Parting of Valve Causing Significant Injury

Maintenance was planned on a defective valve inside an APV compressor room. Work had been completed, and the valve was changed out.

Personnel were in the process of returning the system back online – the isolation valve was opened, causing the valve/fitting to rupture, releasing 300 bar (4,351 psi) of airflow from 4 x 1665 litre accumulator bottles into the room.

At the time of the incident, two IPs were present near the opened valve.

IP-A was hit by airflow/debris and was thrown against the bulkhead, causing significant injury to the left leg and upper body.

IP-B managed to escape the area without injury and raised the alarm. IP-A was transported to the rig’s sick bay before medivac to ABZ hospital.

As a result, a Time Out For Safety (TOFS) was held.

Findings:

• Isolation was not suitable – single isolation achieved.

• Principles of HSG253 Safe Isolation and Reinstatement of Plant were not followed.

• Risk assessment did not suitably address "Stored Energy" Hazard.

• No isolation/de-isolation procedures in place.

• Lack of familiarisation on the equipment.