Designed in response to customer demand, Dutch valve safety product manufacturer Netherlocks has developed the facility for entirely remote operation of its FAITH Partial Stroke Test (PST) system for ESD and HIPPS* valves. This means that the mechanically-safe, fully-online testing of these critical valves can now be initiated and performed from the safety and convenience of the control room, without having to manually access the valve.
Netherlocks adds remote operation to its FAITH Partial Stroke Testing system
Netherlocks’ commitment to innovative design and customer satisfaction has enabled the company to now make this product remotely operable without affecting usability or functionality. Traditionally, an operator would have to access the valve itself to manually insert a key to start a test. The new development means that the whole process can now be done remotely from the control room, making it significantly easier and faster.
The FAITH system at all times facilitates the partial stroke testing of valves, without any risk of overshoot or process interruption. The test is never aborted without getting results, and the unique design means that tests can be performed at real speed – just as it would be for real operation in an emergency. The mechanical limitation on the degree of valve closure guarantees there is no danger of actual shutdown or upsetting the plant due to overshooting of the test angle.
The FAITH’s simple mechanical design is key to the reliability of the system. It is a universal add-on product which is fitted directly between the valve and the actuator and replaces the original couplings. During partial stroke testing, FAITH’s mechanical steel blocking pins ensure that the valve can only turn to the preset test angle (i.e. 20 degrees). This also allows for maintenance during production.
All FAITH systems can be customized to fit directly between the valve and actuator without additional brackets. Models are available for both linear and rotating actuators, and electronic switches can also be added to the FAITH system to allow the control room to monitor the test.
*Emergency Shut Down and High Integrity Pressure Protection System
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Device mounts on new and existing valves with no modifications required
Houston, Texas (June 20, 2012) – Netherlocks Safety Systems’ Valve Position Indicator (VPI) provides process facility control rooms with a reliable remote signal, allowing personnel to maintain awareness of handwheel-operated gate valves’ current position.
The Valve Position Indicator from Netherlocks Safety Systems.
In the process industry, awareness of valves’ current status is essential to avoiding injury and equipment damage. The VPI uses a mechanical counter to convert a valve’s open and closed positions to electronic signals. This ensures the accuracy of valve status signals sent to the control room.
Each VPI is custom built, allowing customers to choose whichever electronic switch they prefer. The device mounts immediately beneath a valve’s handwheel without modifications to the valve. The VPI’s design eliminates externally mounted switches, weak welding, loose wiring and fragile brackets that cause false alarms in traditional monitoring systems. It can be mounted on both new and existing valves.
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1160 wireless VPI units have been ordered from Dutch valve safety specialist Netherlocks by Bilbao Petronor Oil Refinery, part of Spanish oil and gas giant Repsol. Following a very successful three year pilot program, the new equipment will replace existing valve position signalling at the 220,000 barrels-per-day refinery.
Netherlocks supplies over 1000 VPI handwheel valve position indicators to Petronor Bilbao Oil Refinery
The VPI (Valve Position Indicator) was designed by Netherlocks to provide a reliable feedback signal from hand wheel operated valves, converting the open and closed positions to a digital signal by way of a mechanical counter system. Overcoming traditional issues about mounting strength and signal reliability, both the VPI’s mounting method and counter use well-tested and proven designs, which have been used successfully in Netherlocks’ mechanical interlock systems for over 15 years.
The VPI is an ‘add-on’ product, and can be mounted to either new or existing hand wheel operated gate, globe or rising stem valves without interrupting normal process. Coupled with the mechanical counter system, Netherlocks uses an ATEX-approved switch as standard – though customers are able to change this specification if required. Once mounted in place, the ‘open’ and ‘closed’ set points are adjusted and the result is a completely reliable system for valve position indication.
For the Bilbao Petronor Oil Refinery, Petronor wanted a wireless solution, which posed no problem using the VPI technology. Because the counter works simply and mechanically, the valve position tracking will always be reliable at the point of detection – to make the feedback to the control room wireless, it simply required a wireless transmitter to be fitted along with the switch, as per the customer’s specification.
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Key operated interlocks remove human error from valve operation sequences
Houston, Texas (February 23, 2012) – Improper operation of pigging system valves can result in equipment damage, injury or death. Netherlocks Safety Systems Closure Locks eliminate the danger to personnel and equipment by ensuring that correct operation procedures are followed every time pigging operations take place.
Netherlocks’ Closure Locks ensure proper operation of pigging systems.
Pigging systems are used to insert a pipeline inspection gauge (PIG) into a live system transporting gas or liquid media, in order to perform various maintenance operations. Dealing with such high pressure levels, pigging operations require that a precise sequence of valve operation is followed in order to avoid disastrous consequences. Netherlocks’ Closure Locks protect against improper operation of a pigging system’s most important valve, the closure door.
Common accidents that occur during pigging operations often involve the system’s closure door. These incidents include opening the closure door while pressure still remains inside the vessel, opening the main process valve while the closure door is not fully closed, and opening the closure door while a high concentration level of toxins still remains inside the vessel.
Closure Locks are operated using a series of keys that lock into place, and can’t be removed out of sequence. This guarantees that workers always follow the correct valve operation procedure.
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Dutch interlock specialist Netherlocks has now launched its new Interlock System Information (ISI) Touch Screen key management device. As a standalone unit or integrated into either a key cabinet or control panel, the ISI Touch Screen stores all relevant information about an interlock system in a digitised, centralised, user-friendly format that is easily accessible by any operator without a need for specialised training.
New Touchscreen Interlock Management System from industrial and valve safety expert Netherlocks
All relevant interlock keys are shown on screen, and simply touching them will display detailed information about the key itself and the related system: system name, operating sequence logic, P&ID and Location. Additional buttons are present for on-screen instructions, general interlocking information and Netherlocks contact details; company-specific content can also be added if desired. If a printer is connected, operating sequence instructions can even be printed out for future reference away from the console.
By making clear information about the lock system and safety procedures easily available to everyone in the workplace, the ISI Touchscreen helps to keep all workers well-informed to reduce confusion, enhance productivity and improve plant safety.
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Products suitable for all manifold manufacturers
Houston, Texas (November 15, 2011) – Netherlocks’ manifold interlocks ensure that instrumentation valve 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 interlock.
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.
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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.
Netherlocks’ TVL throttle valve lock.
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.
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CKC-Touch Screen provides centralized storage for all interlock information
Houston, Texas (August 5, 2011) – Netherlocks will feature its new CKC-Touch Screen display for key interlocking systems at ChemInnovations 2011 Conference and Expo, September 13-15 at the George R. Brown Convention Center (Houston, Texas). The company will offer hands on demonstrations of the CKC and other process safety interlocking systems at its booth 3020.
Netherlocks’ CKC-Touch Screen, on display at ChemInnovations booth 3020.
Netherlocks’ CKC-Touch Screen is designed to be integrated into interlock key cabinets, or can be mounted separately as a standalone feature. All cabinet keys are displayed on the screen and one touch provides detailed information about that specific key and its corresponding interlock system. The touch screen also includes additional information buttons that provide access to factory contact details, operating manuals, general product information and training instructions.
Netherlocks will also feature demonstrations of its key-operated valve interlocking systems and FAITH partial stroke testing system.
For more information, visit the company’s booth 3020.
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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.
Netherlocks mechanical interlocks safeguard critical industrial processes.
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.
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FAITH system from Netherlocks features simple design for reliable operation
Houston, Texas (May 4, 2011) – For partial stroke testing of valves without overshoot risk or process interruption, Netherlocks offers the FAITH test system. FAITH allows online testing of emergency shutdown (ESD) or high integrity pressure protection system (HIPPS) valves, to reduce degradation and ensure that they operate properly should the need arise.
The FAITH partial stroke testing (PST) system from Netherlocks.
FAITH’s simple mechanical design delivers reliable operation. The system integrates into a valve’s static and dynamic couplings, replacing the original coupling and spool piece. During partial stroke testing, FAITH’s mechanical steel blocking pins ensure that the dynamic coupling can only turn to the preset test angle (ie 20 degrees) to allow flow to continue through the valve during the test without risking overshoot.
All FAITH systems can be customized to fit directly between the valve and actuator without additional brackets. Models are available for both linear and rotating actuators. Electronic switches can also be added to the FAITH system to allow the control room to monitor the test.
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