CCI Innovative

Solutions for

HIPPS Systems -

High Integrity Pressure Protection System

Safety is Our Utmost Priority

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2 HIPPS - Excellence in Innovation

The World Leader in Severe Service Valve Solutions

CCI is a global business specializing in custom engineered solutions

for severe service valve and control applications. For over 45 years, CCI

has maintained industry dominance through our innovative problem

solving approach. CCI’s team of Valve Doctors is focused on developing

solutions to face the industries challenges in control valve, actuation

controls and safety system technology applications.

HIPPS – Safety Considerations for Over Pressurizing and Safety Venting

An important safety consideration in the process industry is the

prevention of loss of containment due to vessel or pipeline overpressure

situations. Loss of containment can have catastrophic effect to human

life and the environment and also have a negative economic impact,

due to production loss and maintenance costs. Conventional designs of

pressure relief or safety valves are used as a primary means of pressure

protection on most applications. However, with increased flow rate

potentials into existing infrastructure, applications where pressure

relief devices are impractical and increased environmental constraints,

the use of HIPPS (High Integrity Pressure Protection System) is widely

becoming accepted as the ultimate protection system. HIPPS is an

independently instrumented reliable system that is designed with higher

system integrity, per established ANSI/ISA and IEC standards, than

process shutdown and emergency shutdown systems.

Last level of safety

CCI Innovative custom

engineered HIPPS

Wide variety of actuator and

valve solutions to optimize

process

Work with the valve and

control experts to mitigate

risk and cost

HIPPS

ESD

PSD

DCS

Since 1961, CCI has provided a unique combination of engineering experience and global resources with one goal: to exceed customer expectations.

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3HIPPS – Safety Instrumented Systems

Safety

Since HIPPS is a type of SIS (Safety Instrumented System), the

requirements of each specific HIPPS applications must be investigated

thoroughly. The SIS standards are performance-based with the safety

integrity level (SIL) as the primary performance measurement. The

SIL represents the necessary risk reduction, as recognized in a user’s

risk reduction analysis. Each SIL level corresponds with a tolerable

probability of failure on demand (PFD) to all HIPPS devices from the

sensor through the logic solver and final elements.

The international standards IEC 61508, IEC 61511, IEC 61131 and the US

standard ANSI/ISA S84.01-1996 are intended to address the framework

for design and the application of SIS in the process industry, through the

definition of the assessment, design, validation and documentation for

SISs.

Safety Integrity

Level

(SIL)

Low Demand

Mode

(Average probability of failure to perform

designed safety function on demand)

High Demand

Mode

(Probability of a dangerous

failure per hour)

4 > 10-5 to < 10-4 > 10-9 to < 10-8

3 > 10-4 to < 10-3 > 10-8 to < 10-7

2 > 10-3 to < 10-2 > 10-7 to < 10-6

1 > 10-2 to < 10-1 > 10-6 to < 10-5

Availability

In most cases, it is not acceptable for the HIPPS to trip and stop the

plant operation due to a single failure. The safety system’s fault tolerance

is therefore one of the most important characteristics for keeping the

process safe and available.

Flexibility

HIPPS is a high quality system with flexible technology and appropriate

services to reduce overall life-cycle costs.

Installation

The justification for HIPPS in the process industry is typically facilitated

by an analysis performed by each plant. There are many factors that must

be taken into account to establish the proper framework for a successful

installation.

CCI Valve Doctors® can help power uprate and life extension programs by studying valve performance and reliability history and recommending enhancement based on extensive experience.

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4 Device Integrity and Architecture

Safety Loop

CCI recognizes that the HIPPS includes all devices required to reach

the desired safety integrity level for the process. The HIPPS includes the

entire instrument loop from the field sensor through the logic solver to

the final elements, along with other possible required devices, such as

SIS user interfaces and communications.

A HIPPS group consists of:

Initiators / Process Sensors

The initiators are the elements measuring the process variables (PV) to

sense an event. The initiators are typically electro-mechanical pressure

switches or electronic pressure transmitters.

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 drives the final elements.

Final Elements

The complete valves/actuators/solenoids assemblies are acted on to

isolate the over pressure detected by the initiators. The CCI solution

(Ball, Gate or Globe valve) is typically designed to close within 2

seconds.

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Field Service Technicians are experts in troubleshooting, critical recalibration and emergency repair.

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5CCI’s HIPPS Monitoring Solution

Initiators

Measurement of process variables

Pressure is the process variable commonly measured in HIPPS.

Traditionally, this variable is monitored using discrete switches as the

input sensor to the safety system. Although these devices are simple

and reliable, evolution of the electronics has made the use of analog

transmitters more suitable and preferable. Analog transmitters 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 separate process connections and diversity in pressure

measurement, when practical, are also recommended.

Interlocking Manifold

A possible option is the use of an Interlocking Manifold in order to

prevent operational errors.

The Interlocking Manifold principle is to permit the closing of the

isolation valves and the opening of the vent valve in predetermined safe

sequence. This will allow a safe and on-line calibration; preventing at the

same time undesired shutdown due to possible faulty operations.

The Logic Solver

The CCI Logic Solver hardware is designed and certified in compliance

with SIL3 or SIL4 performance requirements, as provided in IEC 61508.

ANSI/ISA S84.01-1996, IEC 61508, and IEC 61511 require that the safety

logic be independent from the basic process control and lower level

protection systems.

The Logic Solver can be relays, solid state, or programmable electronic

systems (PES). The CCI Logic Solver is typically PES, provided with

high level of self diagnostics, availability and fault tolerance, SIL 3

certified with simplex or redundant architecture (TMR or 2oo4/QMR) in

compliance with IEC 61131-3.

CCI’s QMR (Quadruple Modular Redundant) technology is 2oo4

architecture characterized by double processors and hardware

comparator on each central processing unit. The safety related single

channel systems and central modules are certified up to AK6/SIL3

without any restrictions. The system is characterized by optimum

diagnostic coverage, such as the central processing units communication

realized by a fast Dual Port RAM (DPR). All QMR characteristics provide

maximum availability and fault tolerance with a redundant system.

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6 HIPPS - Final Elements

Final Element Configurations

The final elements are the physical units that are called upon to isolate

the exposure. The final elements are typically either 1) relays in the

motor control circuit for the shutdown of motor operated valves,

compressor or pumps, or 2) fail safe valves opened or closed using

solenoids. The HIPPS final elements typically are made up of a valve/

actuator/solenoid configuration, as prescribed by the required SIL, in the

desired fail safe configuration.

The CCI HIPPS typically utilizes dual devices in a 1oo2 configuration

(two valves in series) in conjunction with 1oo1 or 1oo2 solenoid. Each

solenoid however can be connected in a 2oo2 configuration to reduce

spurious trips by having two independent outputs from the Logic Solver.

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Installation illustration for final elements showing 1oo2 valves and 1oo1 solenoids

Installation illustration for final elements showing 1oo2 valves and 1oo2 solenoids

Normal Pressure Over Pressure Over Pressure w/HIPPs

-0.0 sec 0.1 sec <2 sec

In Line Danger Safe w/HIPPs

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Illustration for solenoid 2oo2 connection from a redundant Logic Solver

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7HIPPS Final Element Solutions

Final Element Valve/Actuator options

CCI offers a variety of valve/actuator designs specifically suited for

HIPPS service.

Typical offer includes the CCI Rona full-bore ball valve as an ideal

technology for HIPPS.

The valve has practically no pressure loss when fully open.

The quarter turn movement permits almost the same travel and a

very quick closing time.

The valve design does not require the installation of a damper, due

to the absence of mechanical shocks at the stroke end.

The valve construction intrinsically has a “piggable” feature,

allowing the passage for the pipe cleaning “pig” device.

Diagnostics and Testing

CCI HIPPS are supplied with diagnostics designed to detect failures of

devices on-line, significantly improving the availability of the HIPPS.

Examples of standard diagnostics features:

Input signals line monitoring

Automatic partial stroke test routine

CCI also offers actuators with local accessories, enabling the user to

perform a partial stroke test on each valve independently.

The CCI Valve Doctor Approach

CCI’s team of Valve Doctors can provide the support needed during

each phase of a HIPPS project. By using our expertise and experience

in defining HIPPS architecture, fault tree analysis, analyzing pressure

rise and project stroke times and set points, a highly effective and cost

effective solution can be realized.

Final Element

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One damaged part can shut a plant down; CCI can prevent this unnecessary downtime and give you peace of mind.

DRAG is a registered trademark of CCI.©2007 CCI 879 04/05/07

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.

CCI Australia21 Catalina CrescentAvalon, NSW 2107AustraliaPhone: 61 2 9918 4094

CCI Austria(Formerly Spectris Components GmbH)

Lembockgasse 63/1AT-1233 ViennaAustriaPhone: 43 1 869 27 40Fax: 43 1 865 36 03

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CCI China – ShanghaiRoom 902-906, No. 500 Fushan RoadUrban Construction CenterShanghai 200122 ChinaPhone: 0086 21 61636500

CCI Houston (Repair Center)3409 BrinkmanHouston, TX 77018Phone: 713 869 5233

CCI India6th Floor, Warp TowerPlot No. 13, 14 & 15, EPIP ZonePhase 1, Whitefi eld RoadBangalore EastBangalore 560 066IndiaPhone: 0091 80 4190 3000

CCI sales offi ces worldwide:

CCI Italy - FlorenceVia Dell’Industria 1350056 Montelupo Fiorentino (Fl) ItalyPhone: 39 0571 5953203

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Contact us at:info@ccivalve.com

Visit us online for sales and service locations at: www.ccivalve.com

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Industrigatan 1-3, Box 603SE-661 29 Saffl eSwedenPhone: 46 533 689 600Fax: 46 533 689 601

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lm Link 11, P.O. Box 65 8404, WinterthurSwitzerlandPhone: 41 52 264 95 00Fax: 41 52 264 95 01

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