Ian Binney has been a valve interlock specialist since 1982, when he joined Castell. With decades of experience, he has witnessed firsthand the evolution of valve interlocks and their impact on industrial safety.
The origins of valve interlocking
“The concept of interlocking goes back to the early days of the railways and signaling systems,” Ian starts. “I think the concept is often attributed to the Railways. The old-style mechanical signal boxes had mechanisms called frames. And they were interlocked so that you had to operate points and signals in a certain sequence. Also, the railways used a system of key like ‘tokens’ on single track sections to ensure that only one train was in the section at any time. Then along comes James Harry Castell in 1922, and he invents a key interlock. This was a key operated interlock for switchgear and later used for machine guarding as well as many other applications. In the UK, it was called a ‘trapped key interlock,’ in the United States and elsewhere sometimes also ‘captive key interlock.'”
The development of valve interlocks
Ian joined Castell in 1982. “Mike Smith, one of the founders of Smith Flow Control, was actually the person who employed me at Castell,” Ian continues. “Mike Smith later moved to Ellis, which at the time was manufacturing single key valve interlocks. These interlocks used oversized keys that functioned as the lever of a ball valve. Ellis then developed a dual key version, marking the beginning of integral valve interlocks, with an anchor, an adapter, and a lock body designed to fit a valve. Ellis went on to became part of Fortress and then SFC.”
Linear coded key
Smith Flow Control, founded in 1985, introduced the linear card key, a feature still used in Sofis’ Smith and Sofis’ Netherlocks interlocks today. “You simply pushed the key in, and that was it, instead of putting a key in and rotating it as in the traditional way,” Ian explains. This innovation led to widespread acceptance of valve interlocking in the oil, gas, and process industries. “After that, there were various developments,” he continues. “Netherlocks started making their own valve interlocks in 1993. Both companies were acquired by the Halma Group. In 2016, the companies merged into Sofis, with both valve interlocks as separate brands.”
The impact of the linear key
Ian emphasizes the significance of the linear key in valve interlocking. “Linear keys are robust and easy to handle, even with gloved hands. If you’ve got a rotary key of any kind, you’ve got to push it in and turn it. It is operated by using fingertips, whereas a linear key is fist-sized. The coding systems and mechanisms for the linear keys also tend to be more robust. In fact, when the rivets ride along the slots, they’re self-cleaning as well.”
The direct integration of interlocks onto valves was another major breakthrough. “Installing a complete valve interlock assembly directly onto the valve, without the need for bracketry, made things a lot safer,” Ian adds.
Sofis: The market leader in valve interlocks
Smith Flow Control’s journey began with an order from GVA Gotaverken Arendel AB from Sweden, and it has since grown into the industry leader. With the merger of Smith Flow Control and Netherlocks into Sofis, we have manufactured and supplied over 450,000 linear key valve interlocks worldwide, keeping the user’s staff, their sites, the general public and our environment safer.
When asked what makes Sofis the market leader, Ian is quick to respond. “There are many reasons why Sofis stands out. Overall, Sofis has been focusing specifically on valve interlocking, bringing unmatched knowledge and expertise, providing solutions that address complex customer challenges worldwide. We’ve got a core of people with a lot of experience. There’s not much that we haven’t already seen before when it comes to interlocking valves, so to speak. At Sofis, there’s in-depth knowledge of diverse applications, combined with a commitment to understanding the unique needs of our customers. This is important to ensure reliable, efficient, and customized solutions for our customers’ operations.”
A career dedicated to safety
Ian’s journey in the industry began right after university. “I graduated into an oil and gas recession at the beginning of 1982. I was doing the usual student interviews, looking to join an engineering contractor. Unfortunately, in the spring of 1982, they just shut the books and that was it. They weren’t recruiting. Castell offered me a job, which I took.”
Over the years, Ian has been involved in major projects, combining various Sofis products and developing custom solutions. “I basically spent the last 40 years trying to make the world a safer place, and that makes me feel proud,” he says. “What makes my work interesting is trying to find out what our customers really need. A lot of what I do is solving problems, engineering the solution the customer needs and then engineering how we provide it. So, in a sense, we’re developing a bit of safety for our customers daily. Most of my roles have been on the sales side, including some project management and often working with various international EPC contractors and shipyards.”
The value of simplicity in safety
“We’ve got a lot of experience in safeguarding,” Ian explains. “There’s a huge variety of applications that we have made safe over the years, and that knowledge is an important success factor for Sofis.” Making complex systems simple and efficient while keeping them safe is what excites Ian about his work. “Because there are things you can do while designing an interlock system that will actually make the operators’ lives easier in the long term,” he says. “And if you make the operators’ lives easier, they’re more willing to accept the interlocks even though the interlocks are there to guide them through their operating procedure.”
Ian values appreciation in the workplace, acknowledging that a simple “thank you” can go a long way, especially in large, complex projects. “There are many phases in our projects, and you usually don’t get to see the final result; when our projects are installed, commissioned, and working. In fact, when our products leave our factory, it can take two years, or more, before being installed.”
Beyond work: A passion for sailing
Outside of work, Ian has a deep passion for sailing. “I started sailing back in 1987, just as a holiday with my wife. I’ve been sailing every year since, except for 2020.”
For the last eight years, Ian has been involved with The Tall Ships Youth Trust, a youth development charity. “I sail as a watch leader usually with five or six young people in the watch. We give them a new life experience not just a sailing experience. The young people come from all kinds of backgrounds and from across British society; going on the yacht is a whole new experience for them. There are some incredible young people out there and it’s hugely rewarding to see what they can do if they get the chance.”
Ian Binney’s story is one of dedication. To safety, to innovation, and to making a difference both in the workplace and beyond.