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34 Samss 624
34 Samss 624
34-SAMSS-624
18 August 2009
Scope............................................................. 2
Conflicts and Deviations................................. 2
References..................................................... 2
Definitions....................................................... 3
Environmental Conditions.............................. 4
Wellhead Shutdown System Requirements... 6
Hydraulic Based Wellhead
Shutdown System Requirements......... 17
8 Electronic Based Wellhead
Shutdown System Requirements......... 19
9 Nameplates and Tags.................................. 21
10 Inspection and Testing................................. 21
11 Drawings...................................................... 22
12 Other Miscellaneous Requirements............. 22
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
Scope
This specification defines the minimum technical, functional, design and performance
requirements for wellhead real time process control, monitoring, and shutdown systems
for use in outdoor locations both onshore and offshore.
The wellhead control and shutdown system architecture will provide a means to operate
wellhead surface and subsurface safety valves locally and will provide an electronic
base for remote surveillance or well monitoring and control as defined in the Purchase
Order or Functional Specification Document.
This specification provides the minimum requirements for hydraulic, electric-hydraulic,
and electric-electric types of wellhead control and shutdown systems.
This specification does not include the wellhead piping, surface and subsurface safety
valves, and actuators. The Drilling and Workover Engineering Department of Saudi
Aramco is responsible to review and approve SSV and SSSV actuators purchased as
part of the wellhead tree.
Any conflict between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), Data Sheets, or industry standards, codes, and forms
shall be resolved in writing by the Company or Buyer Representative through the
Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.
2.2
Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Process & Control Systems
Department of Saudi Aramco, Dhahran.
References
Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below to the extent specified, unless otherwise noted.
3.1
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
45-SAMSS-005
175-454400
IEC 61000-4-3
Definitions
Hydraulic Wellhead Shutdown System: A control system composed of sensors,
logic, and final control elements (actuators) that utilizes hydraulic fluid pressure for
sensing and for the motive force required to operate SSV's and SSSV's. A hydraulic
system may be pressurized by a manual hand operated pump as in the case of selfcontained surface safety valve systems or via electric pumps.
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
Environmental Conditions
5.1
Environmental
5.1.1 Wellhead shutdown instruments and control components mounted
internal to the shutdown cabinet shall operate continuously under the
following humidity conditions.
Relative Humidity:
Minimum
5%
Maximum
95% (non-condensing)
5.1.2 Portions of the wellhead shutdown system that are mounted externally on
the shutdown cabinet shall operate continuously under the conditions
sporadic water spray such as from rain or offshore sea spray.
Temperature:
Instruments and control systems shall operate continuously under the
following ambient air temperatures without any degradation of the
manufacturer's guaranteed performance:
Outdoor Sheltered
Notes:
Maximum
Minimum
(1),(2),(3)
55C
(131F)
0C
(32F)
Outdoor Unsheltered
Notes:
(2),(3)
65C
(149F)
0C
(32F)
Notes:
(1) "Sheltered" refers to permanent, ventilated enclosures or buildings, or permanently
fixed sunshades with a top and three sides.
(2) For semiconductors and any other instrumentation devices which dissipate internal
heat, an additional 15C shall be added to the above temperatures. An example,
for "Outdoor Sheltered" installation, the equipment must perform at 55 + 15 = 70C.
Similarly, for the "outdoor unsheltered" case, the equipment shall be designed for a
maximum operating temperature of 65 + 15 = 80C.
(3) The designer can take credit for a cabinet closed loop A/C cooling system to
eliminate or reduce the 15C heat rise. For example, when PLC based logic solvers
are used, cabinet A/C cooling units are required and the heat removal capacity of
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
the cooler may be subtracted from the generated heat. No more than 15C
reduction in temperature will be given as credit. The designer shall substantiate his
claim by providing the support data and calculations.
5.2
5.3
20 ppm (vol/vol)
150 ppm (vol/vol)
SO2
10 ppm (vol/vol)
CO
NOx
O3
6
5 ppm (vol/vol)
1 ppm (vol/vol)
Wellhead Shutdown System Requirements
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.1.3
6.1.3.2
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.1.4 Manual Valve Operation: The wellhead shutdown system shall include
open/close pushbuttons for individual manual operation of each well's
surface valve (s). When self-contained hydraulic SSV controls are
provided, a hand pump shall be provided to re-open the valve following
a trip.
6.1.5
Engineering Units
All dimensions and measurements shall be in the "International System of
Units" (SI), and may be followed by the equivalent value in English units
between brackets. When not critical, the equivalent dimensions may be rounded
off to their nearest practical value.
6.3
Wellhead Cabinet
6.3.1 The enclosure (cabinet) shall be rigid, self-supporting and NEMA Type
4X or IEC 60529 Type IP66.
The single cabinet shall be designed with back-to-back internal mounting
construction of electronics (processors, I/O cards, and power supplies)
mounted in the front of the cabinet and the terminations of field wiring
and system interface wiring on the opposite (back) side.
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.3.2 The cabinet shall have external baffle plates to deflect direct sun light.
One (1) inch spacing shall be used between the baffle plate and the
cabinet wall.
6.3.3 When specified, as part of an electro-hydraulic hybrid control system,
hydraulic control components and connections shall be housed within a
separate enclosure outside the main electronic enclosure.
6.3.4 All process connected sensors shall be mounted outside the wellhead
shutdown system cabinet.
6.3.5 Each local wellhead cabinet shall be provided with a sunshade meeting
the requirements of section 5.1 above (top with three sides to prevent
direct sunlight from reaching the cabinet).
6.3.6 Each component mounted in or on the cabinet shall be freely accessible
for maintenance without any requirement to remove one component to
gain access to another.
6.3.7 There shall be no penetrations on the top of the cabinet.
6.3.8 The cabinet construction shall meet the following requirements:
6.3.8.1
6.3.8.2
6.3.8.3
6.3.8.4
Cut-outs shall not be flame cut and all edges and corners shall
be rounded off.
6.3.8.5
6.3.8.6
6.3.8.7
6.3.8.8
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
Electrical Construction
6.4.1 All electrical equipment installed as part of the wellhead cabinet,
sensors, and actuators shall be certified for operation in the intended
hazardous area and installed per NFPA 70, National Electrical Code.
The area classification will be specified in the Purchase Order.
6.4.2 Electrical cables shall enter the local wellhead shutdown cabinet from
the bottom of the cabinet whenever practical.
6.4.3 All cabinets shall be equipped with two drain fittings.
6.4.4 All electronic signal cables within the cabinet shall be shielded.
6.4.5 Power Supply
Saudi Aramco will supply incoming power mains to the cabinet.
Incoming power shall be distributed within the cabinet on individually
fused termination strips.
All system components and field instruments shall be powered from
within the cabinet.
Power Supply terminal block distribution wiring shall not be daisychained using wires or crimp connectors. Jumper bars or preformed
jumper combs designed for the specific terminal blocks being used are
acceptable methods of distributing power supply wiring.
Each power supply shall be capable of being isolated such that any fault
on one component shall not trip or effect the operation of other
equipment. Individual circuit breakers shall be provided for each power
supply unit.
Power supplies of the same output voltage level shall be identical for
interchangeability and spare part requirements.
Fully redundant chassis power supplies shall be used to supply power to
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
Electrical Installation
6.5.1 Cabinet Internal Wire Specifications
6.5.1.1
6.5.1.2
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.5.2.2
6.5.2.3
6.5.2.4
Twist-on wire nut connectors shall not be used for making any
electrical instrumentation terminations.
6.5.3.2
Terminal strip spacing shall allow ample room for plastic wire
ducts and permit training and lacing of cables, and fanning of
individual wires to termination points. Each terminal strip
shall be labeled above or below with the terminal strip number,
as shown on wiring diagrams. Terminals for similar (AC or
DC) current service shall be grouped together and physically
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.5.4.2
6.5.4.3
6.5.4.4
6.5.4.5
6.5.4.6
6.5.4.7
a)
b)
c)
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.5.5.2
6.5.5.3
Plastic wire ducts shall be mounted using screws. Doublesided tape is unacceptable.
6.5.5.4
6.5.5.5
6.5.5.6
6.5.5.7
Hot
Neutral
Ground
Negative
Positive
Black
White or gray
Green or green with yellow tracer
Black
Red
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.5.7.3
2)
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.5.7.4
6.5.7.5
Wire tags shall be installed and oriented such that the tags are
easily read. (Upside down or covering of tag information by
plastic duct covers is not acceptable).
6.5.7.6
6.5.8.2
6.5.8.3
6.5.9 Relays
6.5.9.1
6.5.9.2
6.5.9.3
6.5.9.4
Coil voltage shall be as specified in the Purchase Order. Pullin voltage shall be 80% or less of nominal voltage.
Page 15 of 23
6.5.9.5
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
6.5.12 Grounding
6.5.12.1 Both safety ground and instrumentation circuit ground must
conform to NEC, Article 250. Grounding system
recommendations and requirements provided by manufacturers
of instrumentation and control systems shall be followed.
Wellhead Shutdown Systems shall not have ungrounded
(floating) DC reference grounds.
6.5.12.2 Separate, electrically isolated grounding bars shall be provided.
6.5.12.3 All ground buses shall be made of a solid copper suitably
drilled and tapped for screw terminals and wire lugs, or fitted
with screw-type compression lugs.
6.5.12.4 The preferred location of the ground bus bars is at the bottom
of the cabinet.
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
7.1.3 The hydraulic header shall be sized to adequately handle the needs of the
system.
7.1.4 Relief valves shall be installed within the hydraulic system to prevent
over pressuring within high and low pressure systems.
7.1.5 On multiwell systems, a dump valve shall be installed to return header
pressure back to the hydraulic reservoir.
7.1.6 A hydraulic accumulator shall be supplied when required to handle
thermal expansion and pressure surges in the system.
7.1.7 Accumulators shall be supplied to provide backup hydraulic power. The
sizing of the accumulator system shall meet operating requirements of
the valves and actuators specified by the Drilling and Workover
Engineering Department of Saudi Aramco in 45-SAMSS-005, "Valves
ordered with actuators shall be tested with actuator installed" to ensure
proper valve and actuator operation.
Exception:
Accumulators are not required for manually pumped self-contained
hydraulic surface safety valve actuation systems where the manual pump
itself provides the system power.
7.3
7.4
Process Piping
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
Process fluid shall not be routed within the hydraulic cabinet. Flowline pressure
to the high / low pilots shall be sensed remotely on the pipeline.
7.5
7.6
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
8.1.1 The programmable logic solver shall be safety certified by TUV for SIL
3 applications, suited for continuous operation outdoors, and selected per
requirements of 34-SAMSS-623.
8.1.2 Control requirements for failsafe electric actuators shall be verified with
the supplier of the actuators.
8.2
8.3
8.4
8.5
Where remote monitoring and control are required, wellhead shutdown systems
(PLC logic solver/RTU) shall be capable of communications with the host
SCADA system as defined in the Functional Specification Document.
8.6
The wellhead shutdown systems that utilize electronic safety PLC's shall provide
for the input and output signals (logic solver I/O) as defined within the Purchase
Order or Functional Specification Document. A minimum of 5% installed spare
I/O points shall be provided.
8.7
A side mounted, closed loop cabinet cooling A/C systems shall be considered on
wellhead shutdown cabinets that house programmable logic solvers. The air
conditioner, when specified, shall be purchased from a company that specializes
in the fabrication of standard and custom outdoor enclosures, e.g., Hoffman,
Rittal, etc. The cabinet cooling unit shall be powered using utility AC power.
Commentary Note:
A side mounted, closed loop type cabinet cooling A/C unit is recommended for all
shutdown cabinets that house electronic logic solvers to reduce the possibility of
controller failures due to excessive temperature within the cabinet. The electronic
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34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
logic solver must be still be rated for continuous operations in outdoor ambient
conditions to allow for periods when the HVAC unit is out of service.
10
Nameplates shall be installed on the front of the panel to identify the panel tag
number. The nameplate description shall be as shown on the control panel
schematic. Lettering shall be a minimum of " height.
9.2
9.3
9.4
Control panel pushbuttons, switches, indicating lights and other throughmounted devices shall be identified with the service description on the front.
The rear of the above devices shall be identified with the device tag number.
The nameplates shall be permanently attached using stainless steel screws and
nuts.
9.5
Instruments and accessories mounted inside the cabinet shall be identified with a
nameplate showing the tag number.
9.6
Each cabinet, front and rear, shall be identified with a nameplate located above
each door or pair of doors. The nameplate, as a minimum, shall be the cabinet
name/number as given in the cabinet drawings.
The vendor shall notify Saudi Aramco of the expected date of final inspection
and testing of the integrated wellhead shutdown system. Saudi Aramco
representatives shall be present to witness the testing.
The items manufactured to this specification are subject to verification by the
Saudi Aramco Inspection representative, per the Saudi Aramco Inspection
Requirement 175-454100 and 175-454400 attached to the Purchase Order.
10.2
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11
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
10.3
10.4
Vendor shall supply all test equipment and labor required for testing of the
complete wellhead shutdown system.
10.5
The Cabinet Fabricator shall verify the operation of all instrumentation and
controls. Documented test procedures shall be submitted to Saudi Aramco for
approval not less than thirty (30) days before commencement of test. Tests shall
include, but shall not be limited to:
a)
b)
c)
Complete wiring check with verification that terminal and wiring code
conforms to cabinet design drawings.
d)
e)
Compete tubing logic check with verification that the tubing logic matches
the drawings supplied for review by Saudi Aramco.
f)
Drawings
Commentary Note:
Typically, general drawings are provided to the Cabinet Fabricator from the Design
Contractor. General drawings are not sufficient to review detailed design layouts. The
Cabinet Fabricator shall supply Saudi Aramco detailed drawings for review and approval.
b)
12
34-SAMSS-624
Wellhead Control, Monitoring and Shutdown Systems
c)
d)
12.2
Nonmaterial Requirements
The supplier shall provide nonmaterial items as listed on Form NMR-7907.
18 August 2009
Revision Summary
Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with editorial changes.
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