FRALEX CS-001 — Steam Explosion During a Re-Injection (Full Document)

FRALEX CS-001 — Steam Explosion During Re-Injection | Pressurized Valve Connection Failure | FRALEX ESS

FRALEX STANDARD | CS-001 | Rev. 1.0 | March 2026

82-page full technical analysis of a real steam explosion at a refinery — 16" gate valve, 70 bar boiler water, 290°C. Two fatalities. Complete failure chain from RTJ geometry deviation to catastrophic valve bonnet decoupling.

This case study is required reading for every engineer involved in live intervention, leak sealing, and re-injection work on pressurized systems.

This document covers: Full accident reconstruction and root cause analysis | Complete FRALEX failure chain | Mechanical load analysis: 903 kN axial force on 6 intact bolts out of 20 | Stress Corrosion Cracking — all four conditions identified | Five missed stop points with corrective action | FRALEX Integrity Evaluation Matrix for leak sealing | 4-step decision logic for re-injection and live intervention | Pre-Intervention Screening Checklist and Abandonment Criteria

For: Asset Integrity Managers | HSE Engineers | Leak Sealing Specialists | Plant Operators | Maintenance Engineers | Insurance & Risk Assessors

Keywords: steam explosion, leak sealing failure, re-injection accident, pressurized valve failure, boiler water, stress corrosion cracking, live intervention risk, FRALEX ESS, failure chain analysis, asset integrity, HSE engineering, refinery accident, online leak sealing, intervention decision framework

Language: English | Pages: 82 | Format: PDF

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