Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2013-10-15 — TX
Operator
Genesis Free State Pipeline, Llc
Cause
Material Failure Of Pipe Or Weld
Commodity
Co2 (Carbon Dioxide)
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$70,000
Incident datetime
2013-10-15 18:05
Report number
Location
TX
Narrative
(10-15-2013) 6:05pm - 3" diameter ice ball is spotted on row 8:30pm - upstream valve closed. (10-16-2013) 7:00am - downstream valve closed. (10-20-2013) segment de-pressured and leak site is dug up. The suspected leak point in a joint weld was x-rayed and the leak was found in the weld. A 5' section (2.5' on each side of weld) was cut out. When the cut-out was removed, it was noticed that the pipe had the original x-ray markings designation of a weld repair. It was apparent from looking at the weld that it had been repaired originally. The inside of the weld seam shows the repair was not done correctly. The leak occurred because an original girth weld that had to be repaired was not done correctly. (10-21-2013) all repairs are completed. Pretested pipe was installed. All welds passed inspections. (10-24-2013) the segment is placed back in service. Supplemental a failure analysis was performed by pmi specialists, inc.. The analysis report (final - 11/18/2013) is summarized as thus: "from the appearance and cross section analysis, it is clear that the leak was caused by unfilled cavity in the root pass and haz cracking from the top. The major reason is because of the unfilled cavity in the root pass, which created a huge stress riser on the pipe internal surface and decreased the effective wall thickness. Small cracks developed on the bottom of the root cavity during service. With time, they met with the haz cracks from the top, leading to a through crack. The unfilled cavity in the root pass is caused by slag inclusion, which was not properly cleaned before the repair welding procedure. In this case, most likely, the haz cracks were due to insufficient preheat temperature during repair welding. Since the cracks are small, they were missed by visual examination and x-ray. Supplemental - 1/21/2016 correction to smys entry (part c, question 3c), adding approximate volume of commodity intentionally released to atmosphere to prior to pipe repair (part a, question 10), and adding approximate cost of commodity intentionally released to atmosphere (part d, question 8d).
Detailed record list
Report Received Date
2013-11-13 00:00:00
Iyear
2013
Report Number
20130365
Supplemental Number
21074
Report Type
Supplemental Final
Operator Id
32410
Name
Genesis Free State Pipeline, Llc
Operator Street Address
919 Milam; Suite 2100
Operator City Name
Houston
Operator State Abbreviation
TX
Operator Postal Code
77002-5417
Local Datetime
2013-10-15 18:05:00
Location Latitude
31.93103
Location Longitude
-89.51142
Commodity Released Type
Co2 (Carbon Dioxide)
Unintentional Release Bbls
0.1
Intentional Release Bbls
30699
Recovered Bbls
0
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Air Patrol
Operator Type
Contractor Working For The Operator
Incident Identified Datetime
2013-10-15 18:05:00
System Part Involved
Onshore Pipeline, Including Valve Sites
On Off Shore
Onshore
Shutdown Due Accident Ind
Yes
Shutdown Datetime
2013-10-15 20:30:00
Restart Datetime
2013-10-24 06:24:00
On Site Datetime
2013-10-15 20:05:00
Nrc Rpt Datetime
2013-10-15 21:15:00
Nrc Rpt Num
1063122
Ignite Ind
No
Explode Ind
No
Upstream Valve Type Ind
Manual
Downstream Valve Type Ind
Manual
Num Pub Evacuated
0
Pipe Fac Name
Freestate 20" Co2
Segment Name
9002
Onshore State Abbreviation
Ms
Onshore Postal Code
39116
Onshore City Name
Not Within A Municipality
Onshore County Name
Smith
Designated Location
Survey Station No.
Designated Name
2229+84
Federal
No
Location Type
Pipeline Right-Of-Way
Incident Area Type
Underground
Incident Area Subtype
Under Soil
Depth Of Cover
84
Crossing
No
Pipe Facility Type
Interstate
Item Involved
Pipe
Pipe Type
Pipe Body
Pipe Diameter
20
Pipe Wall Thickness
0.312
Pipe Smys
80000
Pipe Specification
Api 5l X80
Pipe Seam Type
Erw - High Frequency
Pipe Manufacturer
Stubb & Mannesmann Line Pipe, Lp
Pipe Coating Type
Fusion Bonded Epoxy(Fbe)
Installation Year
2006
Manufactured Year
2004
Material Involved
Carbon Steel
Release Type
Other
Release Type Details
Failed Original Construction Repair Weld.
Wildlife Impact Ind
No
Soil Contamination
No
Long Term Assessment
No
Remediation Ind
No
Water Contam Ind
No
Could Be Hca
No
Commodity Reached Hca
No
Est Cost Oper Paid
0
Est Cost Gas Released
86721
Est Cost Prop Damage
70000
Est Cost Emergency
0
Est Cost Environmental
500
Est Cost Other
0
Prpty
157221
Accident Psig
1295
Mop Psig
1797
Accident Pressure
Pressure Did Not Exceed Mop
Pressure Restriction Ind
No
Length Segment Isolated
84110
Internal Inspection Ind
No
Other Inspection Ind
Yes
Internal Inspection Details
Flow Limitations.
Operation Complications Ind
Yes
Low Flow Ind
Yes
Pipeline Function
> 20% Smys Regulated Transmission
Scada In Place Ind
Yes
Scada Operating Ind
Yes
Scada Functional Ind
Yes
Scada Detection Ind
No
Scada Conf Ind
No
Cpm In Place Ind
Yes
Cpm Operating Ind
Yes
Cpm Functional Ind
Yes
Cpm Detection Ind
No
Cpm Conf Ind
No
Investigation Status
No, the operator did not find that an investigation of the controller(s) actions or control room issues was necessary due to: (provide an explanation for why the operator did not investigate)
Investigation Status Details
The leak was minute and cpm could not detect such a small loss of volume.
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Material Failure Of Pipe Or Weld
Cause Details
Design-, Construction-, Installation-, Or Fabrication-Related
Field Exam Ind
Yes
Metallurgical Ind
Yes
Failure Type
Design-, Construction-, Installation-, Or Fabrication-Related
Other Factor
Yes
Other Factor Details
Repaired Girth Weld Failure.
Additional Crack Ind
Yes
Pwf Additional Other Ind
Yes
Collected Data Ind
No
Has Hydrtst Conduc Before Ind
No
Direct Asmnt Conducted
No
Non Destructive Exam Ind
No
Preparer Name
T** B***
Preparer Title
Ms Pipeline Manager
Preparer Email
T**********@g****.com
Preparer Telephone
601-729-3587
Prepared Date
2016-01-21 00:00:00
Authorizer Name
J*** J*****
Authorizer Telephone
713-860-2605
Authorizer Title
Manager Dot Compliance And Facility Security
Authorizer Email
J**********@g****.com
Narrative
(10-15-2013) 6:05pm - 3" diameter ice ball is spotted on row 8:30pm - upstream valve closed. (10-16-2013) 7:00am - downstream valve closed. (10-20-2013) segment de-pressured and leak site is dug up. The suspected leak point in a joint weld was x-rayed and the leak was found in the weld. A 5' section (2.5' on each side of weld) was cut out. When the cut-out was removed, it was noticed that the pipe had the original x-ray markings designation of a weld repair. It was apparent from looking at the weld that it had been repaired originally. The inside of the weld seam shows the repair was not done correctly. The leak occurred because an original girth weld that had to be repaired was not done correctly. (10-21-2013) all repairs are completed. Pretested pipe was installed. All welds passed inspections. (10-24-2013) the segment is placed back in service. Supplemental a failure analysis was performed by pmi specialists, inc.. The analysis report (final - 11/18/2013) is summarized as thus: "from the appearance and cross section analysis, it is clear that the leak was caused by unfilled cavity in the root pass and haz cracking from the top. The major reason is because of the unfilled cavity in the root pass, which created a huge stress riser on the pipe internal surface and decreased the effective wall thickness. Small cracks developed on the bottom of the root cavity during service. With time, they met with the haz cracks from the top, leading to a through crack. The unfilled cavity in the root pass is caused by slag inclusion, which was not properly cleaned before the repair welding procedure. In this case, most likely, the haz cracks were due to insufficient preheat temperature during repair welding. Since the cracks are small, they were missed by visual examination and x-ray. Supplemental - 1/21/2016 correction to smys entry (part c, question 3c), adding approximate volume of commodity intentionally released to atmosphere to prior to pipe repair (part a, question 10), and adding approximate cost of commodity intentionally released to atmosphere (part d, question 8d).
| Report Received Date | 2013-11-13 00:00:00 |
|---|---|
| Iyear | 2013 |
| Report Number | 20130365 |
| Supplemental Number | 21074 |
| Report Type | Supplemental Final |
| Operator Id | 32410 PHMSA Enforcement |
| Name | Genesis Free State Pipeline, Llc |
| Operator Street Address | 919 Milam; Suite 2100 |
| Operator City Name | Houston |
| Operator State Abbreviation | TX |
| Operator Postal Code | 77002-5417 |
| Local Datetime | 2013-10-15 18:05:00 |
| Location Latitude | 31.93103 Google Maps OpenStreetMap |
| Location Longitude | -89.51142 Google Maps OpenStreetMap |
| Commodity Released Type | Co2 (Carbon Dioxide) |
| Unintentional Release Bbls | 0.1 |
| Intentional Release Bbls | 30699 |
| Recovered Bbls | 0 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Air Patrol |
| Operator Type | Contractor Working For The Operator |
| Incident Identified Datetime | 2013-10-15 18:05:00 |
| System Part Involved | Onshore Pipeline, Including Valve Sites |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | Yes |
| Shutdown Datetime | 2013-10-15 20:30:00 |
| Restart Datetime | 2013-10-24 06:24:00 |
| On Site Datetime | 2013-10-15 20:05:00 |
| Nrc Rpt Datetime | 2013-10-15 21:15:00 |
| Nrc Rpt Num | 1063122 NRC Report How to search |
| Ignite Ind | No |
| Explode Ind | No |
| Upstream Valve Type Ind | Manual |
| Downstream Valve Type Ind | Manual |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Freestate 20" Co2 |
| Segment Name | 9002 |
| Onshore State Abbreviation | Ms |
| Onshore Postal Code | 39116 |
| Onshore City Name | Not Within A Municipality |
| Onshore County Name | Smith |
| Designated Location | Survey Station No. |
| Designated Name | 2229+84 |
| Federal | No |
| Location Type | Pipeline Right-Of-Way |
| Incident Area Type | Underground |
| Incident Area Subtype | Under Soil |
| Depth Of Cover | 84 |
| Crossing | No |
| Pipe Facility Type | Interstate |
| Item Involved | Pipe |
| Pipe Type | Pipe Body |
| Pipe Diameter | 20 |
| Pipe Wall Thickness | 0.312 |
| Pipe Smys | 80000 |
| Pipe Specification | Api 5l X80 |
| Pipe Seam Type | Erw - High Frequency |
| Pipe Manufacturer | Stubb & Mannesmann Line Pipe, Lp |
| Pipe Coating Type | Fusion Bonded Epoxy(Fbe) |
| Installation Year | 2006 |
| Manufactured Year | 2004 |
| Material Involved | Carbon Steel |
| Release Type | Other |
| Release Type Details | Failed Original Construction Repair Weld. |
| Wildlife Impact Ind | No |
| Soil Contamination | No |
| Long Term Assessment | No |
| Remediation Ind | No |
| Water Contam Ind | No |
| Could Be Hca | No |
| Commodity Reached Hca | No |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 86721 |
| Est Cost Prop Damage | 70000 |
| Est Cost Emergency | 0 |
| Est Cost Environmental | 500 |
| Est Cost Other | 0 |
| Prpty | 157221 |
| Accident Psig | 1295 |
| Mop Psig | 1797 |
| Accident Pressure | Pressure Did Not Exceed Mop |
| Pressure Restriction Ind | No |
| Length Segment Isolated | 84110 |
| Internal Inspection Ind | No |
| Other Inspection Ind | Yes |
| Internal Inspection Details | Flow Limitations. |
| Operation Complications Ind | Yes |
| Low Flow Ind | Yes |
| Pipeline Function | > 20% Smys Regulated Transmission |
| Scada In Place Ind | Yes |
| Scada Operating Ind | Yes |
| Scada Functional Ind | Yes |
| Scada Detection Ind | No |
| Scada Conf Ind | No |
| Cpm In Place Ind | Yes |
| Cpm Operating Ind | Yes |
| Cpm Functional Ind | Yes |
| Cpm Detection Ind | No |
| Cpm Conf Ind | No |
| Investigation Status | No, the operator did not find that an investigation of the controller(s) actions or control room issues was necessary due to: (provide an explanation for why the operator did not investigate) |
| Investigation Status Details | The leak was minute and cpm could not detect such a small loss of volume. |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Material Failure Of Pipe Or Weld |
| Cause Details | Design-, Construction-, Installation-, Or Fabrication-Related |
| Field Exam Ind | Yes |
| Metallurgical Ind | Yes |
| Failure Type | Design-, Construction-, Installation-, Or Fabrication-Related |
| Other Factor | Yes |
| Other Factor Details | Repaired Girth Weld Failure. |
| Additional Crack Ind | Yes |
| Pwf Additional Other Ind | Yes |
| Collected Data Ind | No |
| Has Hydrtst Conduc Before Ind | No |
| Direct Asmnt Conducted | No |
| Non Destructive Exam Ind | No |
| Preparer Name | T** B*** |
| Preparer Title | Ms Pipeline Manager |
| Preparer Email | T**********@g****.com |
| Preparer Telephone | 601-729-3587 |
| Prepared Date | 2016-01-21 00:00:00 |
| Authorizer Name | J*** J***** |
| Authorizer Telephone | 713-860-2605 |
| Authorizer Title | Manager Dot Compliance And Facility Security |
| Authorizer Email | J**********@g****.com |
| Narrative | (10-15-2013) 6:05pm - 3" diameter ice ball is spotted on row 8:30pm - upstream valve closed. (10-16-2013) 7:00am - downstream valve closed. (10-20-2013) segment de-pressured and leak site is dug up. The suspected leak point in a joint weld was x-rayed and the leak was found in the weld. A 5' section (2.5' on each side of weld) was cut out. When the cut-out was removed, it was noticed that the pipe had the original x-ray markings designation of a weld repair. It was apparent from looking at the weld that it had been repaired originally. The inside of the weld seam shows the repair was not done correctly. The leak occurred because an original girth weld that had to be repaired was not done correctly. (10-21-2013) all repairs are completed. Pretested pipe was installed. All welds passed inspections. (10-24-2013) the segment is placed back in service. Supplemental a failure analysis was performed by pmi specialists, inc.. The analysis report (final - 11/18/2013) is summarized as thus: "from the appearance and cross section analysis, it is clear that the leak was caused by unfilled cavity in the root pass and haz cracking from the top. The major reason is because of the unfilled cavity in the root pass, which created a huge stress riser on the pipe internal surface and decreased the effective wall thickness. Small cracks developed on the bottom of the root cavity during service. With time, they met with the haz cracks from the top, leading to a through crack. The unfilled cavity in the root pass is caused by slag inclusion, which was not properly cleaned before the repair welding procedure. In this case, most likely, the haz cracks were due to insufficient preheat temperature during repair welding. Since the cracks are small, they were missed by visual examination and x-ray. Supplemental - 1/21/2016 correction to smys entry (part c, question 3c), adding approximate volume of commodity intentionally released to atmosphere to prior to pipe repair (part a, question 10), and adding approximate cost of commodity intentionally released to atmosphere (part d, question 8d). |
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