Interlocking Solutions

Section E ASTAVA INTERLOCKING SOLUTIONS

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Table of content 1) Overpressure protection philosophy 2) General information 3) Applications 4) Site preparation 5) HIPPS or PPS 6) Astava Interlocking Solutions 6.1 6.1.1. 6.1.2. 6.1.3. 6.1.4. 6.1.5. 6.1.6. 6.1.7. 6.1.8. 6.2

page 3 3 3 4 4 5

Interlocking manifold .............................................................. 5 Operating an Interlocking manifold ....................................... 6 IEC 61508: SIL 4 Certification................................................. 6 Flowschemes........................................................................... 6 Transbar Mounting .................................................................. 6 P/T ratings for interlocking manifolds ................................... 6 Materials................................................................................... 7 Accessories ............................................................................. 7 Ordering matrix Interlocking manifold .................................. 8 Ordering matrix Interlocking housing ................................... 9 10 11

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

Tel: +31-(0)522-237030 Fax: +31-(0)522-237040 7944 HS MEPPEL THE NETHERLANDS Internet: www.astava.com E-mail: info@astava.com

ASTAVA B.V.

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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.

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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

4) Site preparation

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)

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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)

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.

6.1 Interlocking manifold

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.

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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.

6.1.1. Operating an Interlocking manifold

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

6.1.2. IEC 61508: SIL 4 Certification

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

6.1.3. Flowschemes

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.

6.1.4. Transbar Mounting

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.

6.1.5. P/T ratings for interlocking manifolds

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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

6.1.6. Materials

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.

6.1.7. Accessories

The -001 option: Operating key on side of manifold

Proximity switches for interlocking manifold

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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 4 6 9 12 TT TL F J R S N B Individual test, block-bleed functionality for one instrument Individual test, block-bleed functionality for two instruments Individual test, block-bleed functionality for three instruments Individual test, block, bleed and block functionality for three instruments Individual test, block, bleed and block functionality for four instruments Transbar mounting on top of interlocking Transbar mounting back of interlocking

6.1.8. Ordering matrix Interlocking manifold

Transmitter mounting

Flange size 2 ASME B16.5 - 2003 RF. Flange 2 ASME B16.5 - 2003 RTJ. Flange 2.1/16 API BX Flange Threaded connection NPT Norsok standard L005 2" Butt weld connection (size depending on schedule) Duplex / Flange ratings (barg) AISI 316 254Smo 10 150 lbs 19 barg 20 barg 11 300 lbs 50 barg 52 barg 12 600 lbs 100 barg 104 barg 13 900/1500 lbs 248 barg 259 barg 14 2500 lbs 414 barg 431 barg 18 API 10,000 psi 690 barg Body material Other material Stem material 600 603 605 611 612 691 694 Duplex, W. Nr. 1.4462 Alloy C-276 Duplex, W. Nr. 1.4462 AISI 316 (L) Alloy 625 SuperDuplex 254 Smo (EN 1.4547) AISI 316 (L) Alloy C-276 AISI 316 (L) AISI 316 (L) Alloy 625 Superduplex 254 Smo Alloy K500 Alloy 625 Alloy K500 Alloy K500 Alloy 625 Alloy 625 Alloy 625

Alloy 400 16 barg 42 barg 83 barg 207 barg 345 barg O-ring seal Viton Viton Silicon rubber Silicon rubber Silicon rubber Silicon Rubber Viton

625 / C276 20 barg 52 barg 104 barg 259 barg 431 barg Temp -20/200 Degr C -20/200 Degr C -55/230 Degr C -55/230 Degr C -55/230 Degr C -55/230 Degr C -20/200 Degr C

0 Others on request Explosionproof proximity switches 0 3 .L .D 002 007 012 109 No proximity switches required. 3 Proximity switches for 2 out of 3 interlocking manifold Proximity switch for HIPPS interlocking manifold, Eexi NJ2-12GK-SN (M12x1) Proximity switch for HIPPS interlocking manifold, Eexd 5 mm bore; Minimess test connectors in W. 1.4571 8 mm bore Minimess connectors in W. 1.4571 + Sliding key in slotted plate on side of manifold 10 mm bore; sliding key in slotted plate; Minimess connectors in W. 1.4571 one vent/test 8 mm bore all internal bores sliding key in slotted plate on side of manifold

Options

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6.2 Ordering matrix Interlocking housing
On this page we are showing the ordering matrix. Before specifying the housings the interlocking manifold shall be fully specified as outlined on page E8.
Interlocking housing TS01 Pressure transmitter, 1 pressure switch. TT02 Pressure transmitters. SS0- 2 Pressure switches TTT000 3 Pressure transmitters No measuring devices

Type of transmitter FX01 Flanged transmitter or switch, 1 Screwed pressure transmitter or switch NPT(F) MX0FFF1 Screwed transmitter or switch NPT(M), 1 Screwed transmitter or switch NPT(F) 3 Flanged pressure transmitters or switches

MMM- 3 Pressure transmitters or switches screwed NPT(M) 000 No measuring devices Housing 0 No housing required A H N S U V Blind Housing AISI 316 (L) (W= 700, H=600, D=550) Blind Housing GRP (W=700, H= 700, D= 500) Housing AISI 316 with window safety glass (W=700, H= 600, D= 550) Housing GRP with window safety glass (W=700, H=700, D=500) Housing GRP with window safety glass (W= 430, H = 430, D = 390) Blind housing HA10 cabinet on side (W = 430, H = 390, D =530)

Insulation 0 No insulation I 20 mm polystyrene insulation Heater 0 No heater B block heater 250-25 W, Atex, Eex d 230 V/AC S space heater Thermostat 0No thermostat TThermostat Low temperature alarm 0AWithout low temperature alarm. 1A2PIncluding low temperature alarm. Including Temperature transmitter, Astava PT-100 element probe type

Junction boxes 0JB0- No Junction boxes 1JBG- 1 Junction box polyester 1JBA- 1 Junction box AISI 316 (L) Cable glands 1 Cable glands standard polyamide 4 Cable gland AISI 316 (L) Options 00 No options 01 02 03 earth rail rittal dk pe-rail driptray AISI 316 material Safety switch GHG 151 1301 R001 3 pole Eex de IP66

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7) Photo overview of different solution supplied
(inlet size all DN 50)

2 oo 3 block-bleed 8 mm

1 oo 2 DBB 5 mm

1 oo 2 block-bleed 5 mm

2 oo 3 DBB 10 mm

REFERENCES: ASTAVA INTERLOCKING SOLUTIONS

Among others:

QATAR PETROLEUM WINTERSHALL AG TOTAL BP/AMOCO AGIP

ADMA OPCO SHELL (Global Opcos) STATOIL E.ON/Ruhrgas

ADCO

GASUNIE

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8) Astava flexibility, other options
The above mentioned solutions are solutions for different costumers. In the ordering matrices is always an optional code possible. The code ends with 000 for different options. When ASTAVA is joining projects in an early stage, we are able to provide an optimal solution for each measurement case which will result in cost savings for the total project. If you have any remaining questions regarding the above direct mounting systems don'hesitate to t contact: ASTAVA B.V. Industrieweg 30 7944 HS Meppel The Netherlands Telephone : Fax : E-mail : Internet : +31-(0)522-237030 +31-(0)522-237040 info@astava.com http://www.astava.com

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