CCI Innovative

Solutions for
HIPPS Systems -
High Integrity
Pressure Protection
System
Safety is Our Utmost
Priority
2
HIPPS - Excellence in Innovation
The World Leader in Severe Service Valve Solutions
CCI is a global business specializing in custom engineered solutions
for severe service valve and control applications. For over 45 years, CCI
has maintained industry dominance through our innovative problem
solving approach. CCIs team of Valve Doctors is focused on developing
solutions to face the industries challenges in control valve, actuation
controls and safety system technology applications.
HIPPS Safety Considerations for Over Pressurizing and
Safety Venting
An important safety consideration in the process industry is the
prevention of loss of containment due to vessel or pipeline overpressure
situations. Loss of containment can have catastrophic effect to human
life and the environment and also have a negative economic impact,
due to production loss and maintenance costs. Conventional designs of
pressure relief or safety valves are used as a primary means of pressure
protection on most applications. However, with increased ow rate
potentials into existing infrastructure, applications where pressure
relief devices are impractical and increased environmental constraints,
the use of HIPPS (High Integrity Pressure Protection System) is widely
becoming accepted as the ultimate protection system. HIPPS is an
independently instrumented reliable system that is designed with higher
system integrity, per established ANSI/ISA and IEC standards, than
process shutdown and emergency shutdown systems.
Last level of safety
CCI Innovative custom
engineered HIPPS
Wide variety of actuator and
valve solutions to optimize
process
Work with the valve and
control experts to mitigate
risk and cost
HIPPS
ESD
PSD
DCS
Since 1961, CCI has provided a unique
combination of engineering experience and
global resources with one goal: to exceed
customer expectations.
3
HIPPS Safety Instrumented Systems
Safety
Since HIPPS is a type of SIS (Safety Instrumented System), the
requirements of each specic HIPPS applications must be investigated
thoroughly. The SIS standards are performance-based with the safety
integrity level (SIL) as the primary performance measurement. The
SIL represents the necessary risk reduction, as recognized in a users
risk reduction analysis. Each SIL level corresponds with a tolerable
probability of failure on demand (PFD) to all HIPPS devices from the
sensor through the logic solver and nal elements.
The international standards IEC 61508, IEC 61511, IEC 61131 and the US
standard ANSI/ISA S84.01-1996 are intended to address the framework
for design and the application of SIS in the process industry, through the
denition of the assessment, design, validation and documentation for
SISs.
Safety
Integrity
Level
(SIL)
Low
Demand
Mode
(Average probability
of failure to perform
designed safety
function on demand)
High
Demand
Mode
(Probability of a
dangerous
failure per hour)
4
> 10
-5
to < 10
-4
> 10
-9
to < 10
-8
3
> 10
-4
to < 10
-3
> 10
-8
to < 10
-7
2
> 10
-3
to < 10
-2
> 10
-7
to < 10
-6
1
> 10
-2
to < 10
-1
> 10
-6
to < 10
-5
Availability
In most cases, it is not acceptable for the HIPPS to trip and stop the
plant operation due to a single failure. The safety systems fault tolerance
is therefore one of the most important characteristics for keeping the
process safe and available.
Flexibility
HIPPS is a high quality system with exible technology and appropriate
services to reduce overall life-cycle costs.
Installation
The justication for HIPPS in the process industry is typically facilitated
by an analysis performed by each plant. There are many factors that must
be taken into account to establish the proper framework for a successful
installation.
CCI Valve Doctors

can help power uprate

and life extension programs by studying
valve performance and reliability history
and recommending enhancement based on
extensive experience.
4
Device Integrity and Architecture
Safety Loop
CCI recognizes that the HIPPS includes all devices required to reach
the desired safety integrity level for the process. The HIPPS includes the
entire instrument loop from the eld sensor through the logic solver to
the nal elements, along with other possible required devices, such as
SIS user interfaces and communications.
A HIPPS group consists of:
Initiators / Process Sensors
The initiators are the elements measuring the process variables (PV) to
sense an event. The initiators are typically electro-mechanical pressure
switches or electronic pressure transmitters.
Logic Solver
The Programmable Electronic System (PES) receives the signals from the
initiators, performs the required logics (voting, diagnostics, and partial
stroke test routine) and drives the nal elements.
Final Elements
The complete valves/actuators/solenoids assemblies are acted on to
isolate the over pressure detected by the initiators. The CCI solution
(Ball, Gate or Globe valve) is typically designed to close within 2
seconds.

Field Service Technicians are experts in
troubleshooting, critical recalibration and
emergency repair.
5
CCIs HIPPS Monitoring Solution
Initiators
Measurement of process variables
Pressure is the process variable commonly measured in HIPPS.
Traditionally, this variable is monitored using discrete switches as the
input sensor to the safety system. Although these devices are simple
and reliable, evolution of the electronics has made the use of analog
transmitters more suitable and preferable. Analog transmitters can be
continuously monitored and the operability of the transmitters readily
observed, thus reducing the potential for initiator related failure events.
Most HIPPS applications require 2 or 3 transmitters (1 out of 2 or 2 out
of 3 voting logic) as eld devices. The use of redundant inputs enables
system designers to incorporate diagnostics into the HIPPS, which
signicantly reduces the probability to fail on eld input demand. Other
options like separate process connections and diversity in pressure
measurement, when practical, are also recommended.
Interlocking Manifold
A possible option is the use of an Interlocking Manifold in order to
prevent operational errors.
The Interlocking Manifold principle is to permit the closing of the
isolation valves and the opening of the vent valve in predetermined safe
sequence. This will allow a safe and on-line calibration; preventing at the
same time undesired shutdown due to possible faulty operations.
The Logic Solver
The CCI Logic Solver hardware is designed and certied in compliance
with SIL3 or SIL4 performance requirements, as provided in IEC 61508.
ANSI/ISA S84.01-1996, IEC 61508, and IEC 61511 require that the safety
logic be independent from the basic process control and lower level
protection systems.
The Logic Solver can be relays, solid state, or programmable electronic
systems (PES). The CCI Logic Solver is typically PES, provided with
high level of self diagnostics, availability and fault tolerance, SIL 3
certied with simplex or redundant architecture (TMR or 2oo4/QMR) in
compliance with IEC 61131-3.
CCIs QMR (Quadruple Modular Redundant) technology is 2oo4
architecture characterized by double processors and hardware
comparator on each central processing unit. The safety related single
channel systems and central modules are certied up to AK6/SIL3
without any restrictions. The system is characterized by optimum
diagnostic coverage, such as the central processing units communication
realized by a fast Dual Port RAM (DPR). All QMR characteristics provide
maximum availability and fault tolerance with a redundant system.
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HIPPS - Final Elements
Final Element Congurations
The nal elements are the physical units that are called upon to isolate
the exposure. The nal elements are typically either 1) relays in the
motor control circuit for the shutdown of motor operated valves,
compressor or pumps, or 2) fail safe valves opened or closed using
solenoids. The HIPPS nal elements typically are made up of a valve/
actuator/solenoid conguration, as prescribed by the required SIL, in the
desired fail safe conguration.
The CCI HIPPS typically utilizes dual devices in a 1oo2 conguration
(two valves in series) in conjunction with 1oo1 or 1oo2 solenoid. Each
solenoid however can be connected in a 2oo2 conguration to reduce
spurious trips by having two independent outputs from the Logic Solver.










Installation illustration for nal elements showing
1oo2 valves and 1oo1 solenoids
Installation illustration for nal elements showing
1oo2 valves and 1oo2 solenoids
Normal Pressure Over Pressure Over Pressure w/HIPPs
-0.0 sec 0.1 sec <2 sec
In Line Danger Safe w/HIPPs

Illustration for solenoid 2oo2 connection from a redundant Logic Solver
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HIPPS Final Element Solutions
Final Element Valve/Actuator options
CCI offers a variety of valve/actuator designs specically suited for
HIPPS service.
Typical offer includes the CCI Rona full-bore ball valve as an ideal
technology for HIPPS.
The valve has practically no pressure loss when fully open.
The quarter turn movement permits almost the same travel and a
very quick closing time.
The valve design does not require the installation of a damper, due
to the absence of mechanical shocks at the stroke end.
The valve construction intrinsically has a piggable feature,
allowing the passage for the pipe cleaning pig device.
Diagnostics and Testing
CCI HIPPS are supplied with diagnostics designed to detect failures of
devices on-line, signicantly improving the availability of the HIPPS.
Examples of standard diagnostics features:
Input signals line monitoring
Automatic partial stroke test routine
CCI also offers actuators with local accessories, enabling the user to
perform a partial stroke test on each valve independently.
The CCI Valve Doctor Approach
CCIs team of Valve Doctors can provide the support needed during
each phase of a HIPPS project. By using our expertise and experience
in dening HIPPS architecture, fault tree analysis, analyzing pressure
rise and project stroke times and set points, a highly effective and cost
effective solution can be realized.
Final Element

One damaged part can shut a plant down; CCI

can prevent this unnecessary downtime and
give you peace of mind.
DRAG is a registered trademark of CCI.
2007 CCI 879 04/05/07
Throughout the world, companies rely on CCI to solve their severe service control valve
problems. CCI has provided custom solutions for these and other industry applications for
nearly half a century.
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