HAZARDS OF TRAPPED PRESSURE AND VACUUM

ACCIDENT Pressure testing of choke manifold!

Pressure testing was being performed on a offshore well choke manifold up
to 5,000 psig (345 barg) inside a pressure test bay at an onshore base. While
a workshop foreman and a technician were inside the test bay inspecting the
choke manifold for leaks, a thermowell (3/4" NPT) failed and hit the technician
in the leg, seriously injuring his right knee.
The force acting upon the thermowell can be calculated as follows:
Force = Pressure
Area
Test pressure = 5,000 psi (345 bar)
Affected area = 0.785 sq ins (5.065 cm2)
Therefore, Force = 3,925 pounds (1.8 tons)!

The injury was caused when the technician was struck by a thermowell
ejected from a 3/4" NPT female tapping in a 5,000 psig (345 barg) choke
manifold during a pressure test.
Continued

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HAZARDS OF TRAPPED PRESSURE AND VACUUM

Bullet

The 3/4" NPT Thermowell, which is about 9 inch (23 cm) long and weighs
approximately 2.2 lb (1 kg), struck the technician on his knee from
approximately 20 inch (50 cm). When the thread failed, the stored energy was
released and propelled the thermowell at a velocity of 94 mph (151kmh)!

Severe corrosion had affected the mechanical integrity of the female thread.
The forces generated by the 5,000 psig (345 barg) test pressure overcame
the mechanical strength of the corroded thread and caused the thermowell
to be ejected.

Pressure = Stored Energy.

When pressure acts upon an area, a force is generated.

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