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2023 Second Alert LTI#08 manifold portion detached struck the helper's leg
At around 15:40 Hrs a Sub-Contractor crew was performing pneumatic testing activity for 16" HDPE liner at Dhulaima Water Injection (WI) line section. The helper closed the ball valve to check intermediate pressure. While walking away from the set up, the ball valve on the test plug unit failed and the manifold section detached and swung due to sudden release of pressure. The manifold hit the helper’s left leg causing injuries. After first aid, the helper was evacuated to Ibri hospital for treatment where X ray revealed displaced oblique fracture of tibia and fibula.
How do you verify that pressure-testing equipment is certified and fit for use? What could happen if a pressure-containing component fails during testing? What controls should be in place to prevent equipment movement following a pressure release? How do you identify stored/release energy hazards before starting a pressure test? What barriers are available to protect personnel from flying or swinging equipment? How do you confirm subcontractor equipment meets project and PDO requirements? What lessons from this incident can be applied to other pressure-related activities? Pressure Can Kill – Verify Certification, Secure Equipment, and Stay Out of the Line of Fire
The replaced ball valve was not independently tested and certified before being used in a pressure test. The risk assessment did not adequately consider valve failure and uncontrolled energy release scenarios. The manifold assembly was not sufficiently secured to prevent movement if a component failed. Critical controls such as equipment certification, anchoring requirements, and pressure-release safeguards were not fully specified or verified. Contractor and subcontractor assurance processes did not verify the integrity and certification of all critical pressure-testing components

Category:Second AlertsDocument Type:Safety
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