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Alpha Process Controls Passes Quality Standard Audit With Flying Colours

Alpha Process Controls has reaffirmed its commitment to quality after achieving a respected management standard with distinction.

The UK-based manufacturer of transfer systems for hazardous liquids and gases has been awarded ISO 9001: 2015, the revised and new standard for quality management.

Organisations currently holding the previous standard, ISO 9001: 2008, are required to be assessed for the latest version ahead of the deadline on 14 September 2018.

Alpha Process Controls successfully completed the audit and assessment of its management systems and its ability to consistently provide products that meet customer and applicable statutory regulatory requirements.

As part of the process to achieve the standard, Alpha Process Controls also demonstrated the effective application of its management systems to ensure customer satisfaction.

With more than 40 years’ experience in the market, Alpha Process Controls has established a strong track-record for the design, manufacture and installation of bespoke safety transfer systems for road, rail and marine applications for the oil, gas and petrochemical sectors.

Part of the Knorr-Bremse Group-owned GT Group, Alpha Process Controls has developed solutions for the transfer of products such as LNG following extensive research and development at its headquarters in North East England.

John Lamb, Managing Director of Alpha Process Controls, said: “Quality is at the heart of everything we do at Alpha Process Controls. From our research and development programmes through to installing our technology at locations around the world, focusing on quality encourages confidence from our customers and ensures we deliver efficient and effective solutions.

“We are very proud to achieve this new standard ahead of the September deadline and with flying colours as it is a strong endorsement of our business, which continues to grow in our key markets such as the offshore, ship-to-ship LNG transfer sector.”

The post Alpha Process Controls Passes Quality Standard Audit With Flying Colours appeared first on Alpha Process Controls.

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New Nitrogen Manual Release Innovation Developed For Marine ERC

Alpha Process Controls has developed a new manual actuation system for its Marine Emergency Release Collar (ERC) coupling technology.

Powered by a readily-available nitrogen bottle, the system enables operators to activate the closure and separation of Alpha’s low pressure drop coupling if any transfer issues are identified before an emergency actuation takes place.

By utilising a gas powered operation, the new innovation prevents the need for electrical or hydraulic systems and can be used in a number of transfer applications including Floating Regasification Storage Units (FRSU) and emergency salvage applications, where access to external power sources may be limited.  This is supported by the mobility of the control panel and connected nitrogen canister.

Alpha’s Marine ERC Coupling is available in sizes ranging from four-inch to the most recent addition, a 10-inch coupling designed to support LNG transfers from FRSU vessels.

The couplings feature a two-stage operation that enables the controlled shutdown of internal valves (ESD1) and the coupling separation (ESD2) and can be operated mechanically or through an operator controlled separation.

The ERC can also be specified with a pre-ESD1 alarm, which detects ship separation, and is linked to the ESD1 system to shut down flow lines.

This safety feature complements the ERC’s innovative, inbuilt damping system to reduce the effects of pressure spikes should the coupling be called upon to separate during full flow transfer in the case of a separation event, such as a vessel drift-away.

UK-based Alpha Process Controls has also introduced a further safety innovation to support the requirement for pre-installation checks of the Marine ERC.

A specially-developed Collar Release Test system and a Valve Head Closure unit offers technicians peace of mind ensuring the ERC is transfer-ready prior to installation.

Ben Richardson, Design Manager, Alpha Process Controls, said: “Through continual research and development and our close relationships with key LNG companies, we are consistently developing new innovative features and add-ons for our couplings to meet industry requirements.

“The manual release system enables companies to install a more comprehensive collection of coupling separation options that maintain our high standards of safety.

“Additionally, through the use of nitrogen we are continuing to not feature electrical or hydraulic systems within our couplings, which is not only a cost benefit, but importantly increases flexibility and the range of locations in which the technology can be applied.”

Watch a video about the new innovation by visiting this link: https://youtu.be/RLs0Xpzxj5U

The post New Nitrogen Manual Release Innovation Developed For Marine ERC appeared first on Alpha Process Controls.

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Small-Scale Safety Breakaway Couplings Achieves Sil 2 Certification

Alpha Process Controls’ small-scale Safety Breakaway Couplings for the transfer of hazardous materials, including Liquified Natural Gas (LNG) and Liquid Petroleum Gas (LPG), have achieved a respected industry safety standard.

Alpha Process Controls, a member of the GT Group, provides the Traffic Safety concept of the Knorr-Bremse Group and is part of its vision toward an accident-free future on the road.

Utilised by international industry for more than 40 years for the safe transfer of bulk hazardous liquids and gases, including cryogenics, Alpha’s standard and cryogenic small-scale couplings are now recognised as holding the Safety Integrity Level (SIL) 2 certification.

The certification confirms the Safety Breakaway Couplings’ consistent ability to prevent loss of product during transfer. The passive devices are located between terminal-pipework and flexible loading hoses and typically employed in liquid transfer between terminals and road and rail tankers and ships.

During a towaway incident, the flexible loading hose comes into tension transmitting the load to the breakaway coupling. This causes the pre-determined break bolts to snap, allowing the coupling halves to separate. When the breakaway occurs, each have of the coupling seals immediately, preventing major product spillage.

The units, which are available in 1.5, 2.5, 3, 4, 6, and 8-inch configurations, join Alpha Process Controls’ Marine Emergency Release couplings in holding the recognised reliability rating.

Further demonstrating the safety, integrity and performance of the technology, the couplings were subjected the range to an extensive, independent testing and assessment programme to secure the SIL 2 rating.

The assessment and certification were undertaken by UK consultancy Technis, led by Dr David J Smith, BSc, PhD, CEng, FIEE, FIQA, HonFSaRS, MIGasE. With more than 40 years’ experience in reliability and risk assessment and technical training courses.

A past President of the Safety and Reliability Society, David chairs the IGEM (Chartered Institution of Gas Engineers and Managers) panel, which develops guidelines on safety-related systems, and was a founder member of the Safety Critical Systems Committee of the Institution of Electrical Engineers (now IET).

Alpha Process Controls is recognised as the world-leader in manufacture and supply of couplings and has been at the forefront of the hazardous liquids transfer sector for more than 40 years.

From its base in North East England, the company designs, manufactures and installs the systems, along with loading arms and loading skids, which are supplied to its international client base that includes Shell, BP and Exxon.

John Lamb, Managing Director of Alpha Process Controls, said: “The small-scale systems are important members of our portfolio of safety breakaway couplings and achieving the SIL 2 rating further endorses the safety and integrity of the technology.

“Our simple, but effective release mechanism offers real benefits in terms keeping site personnel safe and assets operational, which has earned Alpha Process Controls a positive reputation across the industry.”

The post Small-Scale Safety Breakaway Couplings Achieves Sil 2 Certification appeared first on Alpha Process Controls.

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Alpha Process Controls Shows Confidence In The Future Of Former Apprentice

Alpha Process Controls, a GT Group Company, has underlined its commitment to the future by taking on a Group apprentice who is already hard at work on an innovative project.

Scot Ellis joined the Peterlee-based division after completing a four-year mechanical engineering apprenticeship with parent company GT Group, which is part of the Knorr-Bremse Group.

The 21-year-old technician is currently involved in the testing and production of modifications for a developmental fuel coupling.

His appointment comes months after design manager Ben Richardson was named as the Energy Industries Council’s Rising Star of 2018. As part of the award, Ben won full tuition fees, worth £17,500, to study an MBA in Oil and Gas Management at the Robert Gordon University in Aberdeen.

Alpha Process Controls is a recognised as a leading manufacturer and supplier of couplings and has been at the forefront of the hazardous liquids transfer sector for more than 40 years. International clients include Shell, BP and Exxon.

Scot, from Peterlee, who gained an HNC qualification, acquired a broad range of skills as part of his apprenticeship, including tool making and quality control, which he is developing further in his new role.

He said: “I’m very grateful to both GT Group for selecting me for the apprenticeship and to Alpha Process Controls for taking me on as a Product Technician.

“The apprenticeship gave me an excellent grounding in mechanical engineering and has provided me with the necessary skills and knowledge to prosper in my new role.

“No two days are the same and I’m really enjoying working for such a forward-thinking company. Being involved in developing a new product makes me feel like I’m making a valuable contribution and I feel a valued member of the Alpha team.”

John Lamb, Managing Director of Alpha Process Controls, said: “We are focused on innovation and engineering excellence and are determined to grow a strong pool of young talent.”

“Scot is one of the real successes of GT Group’s apprenticeship scheme and is now repaying our faith through his excellent work. It’s important that companies such as Alpha Process Controls continue to blend new ideas and methods with established engineering experience to achieve continued success.”  

The post Alpha Process Controls Shows Confidence In The Future Of Former Apprentice appeared first on Alpha Process Controls.

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The Value Of Sil Safety Certification

Over the past decade, the oil, gas and petrochemical industries have undergone significant changes in process safety systems and machine automation. Even so, Safety Integrity Level (SIL) remains a foreign concept among many clients of bespoke engineering systems.

Perhaps you’ve read about safety breakaway couplings achieving SIL2 certification but don’t understand how that could affect you as another end-user or integrator. Is a quick coupler manufacturer with SIL in their portfolio more reliable than one that does not? First, you need to learn the value of this certification for fluid transfer safety solutions and other systems.

What Is SIL Certification?

SIL certification is a classification of a relative risk reduction level and a performance measurement for a safety instrumented function (SIF). According to the International Electrotechnical Commission or IEC 61508 standard, there are two general categories for SIL certification, hardware safety integrity and systematic safety integrity.

There are four SILs: SIL 1, SIL 2, SIL 3, and SIL 4. Fundamentally, the higher the safety integrity level, the higher the associated safety level and the lower the risk of safety failure. There are different requirements for each SIL, but the classification is largely based on risk analysis.

SIL 2 Certification of Cryogenic Breakaway Couplings

Alpha Process Controls, a member of the GT Group, part of the Knorr-Bremse Group, has received a SIL 2 certification for its cryogenic small-scale safety breakaway couplings for the safe transfer of hazardous materials, including liquid natural gas (LNG) and liquid petroleum gas (LPG). Alpha’s small-scale safety breakaway couplings have been used for over four decades by the international industry.

This industry standard SIL 2 certification proves the safety breakaway couplings’ reliability in ensuring no product loss occurs during transfer. These passive devices are found in the middle of the terminal pipework and flexible loading hoses, which are commonly used in liquid transfer procedures between terminals and tankers and ships.

In the event of a tow away, the flexible loading hose comes into tension transferring the load to the breakaway coupling. As a consequence, the pre-determined break bolts snap and the coupling splits in half. The coupling parts are automatically secured shut, preventing product spillage.

The SIL 2 assessment and certification was facilitated and awarded by the UK consultancy Technis spearheaded by Dr David J Smith.

Alpha Process Controls, a member of the GT Group, part of the Knorr-Bremse Group, is an industry leader in the design, manufacturing and installation of custom engineering systems, including marine breakaway couplings, drybreak couplings and cryogenic breakaway couplings. For enquiries, please call +44 (0) 191 586 2366 or send us an email at alpha.sales@gtgroup.co.uk.

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