26 Nov 2012 - Using a car seal to lock a ball valve Here's some useful tips on using cable locks and car seals to lock a valve. Using a cable lock, chain or car seal to lock a valve lever can be difficult. The problems are as follows: 1. If the chain or cable is too near the end of the lever it can be slid off, thereby overriding the valve locking function. 2. If the chain or cable is too near the valve stem, it may be possible to turn the lever regardless of the cable or chain seal device. (The chain or cable could stretch or snap while doing this). If preventing valve operation is absolutely critical, and overriding could lead to a serious, hazardous situation, you should consider using a mechanical valve interlock. If however, it's just to prevent accidental operation, the car seal cable or chain device should be adequate and there are a few steps you can take to prevent overriding.
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26 Nov 2012 - Using a car seal to lock a ball valveHere's some useful tips on using cable locks and car seals to lock a valve.
Using a cable lock, chain or car seal to lock a valve lever can be difficult. The problems are as follows:
1. If the chain or cable is too near the end of the lever it can be slid off, thereby overriding the valve locking
function.
2. If the chain or cable is too near the valve stem, it may be possible to turn the lever regardless of the cable
or chain seal device. (The chain or cable could stretch or snap while doing this).
If preventing valve operation is absolutely critical, and overriding could lead to a serious, hazardous
situation, you should consider using a mechanical valve interlock. If however, it's just to prevent accidental
operation, the car seal cable or chain device should be adequate and there are a few steps you can take to
prevent overriding.
Firstly, double wind the car seal or chain device around the lever, midway along it's length.
You could drill a hole in the valve lever to pass the cable through. To this this, you might need a hot work
permit. Be sure to clear up an swarf afterwards and deburr the hole.
If you are locking the valve in the open position, it's a good idea for the cable or chain to pass around the
valve body/pipeline. In this way it's virtually impossible to turn the valve lever.
If the valve is being locked closed, pass the cable or chain around some nearby pipe or steel work as an
anchor point. But be sure that the cable doesn't then become a trip hazards
Mechanical Valve Interlocks Guarantee Safety in Locking Out Critical Valves
June 2011
Customized systems available for all type of valves
Houston, Texas (June 7, 2011) – Many industrial processes require valves to be secured in a locked-open or locked-
closed position. Netherlocks’ mechanical valve interlocks eliminate human error to ensure that critical valves are
locked in the proper position.
Standard interlocking products use a padlock and key, and provide no information about the current position of the
valve. Netherlocks’ mechanical valve interlocks are operated with two color-coded keys, which through a trapped
key mechanism, control the open and closed position of a valve and communicate its current state. When the
green key is released, the valve is locked in the “locked-open” position. For the red key to be released, the valve
must be locked in the “locked-closed” position. If a valve is left in a midway position between open and closed,
both keys are trapped in the device. Through this system, the current position of the valve is guaranteed.
Netherlocks’ valve interlocks are fully mechanical with no need for electronic wiring. They are easily incorporated
into new construction and are ideal for retrofitting older installations to mitigate potential safety issues.
Netherlocks manufactures a wide range of interlocking devices to fit all types and sizes of valves. All interlocks
feature a simple and robust design. For dependable longtime operation all valve interlock components are made
from corrosion resistant 316 Stainless Steel.
Netherlocks NL-H Universal Locking Device for Handwheel and Lever Operated ValvesMarch 2011
Corrosion-resistant lock ideal for work in corrosive environments
Houston, Texas (March 18, 2011) – Providing secure lockout for all types and sizes of manual valves, Netherlocks
offers the NL-H Hybrid Lock. The NL-H can secure valves in every position, and its universal compatibility
eliminates the need for maintaining an inventory of assorted lockout products for each type of valve on-site.
The universal NL-H uses a flexible steel cable to immobilize a valve’s handwheel or lever. The unit secures to the
valve with a padlock, to ensure the valve cannot be operated. The NL-H is made entirely from corrosion-resistant
316 stainless steel for reliable operation in harsh environments such as in offshore or chemical applications.
Netherlocks’ NL-H saves maintenance personnel’s time, by eliminating the need for scouting trips into the field to
determine the correct lockout product for a valve. By bringing an NL-H to the job site, workers can be assured any
valve will be safely locked out so that work can be completed.
Netherlocks TVL Protects Control Valves’ Calibrated PositionSeptember 2011
Houston, Texas (September 23, 2011) – Netherlocks’ TVL (Throttle Valve Lock) allows users to secure a throttle,
choke or control valve in any position. The TVL is an ideal process control tool for ensuring that specific calibration
settings are not changed without the proper clearance.
The TVL is integrated onto the valve and controlled by a single key which, when removed from the lockbox,
renders the valve inoperable. Products like wires and chains to secure a valve allow small movements even while
the lock is applied. When the TVL is used, it leaves no room for “play” and protects the valve’s calibrated position.
The TVL is constructed from corrosion resistant 316 stainless steel and designed to withstand extreme operating
environments. It features maintenance-free operation and an integrated safety system to prevent unlocking
without the designated key.
Netherlocks Safety Systems B.V. News - www.netherlocks.com
Compliance with New BSEE Regulations for Offshore Drilling from NetherlocksFebruary 2013
ISI Touch Screen displays required safety and environmental information
Houston, Texas (February 13, 2013) –The Interlock System Information (ISI) Touch Screen from Netherlocks
enables offshore oil and gas facilities to comply with new mandatory guidelines from the American Bureau of
Safety and Environmental Enforcement (BSEE).
The ISI Touch Screen stores all relevant information about interlocks, flow charts, instrument diagrams and other
plant specific information in a central place, as required by the mandatory BSEE regulations. It is used in
conjunction with Netherlocks key interlocking systems, integrating into the key cabinet or mounting separately.
Combined with the Netherlocks key interlocking system, ISI eliminates human error and clearly displays
information about each specific key and its corresponding interlock. Information is easily accessible to every
operator in every location.
The regulations are part of the Workplace Safety Rule on Safety and Environmental Management Systems (SEMS),
which covers all offshore oil and gas operations in federal waters. SEMS also mandates the previously voluntary
requirement that facilities develop and maintain a Safety and Environmental Management System as outlined in
the American Petroleum Institute Recommended Practice 75 (RP 75). This includes making safety and
operation on hydraulic manifolds conforms to process protocol. The interlocks are ideal for use on manifolds with
1oo2 (1-out-of-2), 2oo3 and 3oo4 configurations.
Netherlocks’ manifold interlocks are constructed from corrosion resistant 316 stainless steel. They use small
operating keys to control the locked open (LO) and locked closed (LC) positions of the instrumentation valve. When
installed, an operator can no longer deviate from the process procedure. Netherlocks’ manifold interlocks can be
customized to fit any type of manifold manufacturer, including Parker, Swagelok and Aptek.
PSV safety relief systems
Danger
Both onshore and offshore process installations are often provided with pressure relief systems.Having a spare relief capacity enables continuous production while conducting maintenance on your system on a live plant without a shut down of the process.These twin or multiple pressure relief systems are often fitted with isolation block valves upstream and downstream of each safety relief valve.At all times it should be prevented that all relief valves are blocked at the same time.Always open one of the spare lines first before isolating the operational relief valve to avoid overpressure explosions of the pressure vessels.
Solution
To ensure that at least one relief valve will be open at all times a valve interlock can be installed on each upstream and downstream block valve. Taking the start key from the control room commences the change over of the PSV system following the sequence step by step. The system also ensures that the higher pressure rated upstream block valves are closed prior to the lower pressure rated downstream block valves.The quantity of the (safety relief) valves may vary and is always depending on the client requirements.
The upstream and downstream block valves of PSV A and the downstream block valve of PSV B are locked open. (V1, V2 andV4)The upstream block valve of PSV B is locked closed. (V3)Note: The downstream block valve of PSV B is normally kept open because of the higher pressure rating of the upstream block valve of PSV B.
Taking the start key B from the control room commences the change over of the PSV. Insert key B in valve V3 to unlock the closed position of the valve. Open valve V3 and take out key C. Valve V3 is now locked open.All four block valves are locked open consequently both PSV A and B are open.To isolate PSV A unlock the open position of valve V2 by inserting key C. Close valve V2 and take out key D. Valve V2 is now locked closed. Insert key D in valve V1 to unlock the open position of the valve. Close valve V1 and take out key E. Valve V1 is now locked closed. PSV A is now isolated. With key E back in the control room a work permit can be obtained to service PSV A for testing or maintenance.To go back to the original position of the valves the same sequence has to be mirrored. Depending on which key is stored in the key cabinet you have an overview of each status of the valves.
PIG traps
Danger
Pigging systems are often found in the oil and gas industry. They are designed so that the pig is loaded into the launcher, which is pressurized up to launch the pig into the pipeline through a kicker line. The pig is removed from the pipeline via the receiver at the end of each run.If not operated correctly following a predetermined sequence, opening the vessel to the atmosphere can be very dangerous and care must be taken to ensure that the vessel is depressurized prior to opening. If the vessel is not completely depressurized, the pig can be ejected from the vessel and operators have been severely injured when standing in front of an open pig door.
Solution
To ensure that a predetermined sequence is followed while loading and unloading pig traps a mechanical key interlocking system is crucial.Interlocks can be installed on the Closure doors, Main valves (either MOV or manual), Vent valves, Drain valves, Pressure valves and Kicker valves.The system also ensures that the outlet valves are fully open when a pig passes through.Taking the start key from the control room commences the procedure to launch the pig following the sequence step by step. The design can either be a linear concept or as described in this example a nonlinear sequence through a sequence control box (SCB). The predetermined sequence may vary and is always depending on the client requirements.
Products
Lever of handwheel valves:
Closure door lock (SDL CD)MOV lockSequence control box(SCB)Key cabinet
- option 1 integral lock- option 2 bolt lock
Operation
In this example we will follow all required steps to launch a pig safely. Every step in the sequence is predetermined in the sequence control box following the required procedure step by step. To begin ensure that all valves are locked closed.
Depressurize procedure:
1 Open and close the vent valve. Take key A from the sequence control box (SCB). Insert key A in valve V1 (vent) to unlock the closed position of the valve. Open valve V1 and take out key B. Valve V1 is now locked open with key A trapped. Key B travels back to the SCB. Turn the knob of the SCB one step further. Now take key B again from the SCB and follow the mirrored sequence to close the vent valve again. After completion turn the knob of the SCB one step further.
2 Open and close the drain valve. Take key C from the sequence control box (SCB). Insert key C in valve D1 (drain) to unlock the closed position of the
valve. Open valve D1 and take out key D. Valve D1 is now locked open with key C trapped. Key D travels back to the SCB. Turn the knob of the SCB one step further. Now take key D again from the SCB and follow the mirrored sequence to close the drain valve again. After completion turn the knob of the SCB one step further.
Ensure zero pressure of the vessel or else repeat steps 1 and 2 using the return button on the SCB (Optional).
Line up procedure:
3 Open and close the closure door. Take key E from the sequence control box (SCB). Insert key E in the closure door to unlock the closed position. Open the door and insert the pig. Key E is trapped as long as the door is open. Close the door and lock the door by taking out key E. Key E travels back to the SCB. Turn the knob of the SCB one step further.
4 Open and close the vent valve to release any entrapped air. For procedure see step 1.
5 Open and close the pressure valve. Take key F from the sequence control box (SCB). Insert key F in valve P1 (pressure) to unlock the closed position of the valve. Open valve P1 and take out key G. Valve P1 is now locked open with key F trapped. Key G travels back to the SCB. Turn the knob of the SCB one step further. Now take key G again from the SCB and follow the mirrored sequence to close the pressure valve again. After completion turn the knob of the SCB one step further.
6 Open the kicker valve. Take key H from the sequence control box (SCB). Insert key H in valve K1 (kicker) to unlock the closed position of the valve. Open valve K1 and take out key I. Valve K1 is now locked open with key H trapped. Key I travels back to the SCB. Turn the knob of the SCB one step further.
7 Open the main valve. Take key J from the sequence control box (SCB). Insert key J in valve M1 (main) to unlock the closed position of the valve. Open valve M1 and take out key K. Valve M1 is now locked open with key J trapped. Key K travels back to the SCB. Turn the knob of the SCB one step further.
Pig launching:
Slowly close the bypass valve to move the pig until after the barred tee at the downstream than fully open the bypass again. (Normally this is not part of the interlocking sequence)
8 Close the main valve. Take key K again from the SCB and follow the mirrored sequence of step 7 to close the main valve again. After completion turn the knob of the SCB one step further.
9 Close the kicker valve. Take key I again from the SCB and follow the mirrored sequence of step 6 to close the kicker valve again. After completion turn the knob of the SCB one step further.
10 Depressurize the pig trap again by repeating step 1 and step 2.
Storage tanks
Danger
When discharging storage tanks on (petro-) chemical plants there is often a hazard of mixing two or more chemicals by forgetting to close a discharge valve before opening another. This can lead to product degradation or more serious, this can lead to dangerous chemical reactions.During normal operation only one tank should be opened at the same time.
Solution
To prevent opening more than one valve at the same time a valve interlock can be installed on each individual valve leaving them all locked closed to be operated with the same key. This key can be stored in a key cabinet in the control room.
All 3 valves V1, V2 and V3 are locked closed with key A in the control room.Take key A from the control room and select one of the tanks to be opened.If selected for example tank 2, insert key A in the valve V2. Unlock the closed position of the valve and open the valve. Take out key C and return to the key cabinet with this key. Valve V2 is now locked open and valve V1 and V3 remain locked closed. Once the valve V2 is open the key A will be trapped consequently key A cannot be used to open tank 1 or 3. To select another tank take key C from the key cabinet unlock and close valve V2.Take out key A from valve V2. Now all valve locks are locked closed again and you can make a new selection.Depending on which key is stored in the key cabinet you have an overview of each status of the valves. For example if key C is in the key cabinet valve V2 is locked open and all other valves are locked closed.
Lever Valve / Option 2: Bolt Lock
Dimensions
Depending on valve size.
Description
As an alternative for integral valve locks it is also very well possible to use bolt locks for valve interlocking. A mounting system is designed for each valve depending on the type and size of the valve. Besides the economical benefits and the fact that the original lever of the valve is maintained, it has another great advantage. You can install all brackets on the valves before plant start up and you are still able to freely operate any valve as you like. For example closing all valves at the same time for testing of the plant. After you have set up your final valve positions simply mount the bolt locks on each applicable position using a special tool and two M8x30 coded bolts.Alcatraz bolt locks fits on all type of handwheel and lever operated valves such as gate valves, globe valves, ball valves plug valves, butterfly valves and all gear operated valves. A bolt lock is mounted on the mounting system for each locked open and/or locked closed position of the valve. Their applications includes changeover of pressure relief valves, loading and unloading of pig traps, sampling devices etc.
Types of Mounting System Available for Valve Interlocks Using Bolt Locks for Lever Operated Valves
M03/BLOLC
M03/BLO
M03/BLC
Alcatraz mounting system for any lever operated valve, locked open and closed.Alcatraz mounting system for any lever operated valve, locked open.Alcatraz mounting system for any lever operated valve, locked closed.
Features
No black box: the operator can constantly see what he is doing.
Solid and compact construction with a minimum of moving parts.
Material: Stainless steel 316, electro polished.
The key will survive a drop of more than 25 meters.
Very easy and smooth operation, also with gloves.
Exchangeable lock portions and locks.
Resistant against fire and low temperatures.
Resistant against sand, dirt, and moisture.
Very easy to install even when the valve is in operation.
As an alternative for integral valve locks it is also very well possible to use bolt locks for valve interlocking. A mounting system is designed for each valve depending on the type and size of the valve. Besides the economical benefits and the fact that the original handwheel is maintained, it has another great advantage. You can install all brackets on the valves before plant start up and you are still able to freely operate any valve as you like. For example closing all valves at the same time for testing of the plant. After you have set up your final valve positions simply mount the bolt locks on each applicable position using a special tool and two M8x30 coded bolts.Alcatraz bolt locks fits on all type of handwheel and lever operated valves such as gate valves, globe valves, ball valves plug valves, butterfly valves and all gear operated valves. A bolt lock is mounted on the mounting system for each locked open and/or locked closed position of the valve. Their applications includes changeover of pressure relief valves, loading and unloading of pig traps, sampling devices etc.
Types of Mounting System Available for Valve Interlocks Using Bolt Locks
M01/G50
M01/G60
M01/G80
M02/GE
M04/GB
Alcatraz mounting system for gate valve size 1”- 3”.Alcatraz mounting system for gate valve size 4”- 6”.Alcatraz mounting system for gate valve size 8”- and up.Alcatraz mounting system for any gear operated valve. Alcatraz mounting system for any globe valve.
Features
No black box: the operator can constantly see what he is doing.