Valves Interlocks for Industrial Processes

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For different industrial valves we supply interlock solutions.

Alcatraz’ industrial interlocks can be used to protect humans and ensure safe operations. Yearly several 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.

Industrial interlocks applications are well suited for petrochemical, oil & gas, and tank storage companies. These companies have applications like pig traps, pressure safety valves systems and other valve applications. These could be dangerous if they are being entered during operations / maintenance. Our technical engineers will help you find the right solution to protect your employees and machines.

Interlocks for valves

To ensure safe operation of valves, Alcatraz Interlocks provides multi turn locks, with both single and double keys in two sizes to fit correctly on all valve sizes.

Alcatraz integral multi turn (type DML/SML) valve interlocks fit on all types of handwheel operated valves, such as gate,ball, globe, and all gear operated valves. The interlocks are easy to install, even when the valve is in a live process.

They are mounted on multi turn valves to interlock the locked open and/or locked closed position of the valve. The key movement is only possible in fully open / closed position thus providing an extra confirmation that the valve is in the exact desired position as compared to car seals etc.

Alcatraz’ Interlocks for globe valves can be used to control valve flow, ensure safe valve operation, pressure safety valve systems and pig trap systems.

Double block and bleed valve

In order to ensure safe operation of double block and bleed valves, Alcatraz Interlocks provides quarter turn and multi turn interlocks, with both single and double keys in three sizes: small, medium (only quarter) and large.

Double Block and Bleed valve Interlocks come in several variations depending on the type of Double Block and Bleed valves (DBB) and the requirements with regards to Interlocking them. By default, both isolators are interlocked, optionally the bleed valve can also be interlocked. The initiating key from the control room or another Interlocked application is inserted into the first isolator interlock to be unlocked and closed, releasing its locked closed key which is used to unlock and close the 2nd isolator section of the DBB, the 2nd key is released and confirms the DBB valve is fully isolated, the key can now travel further to another application, alternatively it can be used to unlock and open the bleed valve to bleed any excess medium in the DBB valve.

Interlock for Motor operated valve (MOV)

Alcatraz MOV Interlocking applications, are designed to suit Electrical, Pneumatic & Hydraulic controlled actuators. Our solutions are designed to mechanically block various parts of the actuator, such as the local power supply, valve position indicator plate located on top of the gear-unit, and the manual override. Next to our standard mechanical items we can also fit electronic components for digital feedback. It mechanically blocks various parts of the actuator: the power supply, the valve position indicator plate on top of the gear-unit and the manual override of the actuator. Alcatraz Interlocks has designs for different systems. By the exchange of mechanical coded keys between the different components of the actuator, operation of the actuator can incorporated into mechanical interlocked systems.

Quick opening and closure locks

The Alcatraz closure door lock is designed to interlock the closure door of a pigging vessel. The quick opening closure lock prevents the bleed plug from being removed, this means it prevents the closure door from being opened. Only the insertion of a dedicated key releases access to the bleed bolt, so it can be removed. This key is only released after the door is closed and the bleed plug is back in its place.

During the pig launching and receiving procedure, the operating written procedures must be followed carefully by the operators. If the vessel is not drained and vented, or when the isolation valves are not fully closed before opening the closure door, extremely dangerous situations can transpire. The Alcatraz Interlocks closure lock (CL), as a part of an interlocking sequence, prevents these hazardous situations. By guaranteeing and safeguarding that the isolation valves are closed, and the vessel is vented and drained before the closure door can be unlocked and opened.

Key exchange box

A key exchange box (KEB) is used when any number of keys need to release any other numbers of keys. For example, when a single key from a switch needs to release 5 keys to go to several hatches the key exchange box makes this exchange: the key from the switch is inserted, only after which any number of keys can be removed to operate other interlocks. Only when all keys have been returned does this unit allow removal of the initiating key. These key exchange boxes are purely mechanical; however they can be designed to house any kind of electromechanical setup including limit switch or linear solenoid magnets.

The key exchange box of Alcatraz Interlocks comes in various sizes based on your exact needs.

Our Products

Multi Turn Interlock: -3sizes, -Solution for all operations, -Parallel splined HW Connection

Quarter Turn Interlock: -3sizes, Sliding or fixed levers, -ISO & non-ISO footprint suitable

Special Applications: -Cryogenic & more, -Bespoke Mounting solutions, -Switch/Sensor integration

Closure Door Interlock: -Compact & Robust solution, -Available Solenoid, Switch & sensor integration, -Solution for all type of doors.

Double Block and Bleed: Multi & Quarter Turn solutions, -Compact, -Direct control

George: -Partial Stroke Testing, -ESD Function Control, -Maintenance Process Safety

Direct Actuated Valve Interlock: Control, Checking & Isolation, Electric, Pneumatic & Hydraulic-Integrated Control

Key Exchange & Timer: Mechanical & Digital Time delays, Solenoid, Push Button, Switches & Sensors, Configuration fully adaptable.

Digital Key Control: Communication to your DCS/PLC, Store, Detect & Control, Flexible to Clients requirements.

Ex’d Key Control Cabinet: Suitable for all Process Zones, -Full Range of Atex Certification, Client bespoke configurations.

Sequence Control Units: Linear & Non-Linear sequences, Light, Compact & Weatherproof, Digital integration available.

Key Management Interfaces: Store, Control & Intelligence

Interlock Applications

Redefining safe valve options with our outstanding interlocks

Our 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. Our products have a history within Oil & Gas and Chemical markets, 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. By that we want to inspire you with our applications stories regarding interlocking in the different markets.

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.

Advantages of Alcatraz Interlocks for pig trap applications:

1) With the piping networks becoming more and more extensive, pig traps may need to be in remote locations and hence can be subject to extreme weather conditions. Alcatraz Interlocks can operate successfully in a wide variety of extreme weather conditions from a desert environment laden with moisture and very fine dust to extreme cold conditions with temperatures as low as -50°C.

2) As pig traps are used intermittently for maintenance purposes, so there can be quite a long time in which interlocks are not operated at all. Our interlocks are designed to avoid ingress of dirt or contamination by environmental factors irrespective if the key is inserted or not with the help of an automatic closing dust cap and keys which encapsulate the lock portion when entered. This helps in avoiding any surprises when the Interlocks need to be operated.

3) Easy to operate also with gloves.

4) Sometimes the space available for Interlocks on pig traps system is limited (e.g., In FPSO’s). Our Interlocks can be installed in the most convenient way possible (even upside down) without any effect on the key operation. This is with the help of the partial linear and rotational action of the key.

5) The hand wheels / drive tubes all have a parallel splined connection. This spreads operating forces, prevents any loosening of hand wheels (even in scenarios with excessive vibrations) and higher HSE standards.

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.

Solutions to avoid cross contamination?

To automate an existing tank farm from there standardly known hand operated valves, to more actuated systems, is a hugely expensive exercise, which requires Capex investment. However, Alcatraz again can support, by combining a selection of our Mechanical Keyed interlocks which creates a first level of protection, as valves cannot now be incorrectly operated, these items simply replace the current valve hand wheel or lever.

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.

• Catalyst / Desiccant regeneration

Advantages of Alcatraz Interlocks

1) Due to the minimal size and their individual bolt-on nature the Lock Portions and Keys can be fitted on bespoke designed solutions for the full range of applications across all fields of valve interlocking, instrumentation, control panels, atomisation easily connecting (and integrating) to any form of electronic/mechanical components.

2) We can complement our Interlocks with Key Exchange Boxes, Sequence Control Unit, and electrical cabinets to fulfil even the most complex sequence requirements as well as the process requirements related to obtaining certain temperature / pressure values before continuing with the sequence further.

3) In some cases, especially for maintenance scenarios, there can be quite a long time in which interlocks are not operated at all. Our interlocks are designed to avoid ingress of dirt or contamination by environmental factors irrespective if the key is inserted or not with the help of an automatic closing dust cap and keys which encapsulate the lock portion when entered. This helps in avoiding any surprises when the Interlocks need to be operated.

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. Alcatraz 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.

Twin or multiple safety relief valve systems are usually fitted with isolation block valves upstream and downstream of each safety relief valve. It is imperative to open the block valves isolating the spare relief valve before the block valves of the work-piece relief valve are closed. This is a more acute problem if the respective relief valves and isolating block valves are distant or out of sight of each other.

Advantages of Alcatraz Interlocks for PSV system applications:

1) With the piping networks becoming more and more extensive, pig traps may need to be located in remote locations and hence can be subject to extreme weather conditions. Alcatraz Interlocks can operate successfully in a wide variety of extreme weather conditions from a desert environment laden with moisture and very fine dust to extreme cold conditions with temperatures as low as -50°C.

3) Easy to operate also with gloves.

Our Services is inclusive of the following:

Our team of service experts are available to assist you with. Measuring, Installation Commissioning, and Preventive Maintenance matters. To ensure the safety and performance of your people processes, and environment. We are dedicated in providing the best technical support & aftersales.