The circulating water system is a very important system in Ghazlan Steam Power Plant- 4276 MW, as it supplies the sea water to the tubes side of the Condensers during normal operation. A large butterfly cross-connect valve was installed at the circulating water pumps discharge header to isolate the pumps and the header for maintenance. A forced unit shutdown occurred due to valve’s shafts end leakage and collapse after maintenance work. This paper explains the wrong design location of the valve in the piping as the root cause of the problem. Analysis with ASME reference will be presented. This paper will also present potential solutions and actions taken as a lesson learned to avoid occurrence in other plants.

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