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What happened?
A gas leak was identified from a high pressure (CL600) flange in a gas yard.
The leak was isolated and depressured within 30 minutes of being detected.
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Why did it happen?
Poor flange assembly and sealing face condition at the time of original installation, coupled with the stop-start nature of the system over time, caused the flange face to open at the gasket sealing face.
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What did they learn?
On a risk assessed basis, conduct checks of flange face alignment and stud torques for flanges that have not been opened recently. Stud torque checks must be done when system is depressured to avoid line of fire hazards.
Correct flange face alignment and stud torque will prevent releases, even if flange faces are worn.
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Ask yourself or your crew
Are you involved in flange assembly? Do you have flange assembly procedures? Do you follow them? Are you aware of what could happen if they are not followed?
Do you have flange management records dating back to their original installation?
How do you assure the integrity of flanges that have not been opened recently?
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What happened?
A gas leak was identified from a high pressure (CL600) flange in a gas yard.
The leak was isolated and depressured within 30 minutes of being detected.
Why did it happen?
Poor flange assembly and sealing face condition at the time of original installation, coupled with the stop-start nature of the system over time, caused the flange face to open at the gasket sealing face.
What did they learn?
On a risk assessed basis, conduct checks of flange face alignment and stud torques for flanges that have not been opened recently. Stud torque checks must be done when system is depressured to avoid line of fire hazards.
Correct flange face alignment and stud torque will prevent releases, even if flange faces are worn.
Ask yourself or your crew
Are you involved in flange assembly? Do you have flange assembly procedures? Do you follow them? Are you aware of what could happen if they are not followed?
Do you have flange management records dating back to their original installation?
How do you assure the integrity of flanges that have not been opened recently?
A gas leak was identified from a high pressure (CL600) flange in a gas yard. The leak was isolated and depressured within 30 minutes of being detected.
Original material courtesy of Safer Together (Australia)
To access the PDF and PowerPoint versions, please visit https://www.safertogether.com.au/learning-event-bulletins/operating-process-equipment-loss-of-containment-learning-event-bulletin-2
Contain It – Major Accident Hazard Awareness Training: https://www.safertogether.com.au/resources/products-and-programs/contain-it-wa-nt
Process Safety Awareness Videos: https://www.safertogether.com.au/resources/products-and-programs/process-safety-awareness-2
