A butterfly valve on a 36” class 150 flare line operating at 1.5 bar pressure had been stuck in a closed position for an extended period. The stuck valve prevented the backup flare system from being used, thus limiting the options available to undergo planned maintenance without shutting down. The working temperature of the line could range from ambient to cryogenic in the event of a sudden relief of liquids, and the faulty valve needed to be replaced without disturbance to operations. Solutions were required to mitigate HSSE risk associated with the valve replacement, as there were no suitable built-in isolation points close to the stuck valve. The plant operator had evaluated alternatives, concluding that few, if any, robust or cost-effective alternative solutions were available. Clearly, there would be a major facility impact if the valve could not be replaced in a safe and efficient manner
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