34 Samss 628

Materials System Specification
34-SAMSS-628 1 January 2018

Self-Contained Wellhead
High Integrity Protection System - Onshore Oil Service
Document Responsibility: High Integrity Protection Systems Stds, Committee
Contents
1 Scope ............................................................2
2 Conflicts and Deviations..................................2
3 References ....................................................2
4 Definitions ......................................................5
5 Environmental Conditions ...............................6
6 General .........................................................8
7 Mechanical Requirements ............................. 11
8 Identification Tagging.................................... 17
9 Inspection and Testing .................................. 18
10 Packing and Shipping ................................... 19
11 Documentation ............................................. 20
12 Notes to Purchaser ....................................... 21
Revision Summary............................................... 22
Appendix ............................................................. 23
Previous Issue: 10 August 2015 Next Planned Update: 10 August 2018

Revised paragraphs are indicated in the right margin
Contact: Miller, Chan Eldon (millerce) on phone +966-13-8804750
©Saudi Aramco 2018. All rights reserved.

Document Responsibility: High Integrity Protection Systems Standards Committee 34-SAMSS-628
Issue Date: 1 January 2018 Self-Contained Wellhead
Next Planned Update: 10 August 2018 High Integrity Protection System - Onshore Oil Service
1 Scope
1.1 This specification defines the minimum mandatory requirements for a shop
fabricated skid assembly containing all necessary equipment to provide an onshore
wellhead High Integrity Protection System (HIPS) in onshore crude oil service.
1.2 The HIPS skid covered by this specification is self-contained, modular wellhead
HIPS design that is independent from any other control or safety system and will
be designed for outdoor unsheltered onshore installation.
1.3 The HIPS skid includes but is not limited to the following system components:
HIPS gate valves integrated with hydraulic actuators, HIPS pressure pilots, HIPS
hydraulic controls and instrumentation, spool pieces and skid structural elements.
1.4 The HIPS skid shall be limited to installations downstream of the wellhead
production choke valve and upstream of the well pad piping specification break.
2 Conflicts and Deviations
2.1 If there are any conflicts between this specification and associated purchasing,
project, or engineering documents, this specification shall take precedence.
2.2 Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
EK&RD Coordinator.
2.3 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302.
2.4 The designation “Commentary” is used to label a sub-paragraph that contains

comments that are explanatory or advisory. These comments are not mandatory,
except to the extent that they explain mandatory requirements contained in the
specification.
3 References
The following is a summary of all the documents referenced within this specification.
Material or equipment supplied to this specification shall comply with the latest edition of
the references listed below, unless otherwise noted.
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-250 Safety Integrity Level Assignment and Verification
Saudi Aramco: Company General Use
Page 2 of 28
SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering

Requirement
SAEP-351 Bolted Flange Joints Assembly
SAEP-375 HIPS – SAP Tracking System Workflows
Saudi Aramco Engineering Standards

SAES-A-202 Saudi Aramco Engineering Drawing Preparation
SAES-H-001 Coating Selection and Application Requirements for
Industrial Plants and Equipment
SAES-J-002 Technically Acceptable Instrument Manufacturers
Saudi Aramco Materials System Specifications

02-SAMSS-012 Weld Overlayed Fittings, Flanges, and Spool Pieces
04-SAMSS-035 General Requirements for Valves
04-SAMSS-048 Valve Inspection and Testing Requirements
04-SAMSS-049 Inspection and Testing Requirements for API 6A,
10000 PSI Valves
04-SAMSS-055 General Valve Requirements, ISO 10423 (API 6A)
09-SAMSS-069 Qualification requirements for Epoxy Coatings for
Atmospheric Service
12-SAMSS-007 Fabrication of Structural and Miscellaneous Steel
26-SAMSS-051 Hydraulic Oil AW 32 and 68
34-SAMSS-624 Wellhead Control, Monitoring and Shutdown Systems
34-SAMSS-717 Hydraulic Valve Actuators Systems
Saudi Aramco Inspection Requirements

175-026600 Weld Overlayed Flanges, Fittings, and Spool Pieces
175-043600 Valves: Metallic; Includes Gate, Globe, Angle,
Check, Needle, Ball, Plug, Piston, Butterfly
175-045600 Valves & Chokes: API SPEC 6A PSL 3, 10000 PSI 1
13/16"; For Use in Sour Wet Services
Downstream of the Wellhead and Tree Assembly
175-091900 Coating: Shop Applied; For Tanks, Piping, Pipelines
(and Associated Appurtenances & Fittings),
Structures, Process Equipment; Internal &
External; Onshore, Offshore and/or Subsea
Page 3 of 28
175-120100 Steel Structures (Excludes Offshore Structures and

Pre-engineering Metal Buildings)
175-320300 Positive Material Identification (PMI)
175-341001 Hydraulic Valve Actuators
175-344500 Self-Contained Wellhead HIPS Skid – Onshore Oil
Saudi Aramco Forms and Data Sheets

SA-6233-1 Valve Data Sheet
SA-8020-212 Instrument Specification Sheet Pressure and
Differential Pressure Gauges
SA-8020-213 Instrument Specification Sheet Pressure and
D/P Switches
SA-8020-717 Instrument Specification Sheet Hydraulic Valve
Actuators
Saudi Aramco Non-material Requirements

NMR-7930 Non-material Requirements for
3.2 Industry Codes and Standards
American Institute of Steel Construction

AISC Steel Construction Manual
American National Standards Institute

ANSI/NFPA 70 National Electrical Code
American Petroleum Institute (API)

API 6A Wellhead and Christmas Tree Equipment
American Welding Society

AWS D1.1 Structural Welding Code
American Society for Testing and Materials

ASTM A123/A123M Standard Specification for Zinc (Hot-Dip
Galvanized) Coatings on Iron and Steel Products
ASTM A269 Seamless and Welded Austenitic Stainless Steel
Tubing for General Service
ASME BTH-1 Design of Below-the-Hook Lifting Devices

Page 4 of 28
International Electrotechnical Committee

IEC 60529 Degrees of Protection Provided by Enclosures
IEC 61508 Functional Safety of Electrical/Electronic/
Programmable Electronic Safety-related Systems
IEC 61511 Functional Safety - Safety Instrumented Systems for
the Process Industry Sector
International Organization for Standardization

ISO 4406 Hydraulic Fluid Power -- Fluids -- Method for Coding
the Level of Contamination by Solid Particles
National Association of Corrosion Engineers/International Standardization

Organization
NACE MR0175/ Petroleum and Natural Gas Industries-Materials
ISO 15156 for Use in H2S-Containing Environments in Oil and
Gas Production
National Electrical Manufacturers Association

NEMA 250 Enclosures for Electrical Equipment
4 Definitions
1oo2: One out of two voting; if one out of two devices reaches a trip setpoint, a trip is
initiated.
Crude Oil Service: Directly producing crude oil or producing water in support of
crude oil production.
Factory Acceptance Test (FAT): Done at the skid manufacturer’s shop and consists
of functional test of all components using actual or simulated signals.
High Integrity Protection System (HIPS): High availability, fail safe SIL-3 system
that consists of sensors, logic solvers, and final control elements used to prevent over-
pressurization and loss of containment on process and equipment by shutting off the
source of high pressure before exceeding the process design pressure. A HIPS system
is designed as an independent and separate safety protection layer separate from the
ESD system. A HIPS system must be in compliance throughout the systems lifecycle to
the strict conditions of approval resulting from a quantitative risk assessment, dynamic
process simulations, and other specific design considerations.
Hot-dip Galvanized: Meets the requirements of ASTM A123/A123M.

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Modular: A self-contained unit intended to perform a certain function that is

interchangeable with a standard interface; a modular unit may be disconnected and
moved to a new location or replaced with a spare unit without disassembly of
subcomponents.
Nearshore Environment: 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.
Offshore: Overwater.
Site Acceptance Test (SAT): Done at the field location and consists of functional test
of all components using actual field parameters.
Shut in Pressure: The pressure at the wellhead when the well is completely shut in,
also referred to as Shut in Wellhead Pressure (SIWP).
Safety Integrity Level (SIL): The level of overall safety availability for the safety
instrumented function or an Emergency Shutdown system component calculated as one
minus the sum of the average probability of dangerous failures on demand.
Skid: When referenced in this document, the term skid may refer to the structural steel
frame and associated supports and braces specifically manufactured to support the HIPS
Valves and spool pieces or the fully assembled HIPS system inclusive of the structural
steel frame.
Specification: The main body of this document. Does not include the information
contained within the Appendices.
Stainless Steel: Either 316 series or 317 series stainless steel material for the purpose
of this specification.
5 Environmental Conditions
5.1 Temperature
The equipment shall operate continuously under the following ambient air
temperatures without any degradation of the manufacturer's guaranteed
performance:
Outdoor Outdoor
Sheltered (1)(2)(3) Unsheltered (2)(3)
55°C 65°C
Maximum
(131°F) (149°F)
0°C 0°C
Minimum
(32°F) (32°F)

Page 6 of 28
Notes:
(1) “Sheltered” refers to permanent, ventilated enclosures or buildings, or permanently fixed
sunshades with a top and three sides.
(2) For instruments which dissipate internal heat and are installed in custom engineered
enclosures (e.g., enclosures not included in the original manufacturer's temperature
certification), an additional 15°C shall be added to the above maximum temperatures.
An example, for “indoor air conditioned” installation, the equipment must perform at 35 + 15
= 50°C. Similarly, for the “outdoor unsheltered” case, the equipment shall be designed for a
maximum operating temperature of 65 + 15 = 80°C.
(3) For the outdoor installations only, the designer can take credit for forced or passive cooling
to eliminate or reduce the 15°C heat rise. For example, if vortex coolers are used, the heat
removal capacity of the coolers may be subtracted from the generated heat. No more than
15°C reduction in temperature will be given as credit. The designer shall substantiate his
claim by providing the support data and calculations.
5.2 Contaminants
The instrument manufacturer shall ensure that all equipment is designed to

withstand the following air quality requirements.
5.2.1 Dust Concentration
Usual airborne dust concentration is 1 mg/m³. During sandstorms, dust

concentrations may reach 500 mg/m³. Particle sizes are as follows:
95% of all particles are less than 20 micrometers
50% 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.
5.2.2 Other pollutants present in the atmosphere under the most extreme
conditions are:
H2S 20 ppm (Vol/Vol)
Hydrocarbon 150 ppm (Vol/Vol)
SO2 10 ppm (Vol/Vol)
CO 100 ppm (Vol/Vol)
NOx 5 ppm (Vol/Vol)
O3 1 ppm (Vol/Vol)
5.3 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
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the shoreline of the Arabian Gulf or within three kilometers from the shoreline
of the Red Sea.
5.4 Humidity
Outdoor design basis shall be between 5% to 95% relative humidity (non-

condensing).
5.5 Noise
Instruments shall not generate noise exceeding the permissible noise exposure
levels of 85 dBA at a distance of 1 meter radius and shall be rated to operate
continuously at this level.
6 General
6.1 All dimensions and measurements shall be in the “International System of

Units” (SI) followed by the equivalent value in English (conventional) units
between brackets. When not critical, the equivalent dimensions may be rounded
off to their nearest practical value.
6.2 All components shall be of high grade industrial standard varieties rated for
environmental conditions listed in Section 5.
6.3 The following components shall be sourced from the applicable Regulated
Vendor Lists (RVL).
a. HIPS Skid Integrator – 9COM 6000015901 - SKID; WELLHEAD HIPS,
SELF-CONTAINED
b. Instrument Valves/Manifolds - 9COM 6000002768 – MANIFOLD;
VALVE; INSTRUMENT
c. Hydraulic Stainless Tubing - 9COM 6000000068 – TUBING; METALLIC;
STAINLESS STEEL, ASTM
d. Hydraulic Tubing Fittings - 9COM 6000000208 – FITTING; TUBING;
316 SS OR BETTER
e. Instrument Root Valves - 9COM 6000000314 - VALVE: GATE; API 6A,
10,000 PSI
f. HIPS Valves Bare-stem - 9COM 6000015611 – Valve: Gate;
HIPS 1- 13/16 IN & UP, API 6A
g. Actuators - 9COM 6000002902 – ACTUATOR; VALVE; HYDRAULIC
& ELECTRO ROTAR) or 9COM 6000003729 – ACTUATOR:
SSV/SSSV; HYD; SELF CONTAINED.

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6.4 The specific location(s) and environment in which the skids will be installed
shall be specified within the purchasing documents.
6.5 Saudi Aramco Mechanical, 1oo2, Fail-Safe Wellhead HIPS Design
The HIPS function shall be designed to protect all piping and equipment located
downstream of the HIPS to the inlet of the plant with a pressure class less than
the well shut in pressure by detecting high pressure and reliably and quickly
isolating the high pressure through closure of shutdown valves.
Figure 1 - 1oo2 HIPS Schematic
6.5.1 The wellhead HIPS shall provide a 1oo2, fail-safe design via two, series
connected safety valves and hydraulic opening/spring-to-close actuators
that move from the fully open to the fully closed position when actuated
by 1oo2, redundant pressure pilots (process sensors).
6.5.2 1oo2 redundant pressure pilots shall be able to sense/trip on high

pressure set point.
6.5.3 If required in the material requisition, an additional set of 1oo2

redundant pressure pilots able to sense/trip on low pressure set point
shall be provided.
Commentary Notes:
The additional set of 1oo2 redundant pressure pilots able to trip on low
pressure set point is only required when the ESD system/layer is not
equipped with low pressure trip point.
A single set of 1oo2 pressure pilots combining both high and low
pressure set points is acceptable.

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6.5.4 The skid shall be installed downstream of the wellhead production choke
valve and independent self-contained ESD valve in fully rated piping and
upstream of the well pad piping specification break.
6.5.5 All wetted components of the pressure boundary parts shall be Alloy 625,
or Alloy 625 cladded, or functionally equivalent alloy, and comply to
NACE MR0175/ISO 15156. Functionally equivalents are Alloy C276,
Alloy 718, Alloy 725, Alloy 825, and Alloy 925.
6.5.6 The skid shall be completely self-contained, without the need for
external electric or hydraulic power.
6.5.7 The HIPS shall be designed and implemented as a factory assembled, Safety
Integrity Level (SIL) 3 compliant and fail safe system (safety availability of
0.9999). Verification of compliance shall be per SAEP-250.
6.5.8 The Vendor shall verify and document the SIL compliance and safety
availability using their assigned engineer(s) or third party consultant.
The responsible individual for the verification of the HIPS shall be a
certified functional safety engineer/expert, qualified to meet the
competency requirements of IEC 61508 and IEC 61511.
6.5.9 The HIPS SIL verification shall be certified by a Saudi Aramco approved
third party functional safety entity (such as TUV, Exida, or Lloyd’s)
independent of the entity who performed the vendor’s SIL verification.
6.5.10 Skid shall be designed to be transported to, and installed at the site as
one complete unit without requiring field assembly.
6.5.11 The HIPS shall respond to a demand (from sensing to valve full closed)
in less than 10 seconds at or above the set point (high trip process
pressure). The vendor shall provide a table of response times at
pressures below the high trip pressure.
Commentary Note:
Actual valve stroke time will increase at process pressures below the trip
point.
6.5.12 Vendor compliance with the provisions of this SAMSS does not relieve
Vendor from the responsibility to furnish equipment of proper design to
meet the specified environment, application, service, and operating
conditions.

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7 Mechanical Requirements
7.1 Skid Structural Elements
Refer to Saudi Aramco Materials System Specification 12-SAMSS-007.
7.1.1 Steel design shall be in accordance with the AISC, “Steel Construction
Manual” requirements.
7.1.2 Welding shall be in accordance with AWS D1.1 “Structural Welding

Code” requirements. A continuous fillet shall be used to seal all
adjoining members.
7.1.3 HIPS Skid and associated pipe and equipment support and braces shall
be designed to resist, without damage to associated equipment, all loads
and stresses resulting from lifting, handling, transporting, operating and
hydro-testing. Maximum deflection of the base during lifting and
transporting shall not exceed the Length divided by 240.
7.1.4 HIPS Skid shall be of welded construction, rigidly braced with welded
cross members and integral permanent provisions for multiple point
lifting. Jacking facilities shall be provided for base leveling.
7.1.5 The HIPS Skid structural elements shall be hot-dip galvanized in

accordance with ASTM A123/A123M after the completion of the
welding and drilling associated with the fabrication of the skid structure.
It is acceptable to drill holes in the galvanized skid structure to attach
small accessories (e.g., cable clamps) provided the bare metal is touched-
up with zinc-rich paint.
7.1.6 Stainless steel hardware shall be used for the assembly of the complete
skid and for the attachment of any accessories.
7.1.7 Where dissimilar metals are in contact, the contact points shall be
suitably protected to prevent corrosion due to galvanic action.
7.1.8 Skid design must comply with ASME BTH-1 “Design of below the
Hook Lifting Devices”.
7.1.9 The design shall consider the worst case of 100% of the load distributed
between only 2 diagonal/opposing slings/lifting lugs.
7.2 HIPS Valves and Actuators
Refer to Saudi Aramco Materials System Specification 04-SAMSS-035 and

04-SAMSS-055 for the bare-stem valves (9COM 6000015611).

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For actuators refer to either Saudi Aramco Materials System Specification

34-SAMSS-717 (9COM 6000002902 – ACTUATOR; VALVE; HYDRAULIC &
ELECTRO ROTAR) or 34-SAMSS-624 (9COM 6000003729 – ACTUATOR:
SSV/SSSV; HYD; SELF CONTAINED).
7.2.1 Each valve and actuator that make-up the HIPS redundant final elements
shall be supplied as an integrated assembly as specified by the buyer on
SA-6233-1 and SA-8020-717. Refer to Appendix for example data
sheets with minimum requirements. Valves shall be sourced from the
Regulated Vendor Lists (RVL) approved for HIPS.
7.2.2 Actuator sizing and requirements shall be per 34-SAMSS-717.
7.2.3 HIPS valve and actuator assemblies shall have a closing stroke time of
less than10 seconds.
7.2.4 The valve and actuator assemblies shall be fully integrated and tested at
the facility approved for manufacturing the valve.
7.2.5 The HIPS bare valve shall be certified per API 6A Annex F Design
Validation, PR2, requirements.
7.2.6 Valves shall be stored in accordance with the manufacturer’s

recommendations. When the storage interval exceeds the valve
manufacturer’s recommendation the valve shall not be integrated
into the skid without first performing storage maintenance on the valve.
Storage maintenance shall be performed per the valve manufacturer’s
recommendation.
7.2.7 The hydraulic oil shall be per 26-SAMSS-051.
7.2.8 A limited number of actuator lock open caps shall be supplied for
testing. The lock open cap shall be manufactured per API 6A for heat-
sensitive lock-open devices. The cap shall not be left in place during
normal operations. Buyer shall specify the number of sets otherwise one
set of two caps per ten skids.
7.3 HIPS Skid Controls
7.3.1 The hydraulic controls for the HIPS shall be contained within the
skid without external connections. Controls shall use clean hydraulic
fluids as an operating media isolated from the produced well fluid.
The operating and control hydraulic circuits shall be closed, leak tight
and allow no produced fluid fugitive emissions to the environment.

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7.3.2 Process root valves shall be provided for all instrument connections
(pressure pilots and pressure gauge) to the spool pieces and meet API 6A,
PSL-3 Material Class HH, Temperature Class U, PR2, API-6FA.
Refer to Saudi Aramco Materials System Specification 04-SAMSS-035,
04-SAMSS-049 and 04-SAMSS-055 for the bare-stem valves (9COM
6000000314), see Appendix. All instrument connections shall be of a
double block and bleed configuration per Figure 2. A monoflange or top
hat style manifold may be used to facilitate the double block and bleed.
The Calibration Test Valve may be located between or downstream of
the second block valve. The Calibration and Bleed valves shall be
needle valves. Valves shall be oriented to allow easy access for
operators during routine function testing and maintenance.
Figure 2 - Instrument Connection Diagram
7.3.3 All instrument bleed connections shall be oriented to facilitate

connection to a common ½-inch bleed line. Bleed line will be installed
at site by others (Proponent or PMT).
7.3.4 The process connections for the hydraulic sensors (pilots) shall be on the
piping spool provided on the HIPS skid downstream of the redundant
final elements. Each pilot sensing connection shall have a pressure
gauge see Appendix “D”. Close coupling of the hydraulic sensor to the
associated instrument connection valves see Appendix “E” is required.
7.3.5 Each HIPS final element (valve and actuator) shall be equipped with a
double acting manual hand pump to open the associated valve following
a system trip. The pump control shall have a manual override to

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facilitate operation of the valve for startup, maintenance, and testing of

the final element. The manual override shall be self-arming.
7.3.6 A pressure gauge (see Appendix “C”) shall be provided on the spool
piece between the two, HIPS final elements. For connection details see
details on Appendix “E”.
7.3.7 If specified in the purchasing documents by the buyer, final element

proximity limit switches shall be provided on each actuator to facilitate
remote indication of valve open and closed position. The proximity limit
switches shall be labeled, listed, or certified by any of the agencies in the
Approved IECEx Certification Bodies (ExCBs) under the IECEx
Certified Equipment Scheme as meeting the ANSI/NFPA 70 NEC
requirements for the hazardous area and NEMA 250 type 4X (stainless
steel) or IP 66 per IEC 60529.
7.3.9 Instrument Tubing and Fittings

a) Process sensing fittings and instrument valves shall be compatible
with the process medium. As a minimum, the pressure boundary
parts shall be Alloy 625, Alloy 625 cladded, or Alloy C276.
b) Hydraulic tubing, fittings, and valves shall be compatible with the
hydraulic fluid. The tubing and fittings shall be made of the same
material. As a minimum, the tubing shall be Type 316 seamless,
annealed stainless steel per ASTM A269, ¼ -inch OD x 0.035-inch
wall thickness, hardness Rockwell B80 maximum.
c) Hydraulic tube fittings shall be, as a minimum, 316 stainless steel
and shall be double ferruled compression type.
d) Tubing bends shall be used to reduce the number of fittings in
accordance with good construction practices and shall cut tubing
using a tube cutter and deburr the cut surface. Tubing shall be
checked for cleanness prior to connection.
7.3.10 Fire Protection
Fusible valves (one for each HIPS valve) shall be included within each
HIPS valve actuator per 34-SAMSS-717 to ensure fail-safe action in the
event of fire.
7.3.11 The configuration of the pressure pilots shall be 1oo2 and both HIPS
valves shall close simultaneously when a trip condition is sensed by
either pilot.

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7.3.12 The pump control manual overrides, one per HIPS valve, shall be free
from obstruction, easily accessible, and facilitate the closing of the
associated valve with a single movement (depressing, pulling, or
rotating). As an alternative, a local ESD button shall be included on the
skid, free from obstruction, easily accessible, and pull to initiate.
7.3.13 Hydraulic tattletale trip indicators in 316 Stainless Steel shall be installed
to indicate if system tripped on high or low pressure condition.
7.3.14 The hydraulic system shall be cleanliness per 34-SAMSS-717.
7.3.15 Pressure pilots shall be as specified by the buyer on SA-8020-213.

Refer to Appendix for example data sheet with minimum requirements.
7.3.16 Process pressure gauges shall be as specified by the buyer on

SA-8020-212. Refer to Appendix for example data sheet with minimum
requirements.
7.3.17 Hydraulic pumps shall have a check valve in the discharge line of the
pump to the header or other mating component. They shall be double
acting type pumps.
7.3.18 Relief valves shall be installed within the hydraulic system to prevent
over pressuring within high and low pressure systems. These relief
valves shall be maintained in accordance with the manufacturer’s
maintenance manual.
7.3.19 A spring-loaded piston style hydraulic accumulator shall be supplied

when required to handle thermal expansion and pressure surges in the
hydraulic system.
7.3.20 Hydraulic system pressure gauges (high pressure and low pressure) shall
be supplied on the control unit. The hydraulic system pressure gauges
shall be per the hydraulic manufacturer standard.
7.4 Spools
7.4.1 Spools shall be machined from a single piece of forged material, NDE
and tested in accordance with API 6A PSL 3. All wetted surfaces of the
spool pieces shall be cladded with Alloy 625 per 02-SAMSS-012 and
related inspection form 175-026600.
7.4.2 The flanged end-connections and pipe spool ID shall match the HIPS
valves.

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7.4.3 The end-connections and the process connections shall be machined

(studded-in).
7.4.4 Spools shall be hydro-tested per API 6A PSL 3. The water shall not
exceed 30 ppm by mass chlorides.
7.4.5 Bolting of flanges shall be per SAEP-351.
7.5 Painting/Coating
7.5.1 Hot-dip galvanized or stainless steel surfaces shall not be painted or

coated.
7.5.2 HIPS valves, actuators, pipe, piping components, and flanges shall be
externally coated per SAES-H-001 and 09-SAMSS-069 Paint System
APCS-1B.
7.6 Dimensional Constraints
The Self-Contained Wellhead HIPS Skids are intended to be interchangeable

regardless of vendor. All skids should meet the same face to face dimension and
fit within a given skid steel envelope. No skid mounted equipment shall
overhang the skid edge.
7.6.1 Dimension A is maximum distance from center line of pipe to skid edge
including lifting eyes. Skid should be minimum size to meet the
application.
7.6.2 Dimension B is from center line of pipe to bottom of skid steel.
7.6.3 Dimension C shall not exceed inlet/outlet flange face by more than
152.4 mm (6 inches). Skid should be minimum size to meet the
application.
7.6.4 Dimension D is the skid face to face (from inlet flange face to outlet
flange face).
Skid Pipe HIPS A B C D

Rating Valve Size mm (in) mm (in) mm (in) mm (in)
704 480 152.4 1892
API 3000 4-1/16”
(27.7) (18.89) (6) (74.5)
Tolerance All ±5 ±5 ±5 ±10

Page 16 of 28
Smaller valve/pipe sizes may be considered.
Figure 3 - Skid Dimensions
8 Identification Tagging
8.1 An identification tag or name plate made of 316 stainless steel (3 mm minimum
thickness) shall be attached to the equipment securely with stainless steel or
Monel fasteners. The tag or nameplate shall be located so that the information is
clearly visible and legible after the equipment is installed. The tag shall be
marked by raised letters or die stamping with the following information:
a) Purchase Order Number
b) Manufacturer Name and Location
c) Part/Model Number
d) Serial Number
e) Date of Manufacture
f) Mark/Tag Number
g) Total Weight
8.2 The tagging system for all instruments, control devices, enclosures, terminal
blocks, cables, and valves, shall be in compliance with SAES-A-202.

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8.3 The direction of flow shall be marked on the skid piping in a highly visible and
permanent manner.
9 Inspection and Testing
9.1 General
9.1.1 A copy of the Manufacturer's test procedures shall be submitted to Saudi

Aramco HIPS Unit for approval.
9.1.2 The Manufacturer's test procedures shall clearly indicate:

a) The conditions under which the testing is to be carried out;
b) Any standards and/or specifications with which the Manufacturer's
test procedure complies.
9.2 Inspection
9.2.1 Instruments shall be tested, examined, and qualified to the established

manufacturer tests and applicable Industry Standard requirements.
9.2.2 Major components (HIPS valve, actuator, piping, and piping flanges) and
coatings shall be manufactured and are subject to the following
minimum Inspection Requirements of the associated specifications:
a) HIPS Valves 175-043600
b) HIPS Valve Actuators 175-341001
c) Spools API 6A PSL 3 and 175-026600
d) Process Root Valves 175-045600
e) Coatings of HIPS Valve and Actuator Assemblies, Pipe, and
Flanges 175-091900
f) Skid Structural Elements and Steel Coating 175-120100
9.2.3 The integrated skid manufactured to this Specification is subject to the

minimum Inspection Requirements as specified in Saudi Aramco
Inspection Requirements Form 175-344500.
9.2.4 “Set-out” inspection of component parts shall be done prior to assembly

and testing of the overall skid.
9.3 Testing
9.3.1 The assembled skid (valves and piping) shall pass a 30 minute shell
pressure test at 1.5 times the rated pressure. The water shall not exceed
Page 18 of 28
30 ppm by mass chlorides. The assembled skid shall be promptly

drained and dried to remove stagnant water following required hydrotest.
9.3.2 The completed skid shall undergo a Factory Acceptance Test (FAT) per
the manufacturer’s approved test procedure. Manufacturer shall submit
FAT procedure for Saudi Aramco approval. The FAT shall be witnessed
and accepted by a qualified Saudi Aramco Representative at the
Vendor’s facility.
9.3.3 The vendor shall provide all necessary personnel, tools, and test
equipment required for the FAT. Test equipment shall be calibrated with
valid certificates if applicable. Test equipment calibration frequency
shall not be more than one year.
9.3.4 Functional checks during the FAT shall include witness of Fail Safe
Operation, all trip and reset functions, Stroking Speed, full opening and
closing of valves and operation of all accessories under simulated
operating conditions.
9.3.5 The hydraulic system cleanliness shall be per 34-SAMSS-717.
9.3.6 The completed skid shall undergo a Site Acceptance Test (SAT) per the
manufacturer’s approved test procedure. Manufacturer shall submit SAT
procedure for Saudi Aramco approval. The SAT shall be witnessed and
accepted by a qualified Saudi Aramco Representative at the site after
installation.
10 Packing and Shipping
10.1 Before packing, all foreign bodies and traces shall be removed from the skid.
Skid shall be packed and protected against mechanical and corrosive damage.
A non-toxic vapor phase corrosion inhibitor shall be applied to the internal
surfaces of the assembled HIPS equipment. Following application of the
inhibitor, equipment openings shall be sealed vapor tight. The faces of open,
flanged connections shall be coated with a temporary protective coating
(MIL C16173, Grade IV, or equivalent), each connection shall be fitted with a
neoprene gasket, and vapor tight steel cover held in place by a minimum of four
equally spaced bolts.
10.2 Valves must be shipped in the closed position, labelled, and supplied complete
with all required accessories.
10.3 Open tubing fittings and ports shall be capped and / or plugged with metal and /
or plastic caps / plugs.

Page 19 of 28
10.4 All equipment and materials shall be supplied suitably protected from corrosion
during transit, storage, after installation.
10.5 The supplier shall advise any requirements for preservation of equipment and
materials should they require long term (greater than 6 months) storage after
delivery. The supplier shall provide all materials required for preservation and
protection during shipment and storage on site prior to installation.
10.6 All bolts and nuts shall be coated with a temporary protective coating
(MIL C16173, Grade IV, or equivalent).
11 Documentation
All documentation shall be in English and be in compliance with SAES-A-202.

As a minimum the following documents shall be submitted in electronic structured
formats which are word searchable and legible:
11.1 Valve Data
11.1.1 Full Description
11.1.2 Brochures and Technical Information
11.1.3 Data Sheet
11.1.4 Cross Sectional Drawing with Bill of Materials and As Built Drawing
11.1.5 Spare Parts List
11.1.6 API 6A Monogram Certificate
11.1.7 API 6A PR2 Appendix F Certificate
11.1.8 Reproduction of Marking, i.e., Nameplate, NACE, and API 6A monogram
11.1.9 Valve Pressure Test, Functional Test and Calibration Procedures and
Record Sheets
11.2 Hydraulic Schematic of HIPS valve actuation system assembly
11.3 Skid General Assembly Drawing with Bill of Materials and overall weight
11.4 List of recommended spare parts.
11.5 Inspection and Testing Procedures
11.6 List of approved deviations from this engineering specification.

Page 20 of 28
11.7 Installation, Operation, and Maintenance Manuals
11.8 Inspection and Testing Reports including Hydraulic Oil Cleanliness Report
11.9 Wiring Diagrams (if limit switches are provided)
11.10 SIL Certificates of Components issued by an internationally recognized

independent third party (if available)
11.11 Catalog Cut Sheets of Components
11.12 Lifting Procedure and Drawing with certified lifting points and Center of Gravity
11.13 Failure Modes Effect Criticality Analysis (FMECA) Report or a Failure Modes
Effects and Diagnostic Analysis (FMEDA) for the HIPS (HIPS Valves, Actuators,
Hydraulic Controls, and Pilots)
11.14 Material Safety Data Sheet (MSDS) for the Hydraulic Oil
11.15 Certified SIL Verification Report including Reliability Block Diagram or Fault
Tree Analysis
11.16 Packing and Shipping Procedures
11.17 Documentation in accordance with the Nonmaterial Requirements per Form

NMR-7930 attached to the purchase order.
12 Notes to Purchaser
12.1 The following information and documents must be completed and provided to
the supplier:
12.1.1 Tag Numbers for the system per SAEP-375 and instrument components
12.1.2 Composition of produced fluids and chemical injection
12.1.3 HIPS Bare-stem Valve Data Sheet on SA-6233-1
12.1.4 HIPS Valve Actuator Data Sheet on SA-8020-717
12.1.5 HIPS Pilot Data Sheet on SA-8020-213
12.1.6 HIPS Pressure Gauge Data Sheets on SA-8020-212
12.1.7 Nonmaterial Requirements per Form NMR-7930

Page 21 of 28
12.2 In production service with carbon steel piping systems, provisions shall be made
in the piping system to prevent galvanic corrosion due to the cladding of the
HIPS valves and piping.
Revision Summary
10 August 2015 Major revision based on Value Engineering. In addition, prescriptive requirements for
cladding of pipe and valves were included to ensure compatibility of wetted surfaces with
process requirements.
1 January 2018 Editorial revision to delete “(approved by CSD/Material Engineering & Corrosion Control
Division and the original equipment manufacturer of the valves)” from paragraph 10.1.

Page 22 of 28
Appendix
Attached data sheets provide minimum requirements. Buyer shall complete with project
specific requirements. Data sheets are based on 4-1/16” valve size as an example.
a) HIPS Bare-stem Valve Data Sheet on SA-6233-1-ENG
b) HIPS Valve Actuator Data Sheet on SA-8020-717-ENG
c) HIPS Pilot Data Sheet on SA-8020-213-ENG
d) HIPS Pressure Gauge Data Sheets on SA-8020-212-ENG
e) Process Root Valve Data Sheet on SA-6233-1-ENG

Page 23 of 28
a) HIPS Bare-stem Valve Data Sheet on SA-6233-1-ENG

Page 24 of 28
b) HIPS Valve Actuator Data Sheet on SA-8020-717-ENG

Page 25 of 28
c) HIPS Pilot Data Sheet on SA-8020-213-ENG

Page 26 of 28
d) HIPS Pressure Gauge Data Sheets on SA-8020-212-ENG

Page 27 of 28
e) Process Root Valve Data Sheet on SA-6233-1-ENG

Page 28 of 28

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Materials System Specification

34-SAMSS-628 1 January 2018

Previous Issue: 10 August 2015 Next Planned Update: 10 August 2018

©Saudi Aramco 2018. All rights reserved.

2 Conflicts and Deviations

2.4 The designation “Commentary” is used to label a sub-paragraph that contains

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering

Saudi Aramco Engineering Standards

Saudi Aramco Materials System Specifications

Saudi Aramco Inspection Requirements

175-120100 Steel Structures (Excludes Offshore Structures and

Saudi Aramco Forms and Data Sheets

Saudi Aramco Non-material Requirements

3.2 Industry Codes and Standards

American Institute of Steel Construction

American National Standards Institute

American Petroleum Institute (API)

American Welding Society

American Society for Testing and Materials

Saudi Aramco: Company General Use

International Electrotechnical Committee

International Organization for Standardization

National Association of Corrosion Engineers/International Standardization

National Electrical Manufacturers Association

Hot-dip Galvanized: Meets the requirements of ASTM A123/A123M.

Saudi Aramco: Company General Use

Modular: A self-contained unit intended to perform a certain function that is

Nearshore Environment: Defined as any outdoor, onshore location within one

Saudi Aramco: Company General Use

The instrument manufacturer shall ensure that all equipment is designed to

5.2.1 Dust Concentration

Usual airborne dust concentration is 1 mg/m³. During sandstorms, dust

Elements present in dust include compounds of calcium, silicon,

Equipment which is not enclosed or hermetically sealed, but is situated offshore

Outdoor design basis shall be between 5% to 95% relative humidity (non-

6.1 All dimensions and measurements shall be in the “International System of

Saudi Aramco: Company General Use

6.5 Saudi Aramco Mechanical, 1oo2, Fail-Safe Wellhead HIPS Design

Figure 1 - 1oo2 HIPS Schematic

6.5.2 1oo2 redundant pressure pilots shall be able to sense/trip on high

6.5.3 If required in the material requisition, an additional set of 1oo2

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

7.1 Skid Structural Elements

Refer to Saudi Aramco Materials System Specification 12-SAMSS-007.

7.1.2 Welding shall be in accordance with AWS D1.1 “Structural Welding

7.1.5 The HIPS Skid structural elements shall be hot-dip galvanized in

7.2 HIPS Valves and Actuators

Refer to Saudi Aramco Materials System Specification 04-SAMSS-035 and

Saudi Aramco: Company General Use

For actuators refer to either Saudi Aramco Materials System Specification

7.2.2 Actuator sizing and requirements shall be per 34-SAMSS-717.

7.2.6 Valves shall be stored in accordance with the manufacturer’s

7.2.7 The hydraulic oil shall be per 26-SAMSS-051.

7.3 HIPS Skid Controls