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Valve Leak Results in High Pressure Release of hydrocarbons
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Valve Leak Results in High Pressure Release of hydrocarbons
A safety alert from Energy Safety Canada shows what can go wrong when we assume things look right, without actually checking them first.
During a wellbore service in the winter months, a high pressure gas release occurred. The work plan included pumping down the kill line when the downhole operations were completed.
The kill line valves appeared in the closed direction, and no movement was found. This, along with the valve handles being absent, led the workers to believe the valves were closed.
The kill line was pressure tested and a valve began to leak. Operations were shut down to change the valve at which point an uncontrolled pressure release occurred.
The investigation revealed that the valves had been stuck open by ice. No workers were injured.
What Went Wrong:
Wellhead valves were left in operating position.
Valves were not fully functioned and adequately oriented prior to pressure test.
Sub-zero temperatures resulted in ice plugging the wellhead valves.
Actions Taken/Recommendations:
Prior to conducting work, the wellhead’s unique structure and condition should be reviewed including the isolation procedure, valve orientation, and ensure positive confirmation of isolation.
The work authorization process (e.g. safe work permit) must include on-site hazard assessment, hand over documentation and verification.
Safe Operating Procedures should be reviewed before each task and include evaluation of on-site hazards, such as weather impacts like ice, valve and wellhead status and clearly outline responsibilities of workers and supervisors.
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