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HIPPS Black Magic or Science
HIPPS Black Magic or Science
The use of HIPPS is poorly understood and implemented, often causing additional
hazards and affecting reliability and uptime. Here using project examples Theon
Managing Director, Steve Rowbottom, asks why the industry is finding the use of
HIPPS so hard and offers advice on how they can be used to best effect and value.
Example 1
This design example was tabled during a HAZOP as a solution to protect the
separators from over-pressure due to a packed flowline. In summary the issues faced
and problems identified were:
This example relates to a new field and riser, connected to an existing separator. The
proposal uses the Riser ESDV and an additional ESDV as the valves to be closed by
the HIPPS:
In this example, one failure scenario to be protected against is the Riser ESDV
spuriously opening with packed line pressure behind it. This scenario removes one of
the final elements from the design and therefore the system cannot meet the required
SIL.
Also, to achieve fast closure times, the ESDVs will need an additional actuator,
requiring significant structural support (for 12 valves).
Pay now vs Pay Later Lack of holistic lifecycle thinking. A HIPPS system will
sometimes offer a lower capital cost for a project due to the possibility to use lower
pressure systems downstream of the HIPPS valves. However these reduced capital
costs are often out-weighed by the increased operational expenditure due to
maintenance and the increased risk and loss of production of performance verification
testing.
There is also a tendency for high pressure trips provided for process design reasons to
become de-facto HIPPs systems when this was never the original design intent.
Although complex and challenging, HIPPS designed and used properly represent a
valuable solution. There are a number of key points we would urge companies to
consider in their design and use:
Above all we would urge companies to seek advice. At Theon we have the experience
and expertise to help. Our team of experienced process and technical safety engineers
will challenge the design thinking and examine the proposed solution to ensure that
the resulting design is appropriate, fit for purpose and offers the best long term
solution to the issue of pressure protection of equipment.
A trained and highly experienced chemical engineer, Steve Rowbottom has worked
for and run a number of consultancies providing expertise to the energy industry.
Ian Wallis, Theons Director of Safety, Risk & Reliability, has a broad spectrum of
experience encompassing oil & gas, chemicals and nuclear reprocessing.
Ian has significant experience of operating at all levels of company management both
as a consultant and an employee gained through working with contractors, owners and
operators both in the UK and overseas.