34 Samss 627

Materials System Specification
34-SAMSS-627 1 January 2018

Wellhead High Integrity Protection System - Offshore Gas Service
Document Responsibility: High Integrity Protection Systems Stds Committee
Contents
1 Scope ............................................................2
2 Conflicts and Deviations..................................2
3 References ....................................................2
4 Terminology ...................................................6
5 Environmental Conditions ...............................8
6 General ....................................................... 10
7 System Requirements .................................. 13
8 Hips Functional Requirements....................... 27
9 Identification Tagging.................................... 29
10 Inspection and Testing .................................. 30
11 Packing and Shipping ................................... 32
12 Documentation ............................................. 32
13 Notes to Purchaser ....................................... 35
Revision Summary ............................................... 35
Appendix A - HIPS Bare-Stem Valve Datasheet ..... 36

Appendix B - HIPS Hydraulic Actuator Datasheet ... 37
Appendix C - HIPS Logic Solver Datasheet ........... 38
Appendix D - HIPS Pressure Transmitters ............. 39
Appendix E - HIPS SA Applicable Standards
(Overview) ................................................... 40
Previous Issue: 15 February 2016 Next Planned Update: 15 February 2019

Revised paragraphs are indicated in the right margin Page 1 of 40
Contact: Leopoldo Campos (camposlx) on phone +966-13-8804831
©Saudi Aramco 2018. All rights reserved.

Document Responsibility: High Integrity Protection Systems Standards Committee 34-SAMSS-627
Issue Date: 1 January 2018
Next Planned Update: 15 February 2019 Wellhead High Integrity Protection System - Offshore Gas Service
1 Scope
1.1 This specification defines the minimum mandatory requirements for design,
material fabrication, inspection, testing and documentation for Offshore
Wellhead High Integrity Protection Systems (HIPS) rated up to 10,000 psi
(API 6A) in gas service.
1.2 For each wellhead platform the HIPS system includes but is not limited to the
following main system components:
a) Three identical Pressure Transmitters in 2oo3 voting configuration
b) One common Solid State Safety Logic Solver
c) One series HIPS ZV valves skid per wellhead flow path. Each skid is
provided with two hydraulically operated ZV Valves (1oo2) with their
associated actuators, hydraulic controls, intermediate spool piece between
the two ZV Valves, and HPU.
2 Conflicts and Deviations
2.1 If there are any conflicts between this specification and associated purchasing,
project, or engineering documents, this specification shall take precedence.
2.2 Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Coordinator.
2.3 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.
2.4 The designation “Commentary” is used to label a sub-paragraph that contains

comments that are explanatory or advisory. These comments are not mandatory,
except to the extent that they explain mandatory requirements contained in the
specification.
3 References
The following is a summary of all the documents referenced within this specification.
References noted below are a part of this SAMSS and shall be per a specific edition or
the latest edition whichever is specified in the Purchase Order.
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-250 Safety Integrity Level Assignment and Verification
Saudi Aramco: Company General Use
Page 2 of 40
SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering

Requirement
SAEP-354 High Integrity Protective Systems Design Requirements
SAEP-375 High Integrity Protection Systems - SAP Tracking
System Workflows
Saudi Aramco Engineering Standards

SAES-A-007 Hydrostatic Testing Fluids and Lay-Up Procedures
SAES-A-202 Saudi Aramco Engineering Drawing Preparation
SAES-H-004 Protective Coating Selection and Application
Requirements for Offshore Structures
SAES-J-002 List of Inspectable Instruments
SAES-J-003 Instrumentation – Basic Design Criteria
SAES-J-200 Pressure
SAES-L-108 Selection of Valves
SAES-L-109 Selection of Flanges, Stud Bolts, and Gaskets
SAES-Z-002 Regulated Vendors List for Process Automation
Systems
Saudi Aramco Materials System Specifications

02-SAMSS-012 Weld Overlayed Fittings, Flanges, and Spool Pieces
04-SAMSS-049 Inspection and Testing Requirements
for API SPEC 6A, 10000 psi Valves
04-SAMSS-055 General Valve Requirements, ISO 10423 (API 6A)
04-SAMSS-056 Valves and Choke Test Requirements, ISO 10423
04-SAMSS-057 Gate Valve Requirements, ISO 10423
09-SAMSS-069 Qualification Requirements for Epoxy Coating for
Atmospheric Service
26-SAMSS-051 Hydraulic Oil AW 32 and 68
34-SAMSS-621 ESD Systems - Hard-Wired - Solid-State
(Nonprogrammable)
34-SAMSS-634 Local ZV Control Systems
34-SAMSS-717 Hydraulic Valve Actuators Systems
34-SAMSS-820 Instrument Control Cabinet - Indoor

Page 3 of 40
34-SAMSS-821 Instrument Control Cabinet - Outdoor
Saudi Aramco Inspection Requirements

175-026600 Weld Overlayed Flanges, Fittings, and Spool Pieces
175-043000 Valve Materials Certification Requirements
175-043600 Valves: Metallic; Includes Gate, Globe, Angle, Check,
Needle, Ball, Plug, Piston, Butterfly
175-045600 API 6A 10,000 psi Valves
175-091900 Coating: Shop Applied; for Tanks, Piping, Pipelines
(and Associated Appurtenances & Fittings),
Structures, Process Equipment; Internal &
External; Onshore, Offshore and/or Subsea
175-120100 Steel Structures
175-173700 Auxiliary Electrical Systems for Skid-Mounted
Equipment
175-341001 Actuator, Valve, Hydraulic: With Integral or Remote
Power Unit for Rising Stem and Quarter Turn Valves
175-344700 Wellhead High Integrity Protection System - Offshore
Gas Service
Saudi Aramco Forms and Data Sheets

SA-6233-1 Valve Data Sheet
SA-6239 HIPS Logic Solver Datasheet
SA-8020-200 HIPS Pressure Transmitter Datasheet
SA-8020-717 Instrument Specification Sheet Hydraulic Valve
Actuators
Saudi Aramco Non-material Requirements

SA-NMR-7930 Non-material Requirements
3.2 Industry Codes and Standards
American Institute of Steel Construction

AISC 360-10 Steel Specification for Structural Buildings
American Society of Mechanical Engineers

ASME B31.3 Process Piping
ASME BTH-1 Design of Below-the-Hook Lifting Devices
Page 4 of 40
American National Standards Institute

ANSI/NFPA 70 National Electrical Code
American Petroleum Institute (API)

API 6A Wellhead and Christmas Tree Equipment
API RP 2A-WSD Planning, Designing, and Constructing Fixed Offshore
Platforms
American Welding Society

AWS D1.1 Structural Welding Code
American Society of Testing Materials

ASTM A194 Specification for Carbon Steel, Alloy Steel, and
Stainless Steel Nuts for Bolts for High Pressure
and Temperature Service, or Both
ASTM A269 Specification for Seamless and Welded Austenitic
Stainless Steel Tubing for General Service
ASTM A320 Specification for Alloy-Steel and Stainless Steel
Bolting for Low-Temperature Service
ASTM B841 Specification for Electrodeposited Coating of
Zinc-Nickel Alloy Deposits
International Electrotechnical Committee

IEC 60529 Degrees of Protection Provided by Enclosures
IEC 61000 Electromagnetic Compatibility (EMC)
IEC 61508 Functional Safety of Electrical/Electronic/
Programmable Electronic Safety-related Systems
IEC 61511 Functional Safety - Safety Instrumented Systems for
the Process Industry Sector
National Association of Corrosion Engineers/International Standardization

Organization
ISO 10423 Drilling and Production Equipment-Wellhead and
Christmas Tree Equipment
National Electrical Manufacturers Association

NEMA 250 Enclosures for Electrical Equipment

Page 5 of 40
4 Terminology
4.1 Acronyms
EMC Electromagnetically Compatible
FAT Factory Acceptance Test
HART Highway Addressable Remote Transducer Protocol
HIPS High Integrity Protection System
HPU Hydraulic Power Unit
IPL Independent Protection Layer
MAOP Maximum Allowable Operating Pressure
MR Material Requisition
PFD Probability of Failure on Demand
PST Process Safety Time
RTU Remote Terminal Unit
SAT Site Acceptance Test
SCADA Supervisory Control and Data Acquisition System
SIF Safety Instrumented Function
SIL Safety Integrity Level
4.2 Definitions
1oo2: One out of two voting; if one out of two devices performs its function the
system meets its criteria.
2oo3: Two out of three voting; if two out of three devices performs its function
the system meets its criteria.
Emergency Shutdown System (ESD): A system composed of sensors, logic

solvers, and final control elements for the purpose of taking the process, or
specific equipment in the process to a safe state when predetermined conditions
are violated. The system is designed to isolate, de-energize, shutdown or
de-pressure equipment in a process unit. Another term commonly used
throughout the hydrocarbon and petrochemical industry is a Safety Instrumented
System (SIS).
Fail-Safe: The capability to go to a predetermined safe state in the event of a

specific malfunction.
FAT: Factory Acceptance Test, it is performed at RVL approved skid

Page 6 of 40
manufacturer or skid fabricator shop and consists of functional test of all

components using actual or simulated signals.
Fully Rated Pipe: Piping system designed for the maximum allowable working
pressure and temperature of the system.
High Integrity Protection System (HIPS): High availability, fail safe SIL 3
system that consist of sensors, safety logic solvers, and final control elements
used to prevent over-pressurization and loss of containment on process and
equipment by shutting off the source of high pressure before exceeding the
process design pressure. A HIPS system is designed as an independent and
separate safety protection layer separate from the ESD system. A HIPS System
must be in compliance throughout the systems lifecycle to the strict conditions
of approval resulting from a quantitative risk assessment, dynamic process
simulations and other specific design considerations.
HIPS ZV Valves Skid: A single skid-mounted unit that includes but not
limited to ZV safety valves, hydraulic actuators, hydraulic and electrical
controls, intermediate machined spool piece, HPU and associated hydraulic pipe
headers and tubing.
Hot-Dip Galvanized: Metal treatment that meets the requirements of

ASTM A123.
LCP: Local control panel, it is part of the Local ZV Controls per

34-SAMSS-634.
MAOP: Maximum allowable operating pressure, it refers to the line or

equipment to be protected from the overpressure scenario.
Modular: A self-contained unit intended to perform a certain function that is

interchangeable with a standard interface; a modular unit may be disconnected
and moved to a new location or replaced with a spare unit without disassembly
of subcomponents.
Nearshore: Any outdoor, onshore location within one kilometer from the
shoreline of the Arabian Gulf or within three kilometers from the shoreline of
the Red Sea.
Offshore: Overwater.
Onshore: On-land.
Probability of Failure on Demand (PFD): A value that indicates the

probability that a device or system will fail to respond to a demand in a specified
interval of time. PFD equals 1 minus safety availability.
Page 7 of 40
Process Safety Time (PST): The period of time between a trip point being
reached and a hazardous event occurring if no safety measures such as a
shutdown are taken.
Proven-in-Use: A device that has prior successful use in similar environmental

and process conditions, documented as suitable for use in HIPS applications.
Safety Availability: The fraction of time that a safety system is able to

perform its designated function when the process is operating. The safety
system is unavailable when it has failed dangerously. Safety availability is
equal to 1 minus the PFD (dangerous) of the safety function.
Safety Integrity Level (SIL): The level of overall availability for an ESD loop
or ESD system component calculated as 1 minus the sum of the average
probability of dangerous failure on demand.
Safety Loop: A safety instrumented function consisting of input devices

(sensors), logic solver and final control elements. Another term commonly used
throughout the industry is a Safety Instrumented Function (SIF).
SAT: Site Acceptance Test is done at the field location and consists of
functional test of all components using actual field parameters.
Scan Time: HIPS system scan time is the composite of input modules scan,
program execution and output modules state transition time.
Severely Corrosive Environment: Offshore, or onshore within 5 km of

coastline.
Shall: Indicates a mandatory requirement.
SOV: Solenoid Valve, it is part of the solenoid panel installed on each HIPS ZV
valve assembly.
Stainless Steel: Either 316 series or 317 series stainless steel material.
ZV: Automated Safety Valve.
5 Environmental Conditions
5.1 Temperature
The equipment shall operate continuously under the following ambient air
temperatures without any degradation of the manufacturer's guaranteed
performance:

Page 8 of 40
Outdoor Sheltered (1)(2)(3) Outdoor Unsheltered (2)(3)

Maximum 55°C (131°F) 65°C (149°F)
Minimum 0°C (32°F) 0°C (32°F)
Notes:
(1) Refers to permanent, ventilated enclosures or buildings, or permanently fixed sunshades
with a top and three sides.
(2) For instruments which dissipate internal heat and are installed in custom engineered
enclosures (e.g., enclosures not included in the original manufacturer's temperature
certification), an additional 15°C shall be added to the above maximum temperatures.
An example, for “indoor air conditioned” installation, the equipment must perform at
35 + 15 = 50°C. Similarly, for outdoor unsheltered, the equipment shall be designed for a
maximum operating temperature of 65 + 15 = 80°C.
(3) For the outdoor installations only, the designer can take credit for forced or passive
cooling to eliminate or reduce the 15°C heat rise. For example, if vortex coolers are
used, the heat removal capacity of the coolers may be subtracted from the generated
heat. No more than 15°C reduction in temperature will be given as credit. The designer
shall substantiate his claim by providing the support data and calculations.
5.2 Contaminants
The instrument manufacturer shall ensure that all equipment is designed to

withstand the following air quality requirements:
5.2.1 Dust Concentration
Usual airborne dust concentration is 1 mg/m³. During sandstorms, dust

concentrations may reach 500 mg/m³. Particle sizes are as follows:
95% of all particles are less than 20 micrometers
50% of all particles are less than 1.5 micrometers
Elements present in dust include compounds of calcium, silicon,

magnesium, aluminum, potassium, chlorides and sodium. When wetted
(high humidity conditions) these compounds function as electrolytes and
can result in severe corrosion.
5.2.2 Other pollutants present in the atmosphere under the most extreme
conditions are:
H2S 20 ppm (Vol/Vol)
Hydrocarbon 150 ppm (Vol/Vol)
SO2 10 ppm (Vol/Vol)
CO 100 ppm (Vol/Vol)
NOx 5 ppm (Vol/Vol)

Page 9 of 40
O3 1 ppm (Vol/Vol)
5.3 Offshore and Nearshore Environment
Equipment which is not enclosed or hermetically sealed, but is situated offshore

or near-shore, shall be protected against corrosion and operational failure due to
wind-borne sea water spray and the accumulation of wetted salt (NaCl).
Nearshore is defined as any outdoor, onshore location within one kilometer from
the shoreline of the Arabian Gulf or within three kilometers from the shoreline
of the Red Sea.
5.4 Humidity
Outdoor design basis shall be 5% to 95% relative humidity (non-condensing).
5.5 Noise
Instruments shall not generate noise exceeding the permissible noise exposure
levels of 85 Dba at a distance of 1 meter radius and shall be rated to operate
continuously at this level.
6 General
6.1 All dimensions and measurements shall be in the “International System of

Units” (SI) followed by the equivalent value in English (conventional) units
between brackets. When not critical, the equivalent dimensions may be rounded
off to their nearest practical value.
6.2 All components shall be of high grade industrial standard varieties rated for
environmental conditions listed in Section 5.
6.3 Equipment shall be protected against corrosion and operational failure due to
wind-borne sea water spray and the accumulation of wetted salt (NaCl).
6.4 All electrical/instrument shall be Certified according to approved Hazardous

Electrical Area Classification in accordance with NFPA 70.
6.5 The design shall consider temperature-related concerns, such as material

toughness, reduced yield and ultimate strengths, accelerated corrosion/cracking,
and non-metallic material degradation.
6.6 The following components shall be sourced from the applicable Regulated
Vendor Lists (RVL), SAES-Z-002 and 9COMs:
a) Instrument Root Valves
 9COM 6000000314 - VALVE: GATE; API 6A, 10000 PSI
Page 10 of 40
b) Double Block and Bleed 9COM 6000015161 – VALVE BALL: TWIN

BALL, API 6A 10000, DBB
c) HIPS Valves Bare-stem - 9COM 6000015611 – Valve: Gate; HIPS 1-
13/16 IN & UP, API 6A
d) HIPS Valve Actuators - 9COM 6000002902 – ACTUATOR; VALVE;
HYDRAULIC & ELECTRO/HYDRAULIC)
e) HIPS Valve Actuator Hydraulic Power Unit - 9COM 6000002902 –
ACTUATOR; VALVE; HYDRAULIC AND ELECTRO / HYDRAULIC)
f) HIPS ZV Solenoid Valves – 9COM 6000002871 – VALVE; SOLENOID
OPERATED
g) Piping Spool Pieces – To be manufactured in accordance with API 6A by a
Certified facility (API 6A Certification) and cladded per 02-SAMSS-012
h) Safety Logic Solver – Solid State – 9COM 000002725 – ESD: Electronic;
Solid State
i) Control Panels; Outdoor – 9COM 6000002698 – PANEL; CONTROL;
INSTRUMENT; OUTDOOR
j) HIPS 2oo3 Pressure Transmitters – 9COM 000002851 – TRANSMITTER;
PRESSURE
6.7 The specific location(s) and environment in which the HIPS system will be
installed shall be specified within the Material Requisition (MR) and purchasing
documents.
6.8 Each wellhead process flow path is to be provided with a HIPS ZV valves skid
as a single skid-mounted unit which shall include but not limited to ZV safety
valves, hydraulic actuators, hydraulic and electrical controls, intermediate
machined spool piece, HPU and associated hydraulic pipe headers and tubing.
6.9 Each HIPS ZV valves skid shall be provided with redundant 1oo2 fail-close
design ZV valves connected in series via a machined spool piece. The ZV
valves shall be hydraulically actuated with spring return that move the ZV
valves from the fully open to the fully closed position upon receiving a signal
from the common logic solver in response to sensing a high-high pressure in the
production stream to a predefined set-point via the common set of 2oo3 pressure
transmitters.

Page 11 of 40
6.10 Wellhead HIPS Basic Architecture (Saudi Aramco Current Practice)
Note: Up to 4 single well flow paths/production line per logic solver are acceptable.
Note: Up to 4 single well flow paths/production line per logic solver are acceptable.
Figure 1 - HIPS IPL Architecture
Commentary Note:
Multiple flow arms allow functional testing of HIPS ZV’s (via full stroke test)
without process interruption. This is a key operations requirement for Offshore
Gas production platforms.

Page 12 of 40
6.11 The 2oo3 voted pressure transmitters shall be mounted with independent process
taps installed on the production header downstream of the HIPS valves and
upstream of the pipe specification break as shown on Figure 1.
6.12 The HIPS ZV valves skid shall be installed downstream of the wellhead
production choke valve and upstream of the piping specification break.
6.13 See Appendix E for quick reference of applicable Saudi Aramco Standards.
6.14 The HIPS system shall be certified to SIL 3 with a PFD per SAEP-354 by a Saudi
Aramco approved internationally recognized third party safety entity (e.g., TUV,
Exida, or Lloyd’s). Verification of compliance shall be per SAEP-250.
6.15 The Vendor shall verify and document the HIPS SIL compliance and
availability using their assigned engineer(s) or third party consultant.
The responsible individual for the verification of the HIPS shall be a certified
functional safety engineer/expert qualified to meet the competency requirements
of IEC 61508 and IEC 61511.
6.16 Vendor/Contractor compliance with the provisions of this SAMSS does not
relieve vendor/contractor from the responsibility to furnish equipment of proper
design to meet the specified environment, application, service, and operating
conditions.
7 System Requirements
7.1 HIPS Pressure Transmitters
7.1.1 Three totally separated, functionally identical, electronic pressure

transmitters shall detect high-high pressure from the wellhead shut-in
pressure to a predefined set point. The use of pressure switches as input
channels to the logic solver (safety loop) is not allowed.
7.1.2 The pressure transmitters shall be smart electronic transmitters with

±0.5% accuracy or better, 4 – 20 mA HART output, SIL Compliance
Certified, and high burnout.
7.1.3 Pressure transmitters shall comply with minimum requirements in

accordance with SAES-J-200. Reliability performance of the chosen
transmitters shall be suitable for the required process scan time.
The HIPS pressure transmitters shall be the Vendors scope of supply.
See Appendix D.
7.1.4 Each pressure transmitter shall have a ½” MNPT connection and be

close-coupled to a flanged diaphragm seal (glycerin filled) assembled at
the factory with a connection of 1-13/16” ISO 10423/API 6A 10000 psi
Page 13 of 40
pressure class, Type 6BX.
7.1.5 All pressure transmitters shall be compatible with the production fluid
and rated for API 6A 10000 psi piping systems.
7.1.6 Each pressure transmitter shall be installed on individual process

connections separate from a process control or monitoring instrument.
Each transmitter shall be capable of being calibrated in-service
independently.
7.1.7 In addition to the root valve referred on paragraph 7.1.7, the pressure
transmitter assembly (PIT with diaphragm seal assembly) shall be
mounted directly on twin-ball with bleed valve design as Double Block
and Bleed Valve (DBB).
7.1.8 The Double Block and Bleed shall be design API 6A type 6BX, RTJ,
API 6A 60k material (A694-F60) with Inconel 625 clad body (or Integral).
7.1.9 The DBB valves shall be of Modular type, trunnion mounted ball,
block valve gear operated, needle Valve T-Bar operated or hand wheel,
Inconel 625 Trim, metal seat with TC hard facing. Bleed connection
shall be supplied with Autoclave Connection. Refer to Figure 2.
7.1.10 The pressure transmitter with diaphragm seal assembly and DBB valves
shall be mounted directly on top of the root valve. The DBB valves
shall be procured from 9COM 6000015161 and in accordance with
04-SAMSS-055.
Figure 2 - Instrument Connection Diagram

Page 14 of 40
7.1.11 Minimum required ID of the needle valve is to be 10 mm (0.393”) with

autoclave end connections.
7.1.13 The bleed needle valve is to be 19.05 mm (0.750 inches) with Autoclave
end connection plugged.
7.1.14 All instrument bleed connections shall be oriented to facilitate

connection to a common one (1) inch bleed line directed to a safe
location. Bleed line will be installed at site by others.
7.1.15 The Pressure transmitter test port(s) shall be provided with permanent
test connections with end plugs. The permanent test connection shall be
readily accessible for easy hook up with the external pressure simulator
device (e.g., a manual hydraulic pump) used for testing.
Commentary Note:
“Readily accessible” location refers to access an area without the need of
climbing or use of ladders.
7.2 HIPS Safety Logic Solver
7.2.1 The logic solver system shall be designed as a SIL-3 hardwired logic
system utilizing highly reliable and proven-in-use non-programmable
solid state technology of failsafe design in accordance with IEC-61508
and 34-SAMSS-621. In case of any conflict between 34-SAMSS-621
and this specification, the requirements of this specification shall take
precedence. The HIPS logic Solver shall be the Vendors scope of
supply. See Appendix C.
7.2.2 The HIPS system shall be configured to perform the operational and
process requirements shown in basic logic and/or cause and effect
diagrams supplied by the Buyer or Buyer's engineer. The configuration
shall be performed by hardwire connections. The parametrization of
safety settings (such as timers, thresholds, etc.) shall be done using
hardwired jumpers or switches on the logic solver components and shall
not require any use of programming stations or interaction with other
software tools. Operator access to change any HIPS parameters via
communication link shall not be possible.
7.2.3 The Logic Solver System shall employ three independent channels on
separate modules capable of receiving individual 4 – 20 mA signal from
field pressure transmitters.
7.2.4 The logic solver shall vote the pressure transmitters in a 2oo3
configuration and all HIPS ZV valves shall close simultaneously when a
high-high pressure is sensed.
Page 15 of 40
7.2.5 The HIPS Logic Solver shall be equipped with self-diagnostics.

The diagnostic function shall be non-interacting and do not impact the
safe operation of the HIPS. Should diagnostic detect a failure, a fault
signal shall be activated and communicated to RTU and SCADA.
7.2.6 On line setup and testing of each input channel of Logic Solver shall be
possible without shutting down the system.
7.2.7 The Logic Solver shall be of a rugged design and field mountable.
7.2.8 The logic solver shall be fitted inside a free standing panel fully fitted
with all termination, lamps and switches, power distribution, patch
wiring, interposing relays and auxiliaries.
7.2.9 Electro-Magnetic Interference (EMI) and Radio Frequency Interference

(RFI). The logic solver equipment shall carry the CE Mark for
compliance with European EMC Directive 89/336/EEC or shall comply
with immunity levels stated in IEC 61000-6-2. Alternatively, the
VENDOR shall provide testing results to confirm that the equipment will
operate without disturbance when energized and subjected to an
electromagnetic field from a radiating source equivalent to a level 3
disturbance as detailed in IEC 61000-4-3.
7.2.10 The electronics shall reside on withdraw able modules, located in a rack.
Separate modules shall be used for input, output, logic functions,
communications, and power supplies.
7.2.11 The HIPS system design shall allow the replacement of one logic solver
analog input module used to acquire the process pressure to be removed
on-line (i.e., in case of detected failure) without interfering with other
modules.
7.2.12 All modules shall be corrosive resistance against dust and H2S
environment.
7.2.13 The Logic Solver System 2oo3 input voting logic unit shall be provided
with a deviation time delay for process variable input discrepancies
(adjustable, e.g., 5%) and shall be adjustable from 0 to 15 seconds.
In case the set time is exceeded, the 2oo3 voting logic unit shall generate
a deviation alarm annunciated on the front door of the Logic Solver
System cabinet from outside and on the serial link to the RTU and
SCADA. The deviating process variable signal shall be identified and
considered as invalid and the trip logic automatically degraded to 1oo2.
7.2.14 The Logic Solver System shall be provided with trip delay timer, turn on
delay timer and output trip relay (if necessary). The trip delay timer
Page 16 of 40
circuit shall delay the activation of the output trip relay. The trip delay
timer shall be capable of being adjustable from 0.2 to 5 seconds.
7.2.15 The HIPS logic solver shall restart automatically after a power supply
restoration. During and after a restart the system shall remain in a failsafe
state and maintain outputs de-energized until manual reset by operator.
7.2.16 No input bypass is required in a 2oo3 voting architecture.
7.3 Logic Solver Power Supply
7.3.1 Redundant power supplies shall be provided for the HIPS Safety Logic
Solver cabinet and the internal HIPS safety logic solver, modules (or
cards) and field terminations. Each power supply shall be independent
from each other and from any other shutdown system, control and safety
system.
7.3.1.1 Unless otherwise specified, the primary source will be

120 VAC, Single Phase, 60 Hz nominal power from platform
AC power panel.
7.3.1.2 Unless otherwise specified, the secondary source will be

24 VDC power from dedicated platform battery back-up.
7.3.1.3 The VDC power supply shall not be floating and therefore, the
negative pole shall be grounded.
7.3.2 HIPS Chassis Power Supplies
7.3.2.1 Redundant chassis power supplies shall be used in all cases to

supply power to internal HIPS logic solver system modules (or
cards). Chassis power supply may be a device or group of
devices, installed on a separate place in the HIPS cabinet.
7.3.2.2 Each power supply shall be independent from any other

shutdown system, control and safety system; connected via
robust cabling or internal bus structure.
7.3.2.3 Each power supply shall be sized to provide 100% of the

ampacity requirements (at rated voltage, connected load, and
maximum cabinet temperature) for the specified configuration
of I/O cards, logic modules, etc.
7.3.2.4 Decoupling of the redundant power supplies shall be performed

using physically separated devices (e.g., diodes) in order to

Page 17 of 40
allow maintenance on one of the decoupling device without

shutdown of the HIPS.
7.3.3 Field I/O Power Supplies
7.3.3.1 Redundant, switch mode or linear field power supplies shall be

used to power the I/O portion of the HIPS. Each I/O power
supply shall be sized to continuously supply 125% of its
connected load (at rated voltage, ampacity, and at maximum
cabinet temperature).
7.3.3.2 It shall be possible to configure power supplies in either a

master-slave or load sharing arrangement and to locally
monitor the output voltage and current of each power supply.
7.3.3.3 Power supply loads shall be calculated with all points

energized, and all outputs carrying their maximum connected
load. The load calculation shall include provision for installed
spares and future expansion capability.
7.3.3.4 Field I/O power supplies may be the same physical devices as
chassis power supplies; in this case with separate circuit
breakers.
7.4 HIPS Logic Solver Cabinet
7.4.1 The logic solver cabinet shall meet the minimum requirements of
34-SAMSS-820 for indoor cabinets and 34-SAMSS-821 for outdoor.
HIPS Logic Solver cabinets shall be the Vendor scope of supply.
7.4.2 The cabinet shall have a side to side configuration with two lockable
front doors and two integrated swing frames. The HIPS logic Solver
cabinet shall be a combination of a system cabinet and a marshalling
cabinet.
7.4.3 The overall dimensions of the logic solver cabinet shall not exceed
800 mm deep x 1600 mm wide x 2200 mm high.
7.4.4 The cabinet shall be rigid, self- supporting, free standing, floor mounted
and NEMA type 4X in accordance with NEMA 250/NEMA ICS 6 or
IEC 60529 type IP 66 for installation in non-classified area.
7.4.5 The enclosure shall be manufactured of 316L stainless steel material or

better including the door.
7.4.6 The HIPS Logic Solver cabinet shall be provided with local indication
Page 18 of 40
lamps, alarm, lamp test and reset push buttons located on the external
side of the front door of the Logic Solver system cabinet.
7.4.7 For cable entry, the cabinet shall be equipped with cable gland plate on
the bottom of the cabinet enclosure. The gland plate shall be removable,
not be pre-drilled, without cable glands and NPT adaptors.
7.5 HIPS ZV Valves and Actuators
HIPS bare-stem ZV valves shall be in accordance with 04-SAMSS-049,

04-SAMSS-055, 04-SAMSS-056 and 04-SAMSS-057.
7.5.1 Each HIPS ZV valve and actuator shall be supplied as an integrated

assembly per Appendices A and B.
7.5.2 The HIPS ZV valve type shall be reverse acting/floating slab gate full
bore design supplied in accordance with 04-SAMSS-057.
7.5.3 The installation orientation of ZV valve shall be as per Appendix A.
7.5.4 The end connections of the HIPS ZV valves shall be flanged ends,
Type 6BX flanges are of the ring-joint type and are designed with a
raised face, WN and RTJ Type 6BX, API 6A Class 10000 to match
process pipe bore and intermediate spool piece.
7.5.5 The valves shall be designed in accordance with API 6A as per

04-SAMSS-055. The maximum design pressure shall be equal to the
pressure rating specified in the valve data sheet Appendix A.
7.5.6 HIPS ZV valves shall be sourced as per applicable 9COM.

See Section 6.6. The HIPS ZV valve/actuator integrator shall be
responsible for the sizing, valve-actuator interface, assembly and testing
of the whole assembly HIPS ZV valve (bare-stem valve + actuator +
hydraulic controls +HPU).
7.5.7 Each HIPS ZV valve and actuator assembly shall have a closing stroke
time ≤ {Process Safety Time ½}. The PST shall be supplied in the MR
and purchasing documents.
7.5.8 Vendor shall be responsible for ensuring that the stroking time
requirements for the shutdown valves are met.
7.5.9 The whole assembly ZV valve (valve + actuator) shall be designed and
capable of opening and closing against a differential pressure equal to
the maximum shut-in pressure of the well unless otherwise specified in
Appendices A and B.
Page 19 of 40
7.5.10 Applicable valve FEA (Finite Element Analysis) stress analysis shall be
carried out by an independent Third Party Agency in accordance with
ISO 10423/API 6A as per 04-SAMSS-055.
7.5.11 The Vendor shall be responsible that design verification of the valve
include the worst load case (Max. Axial + Max. bending) as per
ISO 10423 (API6A) and 04-SAMSS-055.
7.5.12 ZV valve and actuator assembly shall be subject to PR2 test /30 Years
Service Simulation Test. Applicable tests shall be performed with
closing speeds equal or faster than the required PST ½, the opening
speed shall be equal or greater than 30 seconds.
7.5.13 The valve and actuator assemblies shall be fully integrated and tested at
the facility approved for manufacturing the valve.
7.5.14 The integrated assembly shall be a type qualified assembly per API 6A,
Annex F, Performance Requirement Level PR 2.
7.5.15 ZV valve manufacturer shall issue through the HIPS Integrator a detailed
test procedure of the qualified integrated assembly for review.
7.5.16 The Level PR2 test of the valve and actuator assembly shall be witnessed
and certified by a Saudi Aramco approved party safety entity (TUV,
Exida, or Lloyd’s) independent of the individual who performed the
verification.
7.5.17 Acceptance criteria shall be Zero Leakage per ISO 10423/API 6A PSL 4
as per 04-SAMSS-055.
7.5.18 All results shall be recorded as part of the design validation file per
ISO 10423/API 6A PR2, Annex F. In addition, the actuator hydraulic
pressure across all cycles shall be recorded, identifying the break to open
and break to close values, and provided in both graph and tabular
formats. All the above documentation together with the Independent
Third Party certification shall be submitted to the HIPS Unit for review.
Actuators/HPU
The HIPS hydraulic actuators and HPU shall follow Saudi Aramco
Materials System Specification 34-SAMSS-717. The hydraulic oil shall
be per 26-SAMSS-051.
7.5.19 HIPS ZV valve actuators and HPU shall be sourced from applicable
9COM. See Section 6.6.

Page 20 of 40
7.5.20 The HPU functionality is to generate the required actuator control

pressure. The hydraulic system pressure shall be designed to actuate the
HIPS ZV valves at maximum flow line shut-in pressure specified on the
actuator instrument specification sheet.
7.5.21 The HIPS bare actuator shall be certified per API 6A Annex F Design
Validation, PR2, requirements. See Appendix B.
7.5.22 HIPS ZV valves/actuators assembly with fast closure stroke speeds shall
be provided with capabilities to prevent effects resulting from the rapid
closure of the valve and actuator that may increase wear and tear of
internal components. These capabilities may include end-of-stroke
cushioning devices as referred on Section 5 of 34-SAMSS-717.
7.5.23 HPU accumulators shall be used to provide hydraulic supply to

ZV Valve actuators in case of failure of HPU pumps.
7.5.24 The HPU accumulators shall be capable to provide sufficient hydraulic

fluid for at least three full strokes (open to close 3 times) of the ZV
Valves as per 34-SAMSS-717.
7.6 HIPS ZV Valve Skid Controls
7.6.1 The hydraulic controls (SOV panel, LCP panel, quick-exhaust(s) and
fusible valves) for each HIPS ZV valve assembly (qty. 1 bare-stem HIPS
valve + qty. 1 HIPS actuator) shall be totally separate and independent
from other control and safety systems.
7.6.2 Each HIPS ZV valve assembly shall be supplied with its own separate
and independent hydraulic SOV panel with qty. 1 set of 1oo2 solenoid
valves.
7.6.3 The HIPS ZV solenoid valves shall be used to vent the actuator in the
event of a trip.
7.6.4 The solenoid valves shall be direct-acting, 3-Way (de-energize to trip),

body and junction box in minimum 316 SST, minimum coil insulation
Class F, IP66. The solenoid valves shall be procured per SAES-J-002.
7.6.5 The HIPS ZV solenoid valves shall be sized to meet the required closing
stroke speed in conjunction with any quick-exhaust valve (if applicable).
7.6.6 If quick-exhaust valves are provided, these shall be installed as closed as

possible to the actuator feed/exhaust port or as separate cartridge valves
on the actuator end-cap.

Page 21 of 40
7.6.7 HIPS ZV valves hydraulic control system shall feature a fusible valve
per 34-SAMSS-717, Section 6.3. The outlet of the fusible valve shall be
connected to the hydraulic return line to the HPU.
7.6.8 Each HIPS ZV valve assembly shall be supplied with its own separate
and independent smart partial stroke test device with LCP per
34-SAMSS-634.
7.6.9 The partial stroke testing device shall allow remote partial stroke testing
and diagnostics, communicating via the SCADA system (by others).
7.6.10 The LCP shall allow the operator to locally perform partial stroke
testing, open and close each HIPS ZV valve independently with local
and remote indication and diagnostics.
7.6.11 HIPS ZV valves shall be provided with position transmitters on each

actuator to provide open and closed valve position indication as per
34-SAMSS-717. Additionally, a pressure transmitter shall be provided
to monitor actuator chamber internal pressure to evaluate valve position.
7.6.12 Position and pressure transmitters electrical certification shall be per

project area classification, labeled, listed or certified by any of the
agencies in the Approved IECEx Certification Bodies under the IEC Ex
Certified Equipment Scheme as meeting the ANSI/NFPA 70 NEC
requirements for the hazardous area and NEMA 250 type 4X (stainless
steel) or IP 66 per IEC 60529.
7.6.13 The vendor shall provide open and close visual position indication
mounted on the valve actuator clearly visible and accessible.
7.7 HIPS ZV Valve Spool Piece
7.7.1 The HIPS spool piece is defined as the intermediate spool between the
HIPS series ZV valves. The intermediate spool shall be machined from
a single piece of low alloy forging or ring forging material matching the
design pressure and temperature of ZV valves.
7.7.2 Spool piece OD shall match the process line and HIPS ZV valves mating
flange OD with tolerances per ISO 10423/API 6A.
7.7.3 Spool pieces ID shall match the ID of the HIPS ZV valves.

Commentary Note:
Attention shall be paid to match the final ID after cladding. Refer to 7.5.4
above for HIPS ZV flange end.

Page 22 of 40
7.7.4 The spool piece shall be provided with a process connection to install a
pressure indicator compatible with the production fluid and rated for
API 6A 10,000 psi piping systems.
7.7.5 The pressure indicator shall be provided with a root valve and a double
block and bleed with 1-13/16” process connection. Refer to Figure 2 for
process connection.
7.7.6 Root valve shall be manually operated, gate double-expanding type,

metal seated as per 04-SAMSS-055 and procured from applicable
9COM. See Section 6.6.
7.7.7 The Double block and bleed shall be design API 6Atype 6BX, RTJ,
API 6A 60k material (A694-F60) with Inconel 625 clad body
(or Integral).
7.7.8 The pressure indicator shall be mounted directly on top of the double
block and bleed assembly.
7.7.9 The bleed connection shall be routed to a safe location by means of

instrument piping/hard piping.
7.7.10 The process connection shall be directly machined on the spool piece,
studded-in type, 1-13/16”, full bore, per ISO 10423/API 6A 10000 psi
pressure class, type 6BX.
7.7.11 Spool pieces shall be designed in accordance with ASME B31.3.

The spool piece flanges shall be manufactured API 6A type 6BX,
NDE and tested per ISO 10423/API 6A 10000 psi pressure class PSL 3.
Manufacturer shall have a valid ISO 10423/API 6A license and provide
as part of the documentation corresponding design, NDE, and testing
files.
7.7.12 All wetted parts of the spool piece, including the RTJ type 6BX flanges’
faces and groves, shall be cladded with Inconel 625 with a minimum
thickness after final machining of 3.0 mm (0.119 inches). Cladding shall
be per 02-SAMSS-012 and corresponding inspection form 175-026600.
7.7.13 Vendor shall provide the spool pieces bolting as applicable. Bolting shall
be ASTM A320-L7 (studs) / ASTM A194-7M (nuts). Bolting material
shall be protected from offshore environment as per requirements of
SAES-L-109.
7.7.14 Spool pieces shall be flushed clean from hydro test water and lay-up in
accordance with SAES-A-007.

Page 23 of 40
7.7.15 HIPS spool flange to flange dimensions shall be per Figure 3.
7.8 Skid - Structural Elements
7.8.1 Steel design shall be in accordance with the AISC 360-10, “Steel
Specification for Structural Buildings” requirements.
7.8.2 Welding shall be in accordance with AWS D1.1 “Structural Welding

Code” requirements. A continuous fillet shall be used to seal all
adjoining members.
7.8.3 Skid shall be designed to resist, without damage to associated

equipment, all loads and stresses resulting from lifting and handling.
Maximum deflection of the base during lifting and transporting shall not
exceed L/240.
7.8.4 Skid shall be of welded construction, rigidly braced with welded cross
members and integral permanent provisions for multiple point lifting.
Jacking facilities shall be provided for base leveling.
7.8.5 The Skid structural elements shall be hot-dip galvanized after the
completion of the welding and drilling associated with the fabrication of
the skid structure. It is acceptable to drill holes in the galvanized skid
structure to attach small accessories (e.g., cable clamps) provided the
bare metal final coating is as per SAES-H-004.
7.8.6 The skid structure shall be designed for all applicable structural,
equipment, operating and environmental loads in accordance with API
RP 2A WSD. The skid shall be provided with drip tray and certified
lifting eyes.
7.8.7 Stainless steel hardware shall be used for the assembly of the complete
skid and for the attachment of any accessories.
7.8.8 Where dissimilar metals are in contact, the contact points shall be
suitably protected to prevent corrosion due to galvanic action.
7.8.9 Material type and coating used for structural elements of equipment skid
and saddles shall comply with AISC 360-10 and SAES-H-004.
7.8.10 Skid design must comply with ASME BTH-1 “Design of below the
Hook Lifting Devices”.
7.8.11 The skid design shall consider the worst case of 100% of the load
distributed between only 2 diagonal/opposing slings/lifting lugs.

Page 24 of 40
7.8.12 The skid design shall include provisions for securely and easily bolting
the skid onto the platform deck to facilitate maintenance and removal.
HIPS skid shall not be welded to the offshore platform deck.
Dimensional Constraint
7.8.13 The HIPS ZV Valve Skid shall meet the same face to face dimensions of
this Section.
7.8.14 Each HIPS series ZV Valve shall be mounted on their own independent
skid. No skid mounted equipment shall overhang the skid edge.
7.8.15 Dimension W is the Width of the skid and maximum acceptable distance.
Skid should be minimum size to meet the application.
7.8.16 Dimension X is from center line of pipe to bottom of skid steel.
7.8.17 Dimension Y is the face to face dimension of the API rated HIPS valve
(from inlet flange face to outlet flange face).
7.8.18 Dimension Z is the spool piece between the HIPS valves (from inlet
flange face to outlet flange face).
7.8.19 Dimension E is the distance upstream of ZV Valves (from skid edge to

ZV valve A inlet flange face). Dimension E allows installation for
process inlet connection, HPU, accumulators, etc. Skid should be
minimum size to meet the application.
7.8.20 Dimension L is the overall dimension of the skid that includes ZV

Valves with actuators, spool piece and its auxiliary equipment (HPU,
hydraulic controls, accumulators, etc.).
Note: Below dimensions are based on 9 inches valve size. Other proposed
valve sizes may be considered for review and acceptance.
Skid Pipe HIPS Valve

W X Y Z E L*
Rating (psi) Size
Mm (in) Mm (in) Mm (in) Mm (in) Mm (in) Mm (in)
(API 6A) Mm (in)
2280.6 2200 830 978 1368 5476 8800
10K
(9 in) (86.61) (32.67) (38.50) (53.85) (215.59) (346.45)
Tolerance ± 2.0 ± 2.0 ± 2.0 ± 2.0 ± 2.0 ± 2.0
“L” dimension includes API 6A BX Rings

Page 25 of 40
Figure 3 - Skid Dimensions
7.9 HIPS ZV Valves Skid Assembly
7.9.1 The HIPS ZV valves skid shall be of compact removable spool designed
to accommodate all required components (i.e., ZV valves, intermediate
machined spool, HPU, etc.). The intermediate machined spool and HIPS
ZV valves ends shall be provided with RTJ flange type on both ends.
7.9.2 Each skid assembly shall be made of a modular baseplate with self-
alignment system. All HIPS ZV Valves skids shall be provided with
same envelope dimensions to facilitate interchangeability. Refer to
Figure 3.
7.9.3 The HIPS ZV valves skid shall be designed to be transported to and

installed at the wellhead platform as one complete unit without requiring
field assembly.
7.10 Painting/Coating
7.10.1 Hot-dip galvanized or stainless steel surfaces shall be painted or coated

in accordance with SAES-H-004.
7.10.2 HIPS valves, actuators, pipe, piping components, and flanges shall be
externally coated per SAES-H-004 and 09-SAMSS-069 Paint System
APCS-1B.

Page 26 of 40
8 HIPS Functional Requirements
8.1 Protection Function Overview
8.1.1 The HIPS SIF shall be designed to protect all piping and equipment with
a pressure class less than the well shut in pressure.
8.1.2 The basic function of the HIPS system shall be to detect high-high
pressure to a predetermined set-point and to reliably and quickly isolate
the source of the high pressure through closure of HIPS ZV valves on the
individual wellhead flow arms. The HIPS ZV valves from individual
wellhead flow arms shall close simultaneously when these are controlled
by a common logic solver.
8.1.3 The HIPS system shall be designed to prevent automatic reset of the
system and opening HIPS valves when the process pressure returns to
below the trip threshold.
8.2 Functionality
The HIPS safety loop shall include analog inputs and digital outputs:
Analog Input
8.2.1 The HIPS system shall employ three independent channels capable of
receiving 4-20 mA analog signals from each field pressure transmitter.
8.2.2 The independent channels for pressure transmitters’ signals shall be

processed and voted via a 2oo3 architecture by the common logic solver.
8.2.3 The 2oo3 voting architecture of the pressure transmitters shall allow each
individual channel to be tested and maintained online without bypassing,
one at the time. Bypass key switches are not required.
8.2.4 In degraded mode, the system shall switch from 2oo3 to 1oo2 voting
architecture. The HIPS System shall be configured to trip upon further
degradation of 1oo2 voting due to additional failure.
8.2.5 The voting logic shall individually consider the following conditions of
each analog input signal as a failure: line break, line short, HH (High-
High pressure) threshold exceeded, and deviation of analog input signals.
8.2.6 Measurement range, HH thresholds, and hysteresis shall be configurable

for each AI (Analog Input) channel individually.

Page 27 of 40
Deviation Detection and Monitoring
8.2.7 The three analog inputs signal values (4 – 20 mA) shall be continuously
compared with each other. Should one signal deviate from the others for
longer than the configured deviation time delay, a deviation alarm shall
be generated and the voting logic shall consider this signal being faulty,
same as >HH.
8.2.8 The deviation alarm threshold shall be adjustable in relation to the

measurement range of the pressure transmitter (e.g., 5% of the
measurement range).
Digital Output
8.2.9 The logic solver shall be configured to drive a de-energize to trip output
in case of one of the following events occur:
a) high-high pressure set point is reached by 2oo3 or 1oo2 HIPS
pressure transmitters;
b) Failure of 2oo3 configuration PTs;
Note: Pressure Transmitter signal is considered as faulty,
when AI < 3.6 mA, AI > 21 mA.
c) Safety Critical failure of logic solver modules involved in the Safety
Function;
d) External trip push button activation (Main deck)
8.2.10 The output command from logic solver shall drive (de-energize) four
independent channels per series HIPS ZV valves capable of outputting
24 VDC @ min 1A power supplies to hydraulic solenoid valves; each
ZV valve features a set of 1oo2 hydraulically operated solenoid valves.
8.2.11 Digital output modules shall be of failsafe design. Each output module
shall control a separately fused supply to each associated solenoid valve.
The output fuses shall be monitored by logic solver system diagnostic
and be individually accessible.
8.2.12 The safety related de-energize to trip outputs shall be latched in the de-
energized state until reset. In case an output card is replaced during
operation, the output channels for that card shall remain in failsafe
position until manual reset.
8.2.13 The HIPS system safety loop shall be segregated from, and totally
independent from other shutdown, control and monitoring systems.
All other I/O’s listed in this specification are not part of the safety loop.
Page 28 of 40
HIPS Overall Response Time
8.2.14 The HIPS safety loop shall be designed to achieve an overall response
time ≤ Process Safety Time /2.
8.3 Failure Mode
8.3.1 HIPS systems and their associated safety instrumented functions shall
fail to the safe state or position upon loss of the input and/or output
signals from the common logic solver, system failure of the logic solver,
loss of both redundant power supplies to the logic solver or loss (or drop
below the minimum) hydraulic supply pressure for the ZV valves
hydraulic actuators.
8.3.2 The failure mode of the logic solver shall be fail safe as indicated in
Appendix C, SA-6239-ENG, HIPS Logic Solver.
8.3.3 The failure mode of the ZV Valves with actuators shall be fail closed
as indicated in Appendix A, SA-6233-1-ENG and Appendix B,
SA-8020-717-ENG.
8.3.4 The safe state of hydraulic solenoid valves shall be de-energized to trip
mode.
8.4 Communications
8.4.1 The logic solver shall have simplex RS-485 port to communicate device
states and diagnostics information to the Process Control System /
Remote Terminal Unit. It shall automatically upload data (i.e., Logic
Solver status, alarms, and field I/O monitoring signals) to the Buyer’s
ESD/PCS upon receiving a poll request.
8.4.2 The logic solver shall support Modbus industry standard communication
protocol.
8.4.3 The logic solver shall be capable of operating in a stand-alone manner

with full functionality, independent of communication with BUYER’s
ESD/PCS.
9 Identification Tagging
9.1 An identification tag or name plate made as a minimum of 316 stainless steel
shall be attached to the HIPS skid and Logic Solver securely with stainless steel
or Monel fasteners. The tag or nameplate shall be located so that the
information is clearly visible and legible after the equipment is installed.

Page 29 of 40
The tag shall be marked by raised letters or die stamping with the following
information:
a) Purchase Order Number
b) Manufacturer
c) Part/Model Number
d) Serial Number
e) Date of Manufacture
f) Mark/Tag Number
9.2 An identification tag or name plate per ISO 10423/API 6A made as minimum of
316 stainless steel shall be attached to each HIPS ZV valve and actuators
securely with stainless steel or Monel fasteners. The tag or nameplate shall be
located so that the information is clearly visible and legible after the equipment
is installed. The tag shall be marked by raised letters or die stamping.
Self-adhesive labels are not acceptable.
9.3 The label inscriptions for all instruments and equipment shall be as specified on
the drawings.
9.4 The tagging system for all instruments, control devices, enclosures, terminal
blocks, cables, and valves, shall be in compliance with SAES-A-202 and
SAES-J-003.
9.5 The direction of flow shall be marked on the HIPS ZV valve skid piping.
10 Inspection and Testing
10.1 General
10.1.1 A copy of the Manufacturer's test procedures shall be submitted to

P&CSD/HIPS Unit for approval.
10.1.2 The Manufacturer's test procedures shall clearly indicate:

a) The conditions under which the testing is to be carried out;
b) Any standards and/or specifications with which the Manufacturer's
test procedure complies.
10.2 Inspection
10.2.1 Instruments shall be tested, examined, and qualified to the established

manufacturer tests and applicable Industry Standard requirements.
10.2.2 Major components (HIPS ZV valve, HIPS actuator, and spool pieces)
Page 30 of 40
and coatings shall be manufactured and are subject to the following

minimum Inspection Requirements of the associated specifications:
a) HIPS ZV Valves 175-043000, 175-043600, 175-045600.
b) HIPS ZV Valve Actuators 175-341001.
c) Inconel 625 Cladding 175-026600.
d) Coatings of HIPS ZV Valves (bare-stem valve + actuator),
175-091900.
e) Skid Structural Elements and Steel Coating 175-120100.
f) Auxiliary Electrical Systems 175-173700.
10.2.3 The integrated skid manufactured to this Specification is subject to the

minimum Inspection Requirements as specified in Saudi Aramco
Inspection Requirements Form175-344700.
10.3 Testing
10.3.1 The assembled skid (HIPS valves and spool pieces) shall pass a shell
pressure test (hydro test) per ISO 10423/API 6A PSL 3 with pressure
class per project piping specification. The water shall not exceed
30 ppm chlorides. The assembled skid shall be promptly drained to
remove stagnant water following required hydro test.
10.3.2 The completed HIPS shall undergo a Factory Acceptance Test (FAT) per
the HIPS Integrator’s approved test procedure. HIPS Integrator shall
submit FAT procedure for Saudi Aramco approval at least 30 days prior
commencing FAT. The FAT shall be witnessed and accepted by a
qualified Saudi Aramco Representative at the approved HIPS Fabricator
facility.
10.3.3 The vendor shall provide all necessary personnel, tools, and test
equipment required for the FAT. Test equipment shall be calibrated with
valid certificates if applicable. Test equipment calibration frequency
shall be per project specifications.
10.3.4 Functional checks during the FAT shall include witness of Fail Safe
Operation, all trip and reset functions, Stroking Speed, full opening and
closing of valves, partial stroke testing, operation of all accessories, and
communication simulation with the applicable SCADA system as per
project specification.
10.3.5 The hydraulic system shall be flushed per 34-SAMSS-717.

Page 31 of 40
10.3.6 The completed HIPS shall undergo a Site Acceptance Test (SAT) per
HIPS Integrator’s approved test procedure. HIPS Integrator shall submit
SAT procedure for Saudi Aramco at least 30 days prior commencing
SAT testing. The SAT shall be witnessed and accepted by a qualified
Company Representative at the site after installation. See SAEP-354.
11 Packing and Shipping
11.1 Before packing, all foreign bodies and traces shall be removed from the skid.
Skid shall be packed and protected against mechanical and corrosive damage.
A non-toxic vapor phase corrosion inhibitor shall be applied to the internal
surfaces of the assembled HIPS equipment. Following application of the
inhibitor, equipment openings shall be sealed vapor tight. The faces of open,
flanged connections shall be coated with a temporary protective coating (MIL
C16173, Grade IV, or equivalent), each connection shall be fitted with a
neoprene gasket, and vapor tight steel cover held in place by a minimum of four
equally spaced bolts.
11.2 Valves must be shipped in the closed position, labelled, and supplied complete
with all required accessories.
11.3 Open tubing fittings and ports shall be capped and / or plugged with metal and /
or plastic caps / plugs.
11.4 All equipment and materials shall be supplied suitably protected from corrosion
during transit, storage, after installation.
11.5 The supplier shall advise any requirements for preservation of equipment and
materials should they require long term (greater than 6 months) storage after
delivery. The supplier shall provide all materials required for preservation and
protection during shipment and storage on site prior to installation.
11.6 All bolts and nuts shall be coated with a temporary protective coating
(MIL C16173, Grade IV, or equivalent).
12 Documentation
All documentation shall be in English and be in compliance with SAES-A-202. As a

minimum the following documents shall be submitted in electronic, searchable format:
12.1 HIPS ZV Valve Data
12.1.1 Full Description- Operations Manual
12.1.2 Brochures and Technical Information

Page 32 of 40
12.1.3 Data Sheet
12.1.4 Cross Sectional Drawing with Bill of Materials and As Built Drawing
12.1.5 Spare Parts List
12.1.6 API 6A PR2, Appendix F Certificate
12.1.7 Reproduction of Marking, i.e., Nameplate, NACE
12.1.8 Valve Pressure Test, Functional Test, Seat leakage test, and Calibration
Record Sheets
12.2 HIPS Logic Solver/Logic Cabinet/Pressure Transmitters/Skid
12.2.1 Cabinet General Assembly Drawings with Bill of Materials and overall
weight
12.2.2 Cabinet Fabrication and Assembly Drawings
12.2.3 Cabinet Layout Drawings showing client interfaces
12.2.4 Cabinet heat dissipation calculations
12.2.5 Power and load calculations and certificates
12.2.6 Wiring Diagrams and Schematic Drawings
12.2.7 Functional Design Specification
12.2.8 Logic Drawings
12.2.9 Logic Solver System Block Diagram
12.2.10 Inspection and Testing Procedures and Test Reports
12.2.11 The installation and configuration drawings and documents shall

provide all necessary details for the installation and commissioning of
the Logic Solver System.
12.2.12 List of Approved Deviations from this engineering specification.
12.2.13 Comprehensive Manufacturer’s Literature for all Components
12.2.14 Installation, Engineering, Operation and Maintenance Manuals
12.2.15 Recommended Pre-commissioning and Start-up Spare Parts and

Consumables List
Page 33 of 40
12.2.16 Recommended 2 and 5 years Operations Spare Parts List with detailed
price breakdown.
12.2.17 Lifting Procedure and Drawing with certified lifting points and Center
of Gravity (applicable to all equipment)
12.2.18 Start-up and normal power requirements for complete Logic Solver
and Cabinet.
12.2.19 MODBUS Map
12.2.20 SIL Certificates of Components issued by an internationally

recognized independent third party.
12.2.21 Certified SIL Verification Report including Reliability Block Diagram

or Fault Tree Analysis and Reliability Data and MTBF Figures
12.2.22 Packing and Shipping Procedures
12.2.23 Documentation in accordance with the Non-material Requirements per

Form SA-NMR-7930 attached to the purchase order.
12.2.24 HIPS Pressure Transmitters (2oo3) calibration certificates.
12.3 General
12.3.1 Hydraulic Schematic of HIPS valve actuation system assembly
12.3.2 Inspection and Testing Procedures
12.3.3 Hazardous Area Classification
12.3.4 Reliability Block Diagram (RBD)
12.3.5 Material Safety Data Sheet (MSDS) for the Hydraulic Oil
12.3.6 All documentation shall be in English and be in compliance with

SAES-A-202. As a minimum the following documents shall be
submitted in electronic structured formats which are word searchable
and legible:
12.3.7 VENDOR documentation shall include complete information /

instructions to allow the BUYER organization to install, operate, and
maintain the equipment or material throughout its operating life.
12.3.8 VENDOR Documentation shall include plan layouts, elevations,

sections, design details, weights, and dimensions relevant to equipment
Page 34 of 40
positioning, electrical and instrument connections, required access for

local control, equipment removal, access for maintenance and electric
power consumption.
12.3.9 HIPS System SIL Verification report; certified by third party.

See paragraphs 6.15 and 6.16 above.
12.3.9 VENDOR drawings shall be dimensioned in metric units with imperial

dimensions shown in parenthesis.
12.3.10 All VENDOR drawings, data, and correspondence shall show the
Purchase Order number, job title, location, and equipment tag numbers
as referenced in the Purchase Order. The exception is standard
documents such as manuals for components.
12.3.11 Data sheets shall be supplied for all components of the system and
shall state the respective manufacturer’s operating and construction
specification as applicable.
13 Notes to Purchaser
The following information and documents must be completed and provided to the supplier:
13.1 Tag Numbers for the system per SAEP-375 and instrument components
13.2 Composition of produced fluids and chemical injection
13.3 HIPS Bare-stem Valve Data Sheet on SA-6233-1-ENG
13.4 HIPS Valve Actuator Data Sheet on SA-8020-717-ENG
13.5 HIPS Pressure Transmitter Data Sheet on SA-8020-200-ENG
13.6 Non-material Requirements per Form SA-NMR-7930
13.7 Basic logic and/or cause and effect diagrams
Revision Summary
15 February 2016 New Saudi Aramco Materials System Specification for Offshore Gas production platforms
that require HIPS to protect downstream equipment from the risk of overpressure via high
wellhead topside pressures. This SAMSS describes the HIPS design successfully deployed
on offshore multi-well production platforms within the Hasbah and Arabiyah fields.
1 January 2018 Editorial revision to paragraphs 7.1.7, 7.1.11 Commentary Note, and modified 11.1.

Page 35 of 40
Appendix A - HIPS Bare-stem Valve Datasheet

Page 36 of 40
Appendix B - HIPS Hydraulic Actuator Datasheet

Page 37 of 40
Appendix C - HIPS Logic Solver Datasheet

Page 38 of 40
Appendix D - HIPS Pressure Transmitters

Page 39 of 40
Appendix E - HIPS SA Applicable Standards (Overview)

Page 40 of 40

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Materials System Specification

34-SAMSS-627 1 January 2018

Appendix A - HIPS Bare-Stem Valve Datasheet ..... 36

Previous Issue: 15 February 2016 Next Planned Update: 15 February 2019

©Saudi Aramco 2018. All rights reserved.

2 Conflicts and Deviations

2.4 The designation “Commentary” is used to label a sub-paragraph that contains

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering

Saudi Aramco Engineering Standards

Saudi Aramco Materials System Specifications

Saudi Aramco: Company General Use

34-SAMSS-821 Instrument Control Cabinet - Outdoor

Saudi Aramco Inspection Requirements

Saudi Aramco Forms and Data Sheets

Saudi Aramco Non-material Requirements

3.2 Industry Codes and Standards

American Institute of Steel Construction

American Society of Mechanical Engineers

American National Standards Institute

American Petroleum Institute (API)

American Welding Society

American Society of Testing Materials

International Electrotechnical Committee

National Association of Corrosion Engineers/International Standardization

National Electrical Manufacturers Association

Saudi Aramco: Company General Use

Emergency Shutdown System (ESD): A system composed of sensors, logic

Fail-Safe: The capability to go to a predetermined safe state in the event of a

FAT: Factory Acceptance Test, it is performed at RVL approved skid

Saudi Aramco: Company General Use

manufacturer or skid fabricator shop and consists of functional test of all

Hot-Dip Galvanized: Metal treatment that meets the requirements of

LCP: Local control panel, it is part of the Local ZV Controls per

MAOP: Maximum allowable operating pressure, it refers to the line or

Modular: A self-contained unit intended to perform a certain function that is

Probability of Failure on Demand (PFD): A value that indicates the

Proven-in-Use: A device that has prior successful use in similar environmental

Safety Availability: The fraction of time that a safety system is able to

Safety Loop: A safety instrumented function consisting of input devices

Severely Corrosive Environment: Offshore, or onshore within 5 km of

Shall: Indicates a mandatory requirement.

ZV: Automated Safety Valve.

Saudi Aramco: Company General Use

Outdoor Sheltered (1)(2)(3) Outdoor Unsheltered (2)(3)

The instrument manufacturer shall ensure that all equipment is designed to

5.2.1 Dust Concentration

Usual airborne dust concentration is 1 mg/m³. During sandstorms, dust

Elements present in dust include compounds of calcium, silicon,

Saudi Aramco: Company General Use

5.3 Offshore and Nearshore Environment

Equipment which is not enclosed or hermetically sealed, but is situated offshore

Outdoor design basis shall be 5% to 95% relative humidity (non-condensing).

6.1 All dimensions and measurements shall be in the “International System of

6.4 All electrical/instrument shall be Certified according to approved Hazardous

6.5 The design shall consider temperature-related concerns, such as material

b) Double Block and Bleed 9COM 6000015161 – VALVE BALL: TWIN

Saudi Aramco: Company General Use