordance with good engineering practice, ready to operate in the manner indicated,regardless of whether full details of such completeness, or practice is given.

HIPPS shall be certified in accordance to International Regulations as stipulated in API 521.

1.3 Definition

DEFINITION DESCRIPTION

Company RWE Dea Egypt, in a later project stage, a JV formed between RWE DeaEgypt and EGAS

Vendor Vendor is the party, which designs, manufactures or supplies equipment

3rd party Independent Verification Service The party(s) which carry(s) out all or parts

of verification services of the design, fabrication, installation and testing ofthe System(s)

1.4 Units of Measurements

Units of Measurements shall be in accordance with Environmental Data and Units ofMeasurement document no. 1007-DISQ-0-M-RT-42015.


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2 Referenced Documents

The design, construction, testing and general requirements shall comply with the latest editionof the following specifications, data sheets, codes and standards.

2.1 Project Documentation

NUMBER DESCRIPTION

1007-SSSE1-1-P-DW-48031 P&ID Wellhead SSSE 1-1

1007-DISQ-0-L-SS-39004 Protective Coating Specification

1007-DISQ-0-F-SS-10018 Noise Control Specification

1007-DISQ-0-L-SS-39010 Specifications for Piping Material

1007-DISQ-0-M-RT-42015 Environmental Data and Units of Measurement

2.2 International Codes and Standards

NUMBER DESCRIPTION American National Standards Inst itute (ANSI)

ANSI 6 1.20.1 Pipe Threads

ANSI 816.34 Valve Standard

ANSI 616.5 Steel pipe flanges and flanges fittings

ANSI 616.10 Flange Ends

ANSI 646.1 Surface texture

ANSI/ FCI 70.2 Seat leakage standard

ANSI B 1.20.1 Standard for Pipe Threads, General Purpose

ANSI B2.1 Pipe Threads (Except Dryseal) Specifications, Dimensions, and Gaugingfor Taper and Straight Pipe Threads Including Certain Special

Applications ANSI B16.20 Ring-Joint Gaskets and Grooves for Steel Pipe Flanges

ANSI B 16.47 Large Diameter Steel Flanges NPS 26 Thru NPS 60

ANSI B16.5 Pipe Flanges and Flanged Fittings

ANSI B 16.9 Factory Made Wrought Steel Buttwelding Fittings

ANSI B 16.11 Forged Steel Fittings, Socket Welding and Threaded

ANSI B 31.1 Power Piping Code

ANSI B 31.3 Chemical Plant and Petroleum Refinery Piping

ANSI B 31.4 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols

ANSI B 31.8 Gas Transmission and Distribution Piping Systems

ANSI B16.34 Valves - Flanged and Buttwelding End Steel, Nickel Alloy and OtherSpecial Alloys

ANSI B16.104 Valve Leakage Classifications

ANSI B 36.10M Welded and Seamless Wrought Steel Pipe


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American Petroleum Insti tu te (API)

API 1104 Standard for Welding of Pipelines and Related Facilities

API 2B Specification for Fabricated Structural Steel Pipes

API 500 Recommended practice for classification of locations for electricalinstallations at petroleum facilities classified as Class 1, Division 1 andDivision 2.

API 5L Specification for Line Pipe

API RP 14C Recommended Practice for Analysis, Design, Installation and Testing ofBasic Surface Safety Systems on Offshore Production Platforms

API SPEC 6D Specifications for Pipeline Valves, End Closures, Connectors and Swivels

API SPEC 14D Specifications for Wellhead Surface Safety Valves and Underwater SafetyValves for Offshore Service

API SPEC. 6F Fire test for valves

API 60 Specification for pipe line valves

API 521 Pressure relieving and depressurization systems API STD 598 Valve Inspection and test

API STD 607 Fire Test for Soft Seated Ball Valves

API RP 550 Manual on Installation of Refinery Instruments and Control Systems, Part1 - Process Instrumentation and Control, Section 6 - Control Valves and Accessories

API 554 Process Control and Instrumentation

API SPEC 6D Specifications for Pipeline Valves, End Closures, Connectors and Swivels

American Society for Test ing and Materials (ASTM)

ASTM A193 / 193M Specification for Alloy Steel and Stainless Steel Bolting Materials for

High Temperature Service ASTM A194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-

Pressure/ High-Temperature Service

ASTM A234 Standard Specification for Piping fittings of Wrought Carbon Steel and Alloy Steel for Moderate and Elevated Temperatures

ASTM A269 Standard Specification for Seamless and Welded Austenitic StainlessSteel Tubing for General Service

ASTM A269 Specification for Seamless and Welded Austenitic Stainless Steel Tubingfor General Service

ASTM A320 Specification for Alloy Steel Bolting Materials for Low TemperatureService

ASTM A325 High Strength Bolts for Structural Joints, including SuitableNuts and Plain Hardened Washers

ASTM A370 Methods and Definitions for Mechanical Testing of SteelProducts.

ASTM A403 Standard Specification for Wrought Austenitic Stainless SteelPiping Fittings

ASTM 450/450M Standard Specification for General Requirements for CarbonSteel, Ferritic Alloy, and Austenitic Alloy Steel Tubes.


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ASTM-E 94 Standard recommended practice for radiographic testing

ASTM-E 142 Standard method for controlling quality of radiographic testing

American Society of Mechanical Engineers (ASME)

ASME Section II Material Specifications

ASME Section VIII Pressure Vessels

ASME Section IX Welding and Brazing Qualifications

National Electrical Manufacturers Association (NEMA)

NEMA ICS-2 Industrial Control Devices, Controllers and Assemblies

National Fire Protection Association (NFPA)

NFPA 70 National Electrical Code

NFPA 493 Intrinsically Safe Apparatus

International Electro-technical Commission (IEC)

IEC 664 Insulation co-ordination within low-voltage systems includingclearances and creep age distances for equipment

IEC 60059IEC 60079

IEC Standards Current RatingsElectrical Apparatus for Explosive Gas Atmospheres

IEC 60085 Thermal Evaluation and Classification of Electrical Insulation

IEC 60228 Specification for conductors in insulated cables.

IEC 60331 Fire Resisting Characteristics of Electrical Cables

I EC-60332 Test on Electrical Cables under Fire Conditions

IEC 60364-1 Low-voltage electrical installations

IEC 60529 Degrees of protection provided by enclosures (IP Code)

IEC 60534 Industrial Process Control Valves Inspection & Routine Testing

IEC-61508 Functional Safety – Electrical /Electronic/ Programmable Electronic SafetyRelated Systems

IEC-61511 Functional Safety - Safety Instrumented Systems for the process industrysector

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)

MSS-SP-25 Standard marking system for valves, fittings, flanges and unions.

MSS-SP-54 Quality standards for steel casting radiographic examination method

MSS-SP-55 Quality standards for steel casting visual method

MSS-SP 61 Pressures Testing of Steel Valves


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2.3 Order of Precedence

In case of discrepancies among the various documents, the following order of precedence shallbe applied:

1. Purchase Order and amendments thereto2. Data Sheets and drawings3. This Specification4. Other Referenced Project Specifications5. Egyptian National/Local Codes and Standards6. International Codes and Standards

National Association of Corros ion Engineers (NACE)

MR-01-75 Sulphide Stress Cracking Resistant Metallic Material for Oil FieldEquipment

Instrument Society of America (ISA)

ISA-TR84.00.02-2002 -

Part 3: Safety Instrumented Functions (SIF)-Safety Integrity Level (SIL)Evaluation Techniques Part 3: Determining the SIL of a SIFvia Fault Tree Analysis

German Institute for Standardisation (Deutsches Inst itute für Normung) (DIN)

DIN 3381 Safety devices for gas supply installations operating at working pressures

Briti sh Standard (BS)

BS EN 14382 Safety devices for gas pressure regulating stations and installations

BS 6755-2 Testing of valves. Specification for fire type-testing requirements

Euro Norms (EN)

EN 13463-1

EN 13463-2

EN 13364-3

EN 13364-5

EN 13364-6

EN 13364-7

EN 13364-8

Basic Methods & Requirements for non-electrical equipment for explosiveatmospheresFlow Restricting enclosure, fr

Flame proof enclosure, d

Constructional safety, c

Control of ignition sources, b

Pressurisation, p

Liquid immersion, k


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3 System Descript ion

High Integrity Pressure Protection System (HIPPS) is a specific application of a ShutdownSystem (ESD). The function of a HIPPS is to protect the downstream equipment (vessel or

pipeline) against over-pressure by closing the source. Usually this is done by timely closing thededicated safety shut-off valve to prevent further pressurization of the piping downstream ofthis valve.

The installation of the HIPPS at the Disouq Development Project shall reduce the pipelinedesign pressure to be 100 barg. This shall realise the following advantages:

Reduced cost of pipeline - can constitute a significant portion of field development cost

Reduced pressure rating of downstream equipment separators, process plant, etc.

Increased safety by ensuring reduced pressure.

The entire system, consist of final element, being a safety shut-off valve and its switchingunits, actuator, and mechanical pressure measuring devices able to initiate activation of safetyshut-off valve. These elements shall be all integrated into a single system.

In accordance to lEC 61508, IEC 61511 and ISA TR84.00.02, the HIPPS, consisting of theelements defined above, shall be viewed as a Safety Integrity Function (SIF) and shall betreated as a dedicated safety loop. The loop shall meet the defined Safety Integrity Level. The


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assessed SIL level shall be calculated and confirmed by Vendor and audited by a certified 3rdparty. The following shall be considered when calculating the SIL level:

Device integrity determined by documented and supportable failure rates

Redundancy and voting using multiple devices to ensure fault tolerance

Functional testing at specific intervals to determine that the device can achieve the fail

safe condition

Diagnostic coverage using automatic or on-line methods to detect component or device

failure

Other common causes including those related to the device, design, systematic faults,

installation, and human error

The HIPPS system shall be capable of standalone operation without reliance on externalpower supply or other DCS or ESD equipment.

The HIPPS system shall be separated from the wellhead control system, and it shall act

independently from the wellhead control system, and is configured so that it cannot be over-ridden by the normal control system.

The HIPPS control system must be configured so that the shut off valve closes in the event ofa safety function failure: that is, the system is to “fail safe”.

The HIPPS Vendor shall prove that the supplied system PFD meets the specified SIL level.

The HIPPS design shall be based on hydraulic actuator with accumulator and hand pump forpressurisation.


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4 Extent of Supply

The Vendor shall furnish all system hardware, tubing, parts and materials for a fully functionalsystem.

The Vendor shall prepare system specifications, and test procedures for Factory AcceptanceTesting (FAT), Site Installation, and Site Acceptance Testing (SAT) for the system. TheVendor shall then perform the above testing, and maintain a system log with any correctionsmade.

The Vendor shall obtain 3rd party auditing of the system design, including the SIL levelcalculations and provide all results and conclusions to Company for approval.

Any modifications made to the system design after completion of the 3rd party audit shall besubject to a re-audit of the system.

The Vendor will perform the scope of services stated above in accordance with the provisionsof IEC 61508 and IEC 61511.

4.1 Inclusions

The scope of supply shall include but not be limited to the following:

Voting System:

o Two or three mechanical pressure switches (Initiators)

o Logic solver

Hydraulic actuator

Final element (HIPPS shut off valve)

Cabinet architecture and design.

Foundation details if required

Detailed Specification of the final element (shut off valve) describing material, design

standards, valve and actuator sizing and integration. Detailed specification of the instrumentation such as actuator, initiators, logic solver,

tubing, reset button etc.

Specific safety aspects in accordance to DIN 3381 & EN 14382.

Detailed of all the services, supports, installation and post-installation support services.

Implementation of all functions.

Instrumentation, valves, fittings and tubing.

Special tools

Fabrication and assembly

Lubrication and consumables such as hydraulic oil (first filling), etc.

Inspection & testing (including factory and site acceptance tests)

Painting and protective coating

3rd party certification (where specified in the material requisition)

Supervision of installation

Commissioning and start-up spare parts

List of two years operational spare parts

List of capital spares

Packing, marking and preservation


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Test equipment required for SAT

Documentation as detailed within VDRF and minimum quality surveillance (including

installation, operation and maintenance manuals)

Performance and mechanical guarantees

Warranty.

Spare parts.

Training.

Providing all documentation required for continuous & reliable operation.

4.2 Exclusions

Civil works including foundations


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5 Design Requirements

HIPPS vendor shall be responsible for the complete design, fabrication, testing, supply andguarantee of the HIPPS.

Mechanical HIPPS shall have its own sensing, logic solver and final element loop and shall betotally self-contained.

The mechanical system shall be standalone without requirement for external power sourceand therefore suitable for locations in remote areas.

Considering the consequences relating to escape of gas, injury to personnel, economicallosses caused by damage to capital equipment, loss of production, the required SafetyIntegrity Level has been determined to be SIL 3 system certified according to IEC 61508 andIEC 61511complete with all required hardware configuration, accessories, hydraulic tubing toshut off valve, documentation & drawing requirements and test & inspection requirements.

The required SIL level shall be met over the full lifecycle of the HIPPS. The design life of the

HIPPS system shall be 25 years.HIPPS shall be certified according to IEC 61511 with respect to mechanical actuating andadditional requirements over & above IEC 61508 to achieve fast acting valve.

The system shall be designed to include facilities to allow periodic testing of the HIPPS toprove integrity including:

The reaction speed of the safety shutoff valve.

Determination of leakage rate of the safety shutoff valve.

The interval for periodic testing may be one or two times per year, the vendor shall include inits offer the periodic testing as per above statement.

The HIPPS design package shall be fully based on mechanical instrumentation in order to

achieve the saving on power, installation cost and ease of use.

The HIPPS shall be designed so that no consumption or external power sources of any kindsare required (fully self-contained).

The HIPPS shall be supplied fully tested with all elements of the safety loop integrated.

HIPPS to be provided with substantiated reliability data of the elements in the safety loopbased on actual field data of previously supplied HIPPS systems.

The HIPPS shall automatically close, by means of multiple springs in the actuator to the safeposition (valve closed) upon detection of high pressure.

System speed of response (instrumentation and final control element) shall be selected suchthat overpressure in the protected pipeline is avoided, and pressure surges in the upstream

section of the wells, caused by the closing of the valves, remain acceptable. The Vendor shallprovide Company with recommended pressure setting and speed of response to ensurepipeline protection and accepted pressure surge at well site upstream. Vendor shall supportthe recommendation with detailed study or dynamic modelling.

5.1 HIPPS Safety Loop

The safety loop is a functional unit, consisting of input (initiator), logic solver and output (finalelement).


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The logic solver shall be fully integrated with the valve actuator and shall be fully independent.

5.1.1 Initiator

The initiators are the elements measuring the process variables (PV) to sense pressureincrease. The initiators shall be mechanical pressure switches. A safety loop shall consist of 2or 3 pressure switches (1oo2 voting or 2oo3 voting) to achieve the required SIL level.

Operating Pressure: 65 to 90 barg Design Pressure: 100 barg

Operating Temperature: 10 to 60 °C Design Temperature: -20 to 80 °C

Mechanical pressure switches shall be provided with test units.

All mechanical pressure switches to be tropic proof by proper design & construction bymaterial selection.

Pressure switches voting act as Pressure Measuring & Triggering Device (PMTD), it shallhave set point accuracy suitable to satisfy HIPPS accuracy.

Pressure Switches shall be mounted directly onto the switching device (actuator).

Pressure Switches Voting shall be the only device that directly or indirectly triggers the HIPPS.No other elements of the HIPPS may interfere with the trip command generated by thePressure Switches Voting.

5.1.2 Logic Solver

Logic solver shall receive the pneumatic signals from the initiators, performs the requiredvoting and drives the final elements. Logic Solver hardware shall be designed and certified incompliance with SIL3 performance requirements.

5.1.3 Actuator

The actuator and valve shall be designed, manufactured and assembled by the same Vendor.The actuator is a vital component between the pressure sensing element and the finalelement. It shall be specifically designed for fast reliable stroking over an extended service life.On failure, they are to close the final element.

Actuator shall be of the multiple parallel springs - return piston type. Fail action, by means ofspring force only, shall be fail-close.

Actuator shall be designed to operate the valves against full rated system design pressure atthe specified minimum supply pressure.

Spring force of the actuator for the safety shut off valves in the open position shall be 500%oversized based on the "break away" force requirements in the open position. Available springforce at the closed position shall be at least 150% of the required valve shut off force in the

closed position based on the most unfavourable valve condition.

Opening the valve shall be by means of hydraulic pump installed directly on the actuator.

Actuators shall have a hydraulic end of stroke damping to avoid slamming.

Actuator shall be of the linear stem movement with easy access to shut-off valves / actuatorstem connection. Actuator / shut-off valve stem connection shall be fully enclosed to eliminatedamage of stem by sandstorms or other adverse environmental conditions.


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Actuator shall ensure valve speed to close shall be in accordance to system requirements asper previous points.

Vendor shall supply all accessories to obtain stroke as specified for the valves full stroke.

Actuator shall be mounted directly on the valve.

Yoke, brackets and / or pedestals shall be an integral part of the actuator (and should beaccounted for in the reliability data).

Actuator shall have a dedicated hydraulic tank and a return line .

5.1.4 Final Element

The shut-off valve must meet the requirements of high safety standards in critical applications.The final element shall be designed to be a highly reliable valve and maintain tight shut-offcapabilities under all encountered conditions maintaining the integrity of the elements function.Long periods of inactivity (valve remains fully open for a long period) shall not influence theresponse time of the valve, nor the stroking speed (to close).

The body of the safety shut-off valve shall be of a single piece eliminating leakage paths toatmosphere.

Valve with a flow tendency to open is not allowed.

While valve is in the open position, the sealing mechanism shall exclude any possibility ofdirect erosive action by flow on the seal.

In closed position the valve must ensure bi-directional tightness in accordance to ANSI816.104/ FC170.2 Class VI.

HIPPS valve shall be certified fire safe to API 6FA, API 607 or BS 6755.

Valves shall have zero leakage in accordance with API 598.

The safety shutoff valves must ensure seat tightness for more than 10 cycles under full rateddesign pressure.

The safety shut-off valves shall be supplied with all required accessories.

The safety shut-off valves shall be metal to metal seat due to sand content in the fluid.

HIPPS shut off valve shall comply with the following:

Valve Rating API 5000

Fluid Hydrocarbon gas, water and condensate.

Operating pressure 65-90 barg

Pressure Rating API 5000

Flow Rates, maxima 10, 15 and 20 MMSCFD

Operating Temperature 10 to 60 °C

Maximum Temperature -20 to 80 °C


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The VDRF will require the vendor to confirm the predicted sound power level and maximumoverall sound pressure level in accordance with document no. “1007-DISQ-0-F-SS-10018,Noise Control Specification”.

5.7 Material Certification & Traceabil ity

All field instrumentation shall be supplied with calibration certificates.

The Vendor shall ensure appropriate manufacturing systems and procedures are used toensure full traceability of materials. During manufacture each assembled component shall beclearly and permanently marked in order that it can be traced back to the originally suppliedmaterial certificate and its origin determined.

5.8 Nameplates

The HIPPS System and field instrumentations shall be equipped with a manufacturer’snameplate of 316 stainless steel permanently attached with stainless steel screws or rivetsindicating the specified data. In addition to specified data the following data shall be provided

which is a minimum: Tag number.

Serial number

Model number

Range

Purchase Order Number

Manufacturer’s Name

Year of Manufacture

Valve Inlet and outlet connection sizes and rating

Pressure and temperature rating of the internal pressure retaining components.

Operating ranges and materials of the parts exposed to the process fluid.

And other important design parameters

5.9 Climate Condit ion

The High Integrity Pressure Protection System shall be suitable to operate in the north deltaclimate conditions as per Environmental Data and Units of Measurement, document no. “1007-DISQ-0-M-RT-42015”


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6 Installation, Operation and Maintenance

6.1 Installation and Commission ing

Special installation or commissioning requirements are to be identified by the vendor.

6.2 Maintainability

The system equipment shall be arranged to allow sufficient access for maintenance andoperation. The layout of the system equipment shall reflect a compact ergonomic design withadequate spacing between adjacent equipment and pipe work. Adequate withdrawal space,and/or removable pipe spools shall be provided, where necessary, to permit removal andreplacement of major components of the system.

Piping shall be arranged and supported so that the identified equipment maintenance itemscan be removed without dismantling surrounding equipment other than removing spool piecesadjacent to equipment connections.

The Vendor shall supply necessary special tools to enable periodic testing and maintenance.Instrumentation supplied with the equipment shall be located to permit easy access foroperation, testing and maintenance.

6.3 Special Tools

All special tools that are required for the installation, adjustment, commissioning, operation,testing and maintenance of the HIPPS shall be included in the Vendor’s scope of supply. Thisshall include any special lifting devices required for site installation of the equipment.

6.4 Spare Parts

The spare parts necessary during the construction, commissioning and start-up shall beprovided by the Vendor with the package, unless otherwise specified in the purchase order.

The spare parts for two years operation may be purchased separately from the mainequipment unless otherwise specified in the purchase order. They shall be listed (as perVendor recommendation) and quoted separately from the main equipment as optional item.

6.5 Training

Special training requirements for operators and maintainers are to be identified andrecommended by the vendor.


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7 Preparation for Shipment

All equipment shall (where practical) be supplied fully assembled. In order to minimise theinstallation and pre-commissioning time at site, the equipment shall be suitably packed ready

for shipment. The Vendor shall also include adequate protection and preservation for aminimum of six months outdoor storage from delivery to site. All necessary temporary supportsand other facilities shall also be provided to enable the equipment to be securely anchoredduring transport.

Each equipment item shall be clearly identified on the outside of the packing with a descriptionand tag number so that any packaging need not be removed until such time as the equipmentis ready to be installed.

Spare parts shall be individually packed for long term storage. All exposed or loose parts shallbe completely boxed with identification tag. Gaskets supplied by the fabricator shall be new;gaskets used for shop hydrostatic test are not acceptable.

8 Quality Management

The Vendor and his Sub-Suppliers shall maintain Quality Management Systems in accordancewith BS EN ISO 9001, “Quality Management Systems – Requirements” and in accordancewith Company approved Quality Plan document 1007-DISQ-0-A-QP-10090 rev 00 and theMinimum Quality Surveillance Requirements document 1007-DSQ-0-FO-10091.

These Quality Management Systems shall be adopted by the Vendor throughout the variousphases of the project (Engineering, fabrication, assembly, testing, Inspection, installation andcommissioning).

The Vendor shall manage and implement the work in accordance with an acceptable certifiedmanagement system, covering engineering, purchasing, expediting, fabrication, testing,installation and commissioning in respect of the applicable regulations, Codes and Standards.

8.1 Testing and Inspection

8.1.1 Factory Acceptance Test (FAT)

The Vendor shall perform inspection and testing at his shop in the presence of Companyand/or its representative prior to shipment. Vendor shall be fully responsible for the completedesign, fabrication, inspection, testing, installation and commissioning of all the systemcomponents.

The Vendor shall perform a complete functional test of all the High Integrity PressureProtection System components before making the equipment available for the witnessedFactory Acceptance Test (FAT).

All testing will be conducted in accordance with test procedures. The vendor shall furnish thetest procedures to the Company for review at least 2 months prior to the FAT.

The vendor shall make available, at his cost, all necessary test equipment, tools, cables andpersonnel for the duration of the tests.

The FAT shall be performed at the Vendor’s facilities with a comfortable work environment andeasy access to all equipment.

A test log shall be maintained by the vendor to keep record of the tests carried out, any fault,rectification work done, etc.


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Deficiencies noted during FAT shall be corrected and fully retested to Company satisfaction.Certification of completion of FAT including a list of outstanding deficiencies shall requiresignature by the Company.

Company reserves the right to inspect all stages of manufacturing/assembling/testing of theequipment package at Vendor/Sub-Vendor shop.

Company shall have the right to reject any equipment non-conforming to the purchase orderand referenced specifications.

The Vendor shall carry out all specified testing and inspection required by contractualdocumentation, specifications, applicable codes & standards and the manufacturer’s qualitycontrol system. The Vendor shall retain all required records and documentation pertinent tothese activities.

Acceptance criteria of tests, when not defined by the applicable codes, shall be specified bythe Vendor in the Vendor Quality Control Plan and/or test procedures and shall be sent toCompany for review.

8.1.2 Site Acceptance Test (SAT)

As minimum the SAT shall include the following:

Site Integration Test for mechanical and instrument integration

Commissioning: initial operation test prior to opening of well and at the firstopening of well

Performance Test: multiple operation tests at full flow and pressure

A complete audit of all equipment to verify that it has been received and does nothave any mechanical damage, loose parts, etc.

Verify that agreed outstanding items noted during FAT have been corrected andtested.

Verification that the installation meets the Company specifications

Verification that all equipment is functional

All Site Acceptance Tests shall be carried out with the Vendor’s representative inattendance. All field test instruments to be specified by Vendor and supplied byVendor

The SAT shall include testing of all systems and external interfaces which cannotbe tested during the FAT(s)

Vendor shall submit detailed test procedures to be approved by Company

8.2 Vendor Data Requirements

The Vendor data requirements shall be as specified on the Vendor Data Requirements Form(VDRF) attached to the Material Requisition. The required number of reproducible and copiesshall be as specified.

An installation, operating and maintenance manual (IOM) and manufacturers record book(MRB) shall be provided as detailed in the material requisition.


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Abbreviations L ist

ABBREVIATION DESCRIPTION ANSI American National Standards Institute

API American Petroleum Institute

ASME American Society of Mechanical Engineers

ASTM American Standard for Testing Method

BS British Standard

CCR Central Control Room

CTP Central Treatment Plant

DCS Distributed Control System

DIN Deutsches Institute für Normung “German Institut for Standardisation”

ESD

EN

Emergency Shut Down

European NormFAT Factory Acceptance Test

HIPPS High Integrity Pressure Protection System

IEC International Electro technical Commission

lEE Institution of Electrical Engineers

ISA Instrument Society of America

I/O Input/output

MSS Manufacturers Standardization Society of the Valve and Fittings Industry

NACE National Association of Corrosion Engineers

NEMA National Electrical Manufacturers Association

NFPANPT

National Fire Protection AssociationNational American Standard Taper Pipe Thread

PCS Process Control System

PFD Probability of Failure Demand

PMTD Pressure Measuring & Triggering Device

PV Process Variable

SIF Safety Integrity Function

SI International Standard

SAT Site Acceptance Test

SIL Safety Integrity Level