RZK NSS Atv Pro Qac 90006 00 0 - en

Ural Oil and Gas LLP Rozhkovskoye Field Development
Date Issued: 07/11/2023

NefteStroiService Ltd. LLP
Issue Type: Approved for Construction
Document Number: RZK-NSS-ATV-PRO-QAC-90006-00-0
ROZHKOVSKOYE FIELD DEVELOPMENT PROJECT
Site Acceptance Test (SAT) Procedure - HIPPS
RZK-NSS-ATV-PRO-QAC-90006-00-0
NSS-RZK-PO-006
07/11/2023

RZK-NSS-ATV-PRO-QAC-90006-00-0 Page 1 of 32

Issue Type: Issued for Review
REVISION
0 07/11/2023 Approved for Construction I. Incerti L. Fausti S. Balakrishna
D 11/10/2023 Issued for Review I. Incerti L. Fausti S. Balakrishna
C 21/04/2023 Issued for Review I. Incerti L. Fausti S. Balakrishna

Issued for Interdisciplinary
B 20/04/2023 I. Incerti L. Fausti
Review
A 06/04/2023 Issued for Internal Review I. Incerti L. Fausti
Rev. Date Issue, Modification Prepared Checked Approved


Approvals
Prepared by
Name: Iacopo Incerti
Job Title: Project Manager
Signed:
Date: 07/11/2023
Checked by:
Name: Lorenzo Fausti
Job Title: Project Engineering Manager
Signed:
Date: 07/11/2023
Approved by:
Name: Suresh Balakrishna
Job Title: QAQC Manager
Signed:
Digitally signed by Suresh
Suresh
DN: cn=Suresh,
o=Neftestroiservice Ltd, ou=QA/
QC Department, email=rzk-
mgrqaqc@nss.kz, c=US
Date: Date: 2023.11.09 17:31:16 +05'30'


HOLD RECORD
Where a <HOLD> status has been included within the body of the document please indicate its
location by detailing the relevant page number.
Hold Nr. Section Description of Hold
REVISION HISTORY
Specify significant changes from previous revisions of the document
Rev. Date Description of Revision

A 06/04/2023 Issued for Internal Review
B 20/04/2023 Issued for Interdisciplinary Review
C 21/04/2023 Issued for Review
D 11/10/2023 Issued for Review
0 07/11/2023 Approved for Construction



PROJECT:
Rozhkovskoye Field Development
LOCATION: PLANT:
Kazakhstan Rozhkovskoye
JOB: COMPANY:
AH230201S Ural Oil & Gas LLP , Uralsk
ITEM: CONTRACTOR:
HIPPS Systems NSS - NefteStroiService LTD LLP
DOCUMENT TITLE:
SITE ACCEPTANCE TEST PROCEDURE
HIGH INTEGRITY PRESSURE PROTECTION SYSTEM
0 Approved for Construction ATV HIPPS I. Incerti L. Fausti 07/11/2023 ATV HIPPS DOCUMENT ID:
D Issued for Review ATV HIPPS I. Incerti L. Fausti 11/10/2023 AH230201S_FAT_06
C Issued for Review ATV HIPPS I. Incerti L. Fausti 21/04/2023 CONTRACTOR DOCUMENT ID:
B Issued for Inter Discipline Review ATV HIPPS I. Incerti L. Fausti 20/04/2023 -
A Issued for Discipline Internal Review ATV HIPPS I. Incerti L. Fausti 06/04/2023 COMPANY DOCUMENT ID:
REV DESCRIPTION EXECUTED CONTROLLED APPROVED DATE RZK-NSS-ATV-PRO-QAC-90006-00
This document is property of ATV HIPPS Srl. It is strictly confidential and must not be copied, traced or loaned without their LANGUAGE SHEET:
written permission and has to be returned upon request.
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DOCUMENT TITLE:
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Index
1 SCOPE 3
2 REFERENCE DOCUMENTS AND DRAWINGS 4
2.1 REFERENCE DOCUMENTS 6

2.2 QUALIFICATION LITERATURE & CERTIFICATES 7
2.3 ACRONYMS AND ABBREVIATIONS 8
3 GENERAL SETTINGS 9
3.1 HYDRAULIC SOURCE PRESSURE \9

3.2 PROCESS PRESSURE & TEMPERATURE 9
3.3 TRIP SETPOINTS 9
3.4 CONTROL SYSTEM 10
4 HIPPS SYSTEM INTEGRATION TEST REPORT 11
4.1 TEST INSTRUMENTS AND LOOP SETUP 11

4.2 SYSTEM ASSEMBLY AND CONNECTION 12
4.3 LOGIC SOLVER PRE POWER-UP CHECKS 14
4.4 TRANSMITTERS CALIBRATION TEST 15
4.5 NORMAL PROCESS TEST 16
4.6 SOLENOID VALVES VOTING LOGIC TEST 17
4.7 SYSTEM RESPONSE TIME TEST 18
4.8 PROCESS OVER-VALUE TEST 19
4.9 DBB VALVES FOR MECHANICAL BYPASS TEST 21
4.10 TRANSMITTERS FAULT LOGIC TEST 22
4.11 TRANSMITTERS DISCREPANCY TEST 23
4.12 PARTIAL STROKE TEST 24
5 FINAL INSTRUCTIONS 25
6 PUNCH LIST 26
7 ADDITIONAL NOTES 27
0 Approved for Construction ATV HIPPS DOCUMENT ID:

D Issued for Review AH230201S_FAT_06
C Issued for Review CONTRACTOR DOCUMENT ID:
B Issued for Inter Discipline Review -
A Issued for Discipline Internal Review COMPANY DOCUMENT ID:
REV DESCRIPTION RZK-NSS-ATV-PRO-QAC-90006-00
This document is property of ATV HIPPS Srl. It is strictly confidential and must not be copied, traced or loaned without LANGUAGE: SHEET:
their written permission and has to be returned upon request.
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DOCUMENT TITLE:
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1 SCOPE
The purpose of this Site Acceptance Test (SAT) is to outline the proposed design for
the High Integrity Pressure Protection System (HIPPS).
The SAT shall cover the hardware and software design and outlines as well as
interface details to PLC and ICSS.
The SAT provides information on how the system & associated equipment operates.
SAT will perform at the same time for No.3 pressure transmitters + No.2 hydraulic
actuated slab gate valves + No.1 logic solver cabinet at time for HIPPS system for
Rozhkovskoye Field Development project.
These Instructions are aimed to technicians that will use this test procedure.
These test procedures are utilized in the first instance for ATV HIPPS integrated
testing of the equipment and subsequently form the basis of the SAT.
Each paragraph needs to be corroborated. Paragraphs that represent tests to be

carried out, are complete with relevant tables where a check box column is marked in
case of successful verification.
Completion of the procedures by ATV HIPPS for the internal testing must be in full
compliance with any exceptions listed as N/A, or with a fault recorded on the punch list
document.
The punch items (if any) found during IFAT shall be closed prior to start SAT activity.
SAT shall demonstrate that the whole system is in the same condition defined during
IFAT. It shall prove that no corruption, damage during transport or other
inconveniences occurred.
Hence, the tests described in this document shall be repeated on site to guarantee the
correct functionality of all components.
As far as possible, the SAT shall include all the interfaces to the actual sub-systems,
system redundancy, configuration and physical installations. This implies that field
devices shall be tested from the field through to the end element.
Note: On a successful completion of all tests and the resolution of the punch list
comments, ‘Final Instructions’ section should be signed.
SAT location: Rozhkovskoye field

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DOCUMENT TITLE:
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2 REFERENCE DOCUMENTS AND DRAWINGS
The purpose of this inspection and test document is to ensure that the finished
integrated HIPPS system meet the requirement of the client specification.
APPLICABLE PROJECT SPECIFICATIONS
N° Spec N° Description Rev
1. RZK‐NSS‐000‐DBM‐ENG‐00001‐00 DESIGN BASIS MEMORANDUM ‐ GENERAL
2. RZK‐NSS‐000‐PRO‐PRM‐00001‐00 DOCUMENT NUMBERING PROCEDURE

TECHNICAL SPECIFICATION OF HIGH INTEGRITY PRESSURE PROTECTION SYSTEM
3. RZK‐NSS‐000‐SPC‐INS‐00005‐00
PACKAGES (HIPPS)
4. RZK‐NSS‐000‐SPC‐INS‐00011‐00 Technical Specification for Instrumentation Cables
5. RZK‐NSS‐000‐SPC‐PIP‐00001‐00 Piping Specifications and Material Classes
6. RZK‐NSS‐000‐SPC‐PIP‐00001‐00 Piping Specifications and Material Classes
7. RZK‐NSS‐000‐SPC‐PIP‐00002‐00 Line Pipe Specifications
8. RZK‐NSS‐000‐SPC‐PIP‐00003‐00 LINE PIPE VALVE SPECIFICATIONS
9. RZK‐NSS‐000‐SPC‐PIP‐00004‐00 LINE PIPE EXTERNAL AND THERMAL COATING SPECIFICATIONS
10. RZK‐NSS‐000‐SPC‐PIP‐00005‐00 Line Pipe Fittings Specifications
11. RZK‐NSS‐000‐SPC‐PIP‐00008‐00 GENERAL PAINTING SYSTEM SPECIFICATION
12. RZK‐NSS‐000‐SPC‐PIP‐00008‐00 GENERAL PAINTING SYSTEM SPECIFICATION
13. RZK‐NSS‐000‐SPC‐PIP‐00009‐00 Protective coatings and linings Specifications
14. RZK‐NSS‐000‐SPC‐PIP‐00011‐00 Line Pipe Welding Specifications Including PWHT and NDE
15. RZK‐NSS‐000‐SPC‐PIP‐00012‐00 JOINT COATING AND INSULATION SPECIFICATIONS
16. RZK‐NSS‐000‐SPC‐PIP‐00015‐00 Material Selection Report
17. RZK‐NSS‐CMG‐PID‐PRS‐00001‐01 PIPING AND INSTRUMENTATION DIAGRAM ‐ STANDARD FLOW DIAGRAM LEGEND
18. RZK‐NSS‐CMG‐PID‐PRS‐10001‐01 PIPING AND INSTRUMENTATION DIAGRAM ‐ WELL SITE U10

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DOCUMENT TITLE:
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Process Data Sheets for Equipment, Instruments, Systems, Packages Technical
23. 807‐DS‐ENG‐PR‐10003
Specification – (HIPPS)
24. 807‐REP‐ENG‐GEN‐10008_0 Equipment Selection Report
25. 807‐REP‐ENG‐GEN‐10009_0 Equipment Studies
26. 807‐SPC‐ENG‐MEC‐10004_0 Hot Formed Factory Bends Specifications
27. 807‐SPC‐ENG‐MEC‐10008_0 Pipeline Fittings Specification
28. 807‐SPC‐ENG‐TND‐10000_0 Equipment / Package Specifications (General Requirements for Vendors)
29. 807‐SPC‐PRM‐GEN‐10001_0 BILL OF MATERIAL ‐ REGISTER

Attachment ‐1 ‐ Datasheet ‐ ATV
30. DATA SHEET ‐ HIPPS PACKAGE – WELL SITE (U10, U12, U23, U26, U21)
HIPPS_19Jan23
31. MR_HIPPS Material Requisition ‐ HIPPS (High‐Integrity Pressure Protection System) PANEL
32.
33.
34.
35.
APPLICABLE INTERNATIONAL STANDARDS
N° Spec N° Description Rev
1. API 6D Specification for Wellhead and Christmas Tree Equipment

2.
3.
4.
5.
6. IEC 61508 Functional safety of electrical/electronic/programmable electronic safety‐related systems
7. IEC 61511 Functional safety – Safety instrumented systems for the process industry sector
8.
9.
10.

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DOCUMENT TITLE:
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2.1 REFERENCE DOCUMENTS
This document should be used in configuration with the following document type as
reference. The complete document number and revision should be completed at the
time of the test as it is dependent on the loop being tested.
N° COMPANY DOC ID ATV HIPPS DOC Description

ID
1. RZK-NSS-ATV-DGA-ENG-90001-00 AH230201S_ADW_01 General Arrangement Drawing - HIPPS VALVE 4" ANSI 2500
2. RZK-NSS-ATV-DGA-ENG-90002-00 AH230201S_ADW_02 General Arrangement Drawing - HIPPS VALVE 6" ANSI 2500
3. RZK-NSS-ATV-DGA-ENG-90003-00 AH230201S_ADW_03 Overall Dimension Drawing - HIPPS VALVE 4" ANSI 2500 + ACT.
4. RZK-NSS-ATV-DGA-ENG-90004-00 AH230201S_ADW_04 Overall Dimension Drawing - HIPPS VALVE 6" ANSI 2500 + ACT.
5. RZK-NSS-ATV-DAT-ENG-90001-00 AH230201S_DSH_01 Valve data sheet - HIPPS VALVE 4" ANSI 2500
6. RZK-NSS-ATV-DAT-ENG-90002-00 AH230201S_DSH_02 Valve data sheet - HIPPS VALVE 6" ANSI 2500
7. RZK-NSS-ATV-DIA-ENG-90001-00 AH230201S_ADW_06 Hydraulic Schematic Drawing - HIPPS ACTUATOR
8. RZK-NSS-ATV-WIR-ENG-90001-00 AH230201S_WDW_01 Actuator Wiring Diagram - HIPPS ACTUATOR
9. RZK-NSS-ATV-DAT-ENG-90003-00 AH230201S_DSH_03 Actuator Data Sheet - HIPPS ACTUATOR
10. RZK-NSS-ATV-WIR-ENG-90002-00 AH230201S_WDW_02 Logic Solver Cabinet Wiring Diagrams - HIPPS LSC
11. RZK-NSS-ATV-DIA-ENG-90002-00 AH230201S_CTR_01 Logic Diagrams - HIPPS LSC
12. RZK-NSS-ATV-LST-ENG-90001-00 AH230201S_CTR_02 Hardware Input/Output Signal List - HIPPS LSC
13. RZK-NSS-ATV-LST-ENG-90002-00 AH230201S_CTR_03 Software Input/Output Signal List - HIPPS LSC
14. RZK-NSS-ATV-WIR-ENG-90003-00 AH230201S_WDW_03 Interconnecting Wiring Diagrams & Hook Up Details - HIPPS
15. RZK-NSS-ATV-LAY-ENG-90003-00 AH230201S_ADW_09 Pressure Transmitter Enclosure Layout & Wiring Diagram - HIPPS DBB +
PT ENCLOSURE
16. RZK-NSS-ATV-DGA-ENG-90006-00 AH230201S_ADW_10 Skid General Arrangement Layout - HIPPS VALVE 4" ANSI 2500
17. RZK-NSS-ATV-DGA-ENG-90007-00 AH230201S_ADW_11 Skid General Arrangement Layout - HIPPS VALVE 6" ANSI 2500
18. RZK-NSS-ATV-CSA-ENG-90001-00 AH230201S_ADW_16 Overall System Architecture - HIPPS
19. RZK-NSS-ATV-SPC-ENG-90001-00 AH230201S_FDS_01 Functional Design Specification - HIPPS
20. RZK-NSS-ATV-CSN-ENG-90001-00 AH230201S_FDS_02 Functional Description - HIPPS
21. RZK-NSS-ATV-LST-ENG-90003-00 AH230201S_CTR_04 Cable List - HIPPS
22. RZK-NSS-ATV-PID-ENG-90001-00 AH230201S_PID_01 Piping and Instrument Diagrams - HIPPS
23. RZK-NSS-ATV-IRF-QAC-90001-00 AH230201S_CER_03 Factory Acceptance Test (FAT) Report - HIPPS VALVE

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DOCUMENT TITLE:
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24. RZK-NSS-ATV-IRF-QAC-90002-00 AH230201S_CER_04 Factory Acceptance Test (FAT) Report – HIPPS ACTUATOR
25. RZK-NSS-ATV-IRF-QAC-90003-00 AH230201S_CER_05 Factory Acceptance Test (FAT) Report - HIPPS LSC
26. RZK-NSS-ATV-IRF-QAC-90004-00 AH230201S_CER_06 Factory Acceptance Test (FAT) Report - HIPPS SKID
27. RZK-NSS-ATV-REP-QAC-90001-00 AH230201S_SIL_01 Safety Assessment Report (SAR) - HIPPS
2.2 QUALIFICATION LITERATURE & CERTIFICATES
N° Description
1. Pressure Transmitters (Initiators) - Calibration Certificate
2. Valve Qualification Literature
3. Verification of gauging and calibration of instruments used for checks and tests

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DOCUMENT TITLE:
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2.3 ACRONYMS AND ABBREVIATIONS
AI Analog Input
AO Analog Output
CPU Central Processing Unit
CU Central Module
DBB Double Block & Bleed
DCS Distributed Control System
DI Digital Input
DO Digital Output
ESD Emergency Shut Down System
ESV HIPPS valve
EWS Engineering Work Station
FAT Factory Acceptance Test
HH High High
HFT Hardware Fault Tolerance
HIPPS High Integrity Pressure Protection System
HMI Human Machine Interface
HPU Hydraulic Power unit
I/O Inputs / Outputs
ICSS Integrated Control and Safety System
IFAT Integrated Factory Acceptance Test
IS Intrinsically Safe
ITP Inspection and Test Plan
LL Low Low
LSC Logic Solver Cabinet
MooN Voting Logic: “M” out of “N”
N/A Not Applicable
N2 Nitrogen
PES Programmable Electronic System
PST Partial Stroke Test
PSU Power Supply Unit
PIT Pressure Transmitter
PL Punch List
PG Pressure Gauge
RMS Root Mean Square
RTU Remote Terminal Unit
SAT Site Acceptance Test
SIL Safety Integrity Level
SW Safety Instrumented System
TPIA Third Party Inspector Agency
VAC Voltage Alternating Current
VCD Voltage Direct Current

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DOCUMENT TITLE:
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3 GENERAL SETTINGS
3.1 HYDRAULIC SOURCE PRESSURE
The hydraulic actuators shall be designed to operate at source pressure:
Minimum: 120 bar G.
Nominal: - bar G.
Maximum: 180 bar G.
3.2 PROCESS PRESSURE & TEMPERATURE
The HIPPS valves shall be designed to operate at the process pressure:
Operating pressure: 60 bar G.
Design pressure: 431 bar G.
Design temperature: -43 / +45 °C. (Solar radiation temperature +70 °C)
3.3 TRIP SETPOINTS
The trip setpoints, as specified on the client specification should be as the following:
SETTINGS TABLE
HIPPS LOOP CLOSING TIME

VALVES TAG PITs TAG SET POINT (SENSORS + LOGIC SOLVER
+ FINAL ELEMENTS)
XV-U10-03 / 04 PIT-U10-05A / 05B / 05C HH= 90.0 bar G 3,0 seconds for the system
Travel time for valve opening shall be considering 20 seconds for 4’’ valve and 30
seconds for 6” valve. Opening time is out of safety loop value and shall be considered
for information only and will not be subject to any approval during the SAT.
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3.4 CONTROL SYSTEM
The operator can control the HIPPS system from:
 MIMIC PANEL (on logic solver cabinet front door) with push buttons & lamps
 ICSS through Modbus link.
The Logic Solver Cabinet push buttons commands permit at the operator to perform
the following commands related to the HIPPS valves.
 RESET
 OPEN
 CLOSE
 PST
The ICSS commands are a duplication of the mimic panel main commands.

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4 HIPPS SYSTEM INTEGRATION TEST REPORT
4.1 TEST INSTRUMENTS AND LOOP SETUP
Test Instruments
Record in the following table, the instruments used for the following tests.
Description of Instrument Make/Model Equipment Number Calibration Due Date

RMS digital multi-meter
Pressure source Not Applicable
Pressure gauges
HART Handheld Communicator Not Applicable
Laptop Not Applicable
Software Used in Performing the Tests
Record in the following table, the Software used for the following tests; these are the project
software licensed for the end user.
Description of Software Make/Model Version Serial & Product N° Software Signature

PLC software Schneider / M580S
Positioner software Not Applicable
Modbus Simulator ModScan32 - - -
Inspector Confirmation (REVIEW ONLY)
Inspector Signature
This confirms that all checks have been completed during ATV HIPPS internal test and that any errors are noted on the Punch List
ATV HIPPS: Contractor / TPIA: Company / TPIA: Date:

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DOCUMENT TITLE:
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4.2 SYSTEM ASSEMBLY AND CONNECTION
This section focuses on ensuring correct assembly of the system, and compliance with
manufacturer's instructions. When completing the following sections refer to the
supplied contract documentation, and manufacturer datasheets.
SAT will be performed testing 2 valves at the same time for each HIPPS system.
Whole System Assembly Pre-check
Tick PL No Description of Inspection

Ensure the correct valve assemblies are being tested by inspecting the attached Tag numbers.
Ensure the correct pressure transmitters and DBB isolation valves are being tested by inspecting
the attached Tag numbers.
Ensure the correct Logic Solver Cabinet is being tested by inspecting the front of panel label.
Ensure that the skid assembly and all items listed below are visual accessible and correctly
fastened to process piping:
 HIPPS Valves and Actuators and related Local Control Panels
 Pressure Transmitters and DBB isolation valves
 Logic Solver Cabinet (not as part of skid assembly)
Mechanical

Visually check that the connection between actuators and valves has been performed as per
manufacturer’s instructions.
Visually check that the skid mounting has been performed as per manufacturer’s instructions;
ensure that the Logic Solver Cabinet has been erected as per document RZK-NSS-ATV-MAN-
ENG-90001-00
All the SAT steps are performed with the items pressurized with the process fluid to simulate a
condition as similar as possible to the standard working conditions.
Hydraulic line and control circuit in local control panel

Check that the hydraulic connections are in accordance with the hydraulic schematic.
Check the actuator hydraulic source (HPU and Manual Pump) connections.

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Electrical for HIPPS control cabinet

Connect the incoming power supply to the HIPPS Logic Solver Cabinet (do not switch on).
Open all knife-edges of field terminals.
Connect the pressure transmitters to the logic solver.
Connect the solenoid valves to the logic solver.
Connect the position transmitters to the logic solver.
Connect the limit switches to the logic solver.
ICSS Interface

Check of the connection from ICSS to the logic solver.
Transmitters

Ensure that the PITs are visual accessible and the DBB isolation valves are correctly fastened to
process piping.
Inspector Signature

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4.3 LOGIC SOLVER PRE POWER-UP CHECKS
Earth Fault Check

Using a digital test or ohmmeter, check all inputs and outputs for earth faults.
Continuity check of the Protection Earth P.E. bars, to verify continuity between the earth bar
and all part of the cabinet. Resistance measured should be less than 1 ohm.
Continuity check of the Instrument Earth I.E. bars, to verify continuity between the earth bar and
instrument cable screens. Resistance measured should be less than 1 ohm.
Totally isolation between P.E., and I.E. bars (higher than 10 Mohm).
Stray Voltage Check

Using a multi-meter, check that all the inputs and outputs on the terminal blocks have no stray
voltages connected.
Close all knife-edges.
Logic Solver Incoming Supply
Tick PL No Description of Inspection Recorded Results

Turn on incoming supply.
UPS 1 incoming supply voltage measured at its supply terminals.
UPS 2 incoming supply voltage measured at its supply terminals.
NON UPS incoming supply voltage measured at its supply terminals.
Turn on incoming isolators, circuit breakers and 24VDC circuit breakers.
Inspector Signature

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4.4 TRANSMITTERS CALIBRATION TEST
The pressure transmitters (initiators) calibration must meet the related manufacturer
certificate and the project data. The designed calibration range is 0-100 bar G.

Connect the pressure source and gauge to the PITs manifold and set the pressure as per
following steps.
At 0% of the range check that the AI card on the Logic Solver indicates 0% (4 mA) for
transmitters A, B and C. Check the relevant indication of the PLC & ICSS.
HIPPS LINE PRESSURE TRANSMITTERS

PITs TAG Calibration Range 0% 50% 100%
4- 20 mA= 4- 20 mA= 4- 20 mA=
PIT-U__-05A PLC EU= PLC EU= PLC EU=
ICSS EU= ICSS EU= ICSS EU=
4- 20 mA= 4- 20 mA= 4- 20 mA=
PIT-U__-05B 0÷100 bar G PLC EU= PLC EU= PLC EU=
4- 20 mA= 4- 20 mA= 4- 20 mA=
PIT-U__-05C PLC EU= PLC EU= PLC EU=
Inspector Confirmation
Inspector Signature
This confirms that all checks have been completed and that any errors are noted on the Punch List

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4.5 NORMAL PROCESS TEST
During normal plant activities the valves can be opened (after system reset) and
closed from the LSC push buttons.

Set the normal operating pressure as defined in this procedure.
Ensure the deviation between PITs is less than 2%.
Ensure that the PITs alarm indications are off on PLC & ICSS.
The visual indicator should indicate the valves are closed.
Reset the HIPPS system using reset command push button on LSC or ICSS through Modbus
connection.
Ensure both HIPPS valves remain closed. The visual indicator should also indicate valve closed.
Open the HIPPS valve using open command push button on LSC or ICSS through Modbus
connection.
The relevant HIPPS valve should open
When the HIPPS valve is travelling to open position, check on the PLC & ICSS that the position
transmitter is moving to the open position.
When the HIPPS valve is fully open, ensure the relevant indication on the LSC lamp, PLC &
ICSS. is displaying the valve open. The visual indicator should also indicate valve open.
Close the HIPPS valve using close command push button on LSC or ICSS through Modbus
connection.
The relevant HIPPS valve should close.
When the HIPPS valve is travelling to close position, check on the PLC & ICSS that the position
transmitter is moving to closed position.
When the HIPPS valve is fully close, ensure the relevant indication on the LSC lamp, PLC &
ICSS is displaying the valve close. The visual indicator should also indicate valve closed.
Inspector Signature

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4.6 SOLENOID VALVES VOTING LOGIC TEST
The trip solenoid valves voting logic must meet the client requirement and the project
data. The designed voting logic is 1oo2 (one out of two).

Set the pressure below the HH trip set point with a deviation between PITs less than 2%.
Ensure that both HIPPS valves are open.
On 1st HIPPS valve, de-energize the 1st solenoid valve open the related terminals on LSC
terminal board. Ensure that the 2nd solenoid valve is energize. The HIPPS valve should close.
When the HIPPS valve is fully closed, ensure the relevant indication on LSC lamp, PLC & ICSS
is displaying the valve closed. The visual indicator should also indicate valve closed. Check on
LSC lamp, PLC & ICSS is displaying the failure to open alarm is active.
Open the HIPPS valve closing the terminals opened above. The HIPPS valve should open.
On 1st HIPPS valve, de-energize the 2nd solenoid valve open the related terminals on LSC
terminal board. Ensure that the 1st solenoid valve is energize. The HIPPS valve should close.
is displaying the valve closed. The visual indicator should also indicate valve closed. Check on
LSC lamp, PLC & ICSS is displaying the failure to open alarm is active.
Open the HIPPS valve closing the terminals opened above. The HIPPS valve should open.
Repeat the test for 2nd HIPPS valve.
HIPPS valve TAG XY-U__-03A SOV STATUS XY-U__-03B SOV STATUS TEST RESULT
ENERGIZED ENERGIZED VALVE TRIP
DE-ENERGIZED DE-ENERGIZED VALVE NOT TRIP
XV-U__-03
HIPPS valve TAG XY-U__-04A SOV SOV STATUS XY-U__-04B SOV SOV STATUS TEST RESULT
XV-U__-04
Inspector Signature

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4.7 SYSTEM RESPONSE TIME TEST
Target closing time 3,0 seconds for HIPPS loop (Initiators - Logic Solver - Final
Element)
During the “Process over-value test” (refer to next chapter) record the closing time in
the table here below using a stopwatch or the dedicated logic solver sequence
checking that they meet target closing time. Note that this test doesn’t consider the
PITs response time, so for these components have been added the worst case of
100ms for PIT as per transmitters technical datasheet.
HIPPS valve TAG Closing time test 1 Closing time test 2 Closing time test 3
XV-U__-03
XV-U__-04
Inspector Signature

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4.8 PROCESS OVER-VALUE TEST
The line pressure is acquired by pressure transmitters in voting 2oo3 (two out of three)
logic. The purpose is to protect the HIPPS downstream items from an over pressure.

1st sequence AI1A / CPU1 / DO1A cards active while AI1B / CPU2 / DO1B cards disconnected
2nd sequence AI1B / CPU2 / DO1B cards active while AI1A / CPU1 / DO1A cards disconnected
The steps described below must be performed two times with simplex configuration in
order to prevent eventual Dangerous Undetected failures on PLC redundant cards.
Check for pressure transmitter HH pressure alarm:

Increase PIT PIT-U__-05A pressure above HH trip set point by the pressure source (otherwise
by a hart communicator) isolating the other PTs by the related DBB valves to avoid the
respective alarms. Check the PIT-U__-05A HH pressure alarm switch to 0 on PLC & ICSS.
The HIPPS valves should not close.
Repeat the test for PIT PIT-U__-05B and PIT PIT-U__-05C.
2oo3 voting logic check for pressure transmitters HH pressure alarm:

Increase PITs PIT-U__-05A & PIT-U__-05B pressure above the HH trip set point (remaining
within the deviation alarm limits for PIT PIT-U__-05C) and check the related alarm switch to 0 on
PLC & ICSS. The HIPPS valves should close.
is displaying the valve closed. The visual indicator should also indicate valve closed.
With pressure above the HH threshold reset the HIPPS system and open the HIPPS valves;
being the system in trip condition both the mentioned actions should not have effect.
The HIPPS valves should remain closed.
Decrease PITs PIT-U__-05A & PIT-U__-05B pressure below the HH trip set point.
Check the HH alarm switch to healthy status on PLC & ICSS.
Reset the HIPPS system using reset command push button on LSC or ICSS through Modbus
connection.
Open the HIPPS valve using open command push button on LSC or ICSS through Modbus
connection.
The HIPPS valve should open
Repeat the test for PITs PIT-U__-05A & PIT-U__-05B and PITs PIT-U__-05B & PIT-U__-05C.
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Inspector Signature

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4.9 DBB VALVES FOR MECHANICAL BYPASS TEST
The line pressure is acquired by pressure transmitters in 2oo3 voting logic. For testing,
repairing or calibrating PIT without activating the executive action, each pressure
transmitter signal will be by-passed by means of DBB valve to isolate the related item.
ZSO-U__-05AA / 05BA / 05CA inlet ball valve & ZSO-U__-05AB / 05BB / 05CB outlet
ball valves limit switches, installed on related DBB valves, are dedicated to HIPPS
Line pressure transmitters PIT-U__-05A / 5B / 5C.
Not having an Interlock System, it will be possible to isolate more than one PT at time.
A single value excesses the threshold or single fault shall not interrupt normal
operation. If an initiator input is isolated by DBB valve the input shall be considered
not healthy and the voting logic is degraded to 1oo2 (one out of two).

Close one PIT at a time (PIT-U__-05A) by means the related DBB valve (without bleed the fluid
to avoid the discrepancy alarm) and check if the DBB limit switch (ZSO-U__-05AA) signal turn to
0.
Check on PLC & ICSS the alarm of initiator isolated.
The voting logic will degrade to 1oo2. Generate another cause of trip condition like transmitter
isolated or HH pressure (physically or by a hart communicator) on one of the remaining healthy
PITs and verify that the trip occurs. The HIPPS valves should close.
Repeat the three steps above checking the limit switch ZSO-U__-05AB.
Inspector Signature

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4.10 TRANSMITTERS FAULT LOGIC TEST
On a transmitter fault, the faulty transmitter reverts to a safe state in the Logic solver
application program. The remaining transmitters effectively revert to a 1oo2 (one out of
two) operation. A fault with two transmitters simultaneously will activate a trip (PPS
valve closure).
Considering that valves opening and closing have been checked during the above
tests, the following tests will be carried out without the real stroking of the valves, but
trip signal will be verified checking the led status of the related digital output module.
In the case of 2 PITs in fault status the trip condition occurs.

Open the knife on PIT PIT-U__-05A (otherwise connect the HART handheld communicator and
give the HART command to send over (22.5 mA) or under (2.5 mA) range signal). All the
solenoid valves remain energized. Check on PLC & ICSS the alarm of initiator channel fault.
fault or HH pressure (physically or by a hart communicator) on one of the remaining healthy PITs
and verify that the trip occurs. The HIPPS valves should close.
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4.11 TRANSMITTERS DISCREPANCY TEST
The line pressure is acquired by pressure transmitters in voting 2oo3 logic. If the
difference between PITs median value and the value read by a PIT is greater than 2%
of the PIT range, the input shall be considered not healthy and the voting logic is
degraded to 1oo2 (one out of two).
In the case of 2 PITs in discrepancy status the trip condition occurs.

Simulated by means of a potentiometer or HART command the pressure of the PIT PIT-U__-05A
Set the normal operating pressure as defined of this procedure.
Increase the signal of PIT PIT-U__-05A over 2% of PIT range respect to the median value
Check on PLC & ICSS the alarm of discrepancy.
discrepancy or HH pressure (physically or by a hart communicator) on one of the remaining
healthy initiators and verify that the trip occurs. The HIPPS valves should close.
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4.12 PARTIAL STROKE TEST
The partial stroke test (PST) consists of a partial closure of each HIPPS valve
necessary to check the valve functionality and it gives important information on the
status of the final element assembly.
PST can be initiated:
 manually by the LSC push buttons.
 manually through ICSS commands.
 automatically through Logic Solver by a dedicated timer.

Set the normal operating pressure as defined of this procedure.
Perform the PST on solenoid valve XY-U__-03C using the related command push buttons on
LSC and through ICSS command for HIPPS valve XV-U__-03.
Ensure the relevant indication on PLC & ICSS is displaying the valve position transmitter
decrease under 80% and after increase to 100.0%.
During the test check the relevant indication on ICSS & LSC lamps to verify following indication:
- PST in progress
- PST passed
Force the Automatic partial stroke test in order to initiate the steps logic; both solenoid valves will
be tested in sequence.
Ensure the relevant indication on PLC & ICSS is displaying the valve position transmitter
decrease under 80% and after increase to 100.0%.
During the test check the relevant indication on ICSS & LSC lamps to verify following indication:
- PST in progress
- PST passed
Repeat the test for HIPPS valve XV-U__-04.
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5 FINAL INSTRUCTIONS
TRANSMITTERS CALIBRATION TEST
Result Notes
NORMAL PROCESS TEST

Result Notes
SOLENOID VALVES VOTING LOGIC TEST

Result Notes
SYSTEM RESPONSE TIME TEST

Result Notes
PROCESS OVER-VALUE TEST

Result Notes
DBB VALVES FOR MECHANICAL BYPASS TEST
Result Notes
TRANSMITTERS FAULT LOGIC TEST
Result Notes
TRANSMITTERS DISCREPANCY TEST

Result Notes
PARTIAL STROKE TEST

Result Notes
NOTE: PASS - means Test has been passed and accepted by relevant inspection parties.
FAIL - means Test has failed and acknowledged by ATV HIPPS.
Date: _ _ _ _ _ _ _ Date: _ _ _ _ _ _ _ Date: _ _ _ _ _ _ _
ATV HIPPS: _ _ _ _ _ _ _ Contractor / TPIA: _ _ _ _ _ _ _ Company / TPIA: _ _ _ _ _ _ _

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6 PUNCH LIST
HIPPS SYSTEM – Punch List
PROJECT: Rozhkovskoye Field Development

PLANT: Rozhkovskoye
LOCATION: Kazakhstan
CONTRACTOR: NSS - NefteStroiService LTD LLP
COMPANY: Ural Oil & Gas LLP , Uralsk
ATV HIPPS JOB: AH230201S
ITEM: HIPPS Systems
N° Description Item Action By Solution Within Status
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

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7 ADDITIONAL NOTES
HIPPS SYSTEM – Additional Notes
PROJECT: Rozhkovskoye Field Development

PLANT: Rozhkovskoye
LOCATION: Kazakhstan
CONTRACTOR: NSS - NefteStroiService LTD LLP
COMPANY: Ural Oil & Gas LLP , Uralsk
ATV HIPPS JOB: AH230201S
ITEM: HIPPS Systems
N° Description Item Action By Solution Within Status
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

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Ural Oil and Gas LLP Rozhkovskoye Field Development

Date Issued: 07/11/2023

Document Number: RZK-NSS-ATV-PRO-QAC-90006-00-0

ROZHKOVSKOYE FIELD DEVELOPMENT PROJECT

Site Acceptance Test (SAT) Procedure - HIPPS

Site Acceptance Test (SAT) Procedure - HIPPS

Date Issued: 07/11/2023

Document Number: RZK-NSS-ATV-PRO-QAC-90006-00-0

0 07/11/2023 Approved for Construction I. Incerti L. Fausti S. Balakrishna

D 11/10/2023 Issued for Review I. Incerti L. Fausti S. Balakrishna

C 21/04/2023 Issued for Review I. Incerti L. Fausti S. Balakrishna

Rev. Date Issue, Modification Prepared Checked Approved

Site Acceptance Test (SAT) Procedure - HIPPS

Date Issued: 07/11/2023

Document Number: RZK-NSS-ATV-PRO-QAC-90006-00-0

Job Title: Project Manager

Job Title: Project Engineering Manager

Job Title: QAQC Manager

Site Acceptance Test (SAT) Procedure - HIPPS

Date Issued: 07/11/2023

Document Number: RZK-NSS-ATV-PRO-QAC-90006-00-0

Hold Nr. Section Description of Hold

Specify significant changes from previous revisions of the document

Rev. Date Description of Revision

Site Acceptance Test (SAT) Procedure - HIPPS

Date Issued: 07/11/2023

Document Number: RZK-NSS-ATV-PRO-QAC-90006-00-0

Site Acceptance Test (SAT) Procedure - HIPPS

SITE ACCEPTANCE TEST PROCEDURE

HIGH INTEGRITY PRESSURE PROTECTION SYSTEM

2 REFERENCE DOCUMENTS AND DRAWINGS 4

2.1 REFERENCE DOCUMENTS 6

3.1 HYDRAULIC SOURCE PRESSURE \9

4 HIPPS SYSTEM INTEGRATION TEST REPORT 11

4.1 TEST INSTRUMENTS AND LOOP SETUP 11

0 Approved for Construction ATV HIPPS DOCUMENT ID:

Each paragraph needs to be corroborated. Paragraphs that represent tests to be

SAT location: Rozhkovskoye field

0 Approved for Construction ATV HIPPS DOCUMENT ID:

2 REFERENCE DOCUMENTS AND DRAWINGS

APPLICABLE PROJECT SPECIFICATIONS

N° Spec N° Description Rev

1. RZK‐NSS‐000‐DBM‐ENG‐00001‐00 DESIGN BASIS MEMORANDUM ‐ GENERAL

2. RZK‐NSS‐000‐PRO‐PRM‐00001‐00 DOCUMENT NUMBERING PROCEDURE

5. RZK‐NSS‐000‐SPC‐PIP‐00001‐00 Piping Specifications and Material Classes

6. RZK‐NSS‐000‐SPC‐PIP‐00001‐00 Piping Specifications and Material Classes

7. RZK‐NSS‐000‐SPC‐PIP‐00002‐00 Line Pipe Specifications

8. RZK‐NSS‐000‐SPC‐PIP‐00003‐00 LINE PIPE VALVE SPECIFICATIONS

9. RZK‐NSS‐000‐SPC‐PIP‐00004‐00 LINE PIPE EXTERNAL AND THERMAL COATING SPECIFICATIONS

10. RZK‐NSS‐000‐SPC‐PIP‐00005‐00 Line Pipe Fittings Specifications

11. RZK‐NSS‐000‐SPC‐PIP‐00008‐00 GENERAL PAINTING SYSTEM SPECIFICATION

12. RZK‐NSS‐000‐SPC‐PIP‐00008‐00 GENERAL PAINTING SYSTEM SPECIFICATION

13. RZK‐NSS‐000‐SPC‐PIP‐00009‐00 Protective coatings and linings Specifications

15. RZK‐NSS‐000‐SPC‐PIP‐00012‐00 JOINT COATING AND INSULATION SPECIFICATIONS

16. RZK‐NSS‐000‐SPC‐PIP‐00015‐00 Material Selection Report

18. RZK‐NSS‐CMG‐PID‐PRS‐10001‐01 PIPING AND INSTRUMENTATION DIAGRAM ‐ WELL SITE U10

19. RZK‐NSS‐CMG‐PID‐PRS‐12001‐01 PIPING AND INSTRUMENTATION DIAGRAM ‐ WELL SITE U12

20. RZK‐NSS‐CMG‐PID‐PRS‐21001‐01 PIPING AND INSTRUMENTATION DIAGRAM ‐ WELL SITE U21