Materials System Specification

34-SAMSS-624 Wellhead Control, Monitoring and Shutdown Systems Instrumentation Standards Committee Members
Al-Juaib, Mohammed Khalifah, Chairman Tuin, Rienk, Vice Chairman Al-Dakhil, Tareq Khalil Al-Faer Al Sharif, Hisham Mohammed Al-Harbi, Ahmed Saad Al-Jumah, Yousif Ahmed Al-Khalifa, Ali Hussain Al-Qaffas, Saleh Abdal Wahab Al-Sahan, Fawaz Adnan Al-Saleem, Hesham Salem Chetia, Manoj Ell, Steven Tal Fadley, Gary Lowell Falkenberg, Anton Raymond Grainger, John Francis Mahmood, Balal Mathew, Vinod Qarni, Mahdi Ali Trembley, Robert James

18 August 2009

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 7 Scope............................................................. 2 Conflicts and Deviations................................. 2 References..................................................... 2 Definitions....................................................... 3 Environmental Conditions.............................. 4 Wellhead Shutdown System Requirements... 6 Hydraulic Based Wellhead Shutdown System Requirements......... 17 8 Electronic Based Wellhead Shutdown System Requirements......... 19 9 Nameplates and Tags.................................. 21 10 Inspection and Testing................................. 21 11 Drawings...................................................... 22 12 Other Miscellaneous Requirements............. 22

Previous Issue: 21 June 2009 Next Planned Update: 18 August 2012 Revised paragraphs are indicated in the right margin Primary contact: Balhareth, Hamad Salem on 966-3-8736389
CopyrightSaudi Aramco 2009. All rights reserved.

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Scope This specification defines the minimum technical, functional, design and performance requirements for wellhead real time process control, monitoring, and shutdown systems for use in outdoor locations both onshore and offshore. The wellhead control and shutdown system architecture will provide a means to operate wellhead surface and subsurface safety valves locally and will provide an electronic base for remote surveillance or well monitoring and control as defined in the Purchase Order or Functional Specification Document. This specification provides the minimum requirements for hydraulic, electric-hydraulic, and electric-electric types of wellhead control and shutdown systems. This specification does not include the wellhead piping, surface and subsurface safety valves, and actuators. The Drilling and Workover Engineering Department of Saudi Aramco is responsible to review and approve SSV and SSSV actuators purchased as part of the wellhead tree.

Conflicts and Deviations 2.1 Any conflict between this specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Standard Drawings (SASDs), Data Sheets, or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.2

References Material or equipment supplied to this specification shall comply with the latest edition of the references listed below to the extent specified, unless otherwise noted. 3.1 Saudi Aramco Documents Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement
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Saudi Aramco Materials System Specifications 34-SAMSS-623 45-SAMSS-005 Programmable Controller Based ESD Systems Specification for Wellhead and Christmas Tree Equipment per ANSI/API 6A Nineteenth Edition, July 2004 ISO 10423-2003

Saudi Aramco Inspection Requirements 175-454100 175-454400 Actuator Assembly Hydraulic SSV Valve Assembly Safety SSSV

Saudi Aramco Forms and Data Sheets NMR-7907 3.2 Industry Codes and Standards American Society of Mechanical Engineers ANSI/ASME B1.20.1 Pipe Threads, General Purpose (Inch) Non-Material Requirements for Instrumentation (General)

American Society for Testing and Materials ASTM A269 Standard Specification for Seamless and Welded Austenitic Stainless Steel Tubing for General Service

International Electrotechnical Commission IEC 60529 IEC 61000-4-3 Degrees of Protection Provided by Enclosures (IP Code) Electromagnetic Compatibility (EMC)

National Fire Protection Association NFPA 70 4 Definitions Hydraulic Wellhead Shutdown System: A control system composed of sensors, logic, and final control elements (actuators) that utilizes hydraulic fluid pressure for sensing and for the motive force required to operate SSV's and SSSV's. A hydraulic system may be pressurized by a manual hand operated pump as in the case of selfcontained surface safety valve systems or via electric pumps. National Electrical Code

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Electric-Hydraulic Wellhead Shutdown System: A control system composed of a combination of an electronic PLC based logic solver/RTU and electronic sensors integrated with hydraulic controls to operate SSV's and SSSV's. Electric-Electric Wellhead Shutdown System: A control system composed of a combination of an electronic PLC based logic solver/RTU, electronic sensors, and electric fail-safe actuators on SSV's. Note that electric fail-safe actuators are not available for SSSV's. 5 Environmental Conditions 5.1 Environmental 5.1.1 Wellhead shutdown instruments and control components mounted internal to the shutdown cabinet shall operate continuously under the following humidity conditions. Relative Humidity: Minimum Maximum 5% 95% (non-condensing)

5.1.2 Portions of the wellhead shutdown system that are mounted externally on the shutdown cabinet shall operate continuously under the conditions sporadic water spray such as from rain or offshore sea spray. Temperature: Instruments and control systems shall operate continuously under the following ambient air temperatures without any degradation of the manufacturer's guaranteed performance:
Outdoor Sheltered
Notes:
(1),(2),(3)

Outdoor Unsheltered
Notes:
(2),(3)

Maximum Minimum
Notes:

55C (131F) 0C (32F)

65C (149F) 0C (32F)

(1) "Sheltered" refers to permanent, ventilated enclosures or buildings, or permanently fixed sunshades with a top and three sides. (2) For semiconductors and any other instrumentation devices which dissipate internal heat, an additional 15C shall be added to the above temperatures. An example, for "Outdoor Sheltered" installation, the equipment must perform at 55 + 15 = 70C. Similarly, for the "outdoor unsheltered" case, the equipment shall be designed for a maximum operating temperature of 65 + 15 = 80C. (3) The designer can take credit for a cabinet closed loop A/C cooling system to eliminate or reduce the 15C heat rise. For example, when PLC based logic solvers are used, cabinet A/C cooling units are required and the heat removal capacity of

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the cooler may be subtracted from the generated heat. No more than 15C reduction in temperature will be given as credit. The designer shall substantiate his claim by providing the support data and calculations.

5.2

Offshore and Nearshore Environment Equipment which is not enclosed or hermetically sealed, but is situated offshore or nearshore, shall be protected against corrosion and operational failure due to wind-borne sea water spray and the accumulation of wetted salt (NaCl). Nearshore is defined as any outdoor, onshore location within one kilometer from the shoreline of the Arabian Gulf; all of the Ras Tanura Refinery and Terminal; and within three kilometers from the shoreline of the Red Sea.

5.3

Ambient Air Quality

Commentary Note: Air-borne dust concentrations and contaminant levels are used in mechanical equipment design, when sizing air filters and as a measure of potential dust ingress in bearing housings, lube oil systems, etc.

Dust Concentration: Usual airborne dust concentration is 1 mg/m. During sandstorms, dust concentrations may reach 500 mg/m. Particle sizes are as follows: 95% of all particles are less than 20 micrometers 5% of all particles are less than 1.5 micrometers Elements present in dust include compounds of calcium, silicon, magnesium, aluminum, potassium, chlorides and sodium. When wetted (high humidity conditions), these compounds function as electrolytes and can result in severe corrosion. Other pollutants present in the atmosphere under the most extreme conditions are: H2S Hydrocarbon SO2 CO NOx O3 6 20 ppm (vol/vol) 150 ppm (vol/vol) 10 ppm (vol/vol) 100 ppm (vol/vol) 5 ppm (vol/vol) 1 ppm (vol/vol) Wellhead Shutdown System Requirements

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Wellhead Shutdown System Requirements 6.1 Wellhead Operation and Monitoring The wellhead control and shutdown system vendor shall supply all the material and labor required to design and fabricate an integrated wellhead control and shutdown system and guarantee compatibility/performance of all components that make up the overall wellhead control and shutdown system. 6.1.1 Each wellhead shutdown system shall permit manual and automatic control of individual well safety valves. 6.1.2 All sensors shall have displays available at the operator interface to display process data or the state of input sensors. Electronic wellhead shutdown systems shall display all data on a LCD panel within the local shutdown cabinet.
Commentary Note: Smart instruments and actuators may require the use of a laptop computer for configuration and data collection.

6.1.3

Valve Operation Sequence: The wellhead shutdown system shall provide the interlock and adjustable time delay features such that the automatic closing of all the subsurface and surface safety valves shall be constrained to the following closing sequence, and shall allow for the following manual opening sequence. Where Subsurface Safety Valves (SSSV's) are not required, the operation of the SSSV described below does not apply. 6.1.3.1 Valve Sequence with one Surface valve (SSV) and one Subsurface Safety valve (SSSV). Opening Subsurface Valve (SSSV) Opens, then surface valve (SSV) opens. Closing Surface Valve (SSV) closes, then after a predetermined time delay, Subsurface valve (SSSV) closes. 6.1.3.2 Valve Sequence with two Surface Valves (SSV's) and one Subsurface valve (SSSV). Opening Subsurface valve (SSSV) opens, then upstream surface valve opens, then downstream surface valve opens. Closing Downstream surface valve (SSV) closes, then upstream surface valve (SSV) closes, then after a predetermined time delay the subsurface valve (SSSV) closes.
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6.1.4 Manual Valve Operation: The wellhead shutdown system shall include open/close pushbuttons for individual manual operation of each well's surface valve (s). When self-contained hydraulic SSV controls are provided, a hand pump shall be provided to re-open the valve following a trip. 6.1.5 Manual ESD: A manual emergency shutdown (ESD) button shall be mounted on the front of the wellhead cabinet. The push-button shall be red colored and shall be clearly identified with a nameplate using white letters on red background. The action shall be pull for ESD, push to reset. All surface and subsurface valves shall be closed when activated by a local or remote emergency shutdown (ESD) pushbutton/signal. 6.1.6 Process Shutdown: A manual process shutdown (PSD) button shall be mounted on the front of the wellhead cabinet. The push-button shall be black colored and shall be clearly identified with a nameplate using white letters on blue background. The action shall be pull for ESD, push to reset. All SSV's shall be closed when activated by a local or remote process shutdown (PSD) pushbutton/signal. SSSV's should remain open during a process shutdown. SSSV's only close upon a fire or ESD. SSSV's will close in the sequence stated above. 6.1.7 A manual override function shall be provided as defined in the Functional Specification Document or Purchase Order. 6.2 Engineering Units All dimensions and measurements shall be in the "International System of Units" (SI), and may be followed by the equivalent value in English units between brackets. When not critical, the equivalent dimensions may be rounded off to their nearest practical value. 6.3 Wellhead Cabinet 6.3.1 The enclosure (cabinet) shall be rigid, self-supporting and NEMA Type 4X or IEC 60529 Type IP66. The single cabinet shall be designed with back-to-back internal mounting construction of electronics (processors, I/O cards, and power supplies) mounted in the front of the cabinet and the terminations of field wiring and system interface wiring on the opposite (back) side.

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6.3.2 The cabinet shall have external baffle plates to deflect direct sun light. One (1) inch spacing shall be used between the baffle plate and the cabinet wall. 6.3.3 When specified, as part of an electro-hydraulic hybrid control system, hydraulic control components and connections shall be housed within a separate enclosure outside the main electronic enclosure. 6.3.4 All process connected sensors shall be mounted outside the wellhead shutdown system cabinet. 6.3.5 Each local wellhead cabinet shall be provided with a sunshade meeting the requirements of section 5.1 above (top with three sides to prevent direct sunlight from reaching the cabinet). 6.3.6 Each component mounted in or on the cabinet shall be freely accessible for maintenance without any requirement to remove one component to gain access to another. 6.3.7 There shall be no penetrations on the top of the cabinet. 6.3.8 The cabinet construction shall meet the following requirements: 6.3.8.1 6.3.8.2 6.3.8.3 6.3.8.4 6.3.8.5 6.3.8.6 The cabinet shall be 316 stainless steel or better, minimum 12 gauge. All hardware including hinges, back-pans, sub-pans, latches, fittings, etc., shall be 316 stainless steel. All joints on the cabinet are to be continuously welded and ground smooth. Cut-outs shall not be flame cut and all edges and corners shall be rounded off. Each cabinet shall be provided with lifting rings or tabs. Cabinet doors (front and rear) shall be full-height. All doors shall be dust-tight and reinforced against buckling. The maximum door width shall be 900 mm (36 inches) unless otherwise specified in the Purchase Order. Doors shall be removable doors unless otherwise stated in the Purchase Order. All exterior cabinet doors shall be fitted with door-stop
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6.3.8.7 6.3.8.8

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hardware. The door-stop shall secure the door in the 90 degree open position. 6.3.8.9 The cabinet doors shall be capable of being padlocked.

6.3.8.10 Two grounding studs, diagonally opposed, shall be provided on the base of the wellhead shutdown cabinet for grounding to the local ground grid or platform structure. 6.4 Electrical Construction 6.4.1 All electrical equipment installed as part of the wellhead cabinet, sensors, and actuators shall be certified for operation in the intended hazardous area and installed per NFPA 70, National Electrical Code. The area classification will be specified in the Purchase Order. 6.4.2 Electrical cables shall enter the local wellhead shutdown cabinet from the bottom of the cabinet whenever practical. 6.4.3 All cabinets shall be equipped with two drain fittings. 6.4.4 All electronic signal cables within the cabinet shall be shielded. 6.4.5 Power Supply Saudi Aramco will supply incoming power mains to the cabinet. Incoming power shall be distributed within the cabinet on individually fused termination strips. All system components and field instruments shall be powered from within the cabinet. Power Supply terminal block distribution wiring shall not be daisychained using wires or crimp connectors. Jumper bars or preformed jumper combs designed for the specific terminal blocks being used are acceptable methods of distributing power supply wiring. Each power supply shall be capable of being isolated such that any fault on one component shall not trip or effect the operation of other equipment. Individual circuit breakers shall be provided for each power supply unit. Power supplies of the same output voltage level shall be identical for interchangeability and spare part requirements. Fully redundant chassis power supplies shall be used to supply power to
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internal Programmable Logic Solver system modules (or cards). Field I/O power supplies shall be separated and totally independent of Programmable Logic Solver system chassis power supplies. Fully redundant switch mode or linear (non-switching) types shall be used to power the I/O portion of the electronic wellhead control and shutdown systems. Where multiple on-line DC power supplies are connected to a single power bus, diode auctioning shall be used to facilitate load balancing in the event of a single power supply failure. Where multiple DC power supplies are an integral part of a manufacturer's standard product, the manufacturer's standard method of load sharing shall apply. Power supply outputs shall be individually fused or protected by a circuit breaker. 6.4.6 For electronic based systems, integral battery backed power supply systems shall provide for a minimum of 24 hours of operation (keeping the SSVs open) in the event main power failure. 6.4.7 The Cabinet Fabricator shall supply a minimum of two (2) spare fuses for each type of fuse used within each cabinet. This requirement includes fuses integral to installed electronics. Fuses and circuit breakers shall be readily accessible for maintenance with sufficient clearance from obstructions. Tandem type (dual) circuit breakers in a single molded case shall not be used, as the failure of one breaker requires complete replacement of the assembly. 6.4.8 Equipment shall operate at the supply voltages specified in the purchase order. 6.5 Electrical Installation 6.5.1 Cabinet Internal Wire Specifications 6.5.1.1 General 120 VAC power wiring shall be minimum 14 AWG stranded, copper, PVC-insulated or cross-linked polyethylene. Wire insulation shall be rated for 600 volts, 90C, minimum. Electronic signal wire shall be stranded copper, twisted pair with individual or overall shield, minimum size 18 AWG, 300 V for single conductors or a minimum 20 AWG, 300 V for
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6.5.1.2

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multicore cable. Wire insulation shall be cross-linked polyethylene, PVC, or PTFE, with a minimum temperature rating of 90C. Special electronic signal wires shall be as described in the Purchase Order. 6.5.2 Wiring Methods 6.5.2.1 Cabinets containing electronic equipment with field inputs/outputs (I/O) (e.g., field termination assemblies, I/O modules, etc.) shall have the I/O device pre-wired to intermediate terminal strips within the same cabinet. Exposed electrical connections with voltages greater than nominal 48 volts AC/DC, mounted on cabinet doors, shall have exposed wiring/terminations shrouded by transparent, removable, insulating plastic covers (or equivalent). When screw-type terminals are provided on instruments and other electrical devices, solderless crimp/compression connectors shall be used for connecting stranded copper conductors. Insulated ring lugs, locking-fork or flanged- fork connectors, specifically designed to hold the connector on the terminal in the event of loosening of the terminal screw, shall be used on all such connections.
Commentary Note: Screw-type terminals are defined as those in which the termination method involves the direct compression of the conductor by the underside of the screw head, and which do not contain the conductor within a clamp or yoke.

6.5.2.2

6.5.2.3

6.5.2.4

Twist-on wire nut connectors shall not be used for making any electrical instrumentation terminations.

6.5.3 Terminal Strips 6.5.3.1 6.5.3.2 The termination method shall be channel (rail)-mounted terminal blocks. Terminal strip spacing shall allow ample room for plastic wire ducts and permit training and lacing of cables, and fanning of individual wires to termination points. Each terminal strip shall be labeled above or below with the terminal strip number, as shown on wiring diagrams. Terminals for similar (AC or DC) current service shall be grouped together and physically

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separated from terminals for different service by means of dividers, separate mounting rails or separate enclosures. 6.5.4 Terminal Blocks 6.5.4.1 6.5.4.2 No more than two bare wires shall be connected to each side of a single terminal block. All terminal blocks shall be channel (rail)-mounted, strip-type, with a tubular box clamp connector and compression bar or yoke for wire termination. As a minimum, the thickness of the terminals shall be 5 mm or higher. Terminals shall be made of fire retardant, halogen free, high strength material such as polyamide. Brittle materials such as melamine shall not be used. The disconnect levers for fused terminals and knife-switch terminals shall be hinged. Wires terminated on these terminal blocks shall not have the bare ends coated with or dipped in solder ("tinned"). However, termination of wiring which has individual strands of the copper conductor tinned during manufacture (typical of shield drain wires or for corrosion protection) is acceptable. Direct termination of the bare wire end is acceptable. The terminal block must be suited for the wire size. The use of crimp-on ferrules shall follow the manufacturer's guidelines and the following: a) No more than two conductors shall be terminated per ferrule. (The use of ferrules to daisy chain is not acceptable). Only one ferrule shall be connected to each side of a single terminal block. Ferrules shall be provided with plastic insulating collars.

6.5.4.3

6.5.4.4 6.5.4.5

6.5.4.6

b) c) 6.5.4.7

Multiple-deck terminal blocks shall not be used.

Exception: When provided as an integral part of manufactured electronic equipment, multiple-deck terminal blocks are allowed, but never for direct termination of field cabling.

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6.5.5 Wire Ducts and Looms 6.5.5.1 Plastic wire ducts with removable covers shall be installed in cabinets as required to provide a means of routing and organizing wiring. Wire markers shall be completely presented without being obscured by the duct. In addition to the above, the maximum plastic wire duct fill (including spare capacity) shall not exceed 75% of its depth. Plastic wire ducts shall be mounted using screws. Doublesided tape is unacceptable. Where space limitations preclude the use of plastic wire ducts, wiring shall be neatly loomed and secured with plastic spiral wrapping or tie-wraps and anchors. Wiring between movable parts such as doors shall be installed in flexible hoses. Loomed wiring shall not be installed near sharp-edged surfaces. Wiring shall not be threaded through undressed access holes. Glands or protective grommets shall be used. Vendor-installed cables shall be supported and provided with a strain-relief mechanism for cable connectors.

6.5.5.2 6.5.5.3 6.5.5.4

6.5.5.5 6.5.5.6 6.5.5.7

6.5.6 Wire Color Coding for Power Wires

AC Power Supply: DC Power Supply: Hot Neutral Ground Negative Positive Black White or gray Green or green with yellow tracer Black Red

If the wire insulation cannot be color-coded as above, the wire must be sleeved with the required color. The sleeve shall cover from the cut insulation end to a point past where the conductor enters the plastic wire duct or a minimum of 4 inches, whichever is less. Sleeves shall not be used over green insulation. 6.5.7 Wire Tagging 6.5.7.1 Cables with connector plugs shall be tagged at each end. Each cable tag shall have two labels. The first label (closest to the plug connector) shall identify the device and socket to which
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the plug is to be connected. The second label shall identify the device and socket to which the opposite end of the cable is connected. 6.5.7.2 I/O and interconnecting wiring shall be tagged at each end with two identification tags (or the two may be combined into one tag with sufficient separation between wire numbers). The first tag (closest to the end of the wire) shall identify the terminal number to which the wire is physically connected. The second tag shall identify the terminal number to which the opposite end of the wire is connected.
Commentary Note: Where jumpers are installed between terminal blocks in the same row or column and are clearly visible, wire tagging is not necessary.

Identification shall be in accordance with designations shown on instrument loop diagrams (ILDs). Where wires terminate on instrument or device terminals, the instrument tag number and terminal designation (+) or (-) (if applicable) will be used in lieu of terminal strip identification.
Exception: Alternate wire tagging schemes, which conform to established local practice, may be used for extensions to existing facilities with the prior approval of the operating facility Manager.

6.5.7.3

Wire tag information shall be permanently marked in block alpha numerics or typed on tubular; heat shrinkable, slip-on sleeves. Wrap-around, snap-on or self-adhesive markers shall not be used. Where shrink fit cable markers cannot be installed over pre-made cable and connectors, a suitable tie-wrap or equivalent type permanent marker shall be used.
Exceptions: 1) Alternate wire tagging schemes, which conform to established local practice, may be used for extensions to existing facilities with the prior approval of the operating facility Manager. Plastic sleeves that are specifically designed to fit on a specific wire gauge and come with pre-printed alpha/numeric inserts (such as Grafoplast Trasp System) may be used for wire tags with prior approval of the operating facility Manager.

2)

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6.5.7.4 6.5.7.5

Wire tags shall not be handwritten. Wire tags shall be installed and oriented such that the tags are easily read. (Upside down or covering of tag information by plastic duct covers is not acceptable). Spare pairs/triads in multi-pair/triad cables shall be labeled "SPARE" in addition to the destination and source terminal numbers. All spares are to be terminated.

6.5.7.6

6.5.8 Terminal Coding 6.5.8.1 Each row of terminals shall be clearly identified with an alphanumeric label. Each row of ESD terminals shall additionally be marked to show ESD service. Each row of power supply and bus terminals shall be marked with voltage type and level. (e.g., +24 VDC, or 120 VAC, etc.) Numerical terminal identification and coding shall be assigned sequentially (in ascending order, from top to bottom or left to right). Each vertical row and group of rows shall be labeled separately.

6.5.8.2 6.5.8.3

6.5.9 Relays 6.5.9.1 Relays shall be of the hermetically sealed, 11-pin or 8-pin plug-in type.
Exception: Relays provided as an integral part of manufactured electronic equipment installed within cabinets may use that manufacturer's standard offering.

6.5.9.2

The mounting socket shall be provided with a plastic label, color black-white (relay number engraved into the black core with white surface, dull finish). The relay number shall be shown as presented in the detailed cabinet drawings. Integral socket modules for mounting relays on a DIN rail are acceptable. Coil voltage shall be as specified in the Purchase Order. Pullin voltage shall be 80% or less of nominal voltage.

6.5.9.3 6.5.9.4

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6.5.9.5

Relay configuration and pertinent operating information shall be imprinted on the case.

6.5.10 Push Buttons and Lights Push buttons and lights shall be heavy duty and oil tight with sealed contacts. Push buttons shall have protective mechanisms to prevent accidental activation as required by the detailed design specification. Long-life type derated lamps or LED cluster lamps shall be used. The color of the pushbuttons or lights shall be green for "ON"/"OPEN" and red for "OFF/"CLOSE" positions. Only screw terminals shall be provided on push buttons.
Exception: Existing facilities that currently deviate from the above light color specification may use other conventions in order to keep the lighting philosophy consistent within the facility.

6.5.11 Lamp Test Facilities For all control panel and console indicating lights, a lamp test button shall be installed per panel or console section.
Exceptions: LED or other lamps integral to a manufacturer's electronic instrumentation do not require the lamp test button.

6.5.12 Grounding 6.5.12.1 Both safety ground and instrumentation circuit ground must conform to NEC, Article 250. Grounding system recommendations and requirements provided by manufacturers of instrumentation and control systems shall be followed. Wellhead Shutdown Systems shall not have ungrounded (floating) DC reference grounds. 6.5.12.2 Separate, electrically isolated grounding bars shall be provided. 6.5.12.3 All ground buses shall be made of a solid copper suitably drilled and tapped for screw terminals and wire lugs, or fitted with screw-type compression lugs. 6.5.12.4 The preferred location of the ground bus bars is at the bottom of the cabinet.

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6.5.12.5 A No. 2 AWG screw-type compression lug shall be provided on both ends of each ground bar for interconnection with other ground buses or to the Instrument System Ground Node. 6.5.12.6 The ground bus bars shall be labeled and wired as follows: "AC SAFETY GROUND" for all exposed metal surfaces of cabinets, racks, chassis GND connections, etc. Individual wiring interconnections shall be minimum 14 AWG copper wire, green or green with yellow tracer insulation. This bus shall be directly bolted to the cabinet without the use of insulators. "INSTRUMENT CIRCUIT GROUND" for connecting cable and wire shields and DC Common. Interconnections between shield consolidation points and the bus bar shall be minimum 14 AWG copper wire, green or green with yellow tracer insulation. This bus bar shall be electrically insulated from the cabinet structure. 6.5.13 Lighting, Convenience and Power Distribution Receptacle Outlets 6.5.13.1 Convenience outlets and cabinet lighting shall be provided as specified in the Purchase Order. 6.5.13.2 A switch in the cabinet shall control cabinet lights. 7 Hydraulic Based Wellhead Shutdown System Requirements 7.1 Hydraulic System General Requirements 7.1.1 When a hydraulic based wellhead shutdown system is specified (well sites without reliable electrical power, where a subsurface safety valve (SSSV) is required, or as a fail-safe self-contained valve and actuator system), the hydraulic systems shall be supplied to match the requirements of the wellhead tree valves and actuators specified by Drilling and Workover Engineering Department, Specification number 45-SAMSS-005. 7.1.2 Hydraulic pump(s) shall have a check valve in the discharge line of the pump to the header or other mating component. On multiwell control systems, two pumps shall be provided and discharge to a common header (one primary and one as backup).

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7.1.3 The hydraulic header shall be sized to adequately handle the needs of the system. 7.1.4 Relief valves shall be installed within the hydraulic system to prevent over pressuring within high and low pressure systems. 7.1.5 On multiwell systems, a dump valve shall be installed to return header pressure back to the hydraulic reservoir. 7.1.6 A hydraulic accumulator shall be supplied when required to handle thermal expansion and pressure surges in the system. 7.1.7 Accumulators shall be supplied to provide backup hydraulic power. The sizing of the accumulator system shall meet operating requirements of the valves and actuators specified by the Drilling and Workover Engineering Department of Saudi Aramco in 45-SAMSS-005, "Valves ordered with actuators shall be tested with actuator installed" to ensure proper valve and actuator operation.
Exception: Accumulators are not required for manually pumped self-contained hydraulic surface safety valve actuation systems where the manual pump itself provides the system power.

7.1.8 A panel mounted hydraulic system pressure gauge shall be supplied on the panel. 7.1.9 All hydraulic systems shall have a separate manual hand pump to provide for manual operations of well SSV and SSSV. 7.1.10 Hydraulic control system cabinets shall include a inch NPT drain fitting in the bottom of the cabinet. 7.2 Self-contained, Manually Operated, Hydraulic System Requirements Self-contained, fail-safe, hydraulic systems shall provide local manual control of hydraulically operated SSV's (wellhead and flowlines) and SSSV's (when SSSV's are required). 7.3 When part of an all-electric wellhead shutdown system, SSSV hydraulic systems shall provide valve position indication (open and closed position switches) and an electronic solenoid valve interface (de-energize to close SSSV) to the wellhead shutdown system. Process Piping

7.4

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Process fluid shall not be routed within the hydraulic cabinet. Flowline pressure to the high / low pilots shall be sensed remotely on the pipeline. 7.5 Hydraulic Piping Installation 7.5.1 All piping shall be installed so that each component, including future instruments to be installed in spare places, will be easily accessible for adjustment and calibration. Removal of instruments and components shall be possible without having to remove other instruments and components. 7.5.2 All threaded connections shall be suited for leak tight hydraulic systems (ANSI B1.20.1 tapered or straight thread, O-Ring boss type connections). 7.5.3 All open fittings and bulkhead connections shall be plugged or capped during transportation. 7.6 Tubing and Fittings 7.6.1 Tubing Stainless steel tubing shall be seamless, annealed, minimum wall thickness 1.24 mm, per ASTM A269, Grade TP-316. Tubing shall be inch, 3/8 inch, or inch OD stainless steel. Tubing shall have a 2 to 1 burst safety factor. 7.6.2 Tube fittings shall be 316 stainless steel and shall be suitable for leak tight hydraulic systems. 7.6.3 Incoming and outgoing lines shall terminate in bulkhead fittings. Location and size(s) shall be as specified in the Purchase Order. 7.6.4 Bulkhead fittings and 10% spares, as a minimum, shall be installed with adequate spacing to ensure that any connection can be removed without the need to remove other fittings. 7.6.5 Tubing runs and Bulkhead fitting layouts shall be included in the documentation provided to Saudi Aramco. 8 Electronic Based Wellhead Shutdown System Requirements 8.1 Electronic Programmable Logic Solver

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Document Responsibility: Instrumentation Issue Date: 18 August 2009 Next Planned Update: 18 August 2012

34-SAMSS-624 Wellhead Control, Monitoring and Shutdown Systems

8.1.1 The programmable logic solver shall be safety certified by TUV for SIL 3 applications, suited for continuous operation outdoors, and selected per requirements of 34-SAMSS-623. 8.1.2 Control requirements for failsafe electric actuators shall be verified with the supplier of the actuators. 8.2 Fail-safe electric actuators supplied to operate SSV's shall be selected to meet the valve thrust and bonnet size requirements and delivered to site with the wellhead tree. Sizing of the actuator shall be reviewed by Drilling and Workover Engineering Department to ensure valve/actuator compatibility. Fail-safe electric actuators shall provide de-energize-to-trip control. Primary power to the electric fail-safe actuator shall be required to run the motor and allow the actuator to fully open the valve. Once the valve is open 24 VDC is applied to a solenoid, allowing the valve to stay open. The motor is disengaged and power is removed once the valve is completely open. Once the 24 VDC is removed from the ESD activiated solenoid, the SSV will travel to the closed position. 8.4 Fail-safe electric actuators shall have the capabilities to attach a manual override, hydraulic override, or fusible lock open cap on to the actuator, but not permanently attached. These should only be used during testing or during wire line work over. Where remote monitoring and control are required, wellhead shutdown systems (PLC logic solver/RTU) shall be capable of communications with the host SCADA system as defined in the Functional Specification Document. The wellhead shutdown systems that utilize electronic safety PLC's shall provide for the input and output signals (logic solver I/O) as defined within the Purchase Order or Functional Specification Document. A minimum of 5% installed spare I/O points shall be provided. A side mounted, closed loop cabinet cooling A/C systems shall be considered on wellhead shutdown cabinets that house programmable logic solvers. The air conditioner, when specified, shall be purchased from a company that specializes in the fabrication of standard and custom outdoor enclosures, e.g., Hoffman, Rittal, etc. The cabinet cooling unit shall be powered using utility AC power.
Commentary Note: A side mounted, closed loop type cabinet cooling A/C unit is recommended for all shutdown cabinets that house electronic logic solvers to reduce the possibility of controller failures due to excessive temperature within the cabinet. The electronic

8.3

8.5

8.6

8.7

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Document Responsibility: Instrumentation Issue Date: 18 August 2009 Next Planned Update: 18 August 2012

34-SAMSS-624 Wellhead Control, Monitoring and Shutdown Systems

logic solver must be still be rated for continuous operations in outdoor ambient conditions to allow for periods when the HVAC unit is out of service.

Nameplates and Tags 9.1 Nameplates shall be installed on the front of the panel to identify the panel tag number. The nameplate description shall be as shown on the control panel schematic. Lettering shall be a minimum of " height. A tag shall be attached to each pushbutton, instrument, and valve actuator to identify the device tag number. Nameplates shall be made from laminated plastic, white-black-white (information engraved into the black core) with white surface, dull finish. Control panel pushbuttons, switches, indicating lights and other throughmounted devices shall be identified with the service description on the front. The rear of the above devices shall be identified with the device tag number. The nameplates shall be permanently attached using stainless steel screws and nuts. Instruments and accessories mounted inside the cabinet shall be identified with a nameplate showing the tag number. Each cabinet, front and rear, shall be identified with a nameplate located above each door or pair of doors. The nameplate, as a minimum, shall be the cabinet name/number as given in the cabinet drawings.

9.2 9.3 9.4

9.5 9.6

10

Inspection and Testing 10.1 The vendor shall notify Saudi Aramco of the expected date of final inspection and testing of the integrated wellhead shutdown system. Saudi Aramco representatives shall be present to witness the testing. The items manufactured to this specification are subject to verification by the Saudi Aramco Inspection representative, per the Saudi Aramco Inspection Requirement 175-454100 and 175-454400 attached to the Purchase Order. 10.2 System testing shall consist of the following checks and tests. All process, hydraulic, and electrical systems shall be functionally tested. Electronic wellhead programmable logic solvers shall be tested with simulated inputs. SSSV hydraulic and process connections shall be tested to maximum operating pressure.

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Document Responsibility: Instrumentation Issue Date: 18 August 2009 Next Planned Update: 18 August 2012

34-SAMSS-624 Wellhead Control, Monitoring and Shutdown Systems

10.3 10.4 10.5

All errors or faulty workmanship discovered during this testing shall be corrected to the satisfaction of Saudi Aramco. Vendor shall supply all test equipment and labor required for testing of the complete wellhead shutdown system. The Cabinet Fabricator shall verify the operation of all instrumentation and controls. Documented test procedures shall be submitted to Saudi Aramco for approval not less than thirty (30) days before commencement of test. Tests shall include, but shall not be limited to: a) b) c) d) e) f) A function test of all electronic instruments and electric control circuits and relays. Visual inspection to verify compliance with requirements of this specification. Complete wiring check with verification that terminal and wiring code conforms to cabinet design drawings. A function test of all hydraulic systems. Compete tubing logic check with verification that the tubing logic matches the drawings supplied for review by Saudi Aramco. EMI/RFI Interference (Radiated Susceptibility): The cabinet electronic equipment shall perform within the normal limits without loss of function or degradation of performance when subjected to radiated electromagnetic fields in accordance with IEC 61000-4-3, Level 3, (at a 10 V/m power level), with cabinet doors open.

11

Drawings
Commentary Note: Typically, general drawings are provided to the Cabinet Fabricator from the Design Contractor. General drawings are not sufficient to review detailed design layouts. The Cabinet Fabricator shall supply Saudi Aramco detailed drawings for review and approval.

The detailed drawings, shall as a minimum, contain the following information: a) Cabinet fabrication drawings showing dimensions for exterior, openings, removable plates, doors and door swings, internal cabinet segregation, internal frame supports/bracing, ventilation louvers, lifting bolts, and shipping breaks. Cabinet layout drawings showing the location of all electronic equipment, terminal strips, fuses, plastic ducts, raceways, pushbuttons, name plates, annunciators, rack-mounted equipment, power supplies, convenience outlets, lighting and grounding strips.
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b)

Document Responsibility: Instrumentation Issue Date: 18 August 2009 Next Planned Update: 18 August 2012

34-SAMSS-624 Wellhead Control, Monitoring and Shutdown Systems

c)

Wiring diagrams showing termination strips and all electronic interconnections, with tag names and equipment/terminal identification. Individual loop drawings shall be included for each input and output associated with the PLC/RTU system. Drawings and a written narrative shall be provided for documentation of logic within the PLC/RTU system (ladder logic, cause and effect diagrams, etc.).

d)

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Other Miscellaneous Requirements 12.1 Wellhead shutdown panel Operating Instructions Laminated, brief step-by-step operating instructions shall be attached to the inside of the cabinet door. The operating instructions shall be printed in large (easy to read) font suitable for reference in the field during cabinet operation. 12.2 Nonmaterial Requirements The supplier shall provide nonmaterial items as listed on Form NMR-7907.

18 August 2009

Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued with editorial changes.

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