Gas Leak from Valve Stem to gearbox flange

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Alert ID: 
03584
Description of Task: 

During a routine platform inspection tour, an operator detected a smell of gas from the vicinity of the common injection header isolation valve. Further investigation utilising a gas detector and 'snoop' leak detection liquid determined that the leak was from the valve stem to gearbox flange on this valve. The concentration of the leak was determined to be 9% LEL at 150mm distance from the leak point.

Platform management team were alerted and on verification of the leak, the decision was taken to shut down and vent the plant.

 

An investigation was completed by the on site Valvecare specialist who verified that the leak was from the valve stem seal arrangement, and was likely to be due to the failure of one or more of the stem seal 'O' rings.

Replacement seals were able to be sourced at short notice and work initiated ASAP.

Lessons Identified: 

A more robust Valve care maintenance program to be reviewed

Vendors are currently engaged to compile a comprehensive database of all process valves, identify 'critical' valves with the help of the operations team, and develop routine maintenance schedules to ease / grease and maintain all valves on an appropriate periodicity.

Recommendations: 

The overhaul history of the valve should be reviewed to determine whether a full overhaul of the valve was completed prior to mobilisation.

Vendors are currently engaged to compile a comprehensive database of all process valves, identify 'critical' valves with the help of the operations team, and develop routine maintenance schedules to ease / grease and maintain all valves on an appropriate periodicity.
This maintenance regime should be enacted at soon as possible to ensure that all operating valves are in the best condition that they can be notwithstanding age / duty. This would go some way to providing assurance regarding improved operability and reliability.

Specific Equipment: 

Injection Header Isolation Valve

Incident consequence: 
Hydrocarbon release
Activity: 
Production operations
Location: 
Fixed Installation
Cause of accident or incident: 
Uncontrolled release of a flammable gas or liquid