Overpressure Study

HIPPS AND ESD VALVES CLOSING TIME
STUDY REPORT
EXECUTIVE SUMMARY
This document presents HIPPS and ESD valves closing time study report for the System Section 1 Project.
Study was performed based on Scope of Work and FEED documents provided by Company. The aim of this
study is to determine the HIPPS valve closing time prior to pressure built up at the 600# system to its design
pressure of 800 psig as well as SDV-001/002 valve closing time prior to reach the HIPPS set point. Total of 6
(six) cases have been identified as case matrix in Table 1 of this report.
Summary of the case matrix is representing as below:
SDV-001/002 Peak pressure in downstream of

Closing time the pressure letdown skid (600#)
Case 1:
6 sec 874.9 psig
Disturbance: SDV-325/326 Close
8 sec 876.3 psig
Action: SDV-001/002 close @730 psig (ESD)
10 sec 877.5 psig
16 sec 882.8 psig
HIPPS valve Peak pressure in downstream of
Case 2: Closing time the pressure letdown skid (600#)
Disturbance : SDV-325/326 close 2 sec 813.8 psig
Action: HIPPS valves close @780 psig 3 sec 818.8 psig
4 sec 824.4 psig
Case 3:
6 sec 846.8 psig
Disturbance : PV-208/211 fully open
8 sec 847.5 psig
10 sec 852.2 psig
16 sec 854.9 psig
Case 4:
2 sec 813.4 psig
Disturbance :PV-208/211 fully open
3 sec 826.3 psig
Action: HIPPS valve close @780 psig
4 sec 829.8 psig
Case 5:
6 sec 730.4 psig
Disturbance : Buyer SDV close
8 sec 730.5 psig
10 sec 730.7 psig
16 sec 731.2 psig
Case 6: Closing time the pressure letdown skid (600#)
Disturbance : Buyer SDV close 2 sec 780.09 psig
Action: HIPPS valve close @780 psig 3 sec 780.1 psig
4 sec 780.13 psig
Some sensitivity cases also performed and can be found on section 7 of this report for detail.
Based on the study, it is recommended (refer to section 9 for detail):
1. ESD set point to be changed from 730 psig to 680 psig.

2. HIPPS set point to be changed from 780 psig to 750 psig to keep pressure at low rated pipe
system (600#) below 800 psig (design pressure).
3. ESD signal should also to be sent to the first HIPPS valve to prevent initiation of the second
HIPPS valve, then both HIPPS valves will close during HIPPS initiation, in case of ESD signal
failure.
1. GENERAL PROCESS DESCRIPTION
The incoming gas is received from the offshore pipeline at seabed temperature of 80°F and at over
normal pressure range of 900 - 1100 psig and maximum/minimum pressure of 1300/600 psig. The
outlet gas from the ORF shall be delivered to the pipeline in accordance with GSA 3&4 contract
requirements.
The ORF shall process at maximum of 55 Bbtu/d - the maximum GSA 3&4 contract requirements. For
equipment sizing a 60 MMscfd capacity shall be used – no additional margin shall be employed above
this value.
Gas arriving at the station will be filtered, and then heated to prevent condensation and hydrate
formation when the pressure is reduced in the pressure let down skids. The pressure let down skids will
incorporate a HIPPS system to prevent overpressure of the downstream facilities.
The simplified process schematic is shown as follows;
8” HIPPS 10” Outgoing

& Pressure
Letdown SDVs
8” Water Bath Logic GSA-3
Heater SDVs Solver Metering
To Batam
SDV-101A Water Bath PT SDV-325

Heater A
Filter A
Logic SDV-326
28” Pipeline
Solver
Water Bath
FV-101 Filter B SDV-101B Heater B
PT
GSA-4
16” Incoming Metering
SDVs
SDV-001 900# 600#
SDV-002
Figure 3. ORF Process Schematic

2. OBJECTIVES
The objectives of the study are:

1. To identify overpressure scenarios on the facility
2. To evaluate the SDV-001 closure time to avoid initiation of the HIPPS valve to close.
3. To evaluate the HIPPS valve closure time to keep maximum pressure at 600# piping system still
below 800 psig (design pressure of the metering).
4. To verify the PAHH set points for the ESD and HIPPS to ensure maximum pressure at 600# piping
system still below 800 psig (design pressure of the metering) in conjunction with the valve closing
time.
The following cases matrix will be used as boundary of the study

Table 1. Case Matrix
Case 5 Case 6
Condition Description Case 1 Case 2 Case 3 Case 4
(Note 2) (Note 2)
Initial/Steady
Condition Inlet Condition from WNTS Tie in point
Flowrate (MMscfd) 60
Pressure (psig) 1300
Temperature (deg F) 80
Letdown Skid Pressure Inlet Temp (deg F) 100
Letdown Skid Pressure outlet (Psig) 610
FV-101 Auto
PV-208/211 Auto
Flow to GSA 3 (MMscfd) 38
Flow to GSA 4 (MMscfd) 22
FV-311A Auto
FV-312A Auto
Disturbance Matrix / SDV-325/326 Close Close
Over pressure cause PV-208/211 Fully Open Fully Open
SDV at Buyer Close Close
ESDV/HIPPS Matrix PAHH@730 psig (ESD) Active Fail Active Fail Active Fail
PAHH@780 psig (HIPPS) Not Achieve Active Not Achieve Active Not Achieve Active
SDV- 001/002 (ESD) Close Open Close Open Close Open
SDV- 101A/B (ESD) Note 1 Open Note 1 Open Note 1 Open
SDV-206 & SDV-207 /SDV-209 & SDV-210 Not Active Close Not Active Close Not Active Close
(HIPPS)
SDV- 325/326 (ESD) Close Open Close Open Close Open
Study Result Determine Determine Determine Determine Determine Determine

ESDV HIPPS closing ESDV HIPPS closing ESDV HIPPS closing
(SDV-001/02) time to protect (SDV-001/02) time to protect (SDV-001/02) time to protect
closing time low rating pipe closing time low rating pipe closing time low rating pipe
without HIPPS without HIPPS without HIPPS
active active active
Closing Time to be 6 second 2 second 6 second 2 second 6 second 2 second

reviewed 8 second 3 second 8 second 3 second 8 second 3 second
10 second 4 second 10 second 4 second 10 second 4 second
16 second 16 second 16 second
Note :
1. For the simulation purpose, SDV-101 A/B will not to be reviewed for 10 and 16 seconds closing time case
2. Pipeline to buyer (15 KM and 16”) was modeled without detail info i.e. elevation change, fittings, bathymetry, etc
3. BASIS AND ASSUMPTION
a. Process conditions and well fluid compositions were taken from the HYSYS simulation of Case 1 in
the HYSYS Simulation Report as below:
Inlet Pressure : 1300 psig

Gas Flowrate : 60 MMscfd
Temperature Outlet Water Heater : 100 deg F
Pressure Outlet Letdown Skid : 610 psig.
Table 2. Dry Gas Composition
Component mol% (Average)

CO2 1.25
N2 1.29
C1 92.56
C2 2.76
C3 1.53
iC4 0.54
nC4 0.16
iC5 0.07
nC5 0.02
nC6 0.01
nC7 0.01
nC8 0
nC9 0
nC10+ 0
b. Equipment pressure drop assumption

Basically, HYSYS dynamic simulation will calculate the actual pressure drop across the each
equipment. However, since the detail of the fabrication drawing of below equipment is not available,
hence following assumption is used in the HYSYS dynamic simulation prior disturbance was
applied.
• Max allowable pressure drop across Filter (22MAJ-001A/B) is 15 psi and will be modeled as
a dummy valve.
• Max allowable pressure drop across Water Heater (22EAP-001A/B) is 10 psi
Note: Lower pressure drop will give conservative result
c. Pipeline and Piping Data

Since isometric drawing is not available, pipe length is determined using Pipeline Route Map
Drawing and Piping Plan. No margin to be added on the pipe length. Piping ID based on Piping
Class Specification
Pipeline and Piping straight length is summarized as below (Refer to Appendix A):
(Note 1)
Table 3. Pipe Data
Pipe
Line Identification Size Schedule
Length
Incoming Pipeline 16“ - 6 KM
16”-PG-E1-1044 16” 120 9209 mm
8”-PG-E1-1005 8” 120 9722 mm
8”-PG-E1-1005 8” 120 17276 mm
8”-PG-E1-1007/1014 8” 120 62390 mm
8”-PG-E1-1034/2001 8” 120 31806 mm
8”-PG-D1-2004 8” 80 6206 mm
10”-PG-D1-3001 10” 80 6920 mm
8”-PG-D1-3003 8” 80 5564 mm
8”-PG-D1-3002 8” 80 11564 mm
8”-PG-D1-3013 8” 80 21580 mm
8”-PG-D1-3014 8” 80 16170 mm
10”-PG-D1-3015 10” 80 13348 mm
Pipeline To Buyer 16” - 15 KM
Note 1: Valves and Fittings will be included as input in to the HYSYS Dynamic model
d. Control valve Cv is based on available control valve datasheet, (Refer to Appendix B) and
summarized as below:
Table 4. Control Valve Cv Value
Control Valve Tag No Cv Value
FV-101 545
PV-208/211 477
FV-311A/B 567
e. All Cv’s for the SDV/HIPPS valves will be sized by HYSYS based on 100% valve opening at the
initial mode before disturbance was applied.
f. It was assumed closing time of SDV 101A/B (located at inlet of Water Heater) is 8 second as per
SDV Datasheet . However it will not be modeled for 10 second and 16 second valve closing time
case.
g. For the disturbance due to inadvertently valve close, SDV 325/326 (located @ outlet SDV skid) will
close in 10 second as per SDV Datasheet . Since there is no available datasheet for Buyer SDV’s, it
was assumed valve closing time is 10 second as conservative.
h. ESD set point is 730 psig and HIPPS set point is 780 psig as per P&ID will be used as base case.
i. PSV set pressure (PSV 202/203) is 800 psig.
4. METHODOLOGY
5.1. Software
The simulation was carried out using Aspentech HYSYS version 7.3 with Fluid Package used is Peng
Robinson. Beggs and Brill (1979) is used as the pipe flow correlation to calculate pipe pressure drop.
5.1. Modeling Step
Dynamic simulation steps are presented as follows:
1. Define fluid package (Peng Robinson)
2. Input well fluid composition as per section 4
3. Built HYSYS model (steady state)
4. Input the Pipeline/Piping data into the pipe segment tools, including valves and fittings
5. Input the Cv value of the Control valves as per Table 4
6. Set all control parameters and set points as per Table 1
7. Switch the model from steady state condition to the dynamic mode
8. Fine tune all control systems to get stable dynamic condition
9. Apply disturbance as per Table 1
10. Stop simulation until pressure reach stable value

Figure 4. Base Case Simulation
5. OVERPRESSURE SCENARIO IDENTIFICATION
The following overpressure scenarios are envisaged based on FEED design data from Company:
Table 5. Overpressure Scenario Identification

No Overpressure Case Protection
1. Outlet SDV Skid (25ZZZ-004) blocked, PAHH 215/216 (A/B/C voting 2oo3) set @ 730 psig
due to inadvertently close of will initiate ESD to close all the SDV valves. If
SDV325/326 or manual valve close pressure still increase, then
inside the skid PAHH 209/222 (A/B/C voting 2oo3) set @ 780 psig
will initiate HIPPS to close all the HIPPS valves to
ensure maximum pressure at 600# piping system still
2 Buyer SDVs inadvertently close PAHH 215/216 (A/B/C voting 2oo3) set @ 730 psig
will initiate ESD to close all the SDV valves. If
pressure still increase, then
PAHH 209/222 (A/B/C voting 2oo3) set @ 780 psig
3 Pressure letdown valve (PV-208 or PV- PAHH 215/216 (A/B/C voting 2oo3) set @ 730 psig
211) fully open (Note 1) will initiate ESD to close all the SDV valves. If
4 Blockage at low rated piping (600#) due Water Heater is provided to increase fluid temperature
o
to hydrate to 100 F prior entering Pressure Letdown Skid. Hence
hydrate formation will not occur at any condition (Refer
to Hydrate formation Study rev D, Doc No.CO-12-100-
330-28-RE-P-001).
o
Temperature alarm Low set @ 55 F is provided at
downstream Pressure Letdown Skid.
5 Check valve malfunction at low rated PAHH 215/216 (A/B/C voting 2oo3) set @ 730 psig
piping (600#) will initiate ESD to close all the SDV valves. If
6 Pipeline to Buyer blockage due to pig SOP shall be provided to anticipate pig stuck during
stuck pigging activity.
Note:1. In the event of PV-208/211 fully open, actuator will travel at linear rate of 10% per second.
Dynamic simulations will be carried out for the overpressure scenario no# 1, 2 and 3 in the above Table.
6. RESULTS
Dynamic simulation result for the six cases identified in Case Matrix Table 1 are as follow:
7.1. Case 1
• Case 1 was examined the pressure rise and the maximum pressure achieved in the 600# piping
system (downstream of pressure letdown skid) at the specified SDV-001 closing time in the event
of the overpressure scenario # 1 in table 5. SDV-001 closure time was evaluated to avoid initiation
of the HIPPS valve to close .
• After disturbance was applied, pressure in downstream of the pressure letdown skid increased and
reaches the ESD set point of 730 psig in 10 seconds.
• SDV-001 was triggered to commence closing at 730 psig. The peak pressure in downstream of the
pressure letdown skid (PV-208) for the 6 seconds closing time is 874.9 psig as shown in Figure 5
on the next page or Appendix C for more detail.
• Case 1 summary result is as below:

Table 6. Case 1 Summary Result
SDV-001 Closing time Peak pressure in downstream of

(second) the pressure letdown skid (psig)
6 874.9
8 876.3
10 877.5
16 882.8
From Table 6 above, it can be seen that SDV-001 is failed to prevent initiation of the HIPPS during
ESD (PAHH @ 730 psig) for Case 1, even for the 6 seconds closing time.
Sensitivity check is performed by reducing the ESD set point and SDV closing time as below result:
Table 7. Case 1 Sensitivity Check Result

Peak pressure in
SDV-001 Closing
PAHH Set point (ESD) downstream of the
time
(psig) pressure letdown skid
(second)
(psig)
700 6 872.8
680 4 870.6
From Table 7 above, it can be seen that SDV-001 still failed to prevent initiation of the HIPPS for
Case 1, even valve closing time and ESD trip set point have been reduced to 4 sec and 680 psig
respectively.
Refer to Appendix C for the Case – 1 Strip Chart Snapshoot

Figure 5. Case – 1 with SDV Close in 6 Seconds
7.2. Case 2
system (downstream of pressure letdown skid) at the specified HIPPS closing time in the event of
the overpressure scenario # 1 in table 5 and failure of ESD signal. HIPPS valves closure time was
evaluated to ensure maximum pressure at 600# piping system still below 800 psig (design
pressure of the metering).
reaches the HIPPS set point of 780 psig in 14 seconds.
• HIPPS valves were triggered to commence closing at 780 psig. The peak pressure in downstream
of the pressure letdown skid (PV-208) for the 2 seconds closing time is 813.8 psig as shown in
Figure 6 on the next page or Appendix D for more detail.

HIPPS valve Closing time Peak pressure in downstream of

2 813.8
3 818.8
4 824.4
From Table 8 above, it can be seen that HIPPS valves are failed to prevent pressure at 600# piping
system below 800 psig during HIPPS initiation (PAHH @ 780 psig) for Case 2, even for the 2
seconds closing time.
Sensitivity check is performed by reducing the HIPPS set point as below result:

Peak pressure in
PAHH Set point HIPPS valve
downstream of the
(HIPPS) Closing time
pressure letdown skid
(psig) (second)
(psig)
750 2 791.1
730 2 781.2
From Table 9 above, it can be seen that by reducing HIPPS set point, HIPPS valves with 2
seconds closure time is able to keep pressure at 600# piping system below 800 psig for Case 2
Refer to Appendix D for the Case – 2 Strip Chart Snapshots

Figure 6. Case – 2 with HIPPS Valve Close in 2 Seconds
7.3. Case 3
reaches the ESD set point of 730 psig in 2 seconds.
on the next page or Appendix E for more detail.


6 846.8
8 847.5
10 852.2
16 854.9
From Table 10 above, it can be seen that SDV-001 is failed to prevent initiation of the HIPPS
during ESD (PAHH @ 730 psig) for Case 3, even for the 6 seconds closing time.
Refer to Appendix E for the Case – 3 Strip Chart Snapshoot

7.4. Case 4
reaches the HIPPS set point of 780 psig in 4 seconds.
• HIPPS valves were triggered to commence closing at 780 psig. The peak pressure in downstream
of the pressure letdown skid (PV-208) for the 2 seconds closing time is 813.4 psig as shown in
Figure 8 on the next page or Appendix F for more detail.


2 813.4
3 826.3
4 829.8
From Table 1 above, it can be seen that HIPPS valves are failed to prevent pressure at 600# piping
system below 800 psig during HIPPS initiation (PAHH @ 780 psig) for Case 4, even for the 2
seconds closing time.
Sensitivity check is performed by reducing the HIPPS set point as below result:

Peak pressure in
PAHH Set point HIPPS valve
downstream of the
(HIPPS) Closing time
pressure letdown skid
(psig) (second)
(psig)
750 2 787.7
730 2 784.5
From Table 12 above, it can be seen that by reducing HIPPS set point, HIPPS valves with 2
seconds closure time is able to keep pressure at 600# piping system below 800 psig for Case 4.
Refer to Appendix F for the Case – 4 Strip Chart Snapshots

Figure 8. Case – 4 with HIPPS Close in 2 Seconds
7.5. Case 5
reaches the ESD set point of 730 psig in 694 seconds (11.5 minutes).
(It was assumed pressure letdown valve, stay on the last position after disturbance was applied)
on the next page or Appendix G for more detail.


6 730.4
8 730.5
10 730.7
16 731.2
From Table 13 above, it can be seen that SDV-001 with closing time 16 second is sufficient to
prevent initiation of the HIPPS during ESD (PAHH @ 730 psig) for Case 5.
Refer to Appendix G for the Case – 5 Strip Chart Snapshoot

7.6. Case 6
reaches the HIPPS set point of 780 psig in 982 seconds (16.3 minutes).
(It was assumed pressure letdown valve, stay on the last position after disturbance was applied)
pressure letdown skid (PV-208) for the 2 seconds closing time is 780.09 psig as shown in Figure
10 on the next page or Appendix H for more detail.

2 780.09
3 780.1
4 780.13
From Table 14 above, it can be seen that HIPPS valve with closing time 4 second is sufficient to
keep pressure at 600# piping system below 800 psig during HIPPS initiation (PAHH @ 780 psig).
Refer to Appendix H for the Case – 6 Strip Chart Snapshoot

Figure 10. Case – 6 with HIPPS Close in 2 Seconds
7. CONCLUSION AND FINDINGS
Base on simulation result as summarized on Section 7, it can be concluded as below:
a. Current ESD set point @ 730 psig is not sufficient to prevent initiation of the HIPPS for Case 1 and 3,
even though SDV-001 close in 6 seconds.
b. Decreasing ESD set point to 680 psig with SDV-001 close in 4 seconds is still not sufficient to
prevent initiation of the HIPPS. Hence in the event of PAHH on the facility, ESD system which is as
the primary protection system has been failed to prevent initiation of HIPPS.
c. Current HIPPS set point @ 780 psig is not sufficient to keep pressure at low rated pipe system
(600#) below 800 psig for Case 2 and 4, even though HIPPS valve close in 2 seconds
d. For Case 5, SDV-001 close in 16 seconds is sufficient to prevent initiation of the HIPPS
e. For Case 6, HIPPS valve close up to 4 seconds is sufficient to keep pressure at low rated pipe
system (600#) below 800 psig
f. HIPPS set point should be reduced to 750 psig with 2 seconds closing time in order to keep pressure
at low rated pipe system (600#) below 800 psig.
g. Based on ABI previous experience on other project, it is proposed ESD signal also to be sent to the
first HIPPS valve and then both HIPPS valves will close @ 750 psig in case ESD failure.
Sensitivity case is performed for the above proposal to determined ESD set point to prevent initiation
of the second HIPPS valve to close @ 750 psig. Sensitivity Case result is as below:
Table 15. Sensitivity Case Result

Peak pressure in
First HIPPS valve
Overpressure PAHH Set point (ESD) downstream of the
Closing time
Case (psig) pressure letdown skid
(second)
(psig)
700 2 759.8
SDV 325/326 Close
680 2 748.3
700 2 778.5
PV-208 fully open
680 2 747.2
Refer to Figure 11 and 12 on the next page for the Strip Chart Snapshoot or Appendix I for detail
From Table 15 above, it can be seen that PAHH Set point for ESD at 680 psig is sufficient to prevent
initiation of the second HIPPS valve to close.
Figure 11. Sensitivity Case SDV 325/326 Close and 1st HIPPS Valve Close in 2 Seconds @ 680 psig
Figure 12. Sensitivity Case PV 208 and 1st HIPPS Valve Close in 2 Seconds @ 680 psig
8. RECOMMENDATION
ABI recommends as follow:

1. ESD set point to be changed from 730 psig to 680 psig.
2. HIPPS set point to be changed from 780 psig to 750 psig time to keep pressure at low rated pipe
system (600#) below 800 psig (design pressure).
3. ESD signal should also to be sent to the first HIPPS valve to prevent initiation of the second
HIPPS valve.
4. Both HIPPS valves will close during HIPPS initiation, in case of ESD signal failure.
5. Valve closing time for the HIPPS valves (SDV-206/207/209/210) should be 2 seconds.
6. Solenoid valve configuration for the first HIPPS valve should be changed as below:

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HIPPS AND ESD VALVES CLOSING TIME

Summary of the case matrix is representing as below:

SDV-001/002 Peak pressure in downstream of

Based on the study, it is recommended (refer to section 9 for detail):

1. ESD set point to be changed from 730 psig to 680 psig.

The simplified process schematic is shown as follows;

8” HIPPS 10” Outgoing

SDV-101A Water Bath PT SDV-325

SDV-001 900# 600#

Figure 3. ORF Process Schematic

The objectives of the study are:

The following cases matrix will be used as boundary of the study

Study Result Determine Determine Determine Determine Determine Determine

Closing Time to be 6 second 2 second 6 second 2 second 6 second 2 second

Inlet Pressure : 1300 psig

Table 2. Dry Gas Composition

Component mol% (Average)

b. Equipment pressure drop assumption

c. Pipeline and Piping Data

5.1. Modeling Step

Dynamic simulation steps are presented as follows:

1. Define fluid package (Peng Robinson)

2. Input well fluid composition as per section 4

3. Built HYSYS model (steady state)

5. Input the Cv value of the Control valves as per Table 4

6. Set all control parameters and set points as per Table 1

8. Fine tune all control systems to get stable dynamic condition

9. Apply disturbance as per Table 1

10. Stop simulation until pressure reach stable value

Table 5. Overpressure Scenario Identification

• Case 1 summary result is as below:

SDV-001 Closing time Peak pressure in downstream of

Table 7. Case 1 Sensitivity Check Result

Refer to Appendix C for the Case – 1 Strip Chart Snapshoot

• Case 2 summary result is as below:

HIPPS valve Closing time Peak pressure in downstream of

Table 9. Case 2 Sensitivity Check Result

Refer to Appendix D for the Case – 2 Strip Chart Snapshots

• Case 3 summary result is as below:

SDV-001 Closing time Peak pressure in downstream of

Refer to Appendix E for the Case – 3 Strip Chart Snapshoot

• Case 4 summary result is as below:

HIPPS valve Closing time Peak pressure in downstream of

Table 12. Case 2 Sensitivity Check Result

Refer to Appendix F for the Case – 4 Strip Chart Snapshots

• Case 5 summary result is as below:

SDV-001 Closing time Peak pressure in downstream of

Refer to Appendix G for the Case – 5 Strip Chart Snapshoot

• Case 6 summary result is as below:

Table 14. Case 6 Summary Result

HIPPS valve Closing time Peak pressure in downstream of

Refer to Appendix H for the Case – 6 Strip Chart Snapshoot

Base on simulation result as summarized on Section 7, it can be concluded as below:

Table 15. Sensitivity Case Result

ABI recommends as follow:

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