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Section E ASTAVA INTERLOCKING · PDF fileSection E ASTAVA INTERLOCKING SOLUTIONS . Interlocking solutions E 2 - Interlocking solutions 13-3-2009 Rev.C Table of content ... (HIPPS)

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  • Interlocking Solutions

    13-3-2009 Rev.C E 1 - Interlocking solutions

    Section E

    ASTAVA

    INTERLOCKING

    SOLUTIONS

  • Interlocking solutions

    E 2 - Interlocking solutions 13-3-2009 Rev.C

    Table of content page 1) Overpressure protection philosophy 3 2) General information 3 3) Applications 3 4) Site preparation 4 5) HIPPS or PPS 4 6) Astava Interlocking Solutions 5

    6.1 Interlocking manifold .............................................................. 5 6.1.1. Operating an Interlocking manifold ....................................... 6 6.1.2. IEC 61508: SIL 4 Certification................................................. 6 6.1.3. Flowschemes........................................................................... 6 6.1.4. Transbar Mounting.................................................................. 6 6.1.5. P/T ratings for interlocking manifolds................................... 6 6.1.6. Materials................................................................................... 7 6.1.7. Accessories ............................................................................. 7 6.1.8. Ordering matrix Interlocking manifold .................................. 8 6.2 Ordering matrix Interlocking housing ................................... 9

    7) Photo overview of different solution supplied 10 8) Astava flexibility, other options 11

    ASTAVA B.V. Tel: +31-(0)522-237030 Fax: +31-(0)522-237040

    7944 HS MEPPEL THE NETHERLANDS E-mail: [email protected] Internet: www.astava.com

  • Interlocking Solutions

    13-3-2009 Rev.C E 3 - Interlocking solutions

    1) Overpressure protection philosophy Protection against overpressure is normally obtained by means of a cascade of independant layers of defence, such as:

    - Pressure control system to maintain the process within its normal operating envelope

    - Safeguarding system to maintain the process within the design pressure (DP) limits and consequently maintain system integrity

    - Pressure protection by means of a pressure safety relief valve (PSV) or HIPP system, as last

    layer of defence to maintain the process system within maximum allowable incidental pressure (MAIP = 1.1 x DP). The dynamic response of the safeguarding layer (HPSD) should avoid activation of the last layer of defence (HIPPS). HIPPS shall function independantly of any other layer of defence. The combined use of equipment for HIPPS shall not be tolerated.

    2) General information The installation of a non-relieving high integrity pressure protection system (HIPPS) may be considered to prevent and/or reduce the release of toxic gases or large volumes of non-toxic gas, thereby avoiding or reducing environmental impact. The system may also be used for detecting pipeline rupture. In order to prevent operational errors, an interlocking manifold with a foolproof sliding key design, is part of the system. This sliding key principle will only permit closing and opening of isolating valves and vent valves in a pre-determined safe sequence. This will allow on-line calibration of instruments while preventing any faulty operation and consequently eliminating undesired (nuisance) shut-downs. 3) Applications

    - Pipeline Overpressure Protection Systems o replacing mechanical blow-down valves (PSVs) at both ends of a gas transport line.

    - Gas wells, gas treatment plants and underground storage installations

    o avoiding the necessity for very high, large capacity, flares

    - Petrochemical and sour gas processing installations o avoiding large safety release emissions to atmosphere

    - Economical spec-break design in process installations and compressor stations

    o avoiding pressure beyond the most economical design pressure.

    - Protection of river crossings and railway underpasses.

  • Interlocking solutions

    E 4 - Interlocking solutions 13-3-2009 Rev.C

    4) Site preparation Site preparation for interlocking manifolds and pre-assembled housings is in compliance with common practice. The process nozzle on which the Interlocking Solution is being assembled is placed in 12 oclock upright position on a horizontal process pipe. The 2 vertical self draining process pipe will prevent dirt from collecting in the manifold and therefore it will prevent clogging of the manifold. The Interlocking manifold is engineered in such a way to maximise the self draining of the complete solution

    5) HIPPS or PPS A High Integrity Pressure Protection System (HIPPS) or a Pipeline Protection System (PPS) is designed around the following modules or components, see above mentioned scheme:

    - Astava Interlocking Solution (A+B)

    - Logic Solver (C)

    - Safety valve (D)

  • Interlocking Solutions

    13-3-2009 Rev.C E 5 - Interlocking solutions

    6) Astava Interlocking Solutions The solutions offered by Astava consist out of two separate parts:

    1. Interlocking manifold

    2. Interlocking housing (see section 6 page E9) 6.1 Interlocking manifold General Astava Interlocking manifolds consists out of a one piece body with a 2 flanged connection with a nominal inlet size of DN 50. The large inlet size is being engineered to avoid blockage or clogging of gasses and fluids. However other options like NPT, BSP, BW, or SW are also available but are not used frequently.

    Functionality: 1 out of 2

    Functionality: 2 out of 3

    Functionality: 1 out of 4

    From the common inlet connection of DN 50 separate internal bores are applied differing in size from 5 up to 10 mm. Each transmitter has a separate impulsline, which result in the required separate, independent pressure measurement.

  • Interlocking solutions

    E 6 - Interlocking solutions 13-3-2009 Rev.C

    6.1.1. Operating an Interlocking manifold The sliding key arrangement mechanically enables operators to close one isolating valve at a time, thereby isolating one pressure transmitter or pressure switch only. After closing the isolating valve, the key is at a lower level in the slotted plate. It can only be moved to the corresponding vent valve, which is now at the same lower level. The sliding key system is valid for all types of interlocking manifolds. The valves being on different levels, the sequence of opening and closing the various valves cannot be changed. Operator mistakes cannot be made. The mechanical interlocking system is providing maximum safety for the operator due to sequence of operation as well as maximum availability of clients installation or piping system. 6.1.2. IEC 61508: SIL 4 Certification The complete operating facility, often called the Interlocking manifold or High Integrity Manifold Block (HIMB) has been tested and examined by TUV Systems GmbH in Germany in accordance with the IEC 61508. The test resulted in certification of the Astava Interlocking with a Probability of Failure on Demand (PFD-value) of:

    PFD avg = 4,26 e-5 resulting in a Safety Integrity Level

    Certified SIL 4

    The complete report on SIL 4 certification is available on request at Astava 6.1.3. Flowschemes The flowscheme within the interlocking from process connection to measuring device can differ in various option, herewith the most common:

    - Block-bleed-block-test - Block-block-bleed-test - Block-bleed-test

    6.1.4. Transbar Mounting As a standard Astava applies a Transbar mounting for all measuring devices which eliminates all compression fittings and tubing. The Transbar is bolted to the Interlocking Manifold and flanged pressure transmitters (DIN 19213) can be bolted directly. For screwed pressure transmitters and pressure switches Astava provides adaptors which can be bolted to the Transbar. 6.1.5. P/T ratings for interlocking manifolds The P/T rating of an interlocking manifold is primarily determined by flange rating and flange material. Standard ratings are 150 -2500 lbs or up to 10.000 psi. Also important are the maximum given to the stempacking applied within the Interlocking operating valves.

  • Interlocking Solutions

    13-3-2009 Rev.C E 7 - Interlocking solutions

    6.1.6. Materials As a standard material AISI 316 (L) material is being applied on all wetted parts. Besides this lowest grade of material also Hastelloy, Inconel, Incolloy, Duplex, Monel and Titanium are being applied 6.1.7. Accessories Based on customer specification a variety of accessories is available for the Interlocking manifolds. Standard configuration since the year 2001 contains a sliding key in slotted plate on side of manifold, however further options like minimess connectors and testing through vent instead of seperate test connections are available. For possibilities please ask your contact person within Astava.

    The -001 option: Operating key on side of manifold Proximity switches for interlocking manifold

  • Interlocking solutions

    E 8 - Interlocking solutions 13-3-2009 Rev.C

    6.1.8. Ordering matrix Interlocking manifold Below given are most general options available for the Astava Interlocking Solutions. While each solution is composed on customer specification, Astava has available a wide range of accessories. For special alloys, connections or any other requirement please contact Astava.

    Interlocking manifold 2 Individual test, block-bleed functionality for one instrument

    4 Individual test, block-bleed functionality for two instruments

    6 Individual test, block-bleed functionality for three instruments

    9 Individual test, block, bleed and block functionality for three instruments

    12 Individual test, block, bleed and block functionality for fou

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