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When valve(s) are leaking beyond acceptable leak rate, and valve repair results in unacceptable outage or is just not possible, what are your options?

    1. Boundary isolation & depressurization further upstream, resulting in major outage
    2. Postpone the planned work
    3. Inject grease (leakage will reappear suddenly) or sealants (often in case of emergency, somtimes rendering valves useless for future operation)
    4. (Accept the leakage and continue with the planned work. Remaining risk must be ALARP)

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  • No favourable solution available
  • The leaking valve(s) must be repaired, which involves depressurized headers and associated plant outage
  • Keeping downtime to a minimum requires considerable investment in spare valves and components
  • New or repaired valves often fail again
    • Leakage caused by, for example
      • sand or foreign particles (e.g. corrosion or welding butts) in pipelines
      • Elastic or plastic deformation in sealing surface
      • Seats stuck in seat pockets (no piston effect anymore)
      • leakage over secundairy seals (O-ring damage)
      • corrosion and deposit of corrosion products
    • Root cause of failure often is not mitigated with repair onlyPractically impossible to prevent all root causes (!)

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