Netherlocks Safety Systems B.V. News - from Halma PR - visit www.netherlocks.com

Netherlocks B.V., the Dutch industrial and valve safety expert, has been chosen to supply its trapped key interlocking safety systems by India’s largest engineering and construction conglomerate, Larsen & Toubro Ltd.

The company has ordered Netherlocks products to secure and safeguard ‘pigging’ operations for two major projects. One, in conjunction with Cairn Energy India, involves 39 pig launcher and receiver systems along a cross country pipeline. The other project is from L&T’s Qatar office, with Qatar Petroleum for the SGP project, where initially 12 of the pigging systems will be protected by the interlocks.

Industrial and valve safety systems from Netherlocks B.V. for L&T pigging operations

Pigging is undoubtedly a very effective and efficient cleaning method for pipelines, not interrupting process, but it does carry a potentially high risk factor due to the high pressures and dangerous gasses involved. Although nothing should go wrong if the safe procedures are followed correctly, there is always the chance (mostly attributable to human error) that the procedure itself will not be followed exactly. The trapped key interlocking systems from Netherlocks ensure that each stage of the process can only be started – that each valve can only be operated – once the stage before has been safely completed. In this way, the system mechanically enforces a strict and absolute adherence to safe procedure.

The exact number of locks required varies according to each individual pigging system and client specification, as their processes will be subject to differing numbers of variables – vent, drain, kicker, main, throttle, balance and so on. This then requires different complexities of interlocking systems such as locks on manually operated valves, closures and MOVs. Because pigging procedures are often non-linear processes, requiring steps that may need to be repeated at different stages, or that are dependent on several previous actions, Netherlocks designed the MPCU. The MPCU acts as a ‘mechanical PLC’, checking each stage of the process and releasing keys according to pre-programmed parameters, meaning that the operation can only be performed according to safe procedure.

Interlocking systems such as these provide such an effective baseline safety standard that they are rapidly becoming standard for pigging systems. The simple principle of mechanically enforcing safe working methods significantly reduces risk by essentially taking the ‘human factor’ out of the equation, without negatively affecting performance.

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Petroleos Mexicanos (PEMEX) has chosen Dutch industrial safety specialist Netherlocks B.V. to supply its FAITH partial stroke testing systems for three offshore facilities in the Gulf of Mexico. The FAITH tests ESD (emergency shut-down) valves with a partial stroke operation, therefore not interrupting production during the test.

PEMEX is Latin America’s largest enterprise, and one of the few oil companies that operates the entire production chain from source to market, with a yield of over 3m barrels per day in 2006. The company has used Netherlocks safety equipment for several years, and continues to rely on the simplicity, reliability and functionality of its mechanical safety systems for critical applications.

Partial stroke testing is of major importance to end users, as an important safety step to ensure that an ESD valve will operate as intended, when needed. All valves can become worn or stuck over time, so something as vital as an ESD must be tested frequently in order to meet SIL* standards. A partial stroke test enables testing without halting process flow, meaning tests can be carried out more easily and more often, which should then also create a more reliable ESD system.

The mechanical nature of the FAITH system ensures that the specified degree of opening (test angle) is not exceeded during the test. The Netherlocks device can also be used to block the actuator to perform maintenance on the ESD during production. Instead of relying on a potentially complex electronic system for a simple – but vital – operation, the FAITH is itself a simple, maintenance-free mechanical device that can still offer electronic feedback with optional added components.

*Safety Integrity Level

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Netherlocks B.V. has been designing and manufacturing interlocking, valve control and other industrial safety products for nearly 15 years and is now bringing its expertise to the American market.

The industry that forms such a core of the American economy is ever improving in its productivity and efficiency, yet safety standards and practices have often been overlooked throughout the rapid drive for progress. Events and incidents occur every year – some making headlines, others only affecting those involved – which highlight the need not only for safety measures, but also for ways of making sure that they are effectively applied. Traditional approaches to machine and plant safety in the US have largely relied on more ‘improvised’ systems such as lock-out/tag-out. By contrast in Europe the principles of interlocking safety have long been regarded as a viable, potentially superior alternative depending on the situation.

Interlocking uses a ‘trapped-key’ system, whereby valves, actuators, switches, doors and processes are physically locked in a state until the right key is used. By using a trapped-key system, the next step in any process can only be unlocked and started once the previous step has been completed and the appropriate key released, guaranteeing the correct sequence of events. For instance: a supply valve may need to be completely locked closed before a drainage valve is opened, effectively ensuring that a dangerously high pressure is not going to cause an accident when the drain is activated.

Although a simple example, it effectively demonstrates the underlying principles of mechanical interlocking: human error, mistakes and even ignorance of proper work procedure are physically prevented by a mechanical system which does not interfere with the proper, safe operation of the elements involved. Contrary to some belief, this is one safety measure that should not adversely affect performance. When everything is being done as it should, interlocks do not interfere with normal operation. What they do, however, is make sure that procedures are being safely followed, with no allowance for mistakes, errors of judgement, or dangerous ‘shortcuts’.

The ‘Add-On’ approach taken by Netherlocks aims to make any operation safer by incorporating the right measures in the right places: with the vast majority of incidents and accidents being caused by human error, mechanically enforcing the adherence to safe procedure can dramatically increase worker safety and equipment protection. As expected when dealing with such a serious subject, a safety product is only useful if it is high quality and reliable. If a safety device should fail then the consequences could be grave, especially if people have come to rely on it. Netherlocks is proud to have an excellent, proven reputation for both reliability and quality, and is bringing this now to America.

Customised safety plans are encouraged in order to find and fit the best system possible for any installation, maximising both safety and efficiency. The company’s sales and support teams are available to give advice and training in the planning, implementation and assessment of safety systems, and the company is ready to customise their product range to suit the particular needs of a project. Further information can be found at the Netherlocks website www.netherlocks.com or by contacting them directly at sales@netherlocks.com.

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Netherlocks Safety Systems BV, the Dutch industrial safety specialist, has designed a new universal mounting system to safely and securely fix valve position indicator switches onto handwheel-operated valves. The SMART VPI is made from Stainless Steel AISI 316, suitable for all applications both on- and offshore.

The unique, patented design allows the mounting bracket to attach directly onto the valve stem without affecting the valve itself: a simple and easy add-on. The switchbox for the valve is then mounted onto the bracket with either DIN or ISO configurations. Here it is safely out of the way, not interfering with valve operation, but still securely fixed in place and with protected switches and wiring.

Currently, many switchboxes for handwheel valves are mounted onto weak, external brackets that are inconvenient and unprotected. In technical meetings with end-users, Netherlocks had been told that getting a reliable feedback signal was a common problem. The answer was to design a universal mounting system that could fit any existing valve and switchbox, whilst safely securing and protecting the critical equipment. The SMART VPI is the result, eliminating the traditional drawbacks and universally mounted onto any valve to ensure a reliable valve position signal.

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Dutch industrial safety and valve control expert Netherlocks is launching the SHL – their new Smart Handwheel Lock. The key transfer lock can be fitted easily like a simple Lock-Out device to any size or type of handwheel-operated valve. No valve details, extra parts or customised adaptors are needed, and it locks the wheel into pre-set, safe positions controlled by the interlocking key release mechanism.

Traditionally, valve locks have depended on the precise specification of each valve in order to be fitted effectively. Detailed valve information would need to be collected and used to fashion the mountings for the lock. The unique design of this product means that it can be added onto any existing handwheel-operated valve to mechanically secure it, without the need for such information.

The SHL attaches onto the valve stem underneath the wheel without replacing or altering any part of the valve assembly. No specially machined parts are needed, and the innovative design that attaches the lock to the handwheel still leaves space to grip it. This makes it much easier to simply, securely and safely provide interlocking for handwheel valves: no specific valve information is required, no machined adaptors or mounting brackets are needed, and the lock can be fitted whilst the valve is still operational.

Interlocks minimise the danger caused by the potential for human error: they prevent the valve from being operated until it is safe to do so. The coded key to unlock the valve is only released for use once the correct sequence of precautions has been completed, with each stage of the process enabled only once the previous one is finished. This physically prevents accidental and potentially dangerous actions from being performed, negating the risk of human error.

Netherlocks has been designing and producing interlocking and valve control technology for over 15 years, supplying major companies and projects with safety systems around the world. For more information please visit www.netherlocks.com or email your enquiry to sales@netherlocks.com.

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One of the largest oil-refining projects in China, the Xinjiang Dushanzi Project, is due to have over 700 Netherlocks valve safety devices installed. HQCEC, the EDC contractor for this CNPC* project, recently bought 718 MRL valve locks from the Dutch company to make sure that the highest standards of safety will be ensured in the facility.

Compared to other potential products, Netherlocks’ range was able to offer crucial advantages in terms of improved performance and reliability at low temperatures and in high-stress environments – such as those expected at the Dushanzi site. The Netherlocks valve interlocks eliminate the potential for human error in processes which involve the operation of manual valves, requiring safe procedure to be followed. The locks physically prevent a user from performing potentially dangerous actions, protecting people and property from potential damage: until the correct, unique key is inserted, the Multi-Rotation Lock will not allow the valve to be operated.

So far, this is the largest number of interlocks provided for such a venture in China, reflecting both the size of the project and the increased focus on safety that is becoming so important in China. The increasing demands for oil consumption in the country are placing a strain on the current supply infrastructure, and as a result vast resources are being put into redeveloping existing and building new facilities. Safety systems are an integral part of the modernisation effort, and high-quality interlocks of proven provenance are invaluable in such dangerous applications as this.

The Xinjiang Dushanzi Oil Refining Project is upgrading an existing oil refinery and petrochemical complex located in the Dushanzi district of Karamay City, Xinjiang Uygur Autonomous Region. This new project has had a total investment of around RMB 30 billion (~£2bn GBP); it will reportedly be highest oil and chemical refining investment in the country upon its completion. The plant will be processing over 10 million tons of crude oil per year, and the annual production target of 1.2 million tons of ethylene is expected to earn Dushanzi Petrochemical Company a yearly revenue in excess of RMB 40 billion.

*Note: HQCEC is the Huan Qiu Contracting & Engineering Corporation, and CNPC is the China National Petroleum Company.

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Adaptability can be key to a good safety system, allowing tried and tested methods to be used on new and different applications.  Netherlocks has been designing, developing and producing interlocks and valve control safety devices for over 20 years, improving on existing ideas and implementing entirely new ones.  Recently, they applied their skill and knowledge to developing a fail-safe system for large silo parks.

Silo parks – depots and collection points used by many different companies – face particular problems when it comes to the safe distribution of product.  There are of course the very real and serious safety concerns when dealing with the volumes and volatilities of substance involved.  The factor of human error is always present, and the potential for disruptions, environmental hazards and accidents to occur is a real one.

The second major issue is derived from the multiple client-base, as each company servicing the silos must only retrieve or deposit their own product.  If the wrong product or silo were used, then the costs and disruptions of repairing the situation would be substantial, at the very least.  To this end Netherlocks has integrated their sophisticated PLC controlled key-release system to the silo park’s main valve and loading arms, so that the driver for a company will only be able to initiate the right processes for their company’s material.  This removes the ‘human factor’, thus preventing even the possibility of costly losses or downtimes.

The interlock system also performs a more traditional safety role in ensuring that the fluid can only flow once the right vehicle is in place and ready to receive it, providing an extra layer of security against dangerous spills.  The Netherlocks system is applicable for operations involving solids, liquids and gases.

The Dutch company is committed to providing customised systems to provide mechanical safety solutions to any and all industries.  The fundamental simplicity of the key transfer interlocks is what makes the system so flexible, and even the most complex and non-linear operations can be secured by using their MPCU (Mechanical Process Control Unit).  Netherlocks also has expertise in the field of valve control, and provide machine guarding and Lock-Out/Tag-Out products.  More information on the company can be found at www.Netherlocks.com.

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Netherlocks has updated the design on their partial-stroke emergency shutdown (ESD) and HIPPS valve testing unit, the FAITH.  The device is now available with an incorporated emergency override lever, which can be operated in the unlikely – but possible – event of an ESD needing to be performed whilst the valve is being tested.

 Typically, testing an emergency shutdown valve involves operating it, and thus halting production.  It is not so much a test, as just a planned shutdown.  By using a FAITH, when the right key is inserted into the unit the stroke of the actuator is limited to 20 degrees (can be changed on request): this is enough to make sure that the valve has not stuck, and that it can still be operated, but it does not interrupt production.  This has the added benefit of allowing the valves to be tested more often, thus negating the need for a powerful, over-dimensioned actuator to be fitted ‘just in case’. 

A potential flaw in this method, however, is that an emergency could occur whilst the limit was active, which could be very dangerous indeed.  By building in an ESD override lever, Netherlocks has solved this potential problem.  In the event of an incident during testing, the lever can be rotated to release the stroke limiter and the valve will close, stopping operations. 

Although this may seem to be a very improbable situation, when dealing with issues of safety it always pays to consider and plan for every possible event.  The emergency lever also allows the replacement of solenoid valves, quick exhausts and other safety instrumented system (SIS) components without stopping the process.

The device is completely mechanical and maintenance-free, not needing any wiring, PLC or software, although it can optionally be fitted with switches and solenoids to provide a feedback signal.

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Netherlocks has set up its first office in China, in the capital city of Beijing.  With its head office in the Netherlands, the company has been designing and manufacturing interlocking, valve control and other industrial safety products for nearly 15 years and is now bringing its expertise to the Chinese market.

 The rapid – even explosive – growth of the industrial sector of the Chinese economy means that there is a continually rising need for proven, reliable industrial and process safety products to be available.  The ‘Add-On’ approach taken by Netherlocks aims to make any operation safer by incorporating the right products: with the vast majority of incidents and accidents being caused by human error, mechanically enforcing the adherence to safe procedure can dramatically increase worker safety and equipment protection.  As would be expected when dealing with this field, the quality of product is key to its value.  If a safety device should fail then the consequences could be grave; it is with this in mind that the Dutch company is bringing to Asia their tradition of and reputation for reliability.

On 3-5 April 2007, Netherlocks exhibited at CIPPE 2007(China International Petroleum & Petrochemical Technology and Equipment Exhibition), in order to meet directly with end users and listen to feedback.  The stand drew considerable attention from visitors with its diverse range of high-quality products from its core ranges: interlocks, Lock-Out/Tag-Out, and valve control.

 An interlocking system can be applied to valves, actuators, switches and doors – essentially anything that moves.  By using a trapped-key system, the next step in any process can only be unlocked and started once the previous step has been completed and the appropriate key released, guaranteeing the correct sequence of events.  Non-linear processes such as pigging operations can be controlled by a Mechanical Process Control Unit (MPCU) which will distribute and trap keys according to a pre-programmed sequence, eliminating the chance of operator error.

 When a Lock-Out/Tag-Out system is needed (usually for maintenance or temporary use), the stainless steel NL-H universal device can be attached to doors, valves and switches and then secured with individualised (key-differed) padlocks by a worker to ensure their own safety.

 The Nether-Flex and KMS both aid in actual valve operation: the former by allowing awkwardly placed valves to be used from a remote unit via a flexible cable, the latter by using pneumatic power in a portable actuator to operate valves which require many turns or great force faster and with less strain on the operator.  To monitor the position of handwheel-operated valves, the secure VPI (Valve Position Indicator) unit mechanically measures their status, and can then convert and transmit this data digitally to a remote monitoring station.  For testing ESD (Emergency Shut Down) procedures, the FAITH system can be installed.  Unlike other methods of testing, with this product production is not halted – a distinct benefit when safety must be ensured without interrupting costly operations.

The company’s sales and support teams are also available to give advice and training in the planning and implementation of safety systems, and the company is ready to customise their product range to suit the particular needs of a client.  Further information can be found at the Netherlocks website <www.netherlocks.com> or by contacting them directly.

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Valve-control specialist Netherlocks has developed a device to facilitate the manual operation of problematic valves, whether they are high-torque, difficult to reach or require many handwheel rotations to activate.  The KMS is a portable pneumatic handheld actuator that enables valves to be operated at least 40 times faster than by conventional means.

Opening or closing manual valves can place great strain on an operator’s body, causing unnecessary stress and occasional injury.  It is in an employer’s interest to combat this source of stress, both for the well-being of its workforce and to comply with relevant legislation.

The KMS is suitable for all handwheel-operated valves when used in conjunction with its universal drive plate.  Instead of an expensive actuator, each valve is fitted with a plate, allowing every valve in a plant to be activated by a single KMS.  Since it is air-driven, the KMS is also safe for use in potentially explosive atmospheres.

The portable actuator is supplied in lengths of 480mm or 1182mm.  An optional aluminium storage box is available, including a 20m reeled air hose, an integrated air filter / lubricator and an air reduction valve.

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