Plant flowrates have changed recently, and there have been high levels of vibration on the pipework on the main outlet of the condensate separator.
On at least two previous occasions the position indicator on the Level Control Valve has gone into fault, preventing the control room operator (CRO) from seeing the actual position of the level control valve. So far they have managed their way around this.
- The LCV was not designed for the current flowrates, leading to vibration
- Vibration caused a crack in the 2’’ line connected to the condensate outlet,
- Condensate leaked out at ~8 kg/second. It took 90 minutes for flow to stop, as the leak was on the separator side of the closed ESDV.
- There was a design failure
- People had become accustomed to the vibration
- There was a lack of specialist competence to select the right size of valve
- There was a lack of operations input to projects on valve issues and design
Recommendations for learning:
Is there anything else you would do?