SFC Key Interlocks & Process

Management Systems

Mechanical Control Systems

for Process, Pipeline & Plant
Maintenance Operations
 Smith Flow Control Ltd
6 Waterside Business Park
Eastways Industrial Estate
Witham Essex CM8 3YQ
United Kingdom

Tel: +44 (0)1376 517901

Fax: +44 (0)1376 518720

[email protected]
www.smithflowcontrol.com

03 Intro
06 QL Valve Interlock
08 GL Valve Interlock
10 Closures
12 Actuated Valves
14 Key Management Systems
16 ATL (Anti Tamper Lock)
18 Specials
22 Flexi-Drive
24 Easi-Drive
26 Pressure Protection
28 Pig Traps
30 Fire Deluge Systems
32 Fill In Sheets

2
‘...for over 20 years SFC have never failed to
provide a viable technical solution to a client’s
safety operating problem..’
Mike Smith - Founder & Vice-Chairman

Key Interlock Systems

Smith Flow Control (SFC) was established in 1985 to provide engineered safety solutions for
hazardous operations in the oil & gas and chemical processing industries.
SFC introduced the coded-card linear-key concept in a range of In 1990 SFC became part of Halma plc (quoted on the London
modular key-operated interlocks to regulate operator execution Stock Exchange) and in 1993 acquired ISO 9001 accreditation
of work procedures on any form of host process equipment. certified by Lloyds Register.
Typical applications include every form of valve (including
motorised and instrument valves), switches, vessel closures, Today SFC continues to be managed by its founders who remain
access guards, pressure and temperature sensing systems and committed to providing quality assured products delivered on
rail/road/sea tanker loading systems. time at a competitive price. SFC employs 50 people including 3
SFC's solutions in hazardous processes reduce the scope for Design Engineers dedicated full time to product development
operator error and ensure safe continuous plant operation. using 3D modelling, a full-time Quality Manager and 2 full-time
Works Quality Inspectors. Our manufacturing design office is
Most offshore installations in the North Sea have been staffed by 8 Design Engineers who are all highly trained in the
equipped with SFC systems as well as the majority of related capabilities of AutoCAD which is our chosen state-of-the-art
onshore processing facilities throughout Europe. By 1990 SFC manufacturing design tool. SFC maintains a crew of 4 full time
became the generic term for key interlock safety systems in the fully certified Site Technicians which enable us to offer total
international oil & gas industry and our client base now includes turn-key services to our clients.
most of the major operating companies in all five continents.

OUR COMMITMENT

Smith Flow Control remain committed to providing quality assured products delivered on time at competitive prices.
This maxim was first stated when we formed our company in 1985 and remains the guiding principle for how we
conduct our business today.

We achieve these goals by relying on three core strands in our business culture - Innovation, Realisation and Dedication.

The SFC product range of valve interlocks have evolved over 20 years to provide highly reliable engineered process management
solutions to our clients. We achieve this by harnessing established mechanical principles applied to innovative design concepts
which are brought to realization using advanced CAD systems and exhaustive testing of pre-production prototypes.

The continuous quest for new product development and ongoing product improvement requires a level of energy and
commitment that can come only from a group marked by a collective dedication to being best in the industry.

We remain committed to retaining the confidence of our clients by staying true to the ideals that have gained us the reputation
we enjoy today.

3
 ....."it would be difficult to name a
particular industry that would not
benefit from an SFC coded-card key
interlock system"

As a general principle it may be said that operations which are safe

when performed correctly can have catastrophic consequences when
performed incorrectly. The Oil & Gas and Chemical processing
industries generally have a disciplined approach to design and
operating practice - usually governed by well recognised international
standards and enforced by regulatory authorities and certification
bodies. While good practice begins with good design - both are
ultimately hostage to the ‘Human Factor ’.

Modern process plants are highly automated and regulated by distributed

software management systems which are simply monitored by 'Production'
personnel - often remote from the physical location of the plant itself.

Indeed, some operations such as pig launching or receiving procedures can

be effected in semi-automatic mode using push button controls (again often
from a remote station).

Maintenance procedures however invariably involve human intervention and

interrupt automated processes creating 'abnormal' conditions for the duration
of the work. Loading or unloading of pig traps, changeover of pressure relief
valves, turbine servicing (requiring suspension of CO2 Fire Deluge), coupling or
‘The obligation to adopt best
uncoupling of hoses for loading or discharge of tanker cargoes all involve
practice is a fundamental of safety
management - mechanical key human intervention and are hostage to the possibility of operator error.
safety interlocking is a technology
that has evolved to offer Distributed control systems (DCS) cannot effectively regulate such
sophisticated technical solutions (maintenance) procedures - the SFC ‘Coded Card Key Interlock System’ can!
to complex and hazardous process
applications and which
increasingly is being adopted by
major OpCo's worldwide for
protection of their people, their SFC 'Visual Alert' Key Cabinets
assets and their surrounding provide an effective and
environment' infallible management control
system against unauthorised
or inadvertent operation of
interlocked valves or
associated process
equipment by keeping the
coded keys which initiate the
operation of critical valves
under secure supervisory
control.

4
BE SURE - BE SAFE - CHOOSE SFC - YOUR PARTNER FOR TOTAL PLANT SAFETY & SECURITY.
Controlling the sequence of events in which process vented BEFORE opening of the closure for loading or unloading
activities are conducted has been achieved historically of pigs, or, how the spare pressure safety relief valve is on
using Permit to Work (PtW) systems accompanied by stream BEFORE an in-service relief valve can be isolated and
documented instructions. removed, or, how we prevent a tanker from
departing a loading/discharge station
However, this system is hostage to 'human BEFORE the cargo hoses are
factors' Distractions, failure to interpret disconnected.
correctly, ignorance of the system - all can
lead the operator to make errors which These and any other work tasks
can manifest themselves in executed by human intervention
industrial accidents of varying can be completely regulated by
magnitudes. SFC's coded-card key interlocks
- simple and total mechanical
Trapped Key Interlocks are reliability to prevent operator
simple mechanical devices error or violation to protect your
which can be customised to plant, the surrounding community and
implement a safe sequence of the environment.
operation in any process activity.
In addition to our range of high-integrity coded-
In the following pages we show how our card key interlock safety products, SFC also offer
mechanical key interlock system ensures that pig trap valves are a comprehensive range of valve and process equipment security
disabled and proven shut and the vessel is isolated, drained and products for high and low-criticality applications.
5
 QL Valve Interlocks - For lever-operated valves

QLT

QLR

QL Valve Interlock (QLT & QLR)

QL valve (inter)locks suit all types of lever-o
operated quarter-tturn valves - including ball, butterfly, and plug valves.

Installing the (inter)lock on the host valve is a simple procedure as described below and requires no modification or hot-work to the
host equipment as the anchor and adaptors are custom-machined to suit the valve.

After removing the existing lever

the QL is assembled as follows:
Adaptor Anchor
1. Install lock adaptor

2. Install anchor.

3. Fit SFC nut.

4. Assemble QL lock, secure

lever and tighten bolt.

Bolt

Lock
Body
SFC Nut

Lever

6
 Internal Mechanical Construction

Most offshore installations in the North Sea have been

equipped with SFC systems as well as the majority of
related onshore processing facilities throughout Europe.
QL Valve Interlock

Closed Key Anti-Overide Mechanism

Product Features

Closed Section
316 Stainless steel construction

Linear ‘coded-ccard’ key design

Robust construction

Proven reliability in all climates

Locking Gear Cam
Single or double key versions

Open Key

Open Section

Anti-Tamper
Screw

Lock Body

SFC Nut

SFC Lever

Anchor

Lock Adaptor

For over 20 years SFC have never failed to provide a viable

technical solution to a client’s safety operating problem.

7
 GL Valve Interlocks - For handwheel-operated valves

GLS
GLM

GLM & GLS Valve Interlocks

GL valve (inter)locks suit all types of handwheel operated valves - including gate, globe, and
g e a r -o
operated valves.

Installing the (inter)lock on the host valve is a simple procedure as described below and requires no modification or hot-work to the
host equipment as the anchor and adaptors are custom machined items (Universal adaptors (UAS) may be supplied when precise
valve topworks data is not available).

After removing the existing

handwheel the GL is assembled
as follows:
SFC Nut
Lock 1. Mount lock adaptor and fix
Body SFC nut.
Lock Anchor
Adaptor 2. Locate body to adaptor.

3. Tighten fixing screws (x3).

4. Tighten setting screws to set

“Open” and “Closed” key free
positions.

8
Internal Mechanical Construction

Mechanical Key Interlocks are robust maintenance-free

assemblies which provide reliable operational control of
safety-critical systems involving worker intervention. They
prevent accidents through operator error and greatly reduce
the scope for procedural violations and system abuse.
GL Valve Interlock

Locking Arm
Product Features

316 Stainless steel construction

Linear ‘coded-ccard’ key design

Counter Mechanism
Robust construction

Proven reliability in all climates

Single or double key versions

Key Release Arm Code Bars

Lock Body

Anchor

SFC Nut

Lock Adaptor
For over 20 years SFC have never failed to provide a viable
technical solution to a client’s safety operating problem.

9
 Vessel Closures
Ensure total isolation,
venting and draining
BEFORE opening vessel
closure.

Introduction
The SFC 'DL3' interlock is adaptable to all
Access into pressure vessels is a potentially hazardous types of vessel/access closures and is
exercise. Residual pressure, volumes of residual liquids or very simple to use in pig trap applications
gases all can be harmful - typical examples of these potential especially where the closure incorporates
a bleed device.
hazards include pig traps, slug catchers and filter housings.
The 'DL3' interlock will be designed to
Locking the vessel closure in the closed position ensures access into the interface with the bleed function to
vessel can be achieved only under controlled safe conditions. The operating ensure the bleed screw cannot be
key is held in a secure place - e.g. Control Room or Supervisor's office or is removed until the interlock permit key has
retained (trapped) in some other related interlocked item of equipment. been inserted to unlock the 'DL3'
assembly.
As a minimum, vessel closures are usually interlocked with vessel venting
and draining functions - the interlocking arrangement can be extended to When the 'DL3' is incorporated into vessel
incorporate all process items of equipment relating to the vessel's function. access safety procedures, total
equipment and personnel safety is
assured.

10
Prevent loss of containment of explosive or toxic product.

Any type of closure can

be fitted with the DL3
interlock, regardless of
their method of
operation. Design
details can be provided
on request.

11
 Actuated (Motorised) Valves

Actuated Valves
Interlock system design principles
The most common requirement for key interlocking of power-
Because actuators generate great torque
actuated valves occurs in Pig Launcher/Receiver systems, forces, (b)locking of such valves by
Scraper Traps and Sand Filter systems etc. where power- mechanical restraint is unacceptable -
actuated valves need to be interlocked with manually-o
operated such locking methods would likely induce
damage within the motor assembly.
valves and the vessel closure.
Nonetheless, a key interlock system must
Because of the ultra-critical nature of such valves, special considerations ensure the valve is de-e energised and
arise which the design of a key interlock system must address:- disabled (in both Remote and Local
modes) and that only the appropriate
Where such valves are part of an ESD system, the key interlock system must sequence key is released for continuation
not compromise the valve's fail-safe function. of the procedure dependent on the valve's
verified (Open or Closed) position.
Where pigging operations occur, the key interlock system must verify the
valve's absolute position (Open and/or Closed) independent of any on-b
board A typical operating sequence is given on
instrument indication. the page opposite where it may be
observed the interlock system functions
‘passively’ and relies on the as-built
On electrical actuators where the key interlock system de-energises the
actuator mechanisms to establish and
valve, any anti-condensation heating circuitry etc. must remain confirm the status of the equipment.
uninterrupted.
It may also be observed when such valves
Where actuators are equipped with a manual override facility, the key are in the ‘Open’ (‘Remote’ setting)
interlock system must permit operation of the valve in both modes (or in a position - the valve is free to operate to
combination of both modes - e.g. in the event of a power failure) while ‘Closed’ without hindrance or interruption
maintaining the integrity of the key sequence at all times. by the interlock system.

12
 Equipment Status:- Valve Open Equipment Status:- Valve Closed
'SLU' Switch Unit Locked in 'REMOTE'. 'SLU' Switch Unit Locked 'OFF'.
'HWL' Handwheel Drive Locked 'OFF'. 'HWL' Handwheel Drive Locked 'OFF'.
'A' Key in Control Room. 'D' Key in Control Room.

To Close Valve: To Open Valve:

1. 'A' Key into 'AKE' positional indicator unit. 1. 'D' Key into 'AKE' positional indicator unit.
'B' Key is removed from 'AKE' - 'A' Key trapped. 'C' Key is removed from 'AKE' - 'D' Key trapped.

2. 'B' Key into 'SLU' Switch Unit to unlock. 2. 'C' Key into 'SLU' Switch Unit to unlock.
'SLU' Unit switched to 'LOCAL' ('B' & 'C' Keys trapped). 'SLU' Unit switched to 'LOCAL'('B' & 'C' Keys trapped).
Operate button to close valve. Operate button to open valve.

3. 'SLU' Unit now switched to 'OFF' - 'C' Key is removed. 3. 'SLU' Unit now switched to 'REMOTE' - 'B' Key is removed.
'SLU' Unit locked in 'OFF' position trapping 'B' Key. 'SLU' Unit locked in 'REMOTE' position trapping 'C' Key.

4. 'C' Key into' AKE' Unit - remove 'D' Key trapping 'C' Key. 4. 'B' Key into 'AKE' Unit - remove 'A' Key trapping 'B' Key.
'D' Key is then directed towards continuation of the procedure. 'A' Key is then directed towards continuation of the procedure.

NB The 'D' Key will not release unless the valve has completed NB The 'A' Key will not release unless the valve has completed its
its full stroke to the CLOSED position. full stroke to the OPEN position.

HWL HWL

AKE Unit AKE Unit

SLU Unit SLU Unit

Hydraulic & Pneumatic Actuators Power Failure Mode

A range of comparable designs are also available for spring- In the event of a power failure at anytime during either of the
return and non-return hydraulic actuators and for spring-return above procedures, it is essential the integrity of the key
pneumatic actuators. sequence is maintained if the valve is operated manually.

SFC's range of special process products also includes needle This is achieved simply by locking the 'SLU' Unit in the 'OFF'
valve locks, temperature and pressure sensing locks and a position thereby releasing the 'C' Key. (Even if power is restored,
range of signalling options to meet most process operating with the 'C' Key free, the valve/actuator will remain disabled).
requirements.
The 'C' Key is inserted into the freewheeling 'HWL' handwheel
assembly - this lock functions on a 'declutching' principle. With
the 'C' Key trapped, the 'HWL' drive mechanism may be engaged
thereby enabling the valve to be operated.

While the 'C' Key can be removed from the 'HWL' assembly at any
time, it has to be exchanged through the 'AKE' unit to secure the
continuation key (i.e. the 'A' or 'D' Keys in the above examples)-
these keys will only release provided the valve has completed its
full stroke.
13
 Key Management Systems

SFC 'Visual Alert' and ‘Permit-tto-W

Work’ Key Management Systems
Design features and benefits
The SFC Key Interlock System has been developed through a
Carbon or stainless steel construction.
process of continuous design improvements acquired through
developing client safety management requirements over ‘Glazed’ door provides key status
twenty years. without the need to open.

General to the system is the necessity for an effective and Ingress protection from IP55 to IP66.
efficient key management system that will provide a Lockable doors.
continuous and reliable indication of the status of all
interlocked process systems. External wall mounting brackets.

SFC 'Visual Alert' Key Cabinets provide an effective and infallible Total integrity by using dedicated
management control system against unauthorised or inadvertent operation key locations.
of interlocked valves or associated process equipment by keeping the coded
keys which initiate the operation of critical valves under secure supervisory Complete key status awareness.
control.

The SFC 'Visual Alert' Key Management System dedicates and maintains the
operation of critical valve and process operations totally within the control of
the Designated Authority and the Performing Authority, enabling Permit to
Work (PtW) procedures to be carried out safely and efficiently. The system
concept is totally flexible and is designed in each case to integrate with each
client's operating system and working practices.

14
 Key Cabinets

SFC Process Management Systems provide effective

protection to clients’ investments in plant and equipment
as well as improving employee safety and reducing the
risk of damage to the environment.
SFC Permit to Work (PtW) Systems

Having adopted a good key interlock control system,

Each interlocked system has a dedicated engraved tag location
the next most important step is to apply a good key within the key cabinet. During periods of normal operations, all
management system. interlock system 'permit' (initiating) keys are visually displayed
within the cabinet in dedicated locations.
For storage, ease of access and issue, SFC key cabinets provide
all that is required. Each key cabinet tag is engraved with the relevant piping
package data - this same data is also replicated on each system
A key cabinet should be located in a secure place; typically a key.
Control Room whereby initiating keys are issued by the Shift
Supervisor, Offshore Installation Manager (OIM) or other person When the key is removed, a 'Visual Alert' tag is revealed
in authority. providing details of the key which has been issued, its
designated location, and the words 'WORK IN PROGRESS'.
Cabinets vary in size and can accommodate from 1 - 227 system
initiating (or spare) keys. Keys can be located via means of Control Room staff have clear and easy indication of work status
hooks or holsters (the holster locator provides increased at any time. Key cabinets can also accommodate mimic
capacity). diagrams. These are extracts of the P&ID diagram engraved onto
a Traffelite plaque and show clear details of all valves which are
interlocked.

Pin Coded System

SFC Key Cabinets can incorporate a Pin Code system which

prevents the replacing of a system key incorrectly.
15
 ATL (Anti-TTamper Lock)

Introduction
Many valves on site require a simple-to-use locking device to prevent
accidental or unauthorised operation.

Construction
ATL is available in two sizes covering all valve sizes and is available in 304
Stainless Steel. For remote unmonitored or higher security risk areas, a
carbon steel, case-hardened option is available, which will withstand the
toughest forms of vandalism.

Coding
The units can be uniquely coded or coded alike, dependant on operational
conditions/ requirements.

Operation
With the unit fitted to the valve, the standard SFC tamper-proof coded card
key can be inserted allowing valve operation.

Depending on operational requirements, the valve can be operated to any

position, once the key has been removed, the unit free wheels, preventing
valve operation. Many valves on site require a simple-tto-
use locking device to prevent accidental
or unauthorised operation.
Ordering
The units are available "off the shelf' allowing customers to undertake the The ATL has been developed to fit directly
simple machining operation for fitting, thus reducing order times and to valves in place of the normal
offering an instant security/safety solution. handwheel or operating lever, with little
machining which can easily be
undertaken by the customer.

16
Security Products

Where security lock-off devices are required to provide

mechanical locking of manual operators, SFC offer a full
complement of security and commissioning tools.
If sequential control is unnecessary but a secure lock is
required, the SFC range of security products can provide
the solution you need.
Chainlok

The Chainlok is a unique device which Flag style 'Colour Aware Key' enables
combines the best features of incorporation into interlock (key
padlocks and interlocks. exchange) systems.

A durable body and chain made from Flip caps prevent ingress of foreign
316 Stainless Steel makes it suitable matter when key is removed.
for use in the most hostile
environments. Chainlok comes with
O.5m chain as standard (longer
lengths available on request).

ISO-LLOK

A multi-clasp, when used in

conjunction with SFC padlocks enable
individual personnel to isolate
equipment while they carry out their
work, safe in the knowledge that the
equipment cannot be re-energised
until all padlocks have been removed
from the clasp.

Car Seal

For 'one-time-only' securing of manual Two body and cable sizes are available,
operators, including securing of along with varying lengths of cable.
manual valves, switches, enclosures. A Cable breaking strains are available to
simple 'break-away' screw secures the 1750kg.
seal in place. Removal can only be
achieved by cutting the seal cable. Re-usable car seals are also available.

Ideal for use in commissioning procedures

17
 Specials
Specials

The range of process applications to which

SFC interlocks can be applied is unlimited. As
clients begin to understand the immense
operational capabilities of SFC interlock
systems, they often request unique solutions
to specific problems.

In this section we present some examples of

'specials' we have developed to meet clients'
specific operating safety requirements.

SFC are always pleased to receive a

challenge to provide unique solutions to
clients' individual or special problems.

Pressure Protection - using 3-w

way changeover valves.

Customer Problem:
To remove dependence on chain-drive
mechanisms on mechanically-linked 3-
way changeover valves located upstream
and downstream of dual safety relief
valves.

The client's anxiety arose through concern

for the possible consequences of an
overpressure situation arising in the event
of a failure in the chain drive mechanism
during a relief valve changeover
procedure.

SFC Solution:
SFC's solution enabled removal of the
chain drive mechanism and relied on a
locking arrangement that first established
an intermediate (mid point) safe position
on the downstream 3-way valve assembly.
This permitted the release of a transfer
key that then enabled a full changeover
on the upstream 3-way valve assembly
before releasing a final key to complete
the downstream procedure.

18
3-W
Way Isolating Valve C/W Proximity Sensor

Customer Problem:
To interlock a single acting, pneumatic
actuator on a ball valve.

SFC Solution:
Where single-acting, spring-return
pneumatically actuated valves have to be
incorporated into an interlock sequence,
an interlocked 3-way isolating valve is a
simple and effective solution.

The isolating valve is located upstream of

the actuator control panel. When
operating the isolating valve, air pressure
to the actuator is vented to atmosphere,
thus completely disabling the valve which
will then operate automatically to it’s
designed fail-safe position.

Single or double key arrangements can be

used to isolate the valve in any position.

In the illustration the interlock

incorporates a chassis plate for local wall
mounting, and a proximity sensor for
status indication back to a control room.

This arrangement is a cost effective add-

on control feature to all types of
pneumatic, hydraulic or gas actuators.

Modular Double Block & Bleed Valve

Customer Problem:
Restrictions of space require that a
modular style double block and bleed
valve is used in place of a conventional 3
valve piped arrangement. It is required
that the modular valve is interlocked with
other valves in the system.

SFC Solution:
Modular valves of this type pose greater
problems for interlocking by virtue of their
size and space limitations. SFC designed
a bespoke cam type interlock especially
for this host valve.

19
 Specials

Needle Valve Locks

Customer Problem:
To ensure two ports on an instrument
manifold can never be simultaneously
opened.

SFC Solution:
Needle valves of all types can be fitted
with SFC interlocks. Regardless of body
design, number of operating handles or
method of operation, SFC can supply a
solution to your problem.

In this illustration a 4-port instrument

manifold is equipped with SFC's NVL
interlock. The locking device ensures that
pairs of operating handles can only be
operated one at a time.

Upon opening the first port, the key

becomes trapped. The second port
cannot be opened until such time that the
first port has been closed, thus releasing
the operating key.

The opposite pair of ports are controlled in

the same way with a differently coded key.

Explosion Proof Interlocked Switch

Customer Problem:
To mechanically interlock an electrically
operated device, within a hazardous
environment - ATEX certified.

SFC Solution:
Where mechanical (interlocked) control of
powered equipment is required in a
hazardous area, the SFC switch lock
provides the perfect solution.

In this illustration our 'QL' quarter turn

interlock is fitted to the switch mechanism
of an II 2 G D hazardous area control
switch.

A single or dual key configuration can be

supplied to lock in the 'ON', 'OFF' or both
positions.

Switches for hazardous zone protection

specifications can be provided including
solenoid controlled key release units.

20
Sequence Control Unit

Customer Problem:
To permit complex variations in operating
sequences on launcher/receiver systems.

SFC Solution:
The simplest interlock systems will
normally feature a 'linear sequence'. This
is where the outward 'journey' (operating
steps) are mirrored by the return journey.
However, from time to time non-linear
sequences are necessary. A typical
example of a non-linear sequence is a pig
receiving procedure where double block
and bleed valves control complex nitrogen
purging, pressure equalisation, venting
and draining.

The sequence control unit is a mechanical

key issuing/control device. It is normally
placed locally to the valve system. It
differs from a key exchange unit in that,
upon inserting a permit key, a selector
knob is rotated to a fixed position before
the next key is issued.

Pneumatic Control Valves

Customer Problem:
To interlock a double acting, pneumatic
actuator on a ball valve.

SFC Solution:
For this requirement SFC adapted their
QLA interlock to incorporate a sliding
control lever with forward and backwards
motion.

This linear motion interfaced with the

pneumatic valve operating lever to provide
double acting operation.

21
 Flexi-D
Drive

Flexi-D
Drive
What Industry?
Flexi-Drive is a very versatile product consisting of two stations, joined by a
unique patented linear drive cable. Practically any industry where valves are
used would benefit from the Flexi-Drive
This equipment enables valves and other wheel-operated devices in remote, System. SFC can design and install Flexi-
hard-to-reach or hazardous locations to be operated easily from a Drive to meet strict safety guidelines and
conveniently located and safe handwheel station. regulatory body requirements.
Developed originally for use by the US Navy to operate valves in inaccessible Additional details of all products
locations on board ships, Flexi-Drive can now be applied to any conventional illustrated are available on our web site at
wheel-operated valve/device, in oil, gas and chemical processing plants. It is www.smithflowcontrol.com
suitable for underwater applications and will function reliably in all climatic
conditions.

The cable system can transmit drive to a valve up to 60 metres from the
operator station. The flexible cable system facilitates up to 540° of bends in
the cable run.

22
 Remote Cable Drive Valve Operators

In a hazardous area, below water, in a confined

space, in a pit, where noxious fugitive emissions
prevail or where valves are just plain out of
reach, Flexi-Drive is the answer.
Operation

1 Operator Station Actuator

Input torque at the operator station turns a pinion
shaft that drives a cable gear. Operator stations
2 are available in a variety of gear ratios, providing
a wide range of torque capabilities. A helically
wound steel cable has a pitch the same as that of
the cable gear. This precision gear-cable interface
provides a positive force to the helix cable, which
travels through the flexible conduit to the valve
station actuator.

2 Valve Station Actuator

The valve station serves as the torque-producing
component located at the valve end of the
system. Linear motion of the steel helix cable is
1 converted back into a rotary motion at the valve
station for valve operation.

RVO Systems
The cable system can be passed around and through walls, bulkheads, floors
and any other obstacles to reach the valve.

SFC Flexi-Drive Remote Valve Operator (RVO)

systems comprise of four basic elements:

Operator Station Actuator

Helical Drive Cable

Valve Station Actuator

Valve Drive Coupling

(designed to suit the host equipment)

23
 Easi-D
Drive

Typical gear-
operated gate
valve,
pneumatically
Typical gear-operated ball
driven using a
valve, pneumatically driven
'universal', bolt-on
using a universal ‘bolt-on’
handwheel drive
handwheel drive plate and
plate and reaction
bespoke (custom made)
device.
reaction device.

Easi-D
Drive
Standard equipment and basic
Low cost alternative to permanent dedicated actuators. specifications:
No requirement for dedicated power supply.
Operates from adjacent plant air or single-phase electrical supply. Pneumatic, electric and hydraulic 'drive
Suitable for use in all Hazardous Areas. guns' available.
Ideal for minimum facilities installations.
Suitable for all climatic conditions. ‘Local’ pistol grip type tools available.
Wide band torque capability with variable torque adjustment as standard.
Ideal for moving tight or partially-seized valves. Barrel type tools.
Adaptable to any size/type of valve.
Eliminates operator fatigue and greatly reduces the risk of injury. Customised valve drive adaptors.
Reduces work crew tasks to one-man operation.
Fully portable - can manage banks of valves with a single drive tool. Standard hose length supplied: 3 meters.

Air supply recommendations: 840 I/m

Three simple steps to easi-d
drive (30cfm) @ 5.5 bar (80psi).
installation and use:
Guns available with a range of torque
1 Decide if you want to retain outputs: 100 Nm (74 Ibf ft) to 100,000
the option of manual valve Nm (73, 700 Ibf ft).
operation via the handwheel.
Torque safety cut out facility.
2 Install the relevant easi-drive
equipment. Continuous run and 'dead mans handle'
options.
3 Connect drive gun to power
supply (pneumatic, electric or Calibration certificates supplied.
hydraulic).

24
 Portable Valve Actuators

Pneumatic Tool
Easi-Drive is an efficient and cost-effective alternative to a
dedicated actuator. Wherever you have manually-operated
valves that have high operating torques, hundreds of handwheel
turns to open/close or are just difficult to operate then Easi-
Drive is your solution.

Product Features
Each drive tool has a unique serial number and is supplied with
it’s corresponding certificate of calibration.

The example provided shows the relationship between the input

air supply pressure, via the SFC air filter, regulator and lubro
(FRL) pack and the output torque that the drive tool can
produce.

By adjusting the air pressure you can easily restrict the torque
output of the drive tool for your precise requirements.

Certicate of Calibration

Options

Electrical

Battery
Operated
Hydraulic

Smith Flow Control can also supply an electrical

version of the Easi-D
Drive with features including:

Pistol grip.
Range of voltages. Also available is a range of hydraulic Easi-D
Drive
Customised valve drive adaptors operators, features include:
Switchable maximum torque level feature
LCD display indicates direction of drive and Powerful continuous rotation.
current maximum torque Air and electric powered hydraulic pumps available.
Output +1- feature buttons to adjust torque Can be used subsea via umbilicals and ROV's.
CE and EMC certified Customised valve drive adaptors.
Calibration certificate Calibration certificate.
25
 Pressure Protection

Pressure Protection

Whether onshore or offshore, maintenance procedures to Safety Relief

Systems on live plant cause concern in ensuring that an open path to relief
is maintained at all times during the work exercise.

Most modern piping arrangements include spare relief capacity enabling

continuous production while such maintenance procedures are conducted
on live plant eliminating the requirement to isolate and shut down the
process.

Twin or multiple safety relief valve systems are usually fitted with isolation
block valves upstream and downstream of each safety relief valve - it is
essential to ensure that the block valves isolating the spare relief valve are
opened BEFORE the block valves of the workpiece relief valve are closed.
This issue is a more acute problem if the respective relief valves and isolating
block valves are distant or out of sight of each other.

Various API and ASME codes recognise this hazard and recommend the use
of interlocks to eliminate this possibility. API RP 520 (Pressure Relieving
Systems for Refinery Services - Part II Section 4- Isolation Valve
Requirements) and API RP 14E (Design and Installation of Offshore
Production Platform Piping Systems - Para 5.8b [2] - Relief Device Piping)
specifically recommend interlocks in this situation to ensure that
(over)pressure protection of the vessel is not compromised. These
recommendations are also in accordance with the requirements of ASME -
Section VIII - Appendix M.

Fitting a valve interlock to the upstream and downstream isolating valves on

each safety relief valve (PSV) will ensure these recommendations are
implemented.

An initiating key, issued from a secure location (Control Room) commences

the PSV changeover. Follow the step-by-step procedures in the diagram.
26
 ....... 'apart from the possibility of death or injury to
personnel, or pollution of the locality, what other possible
impact could an over-pressure explosion or rupture of one
of your main process vessels have on your business' ?
Typical ‘4 Block Valve / 5 Key’ Interlock System

PSV 1 PSV 2
V1 - Keys A & B V4 - Keys E & D

V2 - Keys B & C V3 - Keys C & D

ILLUSTRATION STATUS: 2. Key 'D' unlocks and enables the opening of spare inlet block
PSV1 on line: PSV2 isolated valve V3
Block Valves V1, V2 & V4* are Locked Open (LO.)
Block Valve V3 is Locked Closed (LC) 3. V3 is operated to open and is LO by removing Key 'C' - PSV2 is
*Spare outlet (downstream) block valve normally LO especially if now on line.
lower pressure rated than corresponding inlet (upstream) block 4. Key 'C' is transferred to unlock and close inlet block valve V2
valve 5. V2 is LC by removing Key 'B'
6. Key 'B' is transferred to unlock and close outlet block valve V1
Requirement: 7. V1 is LC by removing Key 'A'
There is always an open path to relief. The return of Key 'A' to the Control Room closes-out the work
(Inlet block valves V2 & V3 must never be closed at the same permit and enables the issue of instructions for removal of PSV1
time) for testing and servicing.

Maintenance Task: Twin PSV Changeover Sequence

To commission PSV2 into service. It should be noted this interlock arrangement further ensures
To isolate and permit removal of PSV1 for testing/servicing. that the higher pressure rated inlet block valve V2 is closed
before its corresponding lower pressure rated outlet block valve
Work Sequence: (V1). Conversely, this key interlock arrangement would also
1. Key 'D' is issued from the Control Room to initiate the Permit ensure opening of low pressure outlet block valves before
to Work opening of high pressure inlet block valves.
27
 Pig Traps

Pig Traps
Mechanical Principles
Pig trap accidents involving operator intervention can be
prevented by SFC coded-ccard key interlock systems.

DNV TN B 302 Technical Notes for Fixed Offshore Installations describes pig
traps as 'primary grades sources of hazard'. ASME and API codes equally
recognise pig trap hazards - especially in relation to the risk of opening
closures while the vessel remains under pressure. The Pipelines Safety
Regulations 1996 enacted into UK law in April 1996 requires operators of
pipelines to provide safety systems that ensure persons are protected from
risk to their health and safety - again describing the hazard of opening pig
trap vessels under pressure.
(Bleed devices fitted into closure opening
mechanisms are alone an unreliable
SFC interlocks can be specified to ensure the minimum safety safety arrangement to detect the
arrangement of interlocking the vessel vent valve with the pig trap presence of residual product. They are
closure. This arrangement ensures (to the exclusion of all other prone to wax or hydrates formations
methods) the vessel VENT valve is OPEN before any attempt can be which can obstruct the bleed channel
made to open the closure. inside the vessel thereby misleading the
operator to believe It Is safe to open the
With interlocks fitted to both the vent valve and pig trap closure, a key is closure}.
released when the vent valve is opened - removing the key from the vent
valve locks the valve in the open position This key is coded in common with
the closure lock - only by opening and locking the vent valve can the operator
secure the correct key to proceed to unlock and open the closure.
28
 Safe Loading and Unloading of Pig Traps

....."Imagine the consequences of opening a pig trap

closure with product in the barrel"

....."Imagine the effect of attempting to pass a pig through

a partially open outlet valve"

....."Imagine getting a sniff of H2S "

.....tthese things can happen - have happened!

Pig Traps

Further procedure sequences can be regulated by interlocks to or electronic interlocking arrangements between these valves
include drain valves, nitrogen purge and water flush valves, are suspended through the necessity to isolate these valves
corrosion inhibitor and isotope functions, and indeed main both from 'Remote' and 'Local' settings to the 'Off' position. An
inlet/outlet and kicker valve functions - every system is designed SFC coded-card key interlock system can be fitted to these
to meet clients' unique operating conditions/requirements. valves to mechanically prove their 'closed and isolated' status -
releasing a key which then enables
Key interlocks can be integrated operation of manually-operated
into pig trap control systems even valves related to vent, drain, N2
where the main inlet/outlet valves purge and water flush procedures
and kicker valve are actuated before enabling any attempt to
(MOV's). In this situation, unlock and open the pig trap
launching or receiving pigs is a closure.
semi-automatic process with
operator intervention limited to Only an SFC coded-card key
push-button action either through interlock system can achieve the
a local control panel or effected condition of creating a positive link
from a remote control station. that makes the operation/status of
MOV's and manually-operated
Indeed, these valves may even be valves completely interdependent
programmed with ESD functions. and absolutely reliably ensures
total isolation, venting and draining
However, when it comes to loading of the vessel BEFORE any attempt
or unloading of pigs, an abnormal can be made to open the vessel
condition arises where software closure!

Mechanical Key Safety

Mechanical key safety interlocking is the ONLY technology that can assure the universally accepted requirement in the loading
and unloading of pig traps that the vessel is venting BEFORE it is possible to open the vessel closure. A key is released when
the vent valve is unlocked and opened which then enables unlocking of the closure mechanism. This imperative is defined
variously in the following standards and regulations:-
ASME VIII - Division 1
1996 No. 825 - (UK) Pipeline Safety Regulations (Section 6 - Para. 37 of Guidance on Regulations - UK Health & Safety
Executive).
US DoT - Pipeline Safety Regulations - Part 195 Transportation of Hazardous Liquids by Pipeline (§195.426 Scraper & Sphere
Facilities).
Shell DEP 31.40.10.13 - Gen : Design of Pipeline Pig Trap Systems.

29
 CO2 Fire Deluge Systems

Fire Deluge Systems

Mechanical Principles
International concern over the environmental effect of widespread use of
CFC gases has led to the phasing out of HALON (Halon 1301) as a fire
extinguishing medium and its substitution with Carbon Dioxide (CO2) or other
inert gases.

CO2 is a very effective extinguishing agent and works by reducing oxygen

levels to a point where combustion cannot be sustained. It is a naturally
occurring substance and has no corrupting or polluting effect when released
into the atmosphere - unlike HALON which is a CFC compound.

Automatic CO2 fire extinguishing systems when activated are designed to

deluge an area within seconds. Typical installations include
turbine/generator enclosures, plenum chambers, computer rooms, archives
or any other enclosed area designated as being not-normally-occupied. Such CO2 is potentially fatal - anyone who may
areas are occupied only on an occasional basis usually for the purposes of become trapped in an enclosed space
inspection, maintenance or repair. flooded with CO 2 would very quickly
suffocate.

30
 .......'what's colourless, odourless, is all around us and
can kill a person in less than 2 minutes' ? .......
Safe Practice

Safe practice requires an arrangement which prevents casual or key(s) which enable isolation of the CO2 supply. Based on a key
unauthorised access into a (CO2) protected space and also exchange principle, further keys are released which enable
enables emergency exit at all times from the protected area. The unlocking of the access door(s) and permit the entry of the
safety arrangements should also ensure that all doors and worker(s) to undertake the task at hand.
access hatches remain locked during periods of normal
operations and that access to the protected area is controlled This safety solution from SFC fulfills the safety requirements of
and authorised only by the appointed authority. NFPA12 * and BS 5306. #

SFC interlock systems can be applied for maximum effect to * National Fire Protection Association (USA) - Carbon Dioxide
permit access only under the strictest conditions. Access for Extinguishing Systems - 1993 Edition
inspection or maintenance purposes is only possible by the
issue of an initiating 'permit key' by the appointed authority. This # British Standard - Part 41986 - Specification for Carbon
key may be used to activate visual or audible alarms which Dioxide Systems
denote 'work in progress' and / or the release of secondary

For the period in which work

is being carried out inside
the enclosed space, the
CO2 Supply is isolated and
the worker(s} cannot be
locked in. However, to
ensure total worker safety
each interlocked access
door within the system is
fitted with a failsafe
emergency override escape
mechanism which permits a
worker to strike a panic
button or crash rail that
mechanically overrides the
door latch mechanism.

31
 Gate Valve Fill In Sheet (Specimen only)
Main Dimensions Handwheel Drive Form

AA = .............. CC = .............. W = ................. Y = ................

BB =............... DD =................. X =................. Z = ................

Valve Orientation

Easi-D
Drive Universal Handwheel Drive Plate

A= ....... A= .........

B =. . . . . . . . . C= .......
EE = .............. GG = .............. JJ = .............. LL = ..............
F =. . . . . . . . . G=.........

I=........ J= ......... FF=................ HH =............... KK =.............

K= . . . . . . . . . L= .........

M= ........ N= ......... Preferred Power Supply

Q =. . . . . . . . . P= ......... 1. Pneumatic
2. Electric
S =. . . . . . . . . R= ......... 3. Hydraulic
U =. . . . . . . . . X= ......... Site supply?
Pneumatic air supply pressure psi/bar?
W= ........ AA = . . . . . . . .

Z =. . . . . . . . . CC = . . . . . . . Electrical Supply Rating

BB =. . . . . . . . 1. Rating

LL = . . . . . . . .
Hydraulic Supply Pressure
1. psi/bar
Size. . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Rating . . . . . . . . . . . . . . . . Valve Information

Make. . . . . . . . . . . . . . . . . . . . . . . . . 1. Breakout torque
2. Run torque
3. Reseat torque

32
 Gearbox Fill In Sheet (Specimen only)
Main Dimensions Orientation

Handwheel Stem Form

X= .........

Y= .........

Z= .........

AA = . . . . . . . .

A1 = . . . . . . . .

B1 = . . . . . .

KW = . . . . . . .

A= ......... M= ........

B= ....... M1 = . . . . . . .

C= ......... M2 = . . . . . . .

D= ......... M3 = . . . . . . .

E= ....... N= .........
Easi-D
Drive Universal Handwheel Drive Plate
F= ......... P= .........

G=......... Or Q=.........

H= ......... PCD R= .........

I= ........ S= .........

J= ......... ‘T’ = . . . . . . . .

J1 = . . . . . . . . ‘T1’ = . . . . . . .

K= ......... ‘T2’ = . . . . . . .

L= ......... U= .........

(V) = . . . . . . . . EE = .............. HH = .............. KK = ............

Size. . . . . . . . . . . . . . . . . . W= ........
GG=................ JJ =............... LL =..............
Pressure Rating . . . . . . . .

Make. . . . . . . . . . . . . . . . .

33
 Ball Valve Fill In Sheet (Specimen only)
Main Dimensions Typical Other Form Types

AA = .............. BB = .............. CC = ..............

DD = ..............

Note: Please note that this fill-in sheet is

for example purposes only.

Please contact our technical sales team,

should your valve differ significantly from
the illustration shown.

A= ......... H= .........

B= ......... I= .........

C= ......... J= .........

D= ......... K= .........

E= ......... L=........

F= ......... M= ........

G=......... N= .......

O=.........

Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Rating . . . . . . . . . . . . . . . . . . . . . . . . .

Lever Length . . . . . . . . . . . . . . . . . . . . . . . . . . .

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34
 SFC....Global market interests
We supply and support some of the worlds biggest companies involved in the oil
& gas and petro-chemical industries. Since our formation in 1985 we have
partnered most of the world’s leading oil & gas producers and chemical
processors by developing and delivering innovative engineering solutions to
manage and protect their multi-billion dollar field asset investments.

Our clients rely on our engineering expertise and product reliability to assure
standards of operating safety demanded in modern society. We remain focused
on the continuous task of meeting and exceeding those demands.

As part of a process of on-going product development, Smith Flow Control reserves

the right to amend and change specifications without prior notice.

Published data may be subject to change.

For the very latest version release, visit our website at www.smithflowcontrol.com

35
 SFC Key Interlocks
& Process Management Systems

6 Waterside Business Park

Eastways Industrial Estate
Witham Essex CM8 3YQ
United Kingdom

Tel: +44 (0)1376 517901

Fax: +44 (0)1376 518720

[email protected]
www.smithflowcontrol.com

Edition Date 04/2006