NetherLocks PROCESSINTERLOCKING Quick Fix Manual

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Quick Fix Guide

PROCESSINTERLOCKING

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Page 1 Quick Fix Guide PROCESSINTERLOCKING...
Page 3 Quick Fix Guide PROCESSINTERLOCKING Congratulations on your purchase of a Netherlocks valve interlock! Netherlocks valve interlocks are manufactured with care and are renowned for their high quality. They do not need greasing, neither do parts have to be replaced. For support please contact support@netherlocks.com...
Page 4: Table Of Contents
Reset procedure (close side) Q-cards - Commissioning keys How to remove a Q-card Troubleshooting valve interlocks Key stuck (key cannot be removed) Key does not fit (key cannot be inserted) Key lost Valve is replaced Netherlocks Support programs Service products...
Page 5 > Quickly solve simple issues related to valve interlocks > The final section of this guide explains how Netherlocks can support you maintaining your valve interlocks, by offering maintenance programs, site services and training. The Quick Fix Guide offers 4 colour coded sections:...
Page 6: How Are Valve Interlocks Used
Quick Fix Guide www.netherlocks.com/support How are valve interlocks used? The main functions of valve interlocks are to: > Enforce a predefined valve operating sequence - Create a safer working environment - Save costs and prevent production spill or loss due to...
Page 7 support: +31 (0)172 471 339 Basic principles Valve interlocks are permanently mounted to the valve and guide the operator through a predefined sequence with unique keys for each step. To guarantee that there is always Flare lines an open path to the flare To prevent that the drain and vent Boiler blow-down are opened at the same time...
Page 8: Basic Principles Of Valve Interlocking
Quick Fix Guide www.netherlocks.com/support Basic principles of valve interlocking Key cabinet Lock A Lock B Situation Green start key from key cabinet to lock A Locked closed Operable Yellow switch key from lock A to lock B Locked open Operable...
Page 9 support: +31 (0)172 471 339 Basic principles Position for open key Key code on lock Key code on key Position for close key Green start key is inside the key cabinet in its > dedicated position (green = normal operation) Yellow keys in locks in the field are trapped and >...
Page 10: Valve Interlock Components
Quick Fix Guide www.netherlocks.com/support Valve interlock components NDL exploded view...
Page 11 support: +31 (0)172 471 339 Basic principles Ninety degree lock, for all types of lever operated valves. Legend 1. AISI 431 sliding lever for optimum flexibility 2. AISI 316 body 3. AISI 316 Adaptor - purpose machined - with 4 keyways 4.
Page 12: Ndl Ga Drawing
Quick Fix Guide www.netherlocks.com/support Valve interlock components NDL GA drawing...
Page 13 support: +31 (0)172 471 339 Dimensions Length (mm) Width (mm) Height (mm) Mass of lock (kg)* Lever sizes (mm) Different lever sizes from 230 to * Without bracket- and adaptor Legend 1. Lever 2. Tube NDL 3. Lock body NDL 4.
Page 14: Mrl Exploded View
Quick Fix Guide www.netherlocks.com/support Valve interlock components MRL exploded view...
Page 15 support: +31 (0)172 471 339 Basic principles Multi rotation lock, for all types of handwheel and gear operated valves. Legend 1. CS powder coated hand wheel / optional AISI 316 2. AISI 316 body 3. Original nut will be used if possible 4.
Page 16: Mrl On Gearbox Exploded View
Quick Fix Guide www.netherlocks.com/support Valve interlock components MRL on gearbox exploded view...
Page 17 support: +31 (0)172 471 339 Basic principles Legend 1. CS powder coated hand wheel 2. AISI 316 body 3. AISI 316 adaptor - purpose machined - with 4 keyways 4. Easy to set and reset counters behind counter cover plate 5.
Page 18: Mrl Ga Drawing
Quick Fix Guide www.netherlocks.com/support Valve interlock components MRL GA drawing Key code & serial number engraved on AISI 316 tag plate, permanently fitted to locking device...
Page 19 support: +31 (0)172 471 339 Basic principles Dimensions MRL-S (small type) Length (mm) Width (mm) Height (mm) Mass of lock (kg)* Handwheel sizes Different sizes between 200 and 700 Max. valve spindle diameter (mm) 26 * Without bracket, adaptor and hand wheel Dimensions MRL-L (Large type) Length (mm) Width (mm)
Page 20: Interlock Tag Plates
Quick Fix Guide www.netherlocks.com/support Interlock tag plates 1. Key code open key 2. Key code close key 3. System tag number 4. Serial number (netherlocks-year.serialnumber)
Page 21: Key Tag Plates
Red tag indicates ’in maintenance’ or non-standard situation Yellow tag indicates ‘switching in progress’ Netherlocks strongly recommends the use of red, yellow and green tags, according the ‘traffic light principle’. Still, tag plates can be delivered in alternative colors, following our customers...
Page 22: Key Cabinet Tag Plates
Quick Fix Guide www.netherlocks.com/support Key cabinet tag plates The tagging in a key cabinet is only visible when keys are out, indicating that the system is being operated. Notes > Tag plate texts and colors are specified by the customer...
Page 23: How To Operate Valve Interlocks
support: +31 (0)172 471 339 Operate and reset How to operate valve interlocks Make sure that the code on the key is the same as > the code on the lock To enter key correctly, see engraving on the side of >...
Page 24: How To Reset A Mrl Valve Interlock
Quick Fix Guide www.netherlocks.com/support How to reset a MRL valve interlock Resetting is required when the end stops of a valve change, due to wear or pollution inside the valve. On both sides of the MRL lock there are slotted holes >...
Page 25: Reset Procedure (Open Side)
support: +31 (0)172 471 339 Operate and reset Reset procedure (open side) > Ensure key is fully inserted, and leave it in Confirm both keys are entered > Remove the counter cover on the open side (right) > Notes > To set the MRL, the valve must be fully operable >...
Page 26 Slowly turn the valve back towards its closed position until both set screws are visible (on the open side) If only one or no set screw appears, please contact > Netherlocks or your local interlock partner Untighten both set screws > Fully open the valve >...
Page 27: Reset Procedure (Close Side)
support: +31 (0)172 471 339 Operate and reset Reset procedure (close side) > Ensure key is fully inserted, and leave it in Confirm both keys are entered > Remove the counter cover on the close side (left) >...
Page 28 Slowly turn the valve back towards its open position until both set screws are visible (on the closed side) If only one or no set screw appears, please contact > Netherlocks or your local interlock partner Untighten both set screws > Fully close the valve >...
Page 29: Q-Cards - Commissioning Keys
support: +31 (0)172 471 339 Operate and reset Q-cards - Commissioning keys Functionality > Q-cards allow free operation of an interlock for commissioning and installation purposes Q-cards are dedicated commissioning keys that > are inserted in an interlock during production. They are specifically designed for one time use, >...
Page 30: How To Remove A Q-Card
Quick Fix Guide www.netherlocks.com/support How to remove a Q-card > Fully close valve Remove temporary plastic cover on the close side > Ensure set screws are aligned and flush > > Tighten grub screws...
Page 31 support: +31 (0)172 471 339 Operate and reset > Now remove the Q-Card Insert the correct operating key (cross checking lock > tag and code on key) > Place counter cover Fully open valve > Repeat steps 2 to 7 for the open side of the lock >...
Page 32: Troubleshooting Valve Interlocks
Quick Fix Guide www.netherlocks.com/support Troubleshooting valve interlocks Key stuck (key cannot be removed) > Check if you are considering (removing) the correct key a. Valve open, then right key should be removed b. Valve closed, then left key should be removed >...
Page 33: Key Does Not Fit (Key Cannot Be Inserted)
Check if anything is blocking the key entrance or if > key is damaged If two set screws are not inline please contact > Netherlocks or your local interlock partner...
Page 34: Key Lost
- Lookup interlock serial number on lock tag plate - Check key code of missing key Netherlocks keeps track of all lock serial numbers and corresponding key codes. Based on the lock serial number and key code, new keys can be manufactured and shipped.
Page 35: Valve Is Replaced
> If the valve is another type and/or size, contact Netherlocks or your local interlock partner to determine whether the same lock body can be re-used If topwork is equal to the old valve, the bracket and >...
Page 36: Netherlocks Support Programs
Quick Fix Guide www.netherlocks.com/support Service Products With a various team of service engineers and a global network of certified service partners Netherlocks offers various support programs: Installed base support a. Single maintenance programs: Advantages: maximization of interlock components and system lifetime, increase process uptime, minimize last...
Page 37 support: +31 (0)172 471 339 Maintenance programs Survey > - Visual inspection of locks and cabinets (general condition, missing locks/keys, damage, tagging) - Every 1-3 years depending on criticality of the system Functional check > - Visual inspection of locks and cabinets (see Survey) - Functionality test of locks and sequences (includes resetting of locks if necessary) - Every 1-3 years depending on criticality of the system...
Page 38 A Netherlocks commissioning report per system is issued. c. Supervision: A Netherlocks service engineer will work with the customers installation team in order to ensure installation and commissioning at the highest quality levels. A Netherlocks commissioning report per system is issued.
Page 39 support: +31 (0)172 471 339 Maintenance programs a. Training program end-user: > Maintenance training: Learn about basic interlock functionality, installation, setting and troubleshooting. > Operations training: Learn about Interlock functionality, operation skills (sequences, key operation, etc.) and setting. b. Training program contractor – Installation: Learn about basic interlock functionality, installation and setting.
Page 40 Quick Fix Guide www.netherlocks.com/support Notes...
Page 41 support: +31 (0)172 471 339 Notes...
Page 42 Quick Fix Guide www.netherlocks.com/support Notes...
Page 43 Instruction videos youtube.com/netherlocksproducts Interlock sequence information netherlocks.com/sequence-book Browse through the many sequence designs that we collected in the past 20+ years! Contact us Netherlocks Safety Systems support@netherlocks.com Follow us twitter.com/netherlocks facebook.com/netherlocks linkedin.com/company/netherlocks Visit our support page on LinkedIn Netherlands...