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SAFETY SOLUTIONS

Engineering Services

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The needed to focus on safety to protect you, your plant, and your process.

Process & Pressure Safety

We deliver process and pressure safety solutions for diverse applications in the oil & gas, energy, Marine and industrial sectors. Our process and pressure safety products and services include:

Gas and flame detection (fixed and control panels)

Gas Detector Fixed Controllers & Alarm/Fixed Gas Detector Products/Fixed Flame Detectors/Area Gas Detectors/Fixed Wireless and Wireless alarm/Personal Safety Gas Monitor/Gas Measurement Devices/Legacy Products/Application Engineering. Gas & Flame Detection Applications for Oil & Gas, Energy Fire, FMCG, Data Management.

Valve interlocking

We operates and supports a wide selection of Global Industrial Processes, keeping these working environments safe and secure. Our complete range of mechanical & Electro-mechanical Interlocks are products which are fully adaptable to supply multiple solutions to those requested end-user requirements.

Our products have a history as a solution provider, we ensure process applications within the Green Energy, Oil & Gas, Chemical & Tank Storage segments, where they ensure a safer workplace during Daily Operations, Maintenance & Shutdowns.

However Mechanical & Electro-mechanical interlocks are applicable to many other markets and applications. It is our goal to share the story, to operate safely, and prevent failures which can hurt humans, the environment we live in, and prevent valuable product losses.

Interlocks for Industrial Processes: Industrial interlocks can be used to protect humans and ensure safe operations. Yearly a few accidents happen during operations and maintenance. We have multi turn and quarter turn locks for gate valves, globe valves and gear operated valves to prevent these failures and accidents.

Interlocks for Machine Guarding: Machine guarding interlocks can be used to guard machines and ensure safe operations. Yearly a few accidents happen during operations and maintenance. We have bolt locks, door locks and car seals to prevent these failures and accidents. Machine guarding applications are well suited for paper and pulp, water treatment and food & beverage companies. These companies often use mixers or separators, and these could be dangerous if they are being entered during operations. Our technical engineers will help you find the right solution to protect your employees and machines.

Pig Traps: Pipelines are routinely cleaned with the help of pigs that scrape the lines clean. This is done to remove any debris deposited thus preventing corrosion and undesirable increase in pressure drop.

These pigs are also utilized for commissioning / decommissioning of pipelines as well as to detect and measure the pipeline defects such as corrosion, wall defects and cracks.

This is achieved with the help of Pig traps which launches the pigs into the piping network from one side and receive it at the other end in a safe and controlled manner.

Role of Interlocks

The process of launching and receiving of pigs can be a hazardous operation if performed out of sequence. Hence a safety system is required that can control the process without any dependence on human judgement.

Mechanical Key Interlocks will ensure that sequence of valves and end closure operations is always performed in a predefined, single, and unchanging path. Although there can be variations in the sequence to be performed, the following scenarios are always kept in mind:

Avoiding unintended pressurization of pig trap.

The quick opening closure can only be allowed to open only after depressurization of traps.

It should not be possible to open mainline and kicker line valves when the quick opening closure is open.

Interlock solution for pressure safety systems

Whether onshore or offshore, maintenance procedures to Safety Relief Systems on live plants is a cause for concern, particularly as an open path to relief must be maintained during all times of the work exercise.

The Interlock PSV system ensures maintenance procedures on safety relief systems operate in a safe sequence. Most modern piping arrangements include spare relief capacity, which enables continuous production while routine maintenance procedures are conducted. This eliminates the need to isolate and shut down the process on a live plant, which has major time and cost saving advantages.

Role of Interlocks

Various API and ASME codes recognize this hazard and recommend the use of interlocks to safeguard the process. By fitting an Alcatraz valve interlock to the upstream and downstream isolating valves, it ensures the process occurs only in the safe, designated sequence and recommendations are fully implemented.

Flow control

Across various Industries to be able to meet the process requirements, it is needed to be able to control what product flows and when. To ensure continuous safe operation it is important that the right products flow in and out of a process, certain flows are maintained during operation of specific equipment, under / over / no dosing is prevented and proper maintenance as well as regeneration is ensured.

Role of Interlocks

Interlocks enable the user to control the position of any valve while simultaneously maintaining product flow to equipment like pumps, reactors etc. These valves may be located in inlet, outlet, bypass, regeneration lines etc of processes thus making Interlocks a universal solution for these situations. Interlocks will ensure that sequence of valves and connected equipment is always performed in a predefined and unchanging path. Although there are widespread scenarios that can be offered within this type of application, a few examples have been given below:

Switchover for flowlines of steam generator system, heat exchanger, reactor etc.

Isolation for maintenance of equipment like boiler, tanks, adsorbers etc.

To avoid over / under pressure, Proper dosing, ensuring correct valve operation when pump is running, Catalyst / Desiccant regeneration.

Tank farming / storage

The demand for tank Storage space is a continuously growing business sector. Meaning the pressure for space within the existing facilities is high. Therefore, using the available infrastructure efficiently and without issues or down time is key to the operators.

This is one of the Key factors Alcatraz Interlocks supports its global Tank Storage clients. With open consultation, we support and ensure the correct valve line-up applications, with a preliminary focus to prevent product contamination, discharging of products in or out of the incorrect tank(s), and the transferring of products from tank to ship / truck within a correct piping line up.

Cross contamination a huge factor

Contamination is naturally a huge factor for any storage terminal. Mistakes have a direct cost, and the facilities reputation in handling a clients produce can be severely impacted. Next to that, these types of incidents can create a possible spike in the global deliveries and pricing of these goods. There are many old and modern facilities, where the lining up of these manual valves correctly, can be challenging due to all the piping modifications over the years.

Even with highly talented and experienced operators, using written procedures, the probability of an incorrect valve being operated or simply left open by mistake, within all the crisscrossing of process lines & valves on site, is still there. Plus, a written procedure does not give a final valve position feed-back to the CCR in a real-time aspect.

Safe Isolation of Passing Valves

The DBB-SAVER is used when maintenance work must be executed on a piece of equipment, whilst bordering installation parts remain pressurized and available for operations.

This piece of equipment must be isolated. This is done by valves. Sometimes, valves are only the initial isolation, which makes it possible to safely place blind flanges afterwards.

Either when working on the equipment directly behind the isolation valves or when placing a blind flange, the isolation valves should not have a leak rate beyond the companies pre-defined standards to ensure a safe working place. In case of explosive and/or toxic media the standard is often tight shut off (TSO), which means zero leakage.

 

Safe sequence control of valves |Rupture and bursting discs | Onstream Pipe Inspection and Remediation | Fugitive Emission Inspection and Flare Leaks Detection.

 Pre- Commissioning (CSU)

After over a decade of research and development, we are pioneering in the use of tracer gas leak detection technologies has quickly launched our company to the world stage. The use of helium, ultrasonic instruments, & infrared optical gas imaging (OGI) allows us to achieve world class inspections at the Commissioning/Start-up (CSU) or Turnaround (TAR) phase of any pressurized system. Leveraging advancements in OGI, Lineriders has developed a cost saving leak detection solution that has proven to put projects ahead of schedule without compromising results.

 Fugitive Emission Management: Regulatory Compliance. Data Management & Analysis.

The price on carbon is here. Our Fugitive Emission Management Program will assist you in achieving your ESG goals. The crews are equipped with optical gas imaging cameras to identify leaks from pipelines and facilities. We conduct single leak identification and multi-instrument inspections that require quantification and data management.

Depending on jurisdictional requirements, we applies these standards to our inspections: EPA’s Method 21, the Oil and Gas Methane Partnership (OGMP 2.0), and AER’s Directive 060. These frameworks aim to strengthen environmental standards relating to the emission of methane.

The US Methane Emissions Reduction Action Plan is going to change the way that we identify and repair leaks in the industry. Cutting pollution at home by a large percentage is the main objective of this initiative. Comprehensive Leak Detection and Repair (LDAR) programs can prevent duplicative visits. A tradesperson can identify and repair leaks before leaving site. Repair confirmations are completed directly after the repair is made. This can translate into cost savings and operational efficiency.

Marine and Fire Safety Solutions

We unique Maritime and safety equipment services which include the Supply, Servicing, and other related services. We provide the sale, service, and repair of a wide range of Marine Fire Safety equipment to our clients.

The cost of high-quality equipment is always a contentious issue with vessel Owners and Operators, but the cost of delays and non-functioning equipment is one-hundred-fold more costly.  With a high focus on safety in the marine industry, substandard or unsuitable equipment for this purpose is more often rejected by clients and class societies during vetting inspections.

 Fire Service

Fire Extinguishers, Foam Compound, Fire Suppression Systems, Dry Chemical Powder, Fire Hosing, Hose Couplings, Fire Fighting Foam, Branch pipes, Hose cabinets, Foam Sample Analysis, Fireman outfits, Fire blankets, Fire Axes, Pyrotechnics, CO2 Systems, Air Quality Testing,

Marine Safety Equipment Services:

Inflatable Life Jackets, ISO Foam Life Jackets, SOLAS Lights, MOB Systems, Breathing Devices and FFE, Immersion Suits, Pyrotechnics, Safety Signage, Fire Control Signs, Mandatory Warning Signs, Marine Posters, Hazard Symbols, Fire Lighting Signs

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