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2007 Winner Entry
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Cycling Self-checking Block Valve For Use In Critical Shutdown Systems |
Category: Safety and Security |
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G. Paul Baker, Jr.
Safety Cycling Systems LLC
Denham Springs, LA US
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Entered: 09/12/2007
Patented or Patent Pending
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Within the Petrochemical Industries, the risk of violent, hazardous events caused by a chemical reaction is reduced by the use of a Safety Instrumented System (SIS). These SISs are made up of Safety Instrumented Functions (SIFs) which each monitor a particular parameter and will force the process to a safe state if the parameter’s value exceeds its safe operating limits. If all of the SIFs in SISs would always function correctly, hazardous events would never occur -- no industry worker would ever get hurt or killed. However, at any given point in time, a component of a SIF could have some internal failure, either obvious or hidden.
The obvious failures in a SIS cause the chemical process to shutdown when no parameter has exceeded its allowable values. This interruption of production costs the plant money -- both in lost product that could be sold, in the costs of figuring out it was a “false trip” and restarting the process. The hidden failures, however, are dangerous, because the process is operated while depending on a failed system that cannot safely shut it down.
Most of the components used in a SIS have been enhanced by on-board diagnostics, which will safely shut down the chemical reaction if an internal malfunction is detected. However, the one component not easily checked for hidden failures is the final control element, usually a block valve. This results in the block valve accounting for 80% to 90% of all of the hidden, dangerous failures in a SIS. A block valves ability to stop the chemical reaction, can only be determined by fully stroking the valve, which shuts down the chemical process, costing the plant owner time, product and money.
The patented SafetySIL valve technology allows the block valves in a SIS to be fully stroked without interrupting the flow of the reactants. The first image shows the technology. It consists of two parallel valves in a “Y” manifold. A controller keeps at least one valve open at all times, while cycling between closing one valve, and then the other. A differential pressure transmitter looks for positive and negative differentials between the outlets of the valves. A calibrated amount of differential pressure cannot be present if the closed valve is not fully closed. If the proper amount and polarity of differential pressure is present, the cycling will continue. If there are any failures in any component, hidden or obvious, the cycling cannot be maintained. So, the cycling is the signal; when you’re cycling your safe.
This technology eliminates most of sources of hazardous events, significantly improving the safety and welfare of workers.
These systems can be produced by any valve manufacturer using existing technologies.
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Meet the Entrant, G. Paul Baker, Jr.
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Contact Email: gpaulbakerjr@cox.net |
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Association: Safety Cycling Systems LLC |
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Profession: Project Manager, Architect, Inventor |
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Number of times entering contest previously: 0
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Design Tools:
Pencil and Paper
Physical models
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Software used:
AutoCAD
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G. Paul's favorite design tool:
AutoCAD used in conjunction with Alibre Solid Modeler
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G. Paul's hobbies and activities:
Music, Reading, Drawing, Performing Arts, Dancing, Dining, Theology, Philosophy
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What role does G. Paul believe product design plays in creating a better future?
Good product design creates more efficient products, less costly to produce, more precise tools, easier to use, safer, more convenient, less frustrating, reduces risk of necessary activities, helps prevent accidents.
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