Hydrocarbon HIPS Proof Testing for SIL 3 Selective Well Shutdown
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Solution Overview
Problem
Mandatory testing of High Integrity Protection Systems (HIPS) for offshore gas platforms disrupts gas flow and requires platform shutdown, affecting efficient operation and downstream facilities due to simultaneous closure of final elements during functional tests.
Innovation Solution
A method and system for individual well testing within a hydrocarbon production system using test mode pressure sensors and a Safety Logic Solver (SLS) to allow selective closure of final elements while maintaining flow in other wells, leveraging existing sensors and minimal design changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mandatory HIPS testing is performed with simultaneous closure of all final elements, then Safety Integrity Level 3 (SIL 3) rating is maintained, but gas flow is completely disrupted requiring platform shutdown
Solution Approach 1:
The system segments the testing process by selecting individual wells for proof testing rather than testing all wells simultaneously. The SLS receives well selections and performs testing on specific wells while leaving others operational, thereby maintaining gas flow from non-tested wells while still achieving SIL 3 compliance through targeted testing
Solution Approach 2:
The system applies different operational states to different wells: tested wells have final elements closed during proof testing while non-tested wells continue normal operation. This local differentiation allows partial platform operation during testing, maintaining productivity for non-tested wells while ensuring safety integrity through localized proof testing
2Reliability
If all final elements are closed during functional test, then complete system proof testing is achieved, but downstream processing facilities are adversely affected
Solution Approach 1:
The testing is segmented to affect only selected wells rather than the entire system. By choosing specific wells for proof testing and leaving others operational, the system maintains gas flow to downstream facilities from non-tested wells, reducing the harmful impact on downstream processing while still achieving comprehensive proof testing of the HIPS system
Solution Approach 2:
Instead of closing all final elements (excessive action), the system closes only the final elements associated with selected wells undergoing proof testing (partial action). This partial closure is sufficient to test the HIPS functionality while maintaining adequate gas flow through non-tested wells to downstream facilities
3Reliability
If traditional HIPS testing configuration is used, then SIL 3 compliance is achieved, but platform shutdown is required affecting efficient operation
Solution Approach 1:
The testing process is segmented into individual well selections rather than requiring complete platform shutdown. The SLS enables sequential or selective testing of wells, allowing the platform to continue operating with non-tested wells during the proof testing process, thereby reducing platform shutdown time while maintaining SIL 3 compliance
Solution Approach 2:
The system maintains continuous gas production from non-tested wells during the proof testing process. By allowing selective well testing rather than complete shutdown, the useful action of gas production continues uninterrupted from operational wells, minimizing loss of time and maintaining efficient platform operation
Data Source
AI summary
A selection of a hydrocarbon well of a hydrocarbon production system is received at a safety logic solver (SLS) for proof testing. Test mode pressure sensors attached to a common header of the hydrocarbon production system are activated to monitor a live process condition status of the common header from all wells of the hydrocarbon production system. A simulated overpressure condition is induced in the operation pressure sensors. An indication of overpressure is received at the SLS from at least two operation pressure sensors. Final elements associated with the hydrocarbon well are signaled to close while leaving other wells in the hydrocarbon production system in operation. The operation pressure sensors are restored to a normal pressure condition, and the final elements associated with the selected hydrocarbon well are signaled to re-open the hydrocarbon well.