Online repacking of valves in liquid hydrocarbon service is a practice that, while not common, is used on occasion to avoid the risks associated with shutting down an entire cracker facility. The repacking operation constitutes a period of heightened risk and it must be carefully planned, monitored, and managed.
This paper aims to raise awareness of some less-obvious errors and failures which are possible by sharing a case where a significant release occurred from a manual valve on the recycle line to a LPG splitter column due to catastrophic failure of the valve stem packing, following attempted repacking of the valve. The paper will also share some mitigations which can be pursued to reduce the potential for a similar event and some measures to limit the risk to personnel and the plant should an event like this occur.
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