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A standby condensate pump for reinjecting gas condensate into an oil export line on the Piper (Alpha) platform had been de-energised for maintenance. Its discharge pressure safety valve (PSV) was also removed and blind flange assemblies were fitted to the open PSV pipe connections. Meanwhile, the running condensate pump failed and would not restart. Liquid levels in the gas/liquid separation system were rising and would eventually trigger a total shutdown of the platform if not reversed. Night shift operators were aware the standby pump had been taken out of service for maintenance by the day shift but believed the work had not yet begun, so they decided to re-energise and start the standby pump. Gas condensate leaked from a PSV blind flange assembly; it found an ignition source and exploded. The explosion was soon followed by an oil pipe rupture and pool fire. The incident escalated rapidly as 3 high pressure gas lines ruptured after 20, 50 and 80 mins, respectively, creating a towering inferno. Smoke and flames outside the accommodation module made evacuation by helicopter or lifeboat impossible.
Ask yourself and your crew:
- How can something like this happen here (e.g. on our site)?
- What safety measures (i.e. procedures, controls/barriers) do we have in place to mitigate the risk?
- How do we know the risk controls/barriers are working?
- What improvements or changes should we make to the procedures, controls/barriers or the way we work?
Original content courtesy of IChemE Safety Centre
