PETRONAS TECHNICAL STANDARDS

Mechanical Locking System for Pressure Relief Devices

PTS 16.53.03
January 2017

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplemented by national and international
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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ANNOUNCEMENT

As part of the recent transformation exercise, the PTS numbering system has been revised to 6-digit
numbers and drawings, forms and requisition to 7-digit numbers. All newly revised PTS will adopt this
new numbering system, and where required make reference to other PTS in its revised numbering to
ensure consistency. Users are requested to refer to PTS 00.01.01 (PTS Index) for mapping between
old and revised PTS numbers for clarity. For further inquiries, contact PTS administrator at
ptshelpdesk@petronas.com.my
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE ............................................................................................................................ 5
1.2 GLOSSARY OF TERMS..................................................................................................... 5
1.3 SUMMARY OF CHANGES ............................................................................................... 5
2.0 MECHANICAL LOCKING SYSTEM FOR PRESSURE RELIEF DEVICES ............................... 6
2.1 GENERAL ........................................................................................................................ 6
2.2 TIE- WRAP or CAR SEAL SYSTEM.................................................................................... 7
2.3 CHAIN AND LOCKED....................................................................................................... 7
2.4 MECHANICAL INTERLOCKING ........................................................................................ 7
3.0 BIBLIOGRAPHY .................................................................................................... 10
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1.0 INTRODUCTION

This PETRONAS Technical Standards (PTS) provides the minimum technical requirements for
mechanical locking system of the isolation valves installed upstream and/or downstream of
pressure relief devices.

This PTS also incorporates PETRONAS lesson learnt and best practices.

Mechanical Locking system assures the use of isolation valves of pressure relief devices in the
required predefined position: open or closed to ensure that the required relief path and
capacity is always available.

1.1 SCOPE

1.1.1 This PTS shall be applied to the isolation valves installed upstream and/or downstream of
pressure relief devices for new and existing PETRONAS upstream and downstream facilities.

1.1.2 Mechanical locking system refer to either tie-wrap, chain and locked, mechanical interlocking,
or car-seal based system.

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms & Reading Guide PTS 00.01.03 for
General Definition of Terms & Abbreviations.

1.2.2 Specific Definition of Terms

None.

1.2.3 Specific Abbreviations

None.

1.3 SUMMARY OF CHANGES

This PTS 16.53.03 (January 2017) replaces PTS 16.53.03 (July 2013).
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2.0 MECHANICAL LOCKING SYSTEM FOR PRESSURE RELIEF DEVICES

Whether onshore or offshore, maintenance to pressure relief devices on live plants is a cause
for concern, particularly as an open path to relief and relief capacity must be maintained at all
times.

Most piping arrangements include spare relief capacity in the form of two similar or multiple
pressure relief devices which are fitted with isolation valves upstream and/or downstream of
each pressure relief device. This enables continuous production while maintenance is
conducted and eliminates the need to isolate and shut down the production facility, which
has major time and cost saving advantages.

For single pressure relief device fitted with isolation valves, sources of overpressure shall be
eliminated during the course of pressure relief device isolation.

2.1 GENERAL

2.1.1 Mechanical locking system for pressure relief devices shall(PSR) be provided at isolation valves
installed upstream and/or downstream of pressure relief devices to ensure that the required
relief path and capacity is always available.

2.1.2 Mechanical locking system for pressure relief devices shall(PSR) be secured around the isolation
valve wheel or lever and body to deter unauthorised valve operation.

2.1.3 Mechanical locking systems for pressure relief devices shall have visual tags or markings of
open or close for indicating isolation valves predefined position.

2.1.4 Mechanical locking systems for pressure relief devices shall be placed to the predefined
position: open or closed.

2.1.5 Materials of construction for the mechanical locking system shall be able to withstand
corrosion when exposed to the environment (e.g. rain, high humidity, marine and extreme
temperature).

2.1.6 Material of construction for the mechanical locking system shall be compatible with the
isolation valve to prevent any reaction (e.g. galvanic corrosion) that could impair the
mechanical locking systems or the isolation valve.

2.1.7 Each operating facility shall implement administrative controls to manage the operations and
maintenance of mechanical locking systems to avoid compromising overpressure protection
of equipment. The administrative controls shall include the following:

i. Documenting the type of mechanical locking system applied at the facilities.

ii. Procedures for operating and maintaining mechanical locking system.

iii. Training of the relevant personnel on these procedures.

iv. Assessing the overall effectiveness of mechanical locking system through

scheduled inspection and audit.
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2.1.8 Isolation valve at the outlet of pressure relief device shall be kept open during operation as
shown in Figure 2.2. During pressure relief device maintenance, the outlet isolation valve shall
be closed after the inlet isolation valve is closed.

2.1.9 For new and existing PETRONAS upstream and downstream facilities, consideration should be
given for selection of the appropriate type of locking devices based on the process conditions,
type of pressure relief devices and services.

2.2 TIE- WRAP or CAR SEAL SYSTEM

Tie-wrap or car seal system is a simple device used to lock a valve in open or closed position
using cable tie. Its purpose is to remind workers that the valve shouldn't be operated without
authorization. It is not designed to resist or prevent tempering hence the strength of the cable
is not a factor. Once the tie wrap or car seal is installed, valve operation is only possible by
cutting the cable, thus may indicate tampering or unauthorized operation.

The tie wrap or car seal shall be long enough to reach around the valve wheel or lever and the
valve body to provide sealing function. For ball valves, the tie wrap or car seal shall pass
around the valve lever and a suitable fixed anchor point. The anchor point may be the, valve
body, nearby steel work or an adjacent valve.

For gate valves, the tie wrap or car seal shall pass around the valve handwheel and an anchor
point. The valve bonnet may be used as a suitable anchor point.

Regular checks shall be performed to ensure integrity of tie-wraps or car seal are intact.

2.3 CHAIN AND LOCKED

A chain and locked arrangement uses chain coupled with padlocks. A chain and locked system
provides improves safeguarding against isolation valves tampering as compared to car seal or
tie wrap option.

All locks and keys shall be provided with unique identification numbers, reflecting the relevant
pressure relief devices number and access to the keys are controlled.

2.4 MECHANICAL INTERLOCKING

2.4.1 A mechanical interlocking is a trapped key lock assembly which locks the valve in one or two
positions - openand/or closed - with one key trapped within the lock assembly and the other
free. The lock is arranged such that valves are operated in a sequence from locked open to
locked closed or vice versa.

All locks and keys shall be provided with unique identification numbers, reflecting the relevant
pressure relief device number.

2.4.2 The locks shall be secured to the isolation valves to prevent unauthorized valve operation.

2.4.3 Relief system discharging direct to atmosphere

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i) A single lock shall be provided for each of the isolation valve with only one key in
total.

ii) The key shall be inserted in the lock of the closed isolation valve during operation
and shall be detachable from the lock only by locking open the isolation valve.
Hence, at any time only one isolation valve can be in closed position. (Refer to
Figure 2.1)

Figure 2.1: Interlocking System for Pressure Relief Device Discharging to Atmosphere.

2.4.4 Relief system discharging to a closed system

i) Single lock shall be provided to the outlet isolation valves.

ii) Double locks shall be provided to the inlet isolation valve.

iii) At each of pressure relief device, a single key shall be provided which fits both Lock A
of the inlet isolation valve and lock of the outlet isolation valve.

iv) The key of the outlet isolation valve shall be detachable when the outlet isolation
valve is locked open.

v) The switch key of the inlet isolation valve shall be detachable only when the respective
inlet isolation valve is locked open.

vi) The key of lock A of the inlet isolation valve shall be detachable only when the inlet
isolation valve is locked closed.

vii) The key of Lock A of the inlet isolation valve shall be detachable only when the switch
key is inserted in Lock B of the same inlet isolation valve (Refer to Figure 2.2).
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Figure 2.2: Mechanical Interlocking System for Pressure Relief Devices Discharging to Closed System
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3.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms & Reading PTS 00.01.03
Guide
Design of Pressure Relief, Flare and Vent Systems PTS 16.52.04
Overpressure And Underpressure - Prevention and PTS 16.53.01
Protection

INTERNATIONAL STANDARDS
Sizing, Selection and Installation of Pressure Relief Devices in API RP 520
Refineries
Part II - Installation