Wellhead HIPS Self-Diagnostics for Continuous Production

Solution Overview

Problem

Conventional high integrity protection systems (HIPS) for wellhead pipelines cannot be tested for operation while in use, requiring shutdown for safety testing, which disrupts production and relies on historical data rather than real-time measurements, and lacks automated operator intervention.

Innovation Solution

A HIPS system with surface safety valves, vent control valves, and a safety logic solver that allows for continuous operation during testing, using pressure sensing transmitters and a safety logic solver to monitor and control valve operations, enabling real-time pressure measurement and automatic response to ensure safety without operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional HIPS testing methods are used, then safety testing can be performed, but production must be interrupted and operators must be present manually

Engineering Contradiction:

Improvesafety testingVSAvoidproduction continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs self-diagnostics automatically without requiring operator presence. The safety logic solver autonomously controls valve operations, pressure measurements, and test execution, allowing the HIPS to test itself while maintaining production continuity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system performs preliminary safety testing during normal operation before actual safety events occur. By continuously monitoring pressure and automatically executing test sequences, the system verifies safety functionality in advance without interrupting production.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If conventional HIPS testing methods are used, then safety testing can be performed, but operator intervention is required manually

Engineering Contradiction:

Improvesafety testingVSAvoidoperator intervention

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The system performs self-diagnostics automatically without requiring operator presence. The safety logic solver autonomously controls valve operations, pressure measurements, and test execution, allowing the HIPS to test itself while maintaining production continuity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system continuously monitors pressure measurements and valve positions, providing real-time feedback to the safety logic solver. This automated feedback loop enables the system to detect anomalies, adjust test parameters, and verify safety functionality without manual operator intervention.

Inventive Principle:

Principle #23Feedback

3Reliability

If historical data is used for safety verification, then testing can be performed, but real-time measurements are not available

Engineering Contradiction:

Improvesafety verificationVSAvoidreal-time measurement

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The system continuously monitors pressure measurements and valve positions, providing real-time feedback to the safety logic solver. This automated feedback loop enables the system to detect anomalies, adjust test parameters, and verify safety functionality without manual operator intervention.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces historical data analysis with real-time electronic pressure sensing and automated logic processing. Pressure transmitters continuously measure actual pressure conditions, and the safety logic solver processes this data instantaneously to verify safety functionality with current operational conditions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables continuous operation of the HIPS during testing, reducing production disruptions and ensuring safety by using real-time measurements to verify valve performance and adjust settings as needed, thereby maintaining pipeline integrity.

Implementation Method 1

pressure sensing transmitters and a safety logic solver to monitor and control valve operations, enabling real-time pressure measurement

Methodology Applied

Scientific EffectPressure sensing:

Data Source

PatentUS8725434B2Wellhead hips with automatic testing and self-diagnostics

Publication Date: 2014.05.13 SAUDI ARABIAN OIL CO

AI summary

A method for diagnostics of a high integrity protection system (HIPS) for protection of a pipeline downstream of a wellhead includes: monitoring for initiation of an automatic trip or manual safety shutdown or full shut-off test; determining the process safety time (PST) that elapses between the time at which the upstream pressure reached the trip setpoint and the time at which the upstream pressure reaches the maximum allowable piping pressure (MAPP) of the downstream pipeline; and verifying that the safety critical isolation valves stroked to the fully closed position within ½ PST and that the downstream pressure did not exceed the MAPP. If the verification shows that either of those parameters are not met, then the HIPS signals an alarm to operators, and in the case of a manual safety shutdown or full shut-off test, resets the pressure trip setpoint to a lower level.