Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2013-07-26 — IL
Operator
Bp Pipeline (North America) Inc.
Cause
Equipment Failure
Commodity
Crude Oil
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$10,000
Incident datetime
2013-07-26 08:00
Report number
Location
IL
Narrative
On july 26, 2013 a bp pipeline technician upon exiting the pipeline office identified a loss of primary containment of crude oil in the blake pump station of the bp #1 crude system. The technician contacted the control center which immediately shut down the pipeline. Analysis has determined that a partially buried valve experienced a mechanical failure of a threaded connection in its cast body. It is believed that a pre-existing flaw in the 1950's vintage valve body casting reduced the threaded engagement length, diminishing the frictional forces retaining the 1/2' plug allowing it to back out. The impacted area was remediated and the valve was replaced. The metallurgical cause of the leak could not be conclusively determined primarily because the plug was not recovered from the leak site. Five possible failure scenarios were considered and are discussed below. Failure scenarios 1, 4, and 5 can be ruled out. Failure scenario 1 ' the plug was never inserted following maintenance in 2002. This scenario was ruled out based on background information from bp. The valve would have leaked if the plug was not in the drain port, and the leak would have been discovered. Failure scenario 4 ' the plug blew out during operation. This scenario was ruled out since the threads of port 1 were not sheared off. There was no evidence of mechanical damage to the threads to support this scenario. Failure scenario 5 ' complete corrosion of the internal threads occurred and the plug fell out. This scenario was ruled out since only a portion of the threads of port 1 was corroded, and a majority or all of the threads that would have been in contact with the plug were not significantly corroded. Failure scenario 3 ' the plug blew out during operation because the threads were corroded. This scenario has a low likelihood. Since rolled material, which could be similar to the material of a carbon steel plug, was selectively attacked, it is possible that a carbon steel plug could have been attacked. Also, it is possible that a non-carbon steel plug, that is anodic to steel, was inserted during the maintenance in 2002. Since the other two drain plugs were determined to composed of carbon steel, this is not likely. Therefore, this scenario is possible, but is not considered likely. Failure scenario 2 ' the plug backed out during operation. This scenario is the most likely of the five scenarios. Supporting evidence for this scenario includes the fact that, according to bp, the valve was subjected to vibrations and 2) the threads of the port that leaked are not completely corroded away or sheared off. As described above, there was no mechanical damage of the threads to support shearing off and a majority or all of the threads that would have been in contact with the plug were not significantly corroded. This scenario is the most possible, it's believed to be vibration and could not be definitively confirmed.
Detailed record list
Report Received Date
2013-08-23 00:00:00
Iyear
2013
Report Number
20130289
Supplemental Number
20378
Report Type
Supplemental Final
Operator Id
31189
Name
Bp Pipeline (North America) Inc.
Operator Street Address
150 W. Warrenville Road
Operator City Name
Naperville
Operator State Abbreviation
IL
Operator Postal Code
60563
Local Datetime
2013-07-26 08:00:00
Location Latitude
36.927591
Location Longitude
-96.052414
Commodity Released Type
Crude Oil
Unintentional Release Bbls
535
Recovered Bbls
535
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
Incident Identified Datetime
2013-07-26 08:00:00
System Part Involved
Onshore Pump/meter Station Equipment And Piping
On Off Shore
Onshore
Shutdown Due Accident Ind
Yes
Shutdown Datetime
2013-07-26 08:04:00
Restart Datetime
2013-07-28 16:37:00
On Site Datetime
2013-07-26 08:01:00
Nrc Rpt Datetime
2013-07-26 09:06:00
Nrc Rpt Num
1055152
Ignite Ind
No
Explode Ind
No
Num Pub Evacuated
0
Pipe Fac Name
Blake Pump Station
Segment Name
#1 Crude Pipeline System
Onshore State Abbreviation
Ok
Onshore Postal Code
74022
Onshore City Name
Copan
Onshore County Name
Osage
Designated Location
Survey Station No.
Designated Name
Pump Station
Federal
No
Location Type
Originated On Operator-Controlled Property, But Then Flowed Or Migrated Off The Property
Incident Area Type
Underground
Incident Area Subtype
Under Soil
Depth Of Cover
30
Crossing
No
Pipe Facility Type
Interstate
Item Involved
Valve
Valve Type
Auxiliary Or Other Valve
Installation Year
1956
Material Involved
Carbon Steel
Release Type
Leak
Leak Type
Connection Failure
Wildlife Impact Ind
Yes
Fish Aquatic Impact Ind
Yes
Soil Contamination
Yes
Long Term Assessment
No
Remediation Ind
Yes
Surface Water Remed Ind
Yes
Soil Remed Ind
Yes
Vegetation Remed Ind
Yes
Water Contam Ind
Yes
Surface Contam Ind
Yes
Amount Released
145
Rel Water Name
Unknow Pond
Could Be Hca
Yes
Commodity Reached Hca
No
Est Cost Oper Paid
14000
Est Cost Gas Released
56000
Est Cost Prop Damage
10000
Est Cost Emergency
616000
Est Cost Environmental
1300000
Est Cost Other
0
Prpty
1996000
Accident Psig
631
Mop Psig
1181
Accident Pressure
Pressure Did Not Exceed Mop
Pressure Restriction Ind
No
Pipeline Function
> 20% Smys Regulated Transmission
Scada In Place Ind
Yes
Scada Operating Ind
Yes
Scada Functional Ind
Yes
Scada Detection Ind
Yes
Scada Conf Ind
Yes
Cpm In Place Ind
Yes
Cpm Operating Ind
Yes
Cpm Functional Ind
Yes
Cpm Detection Ind
Yes
Cpm Conf Ind
Yes
Investigation Status
Yes, specify investigation result(s): (select all that apply)
Invest Schedule Ind
Yes
Invest No Control Room Ind
Yes
Invest No Controller Ind
Yes
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Equipment Failure
Cause Details
Malfunction Of Control/relief Equipment
Eq Failure Type
Malfunction Of Control/relief Equipment
Block Valve Ind
Yes
Other Stripped Ind
Threaded Fitting
Additional Vibration Ind
Yes
Preparer Name
S**** F*********
Preparer Title
Dot Compliance Advisor
Preparer Email
F*****@b*.com
Preparer Telephone
281-217-3703
Prepared Date
2015-04-24 00:00:00
Authorizer Name
M****** S******
Authorizer Telephone
630-536-3495
Authorizer Title
Dot Team Leader - Affiliates Us Pipelines
Authorizer Email
M**************@b*.com
Narrative
On july 26, 2013 a bp pipeline technician upon exiting the pipeline office identified a loss of primary containment of crude oil in the blake pump station of the bp #1 crude system. The technician contacted the control center which immediately shut down the pipeline. Analysis has determined that a partially buried valve experienced a mechanical failure of a threaded connection in its cast body. It is believed that a pre-existing flaw in the 1950's vintage valve body casting reduced the threaded engagement length, diminishing the frictional forces retaining the 1/2' plug allowing it to back out. The impacted area was remediated and the valve was replaced. The metallurgical cause of the leak could not be conclusively determined primarily because the plug was not recovered from the leak site. Five possible failure scenarios were considered and are discussed below. Failure scenarios 1, 4, and 5 can be ruled out. Failure scenario 1 ' the plug was never inserted following maintenance in 2002. This scenario was ruled out based on background information from bp. The valve would have leaked if the plug was not in the drain port, and the leak would have been discovered. Failure scenario 4 ' the plug blew out during operation. This scenario was ruled out since the threads of port 1 were not sheared off. There was no evidence of mechanical damage to the threads to support this scenario. Failure scenario 5 ' complete corrosion of the internal threads occurred and the plug fell out. This scenario was ruled out since only a portion of the threads of port 1 was corroded, and a majority or all of the threads that would have been in contact with the plug were not significantly corroded. Failure scenario 3 ' the plug blew out during operation because the threads were corroded. This scenario has a low likelihood. Since rolled material, which could be similar to the material of a carbon steel plug, was selectively attacked, it is possible that a carbon steel plug could have been attacked. Also, it is possible that a non-carbon steel plug, that is anodic to steel, was inserted during the maintenance in 2002. Since the other two drain plugs were determined to composed of carbon steel, this is not likely. Therefore, this scenario is possible, but is not considered likely. Failure scenario 2 ' the plug backed out during operation. This scenario is the most likely of the five scenarios. Supporting evidence for this scenario includes the fact that, according to bp, the valve was subjected to vibrations and 2) the threads of the port that leaked are not completely corroded away or sheared off. As described above, there was no mechanical damage of the threads to support shearing off and a majority or all of the threads that would have been in contact with the plug were not significantly corroded. This scenario is the most possible, it's believed to be vibration and could not be definitively confirmed.
| Report Received Date | 2013-08-23 00:00:00 |
|---|---|
| Iyear | 2013 |
| Report Number | 20130289 |
| Supplemental Number | 20378 |
| Report Type | Supplemental Final |
| Operator Id | 31189 PHMSA Enforcement |
| Name | Bp Pipeline (North America) Inc. |
| Operator Street Address | 150 W. Warrenville Road |
| Operator City Name | Naperville |
| Operator State Abbreviation | IL |
| Operator Postal Code | 60563 |
| Local Datetime | 2013-07-26 08:00:00 |
| Location Latitude | 36.927591 Google Maps OpenStreetMap |
| Location Longitude | -96.052414 Google Maps OpenStreetMap |
| Commodity Released Type | Crude Oil |
| Unintentional Release Bbls | 535 |
| Recovered Bbls | 535 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| Incident Identified Datetime | 2013-07-26 08:00:00 |
| System Part Involved | Onshore Pump/meter Station Equipment And Piping |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | Yes |
| Shutdown Datetime | 2013-07-26 08:04:00 |
| Restart Datetime | 2013-07-28 16:37:00 |
| On Site Datetime | 2013-07-26 08:01:00 |
| Nrc Rpt Datetime | 2013-07-26 09:06:00 |
| Nrc Rpt Num | 1055152 NRC Report How to search |
| Ignite Ind | No |
| Explode Ind | No |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Blake Pump Station |
| Segment Name | #1 Crude Pipeline System |
| Onshore State Abbreviation | Ok |
| Onshore Postal Code | 74022 |
| Onshore City Name | Copan |
| Onshore County Name | Osage |
| Designated Location | Survey Station No. |
| Designated Name | Pump Station |
| Federal | No |
| Location Type | Originated On Operator-Controlled Property, But Then Flowed Or Migrated Off The Property |
| Incident Area Type | Underground |
| Incident Area Subtype | Under Soil |
| Depth Of Cover | 30 |
| Crossing | No |
| Pipe Facility Type | Interstate |
| Item Involved | Valve |
| Valve Type | Auxiliary Or Other Valve |
| Installation Year | 1956 |
| Material Involved | Carbon Steel |
| Release Type | Leak |
| Leak Type | Connection Failure |
| Wildlife Impact Ind | Yes |
| Fish Aquatic Impact Ind | Yes |
| Soil Contamination | Yes |
| Long Term Assessment | No |
| Remediation Ind | Yes |
| Surface Water Remed Ind | Yes |
| Soil Remed Ind | Yes |
| Vegetation Remed Ind | Yes |
| Water Contam Ind | Yes |
| Surface Contam Ind | Yes |
| Amount Released | 145 |
| Rel Water Name | Unknow Pond |
| Could Be Hca | Yes |
| Commodity Reached Hca | No |
| Est Cost Oper Paid | 14000 |
| Est Cost Gas Released | 56000 |
| Est Cost Prop Damage | 10000 |
| Est Cost Emergency | 616000 |
| Est Cost Environmental | 1300000 |
| Est Cost Other | 0 |
| Prpty | 1996000 |
| Accident Psig | 631 |
| Mop Psig | 1181 |
| Accident Pressure | Pressure Did Not Exceed Mop |
| Pressure Restriction Ind | No |
| Pipeline Function | > 20% Smys Regulated Transmission |
| Scada In Place Ind | Yes |
| Scada Operating Ind | Yes |
| Scada Functional Ind | Yes |
| Scada Detection Ind | Yes |
| Scada Conf Ind | Yes |
| Cpm In Place Ind | Yes |
| Cpm Operating Ind | Yes |
| Cpm Functional Ind | Yes |
| Cpm Detection Ind | Yes |
| Cpm Conf Ind | Yes |
| Investigation Status | Yes, specify investigation result(s): (select all that apply) |
| Invest Schedule Ind | Yes |
| Invest No Control Room Ind | Yes |
| Invest No Controller Ind | Yes |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Equipment Failure |
| Cause Details | Malfunction Of Control/relief Equipment |
| Eq Failure Type | Malfunction Of Control/relief Equipment |
| Block Valve Ind | Yes |
| Other Stripped Ind | Threaded Fitting |
| Additional Vibration Ind | Yes |
| Preparer Name | S**** F********* |
| Preparer Title | Dot Compliance Advisor |
| Preparer Email | F*****@b*.com |
| Preparer Telephone | 281-217-3703 |
| Prepared Date | 2015-04-24 00:00:00 |
| Authorizer Name | M****** S****** |
| Authorizer Telephone | 630-536-3495 |
| Authorizer Title | Dot Team Leader - Affiliates Us Pipelines |
| Authorizer Email | M**************@b*.com |
| Narrative | On july 26, 2013 a bp pipeline technician upon exiting the pipeline office identified a loss of primary containment of crude oil in the blake pump station of the bp #1 crude system. The technician contacted the control center which immediately shut down the pipeline. Analysis has determined that a partially buried valve experienced a mechanical failure of a threaded connection in its cast body. It is believed that a pre-existing flaw in the 1950's vintage valve body casting reduced the threaded engagement length, diminishing the frictional forces retaining the 1/2' plug allowing it to back out. The impacted area was remediated and the valve was replaced. The metallurgical cause of the leak could not be conclusively determined primarily because the plug was not recovered from the leak site. Five possible failure scenarios were considered and are discussed below. Failure scenarios 1, 4, and 5 can be ruled out. Failure scenario 1 ' the plug was never inserted following maintenance in 2002. This scenario was ruled out based on background information from bp. The valve would have leaked if the plug was not in the drain port, and the leak would have been discovered. Failure scenario 4 ' the plug blew out during operation. This scenario was ruled out since the threads of port 1 were not sheared off. There was no evidence of mechanical damage to the threads to support this scenario. Failure scenario 5 ' complete corrosion of the internal threads occurred and the plug fell out. This scenario was ruled out since only a portion of the threads of port 1 was corroded, and a majority or all of the threads that would have been in contact with the plug were not significantly corroded. Failure scenario 3 ' the plug blew out during operation because the threads were corroded. This scenario has a low likelihood. Since rolled material, which could be similar to the material of a carbon steel plug, was selectively attacked, it is possible that a carbon steel plug could have been attacked. Also, it is possible that a non-carbon steel plug, that is anodic to steel, was inserted during the maintenance in 2002. Since the other two drain plugs were determined to composed of carbon steel, this is not likely. Therefore, this scenario is possible, but is not considered likely. Failure scenario 2 ' the plug backed out during operation. This scenario is the most likely of the five scenarios. Supporting evidence for this scenario includes the fact that, according to bp, the valve was subjected to vibrations and 2) the threads of the port that leaked are not completely corroded away or sheared off. As described above, there was no mechanical damage of the threads to support shearing off and a majority or all of the threads that would have been in contact with the plug were not significantly corroded. This scenario is the most possible, it's believed to be vibration and could not be definitively confirmed. |
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