Process Interlocking
Process Interlocking
Mechanical interlocking prevents human error by guiding the operator
through a predefined operating sequence. Interlocks are based on the
principle of the exchange of unique keys that only allow the right valves
to be operated in the correct, predefined order.
Mechanical Process Control Unit - MPCU
The MPCU is a mechanically-programmed key exchange system
and functions as a ‘mechanical PLC’. It is installed in the field to guide
operators through complex, non-linear procedures.
Version date 30/06/2014
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Process interlocking Valve positioning Partial stroke testing Valve operation
Process Interlocking
Application Operation
Mechanical interlocks enforce operation of Operation of a MPCU is as follows:
multiple interrelated valves in a predefined order. 1. Enter key in dedicated key position
Reverse operation can only be done in reverse 2. Turn the knob on top of the MPCU
order. A MPCU enables sequences that require 3. The entered key is now trapped
repetitions of steps or reverse operations that are 4. The next key is now released
5. Proceed the valve operation with released key
not performed in reverse order.
A MPCU is required when:
> reverse operation of valves is not in reverse
order of initial operation
> valve is used repeatedly within a sequence
> valve is opened and directly closed before
proceeding to the next sequence step
Some common examples relate to pigging:
> involving H2S
> ensuring multiple vent / drain / purge cycles are
carried out and not by-passed before the closure
door can be opened
Legend
MPCU’s are also used in the following processes: 1 Rotary knob
2 Operating keys
3 Indicator window showing which key to remove
> reactor sequences and which to insert
> filtration skids to preventing vessel implosion 4 Free key slots
> asorber / regenerator processes
> semi-regenerator catalytic reforming units within
gas sweetening
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Process Interlocking
Linear sequence
1: open 2: open 3: open
Control room
Control room
6: close 5: close 4: close
valve A valve B valve C
Example
Open valve A > open valve B > open valve C
Close valve C > close valve B > close valve A
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Process Interlocking
Non-linear sequence
valve A valve B valve C
step 4: open valve B step 6: close valve B
step 2: open valve A step 7: close valve C
step 3: close valve A step 5: open valve C
step 1: start step 8: end
Control room
Example
Open valve A > close valve A > open valve B > open valve C > close valve B > close valve C
MPCU steps
> Upon receipt of authorization, retrieve start key from control room
> Insert start key into the MPCU, turn the knob and retrieve next key (step 1)
> Open valve A by inserting key; next key will be released after opening valve A (step 2)
> Insert key in the MPCU, turn the knob and retrieve same key again
> Close valve A by inserting key; next key will be released after closing valve A (step 3)
> Insert key in the MPCU, turn the knob and retrieve next key
> Open valve B by inserting key; next key will be released after opening valve B (step 4)
> Insert key in the MPCU, turn the knob and retrieve next key
> Open valve C by inserting key; next key will be released after opening valve C (step 5)
> Insert key in the MPCU, turn the knob and retrieve next key
> Close valve B by inserting key; next key will be released after closing valve B (step 6)
> Insert key in the MPCU , turn the knob and retrieve next key
> Close valve C by instering key; next key will be released after closing valve C (step 7)
> Insert key in the MPCU, turn the knob and retrieve next key
> Return key to the control room (step 8)
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Process Interlocking
MPCU features
> Does not require periodic maintenance
> Tamperproof design
> Cabinet protects MPCU against sand, dirt,
snow, ice, moist, etc.
> W ithstands the most extreme operating
environments
> Mounted on site
> Enforces non-linear sequences
SPECIFICS
Internal
Body components Cabinet Programmable Mounting Size & weight Cabinet coating Cabinet door
AISI 316 AISI 316 Carbon No On site Variable (depends Epoxy-polyester Lockable, plain door
coated on number of powder coated,
steel programmed RAL 7035
process steps)
Option: Only in Option:
> AISI 304 combination > glass door
> AISI 316 with carbon
coated steel
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