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1、MANUAL INTERLOCKING SYSTEMS FOR SAFETY/RELIEF VALVES DEP 80.46.30.11-Gen. December 1993 DESIGN AND ENGINEERING PRACTICE USED BY COMPANIES OF THE ROYAL DUTCH/SHELL GROUP This document is confidential. Neither the whole nor any part of this document may be disclosed to any third party without the prio
2、r written consent of Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. The copyright of this document is vested in Shell Internationale Petroleum Maatschappij B.V., The Hague, the Netherlands. All rights reserved. Neither the whole nor any part of this document may be rep
3、roduced, stored in any retrieval system or transmitted PDF created with pdfFactory Pro trial version in any form or by any means (electronic, mechanical, reprographic, recording or otherwise) without the prior written consent of the copyright owner. PDF created with pdfFactory Pro trial version PR
4、EFACE DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of: Shell International Oil Products B.V. (SIOP) and Shell International Exploration and Production B.V. (SIEP) and Shell International Chemicals B.V. (SIC) The Hague, The Netherlands, and other S
5、ervice Companies. They are based on the experience acquired during their involvementwith the design, construction, operation and maintenance of processing units and facilities, and they are supplemented with the experience of Group Operating companies. Where appropriate they are based on, or referen
6、ce is made to, national and international standards and codes of practice. The objective is to set the recommendedstandard for good design and engineeringpractice applied by Group companies operating an oil refinery, gas handling installation, chemical plant, oil and gas production facility, or any
7、other such facility, and thereby to achieve maximum technical and economic benefit from standardization. The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where DEPs may not cover every requirement
8、 or diversity of condition at each locality. The system of DEPs is expected to be sufficiently flexible to allow individual operating companies to adapt the information set forth in DEPs to their own environment and requirements. When Contractors or Manufacturers/Suppliers use DEPs they shall be sol
9、ely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, the Principal will expect them to follow those design and engineering practices which will achieve the same level of integrity
10、as reflected in the DEPs. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal or its technical advisor. The right to use DEPs is granted by SIOP, SIEP or SIC, in most cases under Service Agreements primarily with companies
11、 of the Royal Dutch/Shell Group and other companies receiving technical advice and services from SIOP, SIEP or SIC. Consequently, three categories of users of DEPs can be distinguished: 1)Operating companies having a Service Agreement with SIOP, SIEP, SIC or other Service Company. The use of DEPs by
12、 these Operating companies is subject in all respects to the terms and conditions of the relevant Service Agreement. 2)Other parties who are authorized to use DEPs subject to appropriate contractual arrangements. 3)Contractors/subcontractors and Manufacturers/Suppliers under a contract with users re
13、ferred to under 1) or 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users comply with the relevant standards. Subject to any particular terms and conditions as may be set forth in specific agreements with users, SIOP, SIEP and S
14、IC disclaim any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs or any part thereof. The benefit of this disclaimer shall
15、 inure in all respects to SIOP, SIEP, SIC and/or any company affiliated to these companies that may issue DEPs or require the use of DEPs. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall not, without the prior written consent
16、of SIOP and SIEP, be disclosed by users to any company or person whomsoever and the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written co
17、nsent of SIOP and SIEP. The copyright of DEPs vests in SIOP and SIEP. Users shall arrange for DEPs to be held in safe custody and SIOP or SIEP may at any time require information satisfactory to them in order to ascertain how users implement this requirement. All administrative queries should be dir
18、ected to the DEP Administrator in SIOP. NOTE: In addition to DEP publications there are Standard Specifications and Draft DEPs for Development (DDDs). DDDs generally introduce new procedures or techniques that will probably need updating as further experience develops during their use. The above req
19、uirements for distribution and use of DEPs are also applicable to Standard Specifications and DDDs. Standard Specifications and DDDs will gradually be replaced by DEPs. DEP 80.46.30.11-Gen. December 1993 Page 2 PDF created with pdfFactory Pro trial version TABLE OF CONTENTS 1.INTRODUCTION .4 1.2DIS
20、TRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS4 1.3DEFINITIONS 4 1.4CROSS-REFERENCES 5 2.GENERAL .6 3.INTERLOCKING SYSTEMS .7 3.1DISCHARGE TO ATMOSPHERE .7 3.2DISCHARGE TO FLARE.8 4.REFERENCES 11 DEP 80.46.30.11-Gen. December 1993 Page 3 PDF created with pdfFactory Pro trial version 1.INTROD
21、UCTION This DEP, which is a revision of an earlier publication of the same number dated December 1984, covers interlocking systems for fitting to isolating (block) valves installed upstream and/or downstream of safety/relief (S/R) valves. This DEP should be used for designing interlocking systems fo
22、r new construction projects where such mechanical interlocking systems have been specified. For the design of new units for an Operating Company that has operating experience with an interlocking system(s) differing from those described in this DEP, close contact with the Operating Company is requir
23、ed to make the new interlocking system compatible with the existing system(s). Codes of safety and national and/or local regulations applicable to a location invariably stipulate that the required relief capacity shall always be available during plant operation. For installation of block valves on o
24、ne side or both sides of S/R valves, dispensation has normally to be obtained from the authorities. This will usually be granted only if a reliable system is in place to ensure that adequate relief capacity is permanently available. One method of achieving this is by a mechanical interlocking system
25、, the design of which is covered by this DEP. Other methods of achieving this are contained in DEP 80.45.10.10- Gen. It should be noted that the need for block valves and locking systems is directly influenced by the operating and maintenance philosophies for the particular facility. DEP 80.45.10.10
26、- Gen. provides guidance on the overall design of relief systems that minimise the necessity for such block valves based upon operations and maintenance philosophies. 1.2DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS Unless otherwise authorized by SIPM, the distribution of this document is
27、 confined to companies forming part of the Royal Dutch/Shell Group or managed by a Group company, and to Contractors nominated by them (i.e. the distribution code is “C“ as defined in DEP 00.00.05.05-Gen.). This DEP is intended for use in oil refineries, chemical plants, gas plants and, where applic
28、able, in exploration and production facilities and supply/marketing installations. If national and/or local regulations exist in which some of the requirements may be more stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the requirements are the more stringent
29、and which combination of requirements will be acceptable as regards safety, environmental, economic and legal aspects. In all cases the Contractor shall inform the Principal of any deviation from the requirements of this DEP which is considered to be necessary in order to comply with national and/or
30、 local regulations. The Principal may then negotiate with the Authorities concerned with the object of obtaining agreement to follow this DEP as closely as possible 1.3DEFINITIONS The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commiss
31、ioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor. The Manufacturer/Supplier is the party which manufactures or supplies equipment and services to perform the duties specified by the Contractor. The Principal is the
32、party which initiates the project and ultimately pays for its design and construction. The Principal will generally specify the technical requirements. The Principal may also include an agent or consultant authorised to act for, and on behalf of, the Principal. DEP 80.46.30.11-Gen. December 1993 Pag
33、e 4 PDF created with pdfFactory Pro trial version The word shall indicates a requirement. The word should indicates a recommendation. 1.4CROSS-REFERENCES Where cross-references to other parts of this DEP are made, the referenced section number is shown in brackets. Other documents referenced by thi
34、s DEP are listed in (4). DEP 80.46.30.11-Gen. December 1993 Page 5 PDF created with pdfFactory Pro trial version 2.GENERAL For the safety of personnel and plant equipment, the relief capacity of process equipment shall be fully maintained at all times when the plant is in operation or on stand-by u
35、nder pressure. DEP 80.45.10.10-Gen. covers the overall selection of relief system configurations and recommends that, where operations and maintenance philosophies permit, no block valves are installed in relief systems. Where block valves are required, their use should be minimised, e.g. by siting
36、a single block valve on a combined relief header from a processing train, where maintenance is carried out on a train basis (this block valve shall be locked open during operation of the train). Where, for operational reasons, block valves are fitted upstream and/or downstream of S/R valves a system
37、 must be in place to ensure that the required relief capacity is always available. One method of achieving this is by the installation of a proven interlocking system which makes it impossible to block off the operating S/R valve until other similar relief capacity has been connected to the system.
38、Other methods are described in DEP 80.45.10.10-Gen. Where such an interlocking system is specified, the following provisions shall apply. The block valve locks shall be of robust construction with materials which will withstand corrosion in the environment of application and shall be obtained from s
39、uppliers approved by the Principal. The fully fabricated locks shall be secured to the block valves with a tamper-proof fixture, and shall be sealed without performing any hot work. The keys shall fit only the locks for which they are designed. The valve operating mechanism shall allow operation of
40、the block valve only when the proper key(s) is (are) inserted in the lock. All locks and keys shall be provided with unique identification numbers, reflecting the relevant S/R valve number. The selected lock and key type shall have sufficient space for a clear identification system. DEP 80.46.30.11-
41、Gen. December 1993 Page 6 PDF created with pdfFactory Pro trial version 3.INTERLOCKING SYSTEMS Immediately after removal of an S/R valve (with an installed spare S/R valve in operation), another S/R valve or, if not available, a spool piece (not a blind flange) shall be installed in its place. The
42、spool piece shall remain in place until re-installation of the S/R valve. For details of the spool piece, see (3.2.3). NOTE:The reason for prohibiting the use of a blind flange is that if the block valve upstream of the blind flange were to be opened (which the interlocking system will definitely al
43、low to be done) then the block valve upstream of the operating S/R valve could “legitimately“ be closed, thereby eliminating the relief capacity (or, in the case of multiple S/R valves, reducing the relief capacity to below acceptable limits). Two situations (discharge to atmosphere and discharge to
44、 flare), are described in (3.1) and (3.2), both of which are designed to allow the safe removal of an S/R valve for maintenance. A schematic layout of each is shown in Figures 1 and 2. 3.1DISCHARGE TO ATMOSPHERE Spared S/R valves discharging directly to atmosphere (via individual tail pipes) require
45、 block valves only in the inlet lines of the S/R valves. These block valves shall each be provided with a single lock, but with only one key in total. During operation the key shall be trapped in the lock of the closed block valve of the installed spare S/R valve. The key shall be retractable from t
46、he lock only by locking the block valve in the fully open position. Hence only one block valve can be in the closed position at any time. Figure 1Discharge to atmosphere DEP 80.46.30.11-Gen. December 1993 Page 7 PDF created with pdfFactory Pro trial version 3.2DISCHARGE TO FLARE 3.2.1System descrip
47、tion Spared S/R valves discharging to a closed (flare) system require block valves in both the inlet and outlet lines of the S/R valves. The outlet block valves shall be provided with single locks, and the inlet block valves shall be provided with double locks. Each S/R valve shall be provided with
48、its unique key which fits both lock number 1 of the inlet block valve and the lock of the outlet block valve. The key of the outlet block valve shall be retractable only by locking the outlet block valve in the fully open position. The key of lock number 1 of the inlet block valve shall be retractab
49、le only when the switch key is inserted in lock number 2 of the same inlet block valve. Each set of S/R valves shall be provided with one switch key which fits lock number 2 of all inlet block valves. This switch key shall be retractable only by locking the inlet block valve in the fully open position. This shall only be possible when the key of lock number 1 is inserted in the lock. During operation, only the inlet block valve of the installed spare S