Valve Interlock - Smith Flow COntrol

7/25/2019 Valve Interlock - Smith Flow COntrol

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SFC Key Interlocks & Process

Management Systems


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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

26 Easi-Drive

28 Pressure Protection

30 Pig Traps

32 Fire Deluge Systems

34 Fill In Sheets

2

Smith Flow Control Ltd6 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


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...for over 20 years SFC have never failed to

provide a viable technical solution to a clientssafety operating problem..

Mike Smith - Founder & Vice-Chairman

Key Interlock Systems

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.

SFC introduced the coded-card linear-key concept in a range of

modular key-operated interlocks to regulate operator execution

of work procedures on any form of host process equipment.

Typical applications include every form of valve (including

motorised and instrument valves), switches, vessel closures,

access guards, pressure and temperature sensing systems and

rail/road/sea tanker loading systems.

SFC's solutions in hazardous processes reduce the scope for

operator error and ensure safe continuous plant operation.

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. By 1990 SFC

became the generic term for key interlock safety systems in the

international oil & gas industry and our client base now includes

most of the major operating companies in all five continents.

In 1990 SFC became part of Halma plc (quoted on the London

Stock Exchange) and in 1993 acquired ISO 9001 accreditation

certified by Lloyds Register.

Today SFC continues to be managed by its founders who remain

committed to providing quality assured products delivered on

time at a competitive price. SFC employs 50 people including 3

Design Engineers dedicated full time to product development

using 3D modelling, a full-time Quality Manager and 2 full-time

Works Quality Inspectors. Our manufacturing design office is

staffed by 8 Design Engineers who are all highly trained in the

capabilities of AutoCAD which is our chosen state-of-the-art

manufacturing design tool. SFC maintains a crew of 4 full time

fully certified Site Technicians which enable us to offer total

turn-key services to our clients.

Smith Flow Control (SFC) was established in 1985 to provide engineered safety solutions for

hazardous operations in the oil & gas and chemical processing industries.


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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 andoperating 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 oftenfrom 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

uncoupling of hoses for loading or discharge of tanker cargoes all involve

human intervention and are hostage to the possibility of operator error.

Distributed control systems (DCS) cannot effectively regulate such

(maintenance) procedures - the SFC Coded Card Key Interlock System can!

....."it would be difficult to name aparticular industry that would not

benefit from an SFC coded-card key

interlock system"

The obligation to adopt best

practice is a fundamental of safety

management - mechanical key

safety interlocking is a technology

that has evolved to offer

sophisticated technical solutions

to complex and hazardous processapplications and which

increasingly is being adopted by

major OpCo's worldwide for

protection of their people, their

assets and their surrounding

environment'

SFC 'Visual Alert' Key

Cabinets provide an effective

and 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.


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BE SURE - BE SAFE - CHOOSE SFC - YOUR PARTNER FOR TOTAL PLANT SAFETY & SECURITY.

Controlling the sequence of events in which process

activities are conducted has been achieved historically

using Permit to Work (PtW) systems accompanied by

documented instructions.

However, this system is hostage to 'human

factors' distractions, failure to interpret

correctly, ignorance of the system - all can

lead the operator to make errors which

can manifest themselves in

industrial accidents of varying

magnitudes.

Trapped Key Interlocks are

simple mechanical devices

which can be customised to

implement a safe sequence of

operation in any process activity.

In the following pages we show how our

mechanical key interlock system ensures that pig trap valves are

disabled and proven shut and the vessel is isolated, drained and

vented BEFOREopening of the closure for loading or unloading

of pigs, or, how the spare pressure safety relief valve is on

stream BEFOREan in-service relief valve can be isolated and

removed, or, how we prevent a tanker from

departing a loading/discharge station

BEFORE the cargo hoses are

disconnected.

These and any other work tasks

executed by human intervention

can be completely regulated by

SFC's coded-card key interlocks

- simple and total mechanical

reliability to prevent operator

error or violation to protect your

plant, the surrounding community and

the environment.

In addition to our range of high-integrity coded-

card key interlock safety products, SFC also offer

a comprehensive range of valve and process equipment security

products for high and low-criticality applications.


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QL Valve Interlocks - For lever-operated valves

QLR

QLT

After removing the existing lever

the QL is assembled as follows:

1. Install lock adaptor

2. Install anchor.

3. Fit SFC nut.

4. Assemble QL lock, secure

lever and tighten bolt.

Adaptor Anchor

SFC Nut

Lever

Bolt

LockBody

QL Valve Interlock (QLT & QLR)

QL valve (inter)locks suit all types of lever-operated quarter-turn 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.


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

technical solution to a clients safety operating problem.

Closed Section

Open Section

Internal Mechanical Construction

QL Valve Interlock

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.

Anti-Tamper

Screw

SFC Nut

Lock Body

Closed Key

Open Key

Anti-Overide Mechanism

Locking Gear Cam

SFC Lever

Anchor

Lock Adaptor

Product Features

316 Stainless steel construction

Linear coded-card key design

Robust construction

Proven reliability in all climates

Single or double key versions


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GL Valve Interlocks - For handwheel-operated valves

GLS

GLM

After removing the existing

handwheel the GL is assembled

as follows:

1. Mount lock adaptor and fix

SFC nut.

2. Locate body to adaptor.

3. Tighten fixing screws (x3).

4. Tighten setting screws to set

Open and Closed key free

positions.

SFC Nut

LockAdaptor

LockBody

Anchor

GLM & GLS Valve Interlocks

GL valve (inter)locks suit all types of handwheel operated valves - including gate, globe, and

gear-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).


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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

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

technical solution to a clients safety operating problem.

Locking Arm

Code Bars

Counter Mechanism

Lock Body

Anchor

SFC Nut

Lock Adaptor

Product Features

316 Stainless steel construction

Linear coded-card key design

Robust construction

Proven reliability in all climates

Single or double key versions

Key Release Arm


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Access into pressure vessels is a potentially hazardous

exercise. Residual pressure, volumes of residual liquids or

gases all can be harmful - typical examples of these potential

hazards include pig traps, slug catchers and filter housings.

Locking the vessel closure in the closed position ensures access into the

vessel can be achieved only under controlled safe conditions. The operating

key is held in a secure place - e.g. Control Room or Supervisor's office or is

retained (trapped) in some other related interlocked item of equipment.

As a minimum, vessel closures are usually interlocked with vessel venting

and draining functions - the interlocking arrangement can be extended to

incorporate all process items of equipment relating to the vessel's function.

Vessel Closures

Introduction The SFC 'DL3' interlock is adaptable to alltypes of vessel/access closures and is

very simple to use in pig trap applications

especially where the closure incorporates

a bleed device.

The 'DL3' interlock will be designed to

interface with the bleed function to

ensure the bleed screw cannot be

removed until the interlock permit key has

been inserted to unlock the 'DL3'

assembly.

When the 'DL3' is incorporated into vessel

access safety procedures, total

equipment and personnel safety is

assured.

Ensure total isolation,

venting and draining

BEFORE opening vessel

closure.


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Any type of closure can

be fitted with the DL3

interlock, regardless of

their method of

operation. Design

details can be provided

on request.

Prevent loss of containment of explosive or toxic product.


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Actuated Valves

The most common requirement for key interlocking of power-

actuated valves occurs in Pig Launcher/Receiver systems,

Scraper Traps and Sand Filter systems etc. where power-

actuated valves need to be interlocked with manually-operated

valves and the vessel closure.

Because of the ultra-critical nature of such valves, special considerations

arise which the design of a key interlock system must address:-

Where such valves are part of an ESD system, the key interlock system must

not compromise the valve's fail-safe function.

Where pigging operations occur, the key interlock system must verify the

valve's absolute position (Open and/or Closed) independent of any on-board

instrument indication.

On electrical actuators where the key interlock system de-energises the

valve, any anti-condensation heating circuitry etc. must remain

uninterrupted.

Where actuators are equipped with a manual override facility, the key

interlock system must permit operation of the valve in both modes (or in a

combination of both modes - e.g. in the event of a power failure) while

maintaining the integrity of the key sequence at all times.

Actuated (Motorised) Valves

Interlock system design principles

Because actuators generate great torque

forces, (b)locking of such valves by

mechanical restraint is unacceptable -

such locking methods would likely induce

damage within the motor assembly.

Nonetheless, a key interlock system must

ensure the valve is de-energised and

disabled (in both Remote and Local

modes) and that only the appropriate

sequence key is released for continuation

of the procedure dependent on the valve's

verified (Open or Closed) position.

A typical operating sequence is given on

the page opposite where it may be

observed the interlock system functions

passively and relies on the as-built

actuator mechanisms to establish and

confirm the status of the equipment.

It may also be observed when such valves

are in the Open (Remote setting)

position - the valve is free to operate to

Closed without hindrance or interruption

by the interlock system.


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Equipment Status:- Valve Closed

'SLU' Switch Unit Locked 'OFF'.

'HWL' Handwheel Drive Locked 'OFF'.'D' Key in Control Room.

To Open Valve:

1. 'D' Key into 'AKE' positional indicator unit.

'C' Key is removed from 'AKE' - 'D' Key trapped.

2. 'C' Key into 'SLU' Switch Unit to unlock.

'SLU' Unit switched to 'LOCAL'('B' & 'C' Keys trapped).

Operate button to open valve.

3. 'SLU' Unit now switched to 'REMOTE' - 'B' Key is removed.

'SLU' Unit locked in 'REMOTE' position trapping 'C' Key.

4. 'B' Key into 'AKE' Unit - remove 'A' Key trapping 'B' Key.

'A' Key is then directed towards continuation of the procedure.

NB The 'A' Key will not release unless the valve has completed

its full stroke to the OPEN position.

Equipment Status:- Valve Open

'SLU' Switch Unit Locked in 'REMOTE'.

'HWL' Handwheel Drive Locked 'OFF'.'A' Key in Control Room.

To Close Valve:

1. 'A' Key into 'AKE' positional indicator unit.

'B' Key is removed from 'AKE' - 'A' Key trapped.

2. 'B' Key into 'SLU' Switch Unit to unlock.

'SLU' Unit switched to 'LOCAL' ('B' & 'C' Keys trapped).

Operate button to close valve.

3. 'SLU' Unit now switched to 'OFF' - 'C' Key is removed.

'SLU' Unit locked in 'OFF' position trapping 'B' Key.

4. 'C' Key into' AKE' Unit - remove 'D' Key trapping 'C' Key.

'D' Key is then directed towards continuation of the procedure.

NB The 'D' Key will not release unless the valve has completed

its full stroke to the CLOSED position.

Power Failure Mode

In the event of a power failure at anytime during either of the

above procedures, it is essential the integrity of the key

sequence is maintained if the valve is operated manually.

This is achieved simply by locking the 'SLU' Unit in the 'OFF'

position thereby releasing the 'C' Key. (Even if power is restored,

with the 'C' Key free, the valve/actuator will remain disabled).

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.

Hydraulic & Pneumatic Actuators

A range of comparable designs are also available for spring-

return and non-return hydraulic actuators and for spring-return

pneumatic actuators.

SFC's range of special process products also includes needle

valve locks, temperature and pressure sensing locks and a

range of signalling options to meet most process operating

requirements.

HWL

AKE Unit

HWL

AKE Unit

SLU Unit SLU Unit


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SFC 'Visual Alert' and Permit-to-Work Key Management Systems

The SFC Key Interlock System has been developed through a

process of continuous design improvements acquired through

developing client safety management requirements over

twenty years.

General to the system is the necessity for an effective and

efficient key management system that will provide a

continuous and reliable indication of the status of all

interlocked process systems.

SFC 'Visual Alert' Key Cabinets provide an effective and 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.

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 eachclient's operating system and working practices.

Key Management Systems

Design features and benefits

Carbon or stainless steel construction.

Glazed door provides key status

without the need to open.

Ingress protection from IP55 to IP66.

Lockable doors.

External wall mounting brackets.

Total integrity by using dedicated

key locations.

Complete key status awareness.


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SFC Key Cabinets can incorporate a Pin Code system which

prevents the replacing of a system key incorrectly.

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,

the next most important step is to apply a good key

management system.

For storage, ease of access and issue, SFC key cabinets provide

all that is required.

A key cabinet should be located in a secure place; typically a

Control Room whereby initiating keys are issued by the Shift

Supervisor, Offshore Installation Manager (OIM) or other person

in authority.

Cabinets vary in size and can accommodate from 1 - 227 system

initiating (or spare) keys. Keys can be located via means of

hooks or holsters (the holster locator provides increased

capacity).

Each interlocked system has a dedicated engraved tag location

within the key cabinet. During periods of normal operations, all

interlock system 'permit' (initiating) keys are visually displayed

within the cabinet in dedicated locations.

Each key cabinet tag is engraved with the relevant piping

package data - this same data is also replicated on each system

key.

When the key is removed, a 'Visual Alert' tag is revealed

providing details of the key which has been issued, its

designated location, and the words 'WORK IN PROGRESS'.

Control Room staff have clear and easy indication of work status

at any time. Key cabinets can also accommodate mimic

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


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

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.

The units can be uniquely coded or coded alike, dependant on operational

conditions/ requirements.

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.

The units are available "off the shelf' allowing customers to undertake the

simple machining operation for fitting, thus reducing order times and

offering an instant security/safety solution.

Introduction

Construction

Coding

Operation

Ordering

ATL (Anti-Tamper Lock)

Many valves on site require a simple-to-

use locking device to prevent accidental

or unauthorised operation.

The ATL has been developed to fit directly

to valves in place of the normal

handwheel or operating lever, with little

machining which can easily beundertaken by the customer.


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Where security lock-off devices are required to provide

mechanical locking of manual operators, SFC offer a fullcomplement 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.

Security Products

Chainlok

ISO-LOK

Car Seal

The Chainlok is a unique device which

combines the best features of

padlocks and interlocks.

A durable body and chain made from

316 Stainless Steel makes it suitable

for use in the most hostile

environments. Chainlok comes with

O.5m chain as standard (longer

lengths available on request).

Flag style 'Colour Aware Key' enables

incorporation into interlock (key

exchange) systems.

Flip caps prevent ingress of foreign

matter when key is removed.

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.

For 'one-time-only' securing of manual

operators, including securing of

manual valves, switches, enclosures. A

simple 'break-away' screw secures the

seal in place. Removal can only be

achieved by cutting the seal cable.

Two body and cable sizes are available,

along with varying lengths of cable.

Cable breaking strains are available to

1750kg.

Re-usable car seals are also available.

Ideal for use in commissioning procedures


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Specials

Pressure Protection - using 3-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.

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.


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Modular Double Block & Bleed Valve

Customer Problem:

Restrictions of space require that amodular 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.

3-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. Whenoperating the isolating valve, air pressure

to the actuator is vented to atmosphere,

thus completely disabling the valve which

will then operate automatically to its

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.


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Specials

Needle Valve Locks

Explosion Proof Interlocked Switch

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.

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 lockprovides 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.


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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

trap 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.

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.

Pneumatic Control Valves


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Flexi-Drive

In a hazardous area, below water, in a confined

space, in a pit, where noxious fugitive emissions

prevail or where valves are just simply out of

reach is the answer.


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Description

is a very versatile product consisting of two stations, joined by aunique patented linear drive cable. This equipment enables valves and other wheel-

operated devices in remote, hard-to-reach or hazardous locations to be operated

easily from a conveniently located handwheel.

Developed to operate valves in inaccessible locations, can be applied

to any conventional wheel-operated valve/device, in oil, gas and chemical processing

plants, or any other industrial application. It is suitable for underwater use and will

function reliably in all climatic conditions.

The cable system can deliver adequate torque output for most manual valve situations

and 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.

Remote Cable Drive Valve Operators

The cable system can be

passed around and through

walls, bulkheads, floors and

any other obstacles to reach

the host valve.


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Operator Station ActuatorOperator stations are available in a variety of different 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. The precision gear-cable interface provides a positive force

to the helix cable, which travels through the flexible conduit to

the valve station actuator.

1

Material Spec

316 Body Castings

PB1 Bronze Bearings

IP65 Rating

Capability Over 60 Metres

Can Accommodate 540 Bends

Min Cable Bend Radius 300mm

High Torque Capacity

Totally Maintenance Free

Adaptable To Any Conventional Valve

Flexi-Drive

Valve Station Actuator3

Helical Drive Cable2

SFC systems comprise

of four basic elements:

1 Operator Station Actuator

2 Helical Drive Cable

3 Valve Station Actuator

4 Valve Drive Coupling

(designed to suit the host quipment)

Operation

Valve Drive Coupling Reaction Device4


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Remote Cable Drive Valve Operators

INDICATOR

TURN HANDWHEEL

WATER

LEVEL

What Industry?

Practically any industry where valves are used would benefit fromthe Flexi-Drive System. SFC can design and install Flexi-Drive to

meet strict safety guidelines and regulatory body requirements.

Additional details of all products illustrated are available on our

web site at www.smithflowcontrol.com


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Easi-Drive

Easi-Drive

Low cost alternative to permanent dedicated actuators.

No requirement for dedicated power supply.

Operates from adjacent plant air or single-phase electrical supply.

Suitable for use in all Hazardous Areas.

Ideal for minimum facilities installations.

Suitable for all climatic conditions.

Wide band torque capability with variable torque adjustment as standard.

Ideal for moving tight or partially-seized valves.

Adaptable to any size/type of valve.Eliminates operator fatigue and greatly reduces the risk of injury.

Reduces work crew tasks to one-man operation.

Fully portable - can manage banks of valves with a single drive tool.

Standard equipment and basic

specifications:

Pneumatic, electric and hydraulic 'drive

guns' available.

Local pistol grip type tools available.

Barrel type tools.

Customised valve drive adaptors.

Standard hose length supplied: 3 meters.

Air supply recommendations: 840 I/m

(30cfm) @ 5.5 bar (80psi).

Guns available with a range of torque

outputs: 100 Nm (74 Ibf ft) to 100,000

Nm (73, 700 Ibf ft).

Torque safety cut out facility.

Continuous run and 'dead mans handle'options.

Calibration certificates supplied.

Typical gear-operated gate

valve,

pneumatically

driven using a

'universal', bolt-on

handwheel drive

plate and reaction

device.

Typical gear-operated ball

valve, pneumatically driven

using a universal bolt-on

handwheel drive plate and

bespoke (custom made)

reaction device.

Three simple steps to easi-drive

installation and use:

1 Decide if you want to retain

the option of manual valve

operation via the handwheel.

2 Install the relevant easi-drive

equipment.

3 Connect drive gun to power

supply (pneumatic, electric or

hydraulic).


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27

Portable Valve Actuators

Easi-Drive is an efficient and cost-effective alternative to a

dedicated actuator. Wherever you have manually-operatedvalves that have high operating torques, hundreds of handwheel

turns to open/close or are just difficult to operate then Easi-

Drive is your solution.

Each drive tool has a unique serial number and is supplied with

its 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.

Product Features

Certificate of Calibration

Smith Flow Control can also supply an electrical

version of the Easi-Drive with features including:

Pistol grip.

Range of voltages.

Customised valve drive adaptors

Switchable maximum torque level feature

LCD display indicates direction of drive andcurrent maximum torque

Output +1- feature buttons to adjust torque

CE and EMC certified

Calibration certificate

Also available is a range of hydraulic Easi-Drive

operators, features include:

Powerful continuous rotation.

Air and electric powered hydraulic pumps available.

Can be used subsea via umbilicals and ROV's.

Customised valve drive adaptors.

Calibration certificate.

Options

Pneumatic Tool

Electrical

Hydraulic

BatteryOperated


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29

....... '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

ILLUSTRATION STATUS:

PSV1 on line: PSV2 isolated

Block Valves V1, V2 & V4* are Locked Open (LO.)

Block Valve V3 is Locked Closed (LC)

*Spare outlet (downstream) block valve normally LO especially if

lower pressure rated than corresponding inlet (upstream) block

valve

Requirement:

There is always an open path to relief.

(Inlet block valves V2 & V3 must never be closed at the same

time)

Maintenance Task:

To commission PSV2 into service.

To isolate and permit removal of PSV1 for testing/servicing.

Work Sequence:

1. Key 'D' is issued from the Control Room to initiate the Permit

to Work

2. Key 'D' unlocks and enables the opening of spare inlet block

valve V3

3. V3 is operated to open and is LO by removing Key 'C' - PSV2

is now on line.

4. Key 'C' is transferred to unlock and close inlet block valve V2

5. V2 is LC by removing Key 'B'

6. Key 'B' is transferred to unlock and close outlet block valve V1

7. V1 is LC by removing Key 'A'

The return of Key 'A' to the Control Room closes-out the work

permit and enables the issue of instructions for removal of PSV1

for testing and servicing.

Twin PSV Changeover Sequence

It should be noted this interlock arrangement further ensures

that the higher pressure rated inlet block valve V2 is closed

before its corresponding lower pressure rated outlet block valve

(V1). Conversely, this key interlock arrangement would also

ensure opening of low pressure outlet block valves before

opening of high pressure inlet block valves.

PSV 1V1 - Keys A & B

V2 - Keys B & C

V4 - Keys E & D

V3 - Keys C & D

PSV 2


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30

Applications Pressure Protection

Mechanical Principles

(Bleed devices fitted into closure opening

mechanisms are alone an unreliable

safety arrangement to detect the

presence of residual product. They are

prone to wax or hydrates formations

which can obstruct the bleed channel

inside the vessel thereby misleading the

operator to believe It Is safe to open the

closure}.

SFC interlocks can be specified to ensure the minimum safety

arrangement of interlocking the vessel vent valve with the pig trap

closure. This arrangement ensures (to the exclusion of all other

methods) the vessel VENT valve is OPEN before any attempt can be

made to open the closure.

With interlocks fitted to both the vent valve and pig trap closure, a key is

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.

Pig Traps

Pig trap accidents involving operator intervention can be

prevented by SFC coded-card 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.


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31

Safe Loading and Unloading of Pig Traps

Pig Traps

Further procedure sequences can be regulated by interlocks to

include drain valves, nitrogen purge and water flush valves,

corrosion inhibitor and isotope functions, and indeed main

inlet/outlet and kicker valve functions - every system is designed

to meet clients' unique operating conditions/requirements.

Key interlocks can be integrated

into pig trap control systems even

where the main inlet/outlet valves

and kicker valve are actuated

(MOV's). In this situation,

launching or receiving pigs is a

semi-automatic process with

operator intervention limited to

push-button action either through

a local control panel or effected

from a remote control station.

Indeed, these valves may even be

programmed with ESD functions.

However, when it comes to

loading or unloading of pigs, an

abnormal condition arises where

software or electronic interlocking arrangements between these

valves are suspended through the necessity to isolate these

valves both from 'Remote' and 'Local' settings to the 'Off'

position. An SFC coded-card key interlock system can be fitted to

these valves to mechanically prove their 'closed and isolated'

status - releasing a key which then

enables operation of manually-

operated valves related to vent,

drain, N2 purge and water flush

procedures before enabling any

attempt to unlock and open the pig

trap closure.

Only an SFC coded-card key

interlock system can achieve the

condition of creating a positive link

that makes the operation/status of

MOV's and manually-operated

valves completely interdependent

and absolutely reliably ensures

total isolation, venting and draining

of the vessel BEFORE any attempt

can be made to open the vessel

closure!

....."Imagine the consequences of opening a pig trapclosure with product in the barrel"

....."Imagine the effect of attempting to pass a pig througha partially open outlet valve"

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

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

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 & SphereFacilities).

Shell DEP 31.40.10.13 - Gen : Design of Pipeline Pig Trap Systems.


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32

Applications CO2 Fire Deluge Systems

Fire Deluge Systems

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

areas are occupied only on an occasional basis usually for the purposes of

inspection, maintenance or repair.

Mechanical Principles

CO2 is potentially fatal - anyone who may

become trapped in an enclosed space

flooded with CO2 would very quickly

suffocate.


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33

.......'what's colourless, odourless, is all around us andcan kill a person in less than 2 minutes' ? .......

key(s) which enable isolation of the CO2 supply. Based on a key

exchange principle, further keys are released which enable

unlocking of the access door(s) and permit the entry of the

worker(s) to undertake the task at hand.

This safety solution from SFC fulfills the safety requirements of

NFPA12 * and BS 5306. #

* National Fire Protection Association (USA) - Carbon Dioxide

Extinguishing Systems - 1993 Edition

# British Standard - Part 41986 - Specification for Carbon

Dioxide Systems

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 aworker to strike a panic

button or crash rail that

mechanically overrides the

door latch mechanism.

Safe Practice

Safe practice requires an arrangement which prevents casual or

unauthorised access into a (CO2) protected space and also

enables emergency exit at all times from the protected area. The

safety arrangements should also ensure that all doors and

access hatches remain locked during periods of normal

operations and that access to the protected area is controlled

and authorised only by the appointed authority.

SFC interlock systems can be applied for maximum effect to

permit access only under the strictest conditions. Access for

inspection or maintenance purposes is only possible by the

issue of an initiating 'permit key' by the appointed authority. This

key may be used to activate visual or audible alarms which

denote 'work in progress' and / or the release of secondary


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Handwheel Drive Form

AA = ..............

BB =...............

CC = ..............

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

Y = ................

Z = ................

W = ...............

X =.................

34

Main Dimensions

A = . . . . . . .

B = . . . . . . . . .

F = . . . . . . . . .

I = . . . . . . . .

K= . . . . . . . . .

M = . . . . . . . .

Q =. . . . . . . . .

S = . . . . . . . . .

U =. . . . . . . . .

W = . . . . . . . .

Z = . . . . . . . . .

BB =. . . . . . . .

LL = . . . . . . . .

A1 = . . . . . . . .

C = . . . . . . .

G = . . . . . . . . .

J = . . . . . . . . .

L = . . . . . . . . .

N = . . . . . . . . .

P = . . . . . . . . .

R = . . . . . . . . .

X = . . . . . . . . .

AA = . . . . . . . .

CC = . . . . . . .

Gate Valve Fill In Sheet (Specimen only)

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

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

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

Handwheel size . . . . . . . . . . . . . . . .

A/F

THK

HWHEEL RETAINING NUT


35/40

35

Handwheel Stem Form

Main Dimensions Orientation

Gearbox Fill In Sheet (Specimen only)

A = . . . . . . . . .

B = . . . . . . .

C = . . . . . . . . .

D = . . . . . . . . .

E = . . . . . . .

F = . . . . . . . . .

G = . . . . . . . . .

H = . . . . . . . . .

I = . . . . . . . .

J = . . . . . . . . .

J1 = . . . . . . . .

K = . . . . . . . . .

L = . . . . . . . . .

X = . . . . . . . . .

Y = . . . . . . . . .

Z = . . . . . . . . .

AA = . . . . . . . .

A1 = . . . . . . . .

B1 = . . . . . .

KW = . . . . . . .

M = . . . . . . . .

M1 = . . . . . . .

M2 = . . . . . . .

M3 = . . . . . . .

N = . . . . . . . . .

P = . . . . . . . . .

Q = . . . . . . . . .

R = . . . . . . . . .

S = . . . . . . . . .

T = . . . . . . . .

T1 = . . . . . . .

T2 = . . . . . . .

U = . . . . . . . . .

(V) = . . . . . . . .

W = . . . . . . . .

Or

PCD

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

Pressure Rating . . . . . . . .

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

Handwheel Size . . . . . . . .

Number of Turns . . . . . . .


36/40

36

Ball Valve Fill In Sheet (Specimen only)

Main Dimensions Typical Other Form Types

A = . . . . . . . . .

B = . . . . . . . . .

C = . . . . . . . . .

D = . . . . . . . . .

E = . . . . . . . . .

F = . . . . . . . . .

G = . . . . . . . . .

H = . . . . . . . . .

I = . . . . . . . . .

J = . . . . . . . . .

K = . . . . . . . . .

L = . . . . . . .

M = . . . . . . . .

M1 = . . . . . . .

M2 = . . . . . . .

M3 = . . . . . . .

N = . . . . . . . . .

O = . . . . . . . . .

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

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

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

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

AA = ..............

CC = ..............

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

BB = ..............

Note: Please note that this fill-in sheet is forexample purposes only.

Please contact our technical sales team,

should your valve differ significantly from

the illustration shown.

Flow Direction

of stem(thread size and pitch)


37/40

37

Valve Interlocks

a) The size of the valve to be fitted with each interlock i.e. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

b) The type of valve i.e. Ball, Gate, Globe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

c) The method of valve operation i.e. Lever, Handwheel, Gearbox or Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

d) The required sequence of operation for the interlock system

i.e. two valves, one starts open, one closed - never both valves to be closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

e) Any drawings or P&ID documents that seem appropriate to help us

Information to help us provide you with a quotation:-

Drawing showing system requirements:

Note: If you decide to place an order with us, it would expedite the supply of the material to you if the following

information could be supplied or confirmed in your purchase order:-

We trust that the information supplied is sufficient for your purposes and look forward to supplying your interlock requirements in

the near future. Should you have any queries, then please do not hesitate to contact us, using the above reference, or visit our

website at www.smithflowcontrol.com

a) Full details of all valve top works on which interlocks

are to be fitted or details of the valve supplier (order

number, type, size, class model number, operator, etc)

in order that we can obtain the necessary details on

your behalf. Alternatively, we can quote to survey at site

or free issue valves can be surveyed at the above

address.

b) The sequence of valve and interlock operation.

c) Any markings that you or your client require stamped

on the interlock body, for example a tag no PSV001-V1.

d) Any markings and the key tag colours required by you

or your client, for example PSV001-KEY in black text on

a yellow background.

e) The identification of the final site/platform where the

interlocks will be used to enable the appropriate lock

and key codes to be allocated.

The information that we need is relatively straightforward, and is listed below (a - e).

Please Note! All despatch/lead times provided are from receipt of all the engineering data listed at the bottom of the page.

Therefore, if a particular date must be met, it is in your interest to obtain this information at the earliest opportunity.


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38

Flexi-Drive

Easi-Drive

Valve size(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve type(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handwheel diameter (if applicable) . . . . . . . . . . . . . . . . . . . . . . . . .

Cable length(s) required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number of and total degrees of bends in the cable

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve size(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve type(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current method of valve operation i.e. Handwheel, Gearbox or

Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is the current problem?

i.e. too much time or effort required to operate the valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Essential Information Additional Infromation (Wish List)

Valve torque figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Joined at site or supplied fully assembled? . . . . . . . . . . . . . . . . . .

Are deck or wall penetrations required? . . . . . . . . . . . . . . . . . . . . .

Will the valve ever be submersed? . . . . . . . . . . . . . . . . . . . . . . . . .

Photos of general layout showing valves(s). . . . . . . . . . . . . . . . . . .

Is an operator station pedestal required?. . . . . . . . . . . . . . . . . . . .

Any other environmental considerations?. . . . . . . . . . . . . . . . . . . .

Sketch of system requirements

NB! Full valve topworks would be required in the event of an order (see fill-in sheet)


Drawing showing system requirements:


Note! Full valve topworks details my be required in the event of an order. Please consult the SFC technical sales team for clarification.

Prefered power source:

Pneumatic Electric

Hydraulic Battery

If pneumatic:

a) Does your air supply meet the following minimum

requirements? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

848 1min (30 efm) @ 5.5 Bar (80 psi). . . . . . . . . . . . . . . .

b) Is remote operation required? . . . . . . . . . . . . . . . . . . . . . . .

c) Do you require any extended air supply hoses?

If so, how long? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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39

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 worlds 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 reservesthe 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


40/40

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]

SFC Key Interlocks& Process Management Systems

Documents

Valve Interlock - Smith Flow COntrol