procontrol · a high-integrity pressure protection system ... according to asme viii div ... to...
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High Integrity PressureProtection System
HIPPSApplication
PROCONTROLHIPPS CATALOGUE
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ProControlthe Company
ProControl is an independent highly flexible versatile and professional company specializing in the manufacture and supply of complete valve actuation.Our customers can rely on many years of industry experience and dedicated service, our products have been designed to meet tomorrows requirements in order to achieve maximum efficiency, safety and reliability.
From our factory located in Castell’Arquato, ProControl personnel have built up a sound and strong reputation in being able to supply first class support to our clients, by offering innovative solutions and designs for all applications.ProControl’s talented workforce is also ideally suited to offer clients’ purpose built specifically engineered products as well as a standard product range. ProControl technical expertise can offer creative solutions to clients’ problems thanks to years of experience from the field and to continual research into new technology.Our highly trained personnel is committed to meet today’s fast response demands, responding rapidly and efficiently to clients requirements from the initial inquiry stage throughout contract handling to final delivery and commissioning.Our clients can count on first class after sales support thanks to our efficient rapid response after sales service department, which coordinates together with our service support centres located in all key territories around the world. If required, ProControl’s highly qualified English speaking service engineers can be deployed from our factory at a moment’s notice, and can be onsite anywhere in the world within 24 hours from callout.
ProControlfactory in Aksai,Kazakistan
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ProControl GMBHfactory inLandau-Pfalz,Germany
ProControl srl Headquarter in Italyfactory area m2 8.500
HIPPSINCREASED MARKET DEMAND OF HIGH INTEGRITY PRESSURE PROTECTION SYSTEMHERE’S WHY
ECONOMICREDUCE OPEX (operational expenditure)reduced time spent in test of relief valvesREDUCE DIRECT COSTSreduced of weight for pipeline and vessel downstream the system
SAFETYTOTAL PREVENTIONno possibility of downtime due to overpressure on every kind of downstream packageREDUCE the dangerous effect in case of lack of containment to people, environment and assets
ENVIRONMENTALRESPECT IPCC (Intergovernmental Panel on Climate Change)directives within EC and EPAREDUCE significantly lifecycle emissions: - flaring of hydrocarbons causes damage to the environment - CO2 production is not in line with the Kyoto Protocol
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HIPPSProtection Analysis
Possible Risks MatrixHigh Safety Integrity Level as a necessary risk reduction
SIL
lev
el 1234
DEMAND MODE
LOWProbability of failure on demand
HIGHProbability of a dangerous failure per hour
>10-2 to <10-1 >10-6 to <10-5
>10-3 to <10-2 >10-7 to <10-6
>10-4 to <10-3 >10-8 to <10-7
>10-5 to <10-4 >10-9 to <10-8
PSDProcess Shut Down
45% Protection
DCSDistributed Control
System
70% Protection
HIPPSHigh Integrity Pressure
Protection Systems
100% Protection
ESDEmergency Shut Down
60% ProtectionPSDESDDCS
HIPPS
Choosing a ProControl HIPPS means:
• Increased plant reliability• Certified safety integrity level knowledge and experienced engineers at clients disposal• Third party SIL assessment certification and safety analysis report• A unique partner acting as a single source responsible for the whole system.• Specifically engineered actuators certified SIL3 with a unique integrated quick exhaust valve complete with adjustable end of stroke damper device in order to ensure fast acting stroking times and valve drive train protection.• Unlimited valve torque and thrust coverage.• Fully integrated factory acceptance testing of the complete system• Fully integrated site acceptance testing of the complete system anywhere in the world
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ELECTRONIC HIPPSSystem Overview
A High-Integrity Pressure Protection System (HIPPS) is a safety instrumented system (SIS) designed to prevent over-pressurization in gas, chemical and oil refinery plants. The HIPPS acts as a barrier between a high-pressure and alow-pressure section of an installation, shutting off the source of the high pressure before it exceeds the system design pressure, thus preventing loss of containment through rupture (explosion) of the line or vessel.
The loss of containment can result in:• impact to human life and the environment, when flammable, explosive, or toxic chemicals are released to the atmosphere• economic impact due to production unit replacement/repair costs and production losses
HIPPS are independent reliable systems that operate on a higher Safety Integrity Level (SIL 3) than normal Process Shut Down (PSD) and Emergency Shut Down (ESD) systems.
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Procontrol is a HIPPS system integrator, not only a manufacturer of specially designed HIPPS actuators and related control systems. Together with our partners, who count on many years of experience in the Oil & Gas sector, we are able to supply ultimate integrated customized solutions to meet our clients requirements.
The complete HIPPS system consists of the following main components:• ProControl Actuators (Hydraulic & Pneumatic, Quarter turn or Linear - SIL 3 Certified)• Valves (Ball, Gate - SIL 3 Certified)• Logic Solver (Programmable or Solid State - SIL3 or SIL 4 Certified)• Pressure Transmitter (High Response, Hart Protocol - SIL 2 Certified)• Manifold (Individual Flange Manifolds or Interlocking Manifold)• Skid (designed according to A.I.S.C. – ASD89 – API RP-2A – UBC 97D)• Certifications (FAT Tests and SIL level are under supervision and certified by TÜV)• Comlpete integrated shut down system
HIPPSHIGH INTEGRITY PRESSURE PROTECTION SYSTEM
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ITEM DESCRIPTION NOTES
1 Actuator- Pneumatic- Hydraulic- Electro Hydraulic
2 Valve - Ball or gate, according to API 6A and API 6D
3 Field Initiator- Pressure Transmitters- Mechanical- Pressure Switches
4 Logic Solver- Solid State- PLC Programmable- Mechanical
5 Control Panel - Design according to the Client requirements
6 Skid - Every possible configuration in order to fit every possible customers need
7 Accumulator- For hydraulic backup strokes- For air backup strokes
ProControl Engineering staff designs every safety system according to the Clients requirements, as well as offering alternative progressive solutions.
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HIPPSCHOOSE APPLICABLE SOLUTION THAT TICKS YOUR BOX
PROCONTROL ELECTRONIC HIPPSPROS√ Not dependent field initiator location√ 2oo3 pressure sensing voting logic√ Interlocking manifold with√ Automatic voting logic selection (2oo3 --> 1oo2)√ Automatic & scheduled partial stroke test√ Complete array of diagnostics
CONS√ More complex arrangement√ Higher TCO (Total Cost of Ownership)
PROCONTROL MECHANICAL HIPPSPROS
√ Standalone assembly√ Simpler & indipendent operation
√ Fit for purpose / plug & play√ Integrated pressure sensing / logic solver
√ No electrical wiring√ Lower TCO (Total Cost of Ownership)
CONS√ Partial stroke test only local (no automatic scheduler)
√ Field initiator limited distance from sensing point√ Not integrated SOE (sequance of event)
√ No remote pressure reading
COMMON√ Integral skid Mounted Solution
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MECHANICAL HIPPSSystem Overview
Procontrol is a HIPPS system integrator, not only a manufacturer of specially designed HIPPS actuators and related control systems. Together with our partners, with many years of experience in the Oil & Gas sector, we are able to supply ultimate integrated customized solutions to meet our clients requirements.
The complete HIPPS system consists of the following main components:• ProControl Actuators (Hydraulic & Pneumatic, Quarter turn or Linear - SIL 3 Certified)• Valves (Ball, Gate - SIL 3 Certified)• Power supply : hand pump in self-contained execution or by gas pipeline• Mechanical logic solver built up with pressure switches in 1oo2 configuration ( option : voting 2oo3 )• Manifold (Individual Flange Manifolds or Interlocking Manifold)• Skid (designed according to A.I.S.C. – ASD89 – API RP-2A – UBC 97D)• Certifications (FAT Tests and SIL level are under supervision and certified by TÜV)• Comlpete integrated shut down system• Reduced cost/working parts• Stand alone system
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Quarter TurnPNEUMATIC, HYDRAULIC OR ELECTRO-HYDRAULIC
Actuator Type
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KEY FEATURES• Fabricated entirely from carbon steel• Totally enclosed weatherproof housing - IP67M• Scotch yoke mechanism to suit valve torque requirements• High pressure carbon steel hydraulic cylinder suitable for supply pressures up to 400 bar design• Pneumatic carbon steel cylinder (option stainless steel upon request)• Carbon steel piston with dynamic floating O-ring seals coupled with lubricating piston guide rings• Carbon steel spring cartridge with safety facility which allows safe installation and removal of the whole cartridge assembly• AISI 316SS mechanical position indicator (fully sealed IP67M to avoid ingress into the scotch yoke area) complete with VDI/VDE 3845 NAMUR drive slot for monitoring devices• Bronze sliding blocks which ensure minimum friction, allowing for a long service life and reducing maintenance costs• Bronze thrust bearings and high strength alloy steel chromium plated thrust reaction bar which guides the scotch yoke throughout its stroke and supports all transverse loads generated• ASTM A 320 L7 alloy steel tie rods, with standard electrolytic zinc coating according to ASTM B633 FeZn 12 (option: stainless steel B8M - 17.4.PH)• Alloy steel end travel stops allow for accurate angular stroke adjustment• Design allows 4 x 90° actuator rotation• SIL 3 certified by TÜV• Intergral SIL 3 certified quick exaust complete with adjustable damper system• Actuator torque output up to 1.000.000 Nm• Standard operating temperature range -30°C / +100°C• Special low temperature application up to -60°C• All ProControl pressure containing parts are designed according to ASME VIII div.1 and EN 13445• All ProControl actuators are designed for 30 years’ service life
LinearPNEUMATIC, HYDRAULICOR ELECTRO-HYDRAULIC
Actuator Type
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KEY FEATURES• Fabricated entirely from carbon steel• High pressure carbon steel hydraulic cylinder suitable for supply pressures up to 400 bar design• Pneumatic carbon steel cylinder (option stainless steel upon request)• Carbon steel piston with dynamic floating O-ring seals coupled with lubricating piston guide rings• Carbon steel spring cartridge with safety facility which allows safe installation and removal of the whole cartridge assembly• Visual position indicator directly connected to the valve stem showing actuator / valve full linear stroke• 17.4 PH stainless steel piston rod, which prevents corrosion and allows for minimum sliding friction on dynamic seals• ASTM A 320 L7 alloy steel tie rods, with standard electrolytic zinc coating according to ASTM B633 FeZn 12 (option: stainless steel B8M - 17.4.PH)• Carbon steel mounting adapter with bottom flange machined according to the valve top mounting complete with special coupling mechanism.• Alloy steel galvanized end stoppers available on request• SIL 3 certified by TÜV• Intergral SIL 3 certified quick exaust complete with adjustable damper system• Actuator thrust output up to 10.000.000 N• Standard operating temperature range -30°C / +100°C• Special low temperature application up to -60°C• All ProControl pressure containing parts are designed according to ASME VIII div.1 and EN 13445• All ProControl actuators are designed for 30 years’ service life
VALVESBALL OR GATE
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TOP ENTRY TRUNNION MOUNTED BALL VALVESKEY FEATURES
• Design: 1 Piece cast or forged body with bolted bonnet• Size/Class: ANSI/ASME class up to 4500 Sizes from 1/2” to 56”according to API 6D Sizes from 1”1/13 up to 21”1/4 according to API 6A (up to 15000) Special bore diameters and/or design pressures available upon request• Trim Construction: Direct Trunnion with Floating Seats• Ball/Seat Sealing: Spring Energized Seats, Soft seal with Thermoplastic Seat Inserts or Metal to Metal seal with Hardfaced Ball andSeats,SingleorDoubleBlock&Bleedconfigurationinclosedoropen/closedposition• Over-Pressure Relief: Self-Relieving or Double Piston Effect Seats with Relief Valve• End connections: RF, RTJ, BW, HUB or Norsok L-005 compact Flanges• Body/Bonnet Gasket: Soft with O-Ring or Lip Seal Design, Metal with Ring Joint• Seals: Elastomer O-Rings, PTFE V-Pack or PTFE/Elgiloy Spring Energized Lip Seals• Fire Safe
SIDE ENTRY TRUNNION MOUNTED BALL VALVESKEY FEATURES• Design: 2 or 3 pieces (Bolted Body or Fully Welded)• Size/Class: ANSI/ASME class up to 4500 Sizes from 1/2” to 56”according to API 6D API classes from 3000 to 15000 Special bore diameters and/or design pressures available upon request• Trim Construction: Direct Trunnion or Plate Supported Ball with Floating Seats
• Ball/Seat Sealing:Spring Energized Seats, Soft seal with Thermoplastic Seat Inserts or Metal to Metal seal with Hardfaced Ball andSeats,SingleorDoubleBlock&Bleedconfigurationinclosedoropen/closedposition• Over-Pressure Relief: Self-Relieving or Double Piston Effect Seats with Relief Valve• End connections: RF, RTJ, BW, HUB or Compact Flanges• Seals: Elastomer O-Rings, PTFE V-Pack or Spring Energized Lip Seals• Fire Safe
THROUGH CONDUIT VALVESKEY FEATURES• Design: Slab, Single Expanding, double expanding, direst or reverse acting• Class: API 6D, API 6A, ASME B16.34• Pressure Class: ANSI 150#-4500#• Size range: from ½” to 24”• API 6A Pressure Class: 3000-15000• API 6A Size Range: from 1.13/16” to 11”• Ends: BW, RF, RJ, HUB, Compact Flange• Main Materials: Carbon Steel, Low temperature Carbon Steel , Stainless Steel, Duplex, Super Duplex, Low & High Alloy Steel, Titanium and any other special on request
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DESCRIPTIONProControl select only the best valve producer proven from field in order to satisfy the Oil & Gas demands.All the valves are certified API 6A and API 6D
Logic Solver or PLC ProgrammableLOGIC SOLVER
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DESCRIPTIONThe logic solver is responsible for the activation of the relevant signal outputs on the basis of the preconfigured applications and inputs from the initiators.PLC available on the market, SIL 3 certified, are used as logic solver. The system consist of a Central Processing Unit (CPU) and fail-safe, redundant, I/O card suitable for safety-related applications.All safety communication between the control unit and the associated I/O cards are redundant.The logic solver can also be engineered based on Solid State Logic (SSL).Control Cabinet can be supplied suitable for hazardous area installation in EEx-d enclosure IP-66 or for safe area installation in standard 19” rack cabinet IP-54.
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SOLID STATE
• Safety Integrity Level Up to SIL 4• MTBF > 200 years• Switching time 2-10 ms• Scalable redundancy• Communicates via OPC, PROFIBUS DP, MODBUS• Monitoring for open and short circuits
PLC PROGRAMMABLE
• Safety Integrity Level Up to SIL 3• Flexible redundancy management• Maximum reliability• Drag & Drop engineering• Hot-swapping of modules• Comprehensive, tried-and-tested range of I/Os
CONTROL PANELS
DESCRIPTIONThe control system is completetly engineered by ProControl.The philosofy proposed is discussed with the client in order to find out the best solution for the application required.The control systems are assembled and tested in ProControl factory by our expert technicians and the materials used are suitable for site environement according to customer specifications.
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INTERLOCKING or DBB MANIFOLD series
DESCRIPTIONProControl propose two different manifold configurations: Individual or Interlocking.
The Individual Manifold series is normally used in restriced space with O.S.&Y. stop valve
The main function of the Interlocking Manifold is to permanently ensure the continuity of information between the process fluid and the pressure sensors and requires unrestricted space.
The peculiarities of the Interlocking Manifold consist in forcing the user to follow a predefined set of sequential operations.
Both Individual and Interlocking Manifold can be supplied as loose items or assembled on board our skid .
KEY FEATURES• Electronic Pressure Transmitter field initiators can only be used where electric supply and signals are present and cabled to the Control Room and Plant Monitoring system.
• Mechanical Pressure Switch field initiators are used in a stand-alone scenario where no electric supply and signals are available.
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LOCATION
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ProControlis located at the foot hills of an ancient medieval castel built in the early XII century.
With excellent road accessibility connections from the A1 motorwayClosest railway stations are Fiorenzuola, Fidenza and Piacenza.
Closest airports are
Milan Linate (1 hour),Milan Malpensa (1 &1/2 hours),Bergamo (1 hour),Bologna (1 hour) orParma (45 minutes).
ProControl
Giulio Zani, Managing [email protected]
Sales [email protected]
Località Sforzesca29014 - Castell’ArquatoPiacenza (Italy)
Ph. +39 523 893025Fax +39 523 893149
ProControl S.r.l.Località Sforzesca29014 - Castell’ArquatoPiacenza (Italy)Phone: +39 523 893025 Fax: +39 523 [email protected]
ProControl GmbHAlbert Einstein Strasse 25 D-76829 - Landau - PfalzGermany Phone: +49 6341 98761-0Fax: +49 6341 [email protected]
ProControl Kazakhstanc/o Aksai Industrial ,Aksai, 184/1 Iksanova St090300, Burlin region West Kazakhstan Oblast,KazakhstanPhone: +77 11 [email protected]