During steady state operations on 10/06/13 at approximately 15:30hr, a scaffolding operative alerted the Operations Team Leader to a smell of hydrocarbon gas near to the area of his work. The Operations
Team Leader and a Production Technician immediately visited the area with a gas detector and identified that there was a hydrocarbon gas leak emanating from a ball valve sealant injection fitting on a 14" manual
block valve. The Operations Team Leader determined that the leak was sufficient to instruct an immediate controlled shutdown and blowdown. Once all residual pressure had been blown down the valve was checked and no leak detected.
The investigation produced a list of 9 solutions to implement. Highlights of these solutions are as follows;
perform proactive analysis, maintenance and change out of the sealant injector arrangements installed on BG Groups Assets in line with our revised valve maintenance strategy; BG Group best practice improvements; procedural adherence improvements; valve healthcare contract management improvements.
- Perform proactive analysis, maintenance and change out of the sealant injector arrangements installed on our Assets in line with our revised valve maintenance strategy.
- Improve awareness of thread connection guideline.
- Improve the mechanism to implement guidelines offshore.
- Perform failure analysis on component(s).
- Clarify expectations in the global valve contract around procedures and certification
- Complete the visual inspection of the remaining sealant injectors and explore other inspection techniques to ascertain if it is possible to detect failure of the inner check valve.
- Change design of sealant injector to industry best practice (implement a company global “Best Practice”).
- Investigation information to be shared with platform safety reps
- Step Change Safety Alert to be raised.
Ball valve sealant injection fitting