IOGP high potential event report

Incident description:

A high potential incident occurred when an 8kg vertical line packer fell 10 metres to grade. There were no injuries associated with this incident.

What Went Wrong:

The stitch welds between the vertical packer and the pipe support experienced crevice corrosion jacking and failed, leading to the dropped object. Incorrect installation procedures led to the packer being stitch welded instead of full seal welded. The packer itself showed signs of surface corrosion only, with no obvious visual indications that the welds were failing (i.e. inspections were unlikely to detect the issue). Inspection procedures were inadequate as they did not identify the failure.

Corrective Actions:

A warning sign was that it had exceeded it’s original design lift of 20 years (BOD). Stitch welds have a life of 20 years however fully sealed welds maintain integrity for longer. The importance of QA/QC processes, which should have picked up the stitch welds during installation. Failure to learn from similar events that have occurred. Update engineering standards and global piping and inspection procedures. This to ensure a mandate for full seal welding of packers and then to specifically identify packers, pipe shoes and other susceptible items.