Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2014-09-10 — KS
Operator
Koch Pipeline Company, L.p.
Cause
Equipment Failure
Commodity
Crude Oil
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$6,915
Incident datetime
2014-09-10 14:30
Report number
Location
KS
Narrative
On september 10, 2014, koch pipeline company, l.P. "kpl" personnel were performing daily rounds at the clearbrook terminal. Kpl operating personnel noticed that booster can pump 701a appeared to be weeping crude. Approximately .24 barrels of crude oil was released to the ground around the booster pump area. The operator notified maintenance personnel to respond. The maintenance personnel isolated pump 701a, drained the piping, and installed a new pump seal. An oil spill response contractor was deployed to assist with clean up. During startup, it was noted that the shaft had excessive movement which indicated worn internal pump components. The pump was then isolated and locked out. The maintenance personnel proceeded to replace the pump with a rebuilt spare out of inventory. The total amount of soil remediated was approximately 30 cubic yards. *additional information leading up to the event: on march 7th 2012, while making daily rounds, a potential maintenance concern with the 701a pump was identified. Maintenance personnel were notified and after further assessment, it was determined that a no-flow overheating event had taken place. This occurrence was a result of attempting to operate at a three pump rate. Pump 701a was unable to put up enough discharge pressure to move oil against the discharge pressure of the other two pumps. As a result a new seal, unit discharge valve, and check valve were replaced along with all flange gaskets and bolts. A new type of seal was installed with a secondary isolator made of brass. The unit was commissioned to service on may 7th, 2013 and monitored for a period of time. Routine inspections revealed vibration in the unit. Vibration levels increased and a decision was made to replace the unit. However, approximately one week prior to the scheduled pump replacement, the seal failed on the pump causing a release of 0.24 barrels of crude oil. Investigation of the event revealed that movement of the shaft due to shaft vibration caused the brass secondary seal internal clearance components to start rubbing causing the unit to heat up, expand and lock in place. This created a situation where the seal sleeve and secondary seal stopped rotating with the shaft. The pump shaft continued to rotate, causing the internal seal sleeve elastomer o-ring to fail, resulting in a release of crude oil to the soil. It should be noted that the pump was still operational after the seal failure, however, a decision was made to accelerate the already scheduled pump replacement from inventory, rather than simply replacing the seal, and then replacing the entire pumping unit the following week.
Detailed record list
Report Received Date
2014-10-03 00:00:00
Iyear
2014
Report Number
20140350
Supplemental Number
21448
Report Type
Supplemental Final
Operator Id
22855
Name
Koch Pipeline Company, L.p.
Operator Street Address
4111 East 37th Street North
Operator City Name
Wichita
Operator State Abbreviation
KS
Operator Postal Code
67220
Local Datetime
2014-09-10 14:30:00
Location Latitude
47.68412
Location Longitude
-95.41216
Commodity Released Type
Crude Oil
Unintentional Release Bbls
0.24
Recovered Bbls
0.24
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
Incident Identified Datetime
2014-09-10 14:30:00
System Part Involved
Onshore Terminal/tank Farm Equipment And Piping
On Off Shore
Onshore
Shutdown Due Accident Ind
No
Shutdown Explain
The Pump Was Isolated From The Terminal And A Line Shutdown Was Not Required.
On Site Datetime
2014-09-10 14:30:00
Nrc Rpt Num
Nrc Notification Not Required
Ignite Ind
No
Explode Ind
No
Num Pub Evacuated
0
Pipe Fac Name
Clearbrook Terminal
Segment Name
Clearbrook Terminal
Onshore State Abbreviation
Mn
Onshore Postal Code
56634
Onshore City Name
Clearbrook
Onshore County Name
Clearwater
Designated Location
Milepost/valve Station
Designated Name
0
Federal
No
Location Type
Totally Contained On Operator-Controlled Property
Incident Area Type
Aboveground
Incident Area Subtype
Typical Aboveground Facility Piping Or Appurtenance
Crossing
No
Pipe Facility Type
Interstate
Item Involved
Pump
Installation Year
1985
Material Involved
Carbon Steel
Release Type
Leak
Leak Type
Seal Or Packing
Wildlife Impact Ind
No
Soil Contamination
Yes
Long Term Assessment
No
Remediation Ind
No
Water Contam Ind
No
Could Be Hca
Yes
Commodity Reached Hca
No
Est Cost Oper Paid
0
Est Cost Gas Released
23
Est Cost Prop Damage
6915
Est Cost Emergency
0
Est Cost Environmental
40864
Est Cost Other
0
Prpty
47802
Accident Psig
118
Mop Psig
285
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
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 operator did not investigate because the controllers did not perform any remote actions that would have affected the release at the time the release was discovered.
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Equipment Failure
Cause Details
Pump Or Pump-Related Equipment
Eq Failure Type
Pump Or Pump-Related Equipment
Other Pump Ind
Seal/packing Failure
Additional Vibration Ind
Yes
Preparer Name
K** G*****
Preparer Title
Dot Compliance Specialist
Preparer Email
K*********@k***********.com
Preparer Telephone
651-438-1775
Prepared Date
2016-06-17 00:00:00
Authorizer Name
K** G*****
Authorizer Telephone
651-438-1775
Authorizer Title
Dot Compliance Specialist
Authorizer Email
K*********@k***********.com
Narrative
On september 10, 2014, koch pipeline company, l.P. "kpl" personnel were performing daily rounds at the clearbrook terminal. Kpl operating personnel noticed that booster can pump 701a appeared to be weeping crude. Approximately .24 barrels of crude oil was released to the ground around the booster pump area. The operator notified maintenance personnel to respond. The maintenance personnel isolated pump 701a, drained the piping, and installed a new pump seal. An oil spill response contractor was deployed to assist with clean up. During startup, it was noted that the shaft had excessive movement which indicated worn internal pump components. The pump was then isolated and locked out. The maintenance personnel proceeded to replace the pump with a rebuilt spare out of inventory. The total amount of soil remediated was approximately 30 cubic yards. *additional information leading up to the event: on march 7th 2012, while making daily rounds, a potential maintenance concern with the 701a pump was identified. Maintenance personnel were notified and after further assessment, it was determined that a no-flow overheating event had taken place. This occurrence was a result of attempting to operate at a three pump rate. Pump 701a was unable to put up enough discharge pressure to move oil against the discharge pressure of the other two pumps. As a result a new seal, unit discharge valve, and check valve were replaced along with all flange gaskets and bolts. A new type of seal was installed with a secondary isolator made of brass. The unit was commissioned to service on may 7th, 2013 and monitored for a period of time. Routine inspections revealed vibration in the unit. Vibration levels increased and a decision was made to replace the unit. However, approximately one week prior to the scheduled pump replacement, the seal failed on the pump causing a release of 0.24 barrels of crude oil. Investigation of the event revealed that movement of the shaft due to shaft vibration caused the brass secondary seal internal clearance components to start rubbing causing the unit to heat up, expand and lock in place. This created a situation where the seal sleeve and secondary seal stopped rotating with the shaft. The pump shaft continued to rotate, causing the internal seal sleeve elastomer o-ring to fail, resulting in a release of crude oil to the soil. It should be noted that the pump was still operational after the seal failure, however, a decision was made to accelerate the already scheduled pump replacement from inventory, rather than simply replacing the seal, and then replacing the entire pumping unit the following week.
| Report Received Date | 2014-10-03 00:00:00 |
|---|---|
| Iyear | 2014 |
| Report Number | 20140350 |
| Supplemental Number | 21448 |
| Report Type | Supplemental Final |
| Operator Id | 22855 PHMSA Enforcement |
| Name | Koch Pipeline Company, L.p. |
| Operator Street Address | 4111 East 37th Street North |
| Operator City Name | Wichita |
| Operator State Abbreviation | KS |
| Operator Postal Code | 67220 |
| Local Datetime | 2014-09-10 14:30:00 |
| Location Latitude | 47.68412 Google Maps OpenStreetMap |
| Location Longitude | -95.41216 Google Maps OpenStreetMap |
| Commodity Released Type | Crude Oil |
| Unintentional Release Bbls | 0.24 |
| Recovered Bbls | 0.24 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| Incident Identified Datetime | 2014-09-10 14:30:00 |
| System Part Involved | Onshore Terminal/tank Farm Equipment And Piping |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | No |
| Shutdown Explain | The Pump Was Isolated From The Terminal And A Line Shutdown Was Not Required. |
| On Site Datetime | 2014-09-10 14:30:00 |
| Nrc Rpt Num | Nrc Notification Not Required NRC Report How to search |
| Ignite Ind | No |
| Explode Ind | No |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Clearbrook Terminal |
| Segment Name | Clearbrook Terminal |
| Onshore State Abbreviation | Mn |
| Onshore Postal Code | 56634 |
| Onshore City Name | Clearbrook |
| Onshore County Name | Clearwater |
| Designated Location | Milepost/valve Station |
| Designated Name | 0 |
| Federal | No |
| Location Type | Totally Contained On Operator-Controlled Property |
| Incident Area Type | Aboveground |
| Incident Area Subtype | Typical Aboveground Facility Piping Or Appurtenance |
| Crossing | No |
| Pipe Facility Type | Interstate |
| Item Involved | Pump |
| Installation Year | 1985 |
| Material Involved | Carbon Steel |
| Release Type | Leak |
| Leak Type | Seal Or Packing |
| Wildlife Impact Ind | No |
| Soil Contamination | Yes |
| Long Term Assessment | No |
| Remediation Ind | No |
| Water Contam Ind | No |
| Could Be Hca | Yes |
| Commodity Reached Hca | No |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 23 |
| Est Cost Prop Damage | 6915 |
| Est Cost Emergency | 0 |
| Est Cost Environmental | 40864 |
| Est Cost Other | 0 |
| Prpty | 47802 |
| Accident Psig | 118 |
| Mop Psig | 285 |
| 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 | 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 operator did not investigate because the controllers did not perform any remote actions that would have affected the release at the time the release was discovered. |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Equipment Failure |
| Cause Details | Pump Or Pump-Related Equipment |
| Eq Failure Type | Pump Or Pump-Related Equipment |
| Other Pump Ind | Seal/packing Failure |
| Additional Vibration Ind | Yes |
| Preparer Name | K** G***** |
| Preparer Title | Dot Compliance Specialist |
| Preparer Email | K*********@k***********.com |
| Preparer Telephone | 651-438-1775 |
| Prepared Date | 2016-06-17 00:00:00 |
| Authorizer Name | K** G***** |
| Authorizer Telephone | 651-438-1775 |
| Authorizer Title | Dot Compliance Specialist |
| Authorizer Email | K*********@k***********.com |
| Narrative | On september 10, 2014, koch pipeline company, l.P. "kpl" personnel were performing daily rounds at the clearbrook terminal. Kpl operating personnel noticed that booster can pump 701a appeared to be weeping crude. Approximately .24 barrels of crude oil was released to the ground around the booster pump area. The operator notified maintenance personnel to respond. The maintenance personnel isolated pump 701a, drained the piping, and installed a new pump seal. An oil spill response contractor was deployed to assist with clean up. During startup, it was noted that the shaft had excessive movement which indicated worn internal pump components. The pump was then isolated and locked out. The maintenance personnel proceeded to replace the pump with a rebuilt spare out of inventory. The total amount of soil remediated was approximately 30 cubic yards. *additional information leading up to the event: on march 7th 2012, while making daily rounds, a potential maintenance concern with the 701a pump was identified. Maintenance personnel were notified and after further assessment, it was determined that a no-flow overheating event had taken place. This occurrence was a result of attempting to operate at a three pump rate. Pump 701a was unable to put up enough discharge pressure to move oil against the discharge pressure of the other two pumps. As a result a new seal, unit discharge valve, and check valve were replaced along with all flange gaskets and bolts. A new type of seal was installed with a secondary isolator made of brass. The unit was commissioned to service on may 7th, 2013 and monitored for a period of time. Routine inspections revealed vibration in the unit. Vibration levels increased and a decision was made to replace the unit. However, approximately one week prior to the scheduled pump replacement, the seal failed on the pump causing a release of 0.24 barrels of crude oil. Investigation of the event revealed that movement of the shaft due to shaft vibration caused the brass secondary seal internal clearance components to start rubbing causing the unit to heat up, expand and lock in place. This created a situation where the seal sleeve and secondary seal stopped rotating with the shaft. The pump shaft continued to rotate, causing the internal seal sleeve elastomer o-ring to fail, resulting in a release of crude oil to the soil. It should be noted that the pump was still operational after the seal failure, however, a decision was made to accelerate the already scheduled pump replacement from inventory, rather than simply replacing the seal, and then replacing the entire pumping unit the following week. |
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