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Saudi Aramco
Drilling & Workover Organization
Trapped Pressure Incident

July 2014
The Alerts are provided to all Drilling and Workover Operations Foremen and Liaisonmen so that we all learn from the
experiences of others. The knowledge of this incident could prevent similar ones from happening in the future.
Saudi Aramco policy requires the information in this Alert to be communicated to all crew members and documented on
morning reports.

What happened?

July 2014. After testing the manual choke valve, the rig crew was instructed by Rig Manager to
open the same valve. Aramco foreman asked the Rig Managers if there was trapped pressure
behind the valve since it was too hard and difficult to be open. The Rig Manager indicated that
there was no pressure and that it was safe to open the valve. After that, a sudden sound
indicating presence of internal pressure was heard close to the choke manifold area (last
pressure test was 8500 psi). This could have resulted in injury in case there was a leak.
Fortunately no injury occurred as a result of this.

Consequences:
 This is a high potential event that could have resulted in injury due to the release of
trapped pressure.

Why did it happen?

 The contained trapped pressure was not recognized and bled off correctly.
 Poor supervision; the Rig Manager directed Crews to open the manual choke valve
without verifying the pressure was effectively bled off.

 Operating procedures were not followed properly.

What should be done to prevent reoccurrence?

 To release pressure prior to opening or working on systems. Moving parts shall be in full
rest and power must be completely isolated/locked in order to avoid high potential risk
of injury due to the stored energy or trapped pressure.
 Enforce strict compliance with written procedures for pressure-testing operations. This
includes a step-by-step process for pressurizing and depressurizing a system.
 Individuals shall never approach pressurized valves/lines unless it is confirmed by the
Supervisor that the pressure has been bled off completely.

 Crews shall be adequately supervised during pressure testing to ensure safety.