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SYNOPSIS
This document presents the On-Line Test Procedure for High Integrity pressure protection System (HIPPS) on
Flare Mitigation (CDU) Unit 011, Butane Splitter Unit 64, Marine Heavy Fuel Oil (MHFO) Unit 11, Catalytic Hydro
Desulphurizer (CHD) Unit 032.
This document is a part of SAMREF Clean Fuels Project (CFP). The intent is to implement SAMREF CFP
according to the requirements described in CFP project documents, Global Practices (GPs) and Design Practices
(DPs), Industry Codes and Standards, SAMREF specific standards, specifications, and procedures,
WorleyParsons corporate and project level standards and best practices, and industry standards.
Disclaimer
This document has been prepared on behalf of and for the exclusive use of SAMREF, and is
subject to and issued in accordance with the agreement between SAMREF and WorleyParsons.
Copying this document without the permission of SAMREF and WorleyParsons is not permitted.
.
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TABLE OF CONTENTS
1
INTRODUCTION........................................................................................................................................................4
FLAREMITIGATION(CDU011)..................................................................................................................................6
HIPPSBUTANESPLITTERUNIT064..........................................................................................................................19
MARINEHEAVYFUELOIL(MHFO)UNIT11..............................................................................................................30
CATALYTICHYDRODESULPHURIZER(CHD)UNIT032...............................................................................................35
5.1
5.2
TRAIN1......................................................................................................................................................................35
TRAIN2......................................................................................................................................................................45
List of Appendices
Appendix A FLARE MITIGATION (CDU 011) HIPPS REFERENCE DOCUMENTS ........................................... 55
Appendix B HIPPS BUTANE SPLITTER UNIT 064 REFERENCE DOCUMENTS ............................................. 63
Appendix C MARINE HEAVY FUEL OIL UNIT 11 REFERENCE DOCUMENTS ................................................ 69
Appendix D CATALYTIC HYDRO DESULPHURIZER UNIT 32 REFERENCE DOCUMENTS ........................... 72
Appendix E SAFEPLEX SIL 3 (SOV PANEL) TECHNICAL PRODUCT GUIDE ................................................. 79
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INTRODUCTION
This document presents the technical guideline for conducting on-line testing of the High Integrity Pressure
Protection System (HIPPS) valves, pumps, and transmitters installed on Flare Mitigation (CDU) Unit 011, Butane
Splitter Unit 64, Marine Heavy Fuel Oil (MHFO) Unit 11, Catalytic Hydro Desulphurizer (CHD) Unit 032.
Actual on-line testing procedure shall be a part of SAMREF Operation Manual
HS-xxx (2oo3) ESD push button near HIPPS isolation valves is activated or
HS-xxx (2oo3) ESD push button near pumps (on CDU and MHFO units) is activated or
XV-xxx1 and XV-xxx2 will close to cut off process line and
Then
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Test Method
Interval
12 month
99.90+% to 99.99% / 3
3 month
99.90+% to 99.99% / 3
Transmitters
maintenance/calibration
12 month
99.90+% to 99.99% / 3
12 month
99.90+% to 99.99% / 3
3 month
99.90+% to 99.99% / 3
Test data shall be recorded and stored for the life of the HIPPS. Test data shall include but not limited by the
following:
1) StrokingtimeforeachHIPPSvalve;
2) Adetaileddescriptionofallobserveddeficiencies/deviations
The list of Appendixes:
1) Appendix A: CDU 11 P&IDs C0EF-011B1-002A; C0EF-011B1-008; C0EF-011B1-009A; C0EF011B1-020; Figure 1 SOV Panel 11-XV-1001 Layout; Figure 2 SOV Panel 11-XV-1002 Layout; Figure
3 Heater charge pumps HIPPS Cabinet Layout.
2) Appendix B: Butane Splitter Unit 64 P&IDs C0EF-011B1-002A; C0EF-064B1-004; C0EF-064B1-001;
Figure 1 SOV Panel 64-XV-1001 Layout; Figure 2 SOV Panel 64-XV-1002 Layout; Figure 3 Butane
Splitter HIPPS Cabinet Layout.
3) Appendix C: MHFO Unit 11 P&IDs C0EF-011B1-017; Figure 1 MHFO HIPPS Cabinet Layout.
4) Appendix D: CHD Unit 32 P&IDs C0EF-032B1-003D-E; Figure 1 SOV Panel 11-XV-1000 Layout;
Figure 2 SOV Panel 11-XV-1001 Layout; Figure 3 SOV Panel 11-XV-1003 Layout Figure 4 SOV
Panel 11-XV-1004 Layout; Figure 5 CHD HIPPS Cabinet Layout;
5) Appendix E: Safeplex SILstroke-3E (SSOV Panel) Technical Product Guide.
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The Operator actions and observations during HIPPS operation and testing.
For reference see Appendix A: CDU 11 P&IDs C0EF-011B1-002A; C0EF-011B1-008; C0EF-011B1-009A;
C0EF-011B1-020. Figure 1 SOV Panel 11-XV-1001 Layout; Figure 2 SOV Panel 11-XV-1002 Layout; Figure 3
Heater charge pumps HIPPS Cabinet Layout.
STEP
Operation
Task
Operator Action
Observation/Logic Response
1.1
1.2
HIPPS at
Normal
Operation.
1.3
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SOV Panel: solenoid status lights 11-EL520A/B/C/D are ON. Local Alarm light
EL-526 is OFF.
SOV Panel: solenoid status lights EL521A/B/C/D are ON. Local Alarm light
EL-527 is OFF.
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STEP
Operation
Task
Operator Action
Observation/Logic Response
1.4
1.5
1.6
11-XA-1029A 11-HV-803/804
bypass valves open
SOV Panel
Solenoid
Functional
Test
2.1
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STEP
Operation
Task
Operator Action
843 in A position and then
release
Hold selector switch 11-HS843 in B position and then
release
Observation/Logic Response
Light 11-EL-520A goes OFF and then ON
when switch 11-HS-843 position A
released
Light 11-EL-520B goes OFF and then ON
when switch 11-HS-843 position B
released
2.2
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STEP
Operation
Task
Operator Action
Hold selector t switch 11-HS848 in C position and then
release
Hold selector switch 11-HS848 in D position and then
release
Observation/Logic Response
Light 11-EL-521C goes OFF and then ON
when switch 11-HS-848 position C
released
Full Stroke
Test (FST)
HIPPS Isolation Valve 11-XV-1001
3.1
3.2
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Start FST:
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STEP
Operation
Task
3.3
Operator Action
Observation/Logic Response
3.4
3.5
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STEP
Operation
Task
Operator Action
Ensure that Local Alarm on
SOV Panel is OFF
Open HIPPS bypass valve
11-HV-804 across the
HIPPS Isolation Valve 11XV-1002
3.7
3.8
Start FST:
Observation/Logic Response
OFF.
DCS point 11-XA-1028:- Bypass valve 11HV-804 OPEN.
P1 Alarm Bypass Valve Open 11-XA1029A activated.
After FST started the HIPPS LS de-energizes the
solenoids in the respective SOV panel and
closes HIPPS Isolation Valve.
3.9
3.10
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STEP
Operation
Task
Operator Action
Observation/Logic Response
P1 Alarm Bypass Valve Open 11-XA1029A is OFF (returns to normal).
Partial
Stroke
Test (PST)
HIPPS Isolation Valve 11-XV-1001
4.1
4.2
Starts PST:
4.3
NOTES:
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STEP
Operation
Task
Operator Action
Observation/Logic Response
4.5
Start PST:
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STEP
Operation
Task
Operator Action
Observation/Logic Response
11-EL-521A/B/C/D are ON.
Notes:
1) If the valve travel takes longer
than initial valve signature time, the
Operator shall take actions
described in Operation manual.
Heater
Charge
Pumps 11G-02A/B/C
Trip Test
Pump 11-G-02A trip test
5.1
5.2
5.3
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STEP
Operation
Task
5.4
Operator Action
Place pumps 11-G-02B and 11-G02C on bypass by turning bypass
switches 11-HS-831B and 11-HS831C
Observation/Logic Response
DCS points Pump Bypass 11-HL-831B
and 11-HL-831C
Make sure that the pumps 11-G-02B, 11G-02C are running by observing the
Pump Run lights 11-EL-517A,and 11EL-518A on HIPPS cabinet.
5.5
Pump
Stop
light
11-EL-516B
illuminated on HIPPS cabinet
5.6
5.7
is
Heater
Charge
Pumps 11G-02A/B/C
Interposing
Relays
Test
Pump 11-G-02A interposing relays
test
6.1
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STEP
Operation
Task
Operator Action
Observation/Logic Response
6.2
Make sure that the pumps 11-G-02A, 11G-02B are running by observing the
Pump Run lights 11-EL-516A,and 11EL-517A in HIPPS cabinet.
6.3
6.4
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STEP
Operation
Task
Operator Action
Observation/Logic Response
Pressure
Transmitters
11-PT1230A/B/C
Functional
Test
7.1
7.2
7.3
Provide
standard
pressure
transmitter
maintenance
and
calibration as per Supplier Test and
Calibration procedure.
7.4
NOTE:
1) During bypassed Pressure
Transmitter Test, if a trip
condition occurs, HIPPS LS
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STEP
Operation
Task
Operator Action
Observation/Logic Response
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The Operator actions and observations during HIPPS operation and testing.
STEP
Operation
Task
Operator Action
Observation/Logic Response
1.1
1.2
HIPPS at
Normal
Operation.
SOV Panels: green lights 64ZLH-1001A and 64-ZLH1002A ESDV Open are ON
DCS alarms: 64-XA-1028 and
64-XA-1029 Bypass Valve
OPENED not activated.
SOV Panel: solenoid status
lights 64-EL-520A/B/C/D are
ON. Local Alarm light 64-EL526 is OFF.
SOV Panel: solenoid status
lights 64-EL-521A/B/C/D are
ON. Local Alarm light 64L527 is OFF.
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STEP
Operation
Task
1.3
Operator Action
Verify all maintenance/bypass switches on
HIPPS cabinet in SIH-5 normalized
Observation/Logic Response
HIPPS Cabinet Bypass lights
64-XL-P-1230A/B/C are OFF.
DCS alarms 64-HA_P1230A/B/C are OFF.
1.4
1.5
P1 Indication/alarm screen in
SIH 5: No alarms activated:
64-XA-1025A Common
bypass alarm
64-XA-1022 Deviation
alarm
64-XA-1023A Forced
logic alarm
64-PAH-1230 Pre-S/D
pressure High alarm
64-XA-1031 Processor
fault alarm
SOV Panel
Solenoid
Functional
Test
2.1
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STEP
Operation
Task
Operator Action
Observation/Logic Response
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STEP
Operation
Task
Operator Action
Observation/Logic Response
Full Stroke
Test (FST)
HIPPS Isolation Valve 64-XV-1001
3.1
3.2
Start FST:
STEP
Operation
Task
Operator Action
on SOV Panel. FST Request signal sent to
HIPPS Logic solver.
3.3
Observation/Logic Response
DCS light FST Request 64HL-837 activated
SOV Panel: green light 64ZLH-1001A ESDV OPEN
goes OFF
Red light 64-ZLL-1001A ESDV
CLOSED is ON.
SOV Panel: solenoid status
green lights 64-EL520A/B/C/D are OFF.
Local Alarm light 64-EL-526
is ON.
DCS discrepancy 64-XA-1001
alarm is OFF.
3.4
3.5
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STEP
Operation
Task
Operator Action
Observation/Logic Response
3.7
Start FST:
3.8
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STEP
Operation
Task
Operator Action
Observation/Logic Response
alarm is OFF.
3.9
3.10
Partial
Stroke Test
(PST)
HIPPS Isolation Valve 64-XV-1001
4.1
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STEP
Operation
Task
4.2
Operator Action
Observation/Logic Response
Starts PST:
NOTES:
1) If the valve travel takes longer than initial
valve signature time, the Operator shall take
actions described in Operation manual.
2) During PST, if a trip condition occurs
HIPPS LS will abandon PST and initiate trip of
the HIPPS.
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STEP
Operation
Task
Operator Action
Operator ensures that Local Alarm on
SOV Panel is OFF
Operator ensures that HIPPS bypass
valve 11-HV-804 across the HIPPS
Isolation Valve 64-XV-1002 is
CLOSED.
4.5
Start PST:
Observation/Logic Response
LOCAL Alarm amber light 64EL-527 is OFF.
4.6
Notes:
1) If the valve travel takes longer than initial
valve signature time, the Operator shall take
actions described in Operation manual.
2) During PST, if a trip condition occurs
HIPPS LS will abandon PST and initiate trip of
the HIPPS.
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STEP
Operation
Task
Operator Action
Observation/Logic Response
Pressure
Transmitters
PT1230A/B/C
Functional
Test
5.1
5.2
5.3
Provide
standard
pressure
transmitter
maintenance and calibration as per Supplier
Test and Calibration procedure.
5.4
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STEP
Operation
Task
Operator Action
NOTE:
Observation/Logic Response
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The Operator actions and observations during HIPPS operation and testing.
STEP
For reference see Appendix C: MHFO Unit 11 P&IDs C0EF-011B1-017; Figure 1 MHFO HIPPS Cabinet Layout.
Operation
Task
Operator Action
Observation/Logic Response
HIPPS at
Normal
Operation.
1.1
1.2
1.3
1.4
1.5
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STEP
Operation
Task
Operator Action
Observation/Logic Response
-
MHFO
Booster
Pumps 11G-21A/B
Trip Test
Pump 11-G-21A trip test
21
2.2
2.3
2.4
Make sure that the pumps 11-G-21A, and 11G-21B are running by observing the Pump
Run lights 11-EL-512A2,and 11-EL-513A2
on HIPPS cabinet.
2.5
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STEP
Operation
Task
Operator Action
Observation/Logic Response
2.6
2.7
NOTE:
The same procedure is
repeated to test trip for pumps
11-G-21B.
Booster
MHFO
pumps 11G-021A/B
Interposing
Relays
Test
Pump 11-G-21A interposing
relays test
3.1
Ensure that one pump is
running and one on standby for
example 11-G-21A is running
and 11-G-21B is on standby.
3.2
3.3
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STEP
Operation
Task
3.4
Operator Action
Observation/Logic Response
Pressure
Transmitters
PT1224A/B/C
Functional
Test
4.1
4.2
4.3
Provide
standard
pressure
transmitter maintenance and
calibration as per Supplier Test
and Calibration procedure.
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STEP
Operation
Task
4.4
Operator Action
After test completed re-connect
11-PT-1224A to process and
turn off bypass switch 11HS_P-1224A.
Observation/Logic Response
HIPPS cabinet Transmitter in Bypass light
11-XL_P-1224A is OFF.
DCS Transmitter in Bypass alarm 11-HA_P1224A is OFF
DCS indication 11-PI-1224A enabled.
Common bypass P1 alarm 11-HA-812 is
OFF.
NOTE:
1. During Pressure
Transmitter bypass, if a trip
condition occurs, HIPPS LS
will initiate trip based on
measurements of the
remaining two transmitters.
HIPPS.
2. The same procedure is
repeated
to
test
transmitters PT-1224B and
PT-1224C.
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5.1 TRAIN 1
The Operator actions and observations during HIPPS operation and testing.
STEP
For reference see Appendix D: CHD Unit 32 P&IDs C0EF-032B1-003D-E; Figure 1 SOV Panel 32-XV-1000
Layout; Figure 2 SOV Panel 32-XV-1001 Layout; Figure 3 CHD HIPPS Cabinet Layout.
Operation
Task
Operator Action
Observation/Logic Response
1.1
1.2
HIPPS at
Normal
Operation.
1.3
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STEP
Operation
Task
Operator Action
SIH-5 normalized
Observation/Logic Response
DCS alarms 32-HA_P-1251A/B/C are OFF.
1.4
32-XA-1295 is OFF.
1.5
1.6
SOV Panel
Solenoid
Functional
Test
2.1
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STEP
Operation
Task
2.2
Operator Action
Hold selector switch 32HS-935FC/FD in FC
position and then
release
Observation/Logic Response
Full Stroke
Test (FST)
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STEP
Operation
Task
3.1
Operator Action
Observation/Logic Response
3.2
Start FST:
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STEP
Operation
Task
3.4
Operator Action
After FST complete Operator
push and hold Local Reset
push button 32-HS-935B.to
restore normal Valves
operation.
Observation/Logic Response
Operator holds 32-HS-935B until HIPPS Valve
32-XV-1000 opens.
SOV Panel: green light 32- ZLH-1005 ESDV
OPEN goes ON.
NOTE:
Only one HIPPS valve at a time shall be tested.
3.5
3.6
3.7
Start FST:
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STEP
Operation
Task
3.8
Operator Action
Observation/Logic Response
3.9
3.10
Partial
Stroke Test
(PST)
4.1
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STEP
Operation
Task
Operator Action
Observation/Logic Response
4.2
Starts PST:
NOTES:
After PST complete SOV Panel: green light 32ZLH-1005 ESDV OPEN goes ON.
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STEP
Operation
Task
4.4
Operator Action
Observation/Logic Response
4.5
Starts PST:
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STEP
Operation
Task
Operator Action
2) During PST, if a trip condition
occurs HIPPS LS will abandon
PST and initiate trip of the
HIPPS.
Observation/Logic Response
ZLH-1007 ESDV OPEN goes ON.
Pressure
Transmitters
PT1251A/B/C
Functional
Test
5.1
5.2
5.3
Provide
standard
pressure
transmitter maintenance and
calibration as per Supplier Test
and Calibration procedure.
5.4
NOTE:
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STEP
Operation
Task
Operator Action
Observation/Logic Response
1. During bypassed
Pressure Transmitter
Test, if a trip condition
occurs, HIPPS LS will
initiate trip based on
measurements of the
remaining two
transmitters. HIPPS.
2. The same procedure is
repeated to test
transmitters 32-PT1251B and 32-PT1251C.
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5.2 TRAIN 2
The Operator actions and observations during HIPPS operation and testing.
STEP
See Appendix D: CHD Unit 32 P&IDs C0EF-032B1-003D-E; Figure 1 SOV Panel 32-XV-1003 Layout; Figure 2
SOV Panel 32-XV-1004 Layout; Figure 3 CHD HIPPS Cabinet Layout.
Operation
Task
Operator Action
Observation/Logic Response
1.1
1.2
HIPPS at
Normal
Operation.
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STEP
Operation
Task
Operator Action
Observation/Logic Response
1.4
32-XA-1298 is OFF.
1.5
1.6
SOV Panel
Solenoid
Functional
Test
2.1
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STEP
Operation
Task
Operator Action
position and then
release
Hold selector switch 32HS-942FC/FD in FD
position and then
release
2.2
Observation/Logic Response
Full Stroke
Test (FST)
3.1
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STEP
Operation
Task
Operator Action
Conduct SOV Panel
Solenoid Functional
Test . .All four
solenoids shall pass
functional test (for
SOV Panel solenoids
XY-10003A, B, C, D
functional test
sequence see step 2).
Ensure that Local Alarm
on SOV Panel is OFF
Open HIPPS bypass
valve 32-HV-942
across the HIPPS
Isolation Valve 32-XV1003.
3.2
Start FST:
Observation/Logic Response
3.4
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STEP
Operation
Task
Operator Action
restore normal Valves
operation.
Observation/Logic Response
OPEN goes ON.
NOTE:
Only one HIPPS valve at a time shall be tested.
3.5
3.6
3.7
Start FST:
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STEP
Operation
Task
Operator Action
Observation/Logic Response
XV-1004 is closed
3.9
3.10
Partial
Stroke
Test (PST)
4.1
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STEP
Operation
Task
Operator Action
Operator ensures that
HIPPS bypass valve
32-HV-942 across the
HIPPS Isolation Valve
32-XV-1003 is
CLOSED.
4.2
Starts PST:
Observation/Logic Response
P1 Alarm Bypass Valve Open 32-XA-1298 is
not activated.
NOTES:
After PST complete SOV Panel: green light 32ZLH-1012 ESDV OPEN goes ON.
4.4
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STEP
Operation
Task
Operator Action
Panel Solenoid
Functional Test . .All
four solenoids shall
pass functional test.
4.5
Observation/Logic Response
NOTES:
After PST complete SOV Panel: green light 32ZLH-1014 ESDV OPEN goes ON.
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STEP
Operation
Task
Operator Action
Observation/Logic Response
Pressure
Transmitters
PT1255A/B/C
Functional
Test
5.1
5.2
5.3
Provide
standard
pressure
transmitter maintenance and
calibration as per Supplier Test
and Calibration procedure.
5.4
NOTE:
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STEP
Operation
Task
Operator Action
Observation/Logic Response
3. During bypassed
Pressure Transmitter
Test, if a trip condition
occurs, HIPPS LS will
initiate trip based on
measurements of the
remaining two
transmitters. HIPPS.
4. The same procedure is
repeated to test
transmitters 32-PT1255B and 32-PT1255C.
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1)
2)
3)
4)
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1)
2)
3)
4)
5)
6)
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