Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2016-04-02 — TX
Operator
Tc Oil Pipeline Operations Inc
Cause
Material Failure Of Pipe Or Weld
Commodity
Crude Oil
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$1,446,227
Incident datetime
2016-04-02 12:38
Report number
Location
TX
Narrative
On 2 april, 2016, a release of oil was reported, and confirmed, at mp 411, or freeman ps+4. A contributing factor to the leak appears to be construction related, associated with a failed pipeline girth weld. Approximately 220 barrels of crude has been spilled; remediation is continuing at the time of this initial report. Preliminary and final metallurgical analysis have been performed. Integrity verification work has been conducted and completed. Rcfa: a metallurgical failure analysis of the weld was performed for transcanada by an independent third party approved by PHMSA . The failure analysis identified that the crack initiation and propagation mechanisms occurred at elevated temperature implying that the crack formed during the welding process. Evidence to support this statement includes high-temperature oxides found on the fracture surface and metallographic images appearing to show hot tearing in the vicinity of the main crack. The crack initiated at an isolated weld defect at the toe of the root of the weld at the 6 o'clock position along the inner diameter (id) of the girth weld and propagated through wall during the welding process. Overall, the leak was caused by a through-wall crack 3-11/16 inch long at the outer diameter (od) by 6.2 inch long at the id. Fracture surface erosion markings revealed two leak paths corresponding to the location of the leaks observed in the field and during laboratory testing. The length of the leak was small, measuring approximately 17% of the overall crack length at the od. It was postulated that the non-leaking area of the through-wall crack may have been too narrow for oil or water to flow. 20160823 update: corrected lat/long coordinates to proper format. 20161207 update: depth of cover updated, pipe seam type defined, costs reported, and rcfa updated (above). 20,428.52 tons of solid materials were removed from the site, and 1,174.25 tons of liquid wastes were disposed of. 20170125 update: changed volume to 400 barrels to match amount reported to nrc and other government agencies.
Detailed record list
Report Received Date
2016-05-02 00:00:00
Iyear
2016
Report Number
20160135
Supplemental Number
22043
Report Type
Supplemental Final
Operator Id
32334
Name
Tc Oil Pipeline Operations Inc
Operator Street Address
Bank Of America Center - 700 Louisiana Street
Operator City Name
Houston
Operator State Abbreviation
TX
Operator Postal Code
77002-2700
Local Datetime
2016-04-02 12:32:00
Location Latitude
43.240356
Location Longitude
-97.459258
Commodity Released Type
Crude Oil
Unintentional Release Bbls
400
Recovered Bbls
400
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Notification From Public
Incident Identified Datetime
2016-04-02 12:38:00
System Part Involved
Onshore Pipeline, Including Valve Sites
On Off Shore
Onshore
Shutdown Due Accident Ind
Yes
Shutdown Datetime
2016-04-02 12:50:00
Restart Datetime
2016-04-10 09:00:00
On Site Datetime
2016-04-02 13:30:00
Nrc Rpt Datetime
2016-04-02 15:15:00
Nrc Rpt Num
1144321
Ignite Ind
No
Explode Ind
No
Upstream Valve Type Ind
Remotely Controlled
Downstream Valve Type Ind
Remotely Controlled
Num Pub Evacuated
0
Pipe Fac Name
Keystone Pipeline
Segment Name
Phase 1, Spread 4b
Onshore State Abbreviation
Sd
Onshore Postal Code
57029
Onshore City Name
Not Within A Municipality
Onshore County Name
Hutchinson
Designated Location
Milepost/valve Station
Designated Name
Mp 411
Federal
No
Location Type
Pipeline Right-Of-Way
Incident Area Type
Underground
Incident Area Subtype
Under Soil
Depth Of Cover
107
Crossing
Yes
Road Crossing Ind
Yes
Road Type
Bored/drilled
Pipe Facility Type
Interstate
Item Involved
Weld, Including Heat-Affected Zone
Pipe Diameter
30
Pipe Wall Thickness
0.386
Pipe Smys
70000
Pipe Specification
Api 5l Pslii X70
Pipe Seam Type
Spiral Welded
Pipe Manufacturer
Evraz
Pipe Coating Type
Fusion Bonded Epoxy(Fbe)
Weld Subtype
Pipe Girth Weld
Installation Year
2009
Manufactured Year
2008
Material Involved
Carbon Steel
Release Type
Leak
Leak Type
Crack
Wildlife Impact Ind
No
Soil Contamination
Yes
Long Term Assessment
No
Remediation Ind
Yes
Soil Remed Ind
Yes
Water Contam Ind
No
Could Be Hca
No
Commodity Reached Hca
No
Est Cost Oper Paid
732618
Est Cost Gas Released
11620
Est Cost Prop Damage
1446227
Est Cost Emergency
1608352
Est Cost Environmental
5269522
Est Cost Other
0
Prpty
9068339
Accident Psig
1189
Mop Psig
1337
Accident Pressure
Pressure Did Not Exceed Mop
Pressure Restriction Ind
No
Length Segment Isolated
Unknown
Internal Inspection Ind
Yes
Operation Complications 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 leak being caused by a failed weld prior to in-service operations.
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
Metallurgical Ind
Yes
Failure Type
Design-, Construction-, Installation-, Or Fabrication-Related
Other Factor
Yes
Other Factor Details
Cracking Occured At Elevated Temperature, Implying Formed During Manufacturing
Additional Crack Ind
Yes
Collected Data Ind
Yes
Axial Magnetic Flx Lkg Ind
Yes
Axial Recent Year
2016
Other Recent Year
2016
Has Hydrtst Conduc Before Ind
No
Direct Asmnt Conducted
No
Non Destructive Exam Ind
No
Preparer Name
E*** H*****
Preparer Title
Us Regulatory Compliance Specialist
Preparer Email
E**********@t**********.com
Preparer Telephone
4024907253
Prepared Date
2017-01-25 00:00:00
Authorizer Name
D** C*******
Authorizer Telephone
7014831434
Authorizer Title
Us Regulatory Compliance Engineer
Authorizer Email
D***********@t**********.com
Narrative
On 2 april, 2016, a release of oil was reported, and confirmed, at mp 411, or freeman ps+4. A contributing factor to the leak appears to be construction related, associated with a failed pipeline girth weld. Approximately 220 barrels of crude has been spilled; remediation is continuing at the time of this initial report. Preliminary and final metallurgical analysis have been performed. Integrity verification work has been conducted and completed. Rcfa: a metallurgical failure analysis of the weld was performed for transcanada by an independent third party approved by PHMSA . The failure analysis identified that the crack initiation and propagation mechanisms occurred at elevated temperature implying that the crack formed during the welding process. Evidence to support this statement includes high-temperature oxides found on the fracture surface and metallographic images appearing to show hot tearing in the vicinity of the main crack. The crack initiated at an isolated weld defect at the toe of the root of the weld at the 6 o'clock position along the inner diameter (id) of the girth weld and propagated through wall during the welding process. Overall, the leak was caused by a through-wall crack 3-11/16 inch long at the outer diameter (od) by 6.2 inch long at the id. Fracture surface erosion markings revealed two leak paths corresponding to the location of the leaks observed in the field and during laboratory testing. The length of the leak was small, measuring approximately 17% of the overall crack length at the od. It was postulated that the non-leaking area of the through-wall crack may have been too narrow for oil or water to flow. 20160823 update: corrected lat/long coordinates to proper format. 20161207 update: depth of cover updated, pipe seam type defined, costs reported, and rcfa updated (above). 20,428.52 tons of solid materials were removed from the site, and 1,174.25 tons of liquid wastes were disposed of. 20170125 update: changed volume to 400 barrels to match amount reported to nrc and other government agencies.
| Report Received Date | 2016-05-02 00:00:00 |
|---|---|
| Iyear | 2016 |
| Report Number | 20160135 |
| Supplemental Number | 22043 |
| Report Type | Supplemental Final |
| Operator Id | 32334 PHMSA Enforcement |
| Name | Tc Oil Pipeline Operations Inc |
| Operator Street Address | Bank Of America Center - 700 Louisiana Street |
| Operator City Name | Houston |
| Operator State Abbreviation | TX |
| Operator Postal Code | 77002-2700 |
| Local Datetime | 2016-04-02 12:32:00 |
| Location Latitude | 43.240356 Google Maps OpenStreetMap |
| Location Longitude | -97.459258 Google Maps OpenStreetMap |
| Commodity Released Type | Crude Oil |
| Unintentional Release Bbls | 400 |
| Recovered Bbls | 400 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Notification From Public |
| Incident Identified Datetime | 2016-04-02 12:38:00 |
| System Part Involved | Onshore Pipeline, Including Valve Sites |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | Yes |
| Shutdown Datetime | 2016-04-02 12:50:00 |
| Restart Datetime | 2016-04-10 09:00:00 |
| On Site Datetime | 2016-04-02 13:30:00 |
| Nrc Rpt Datetime | 2016-04-02 15:15:00 |
| Nrc Rpt Num | 1144321 NRC Report How to search |
| Ignite Ind | No |
| Explode Ind | No |
| Upstream Valve Type Ind | Remotely Controlled |
| Downstream Valve Type Ind | Remotely Controlled |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Keystone Pipeline |
| Segment Name | Phase 1, Spread 4b |
| Onshore State Abbreviation | Sd |
| Onshore Postal Code | 57029 |
| Onshore City Name | Not Within A Municipality |
| Onshore County Name | Hutchinson |
| Designated Location | Milepost/valve Station |
| Designated Name | Mp 411 |
| Federal | No |
| Location Type | Pipeline Right-Of-Way |
| Incident Area Type | Underground |
| Incident Area Subtype | Under Soil |
| Depth Of Cover | 107 |
| Crossing | Yes |
| Road Crossing Ind | Yes |
| Road Type | Bored/drilled |
| Pipe Facility Type | Interstate |
| Item Involved | Weld, Including Heat-Affected Zone |
| Pipe Diameter | 30 |
| Pipe Wall Thickness | 0.386 |
| Pipe Smys | 70000 |
| Pipe Specification | Api 5l Pslii X70 |
| Pipe Seam Type | Spiral Welded |
| Pipe Manufacturer | Evraz |
| Pipe Coating Type | Fusion Bonded Epoxy(Fbe) |
| Weld Subtype | Pipe Girth Weld |
| Installation Year | 2009 |
| Manufactured Year | 2008 |
| Material Involved | Carbon Steel |
| Release Type | Leak |
| Leak Type | Crack |
| Wildlife Impact Ind | No |
| Soil Contamination | Yes |
| Long Term Assessment | No |
| Remediation Ind | Yes |
| Soil Remed Ind | Yes |
| Water Contam Ind | No |
| Could Be Hca | No |
| Commodity Reached Hca | No |
| Est Cost Oper Paid | 732618 |
| Est Cost Gas Released | 11620 |
| Est Cost Prop Damage | 1446227 |
| Est Cost Emergency | 1608352 |
| Est Cost Environmental | 5269522 |
| Est Cost Other | 0 |
| Prpty | 9068339 |
| Accident Psig | 1189 |
| Mop Psig | 1337 |
| Accident Pressure | Pressure Did Not Exceed Mop |
| Pressure Restriction Ind | No |
| Length Segment Isolated | Unknown |
| Internal Inspection Ind | Yes |
| Operation Complications 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 leak being caused by a failed weld prior to in-service operations. |
| 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 |
| Metallurgical Ind | Yes |
| Failure Type | Design-, Construction-, Installation-, Or Fabrication-Related |
| Other Factor | Yes |
| Other Factor Details | Cracking Occured At Elevated Temperature, Implying Formed During Manufacturing |
| Additional Crack Ind | Yes |
| Collected Data Ind | Yes |
| Axial Magnetic Flx Lkg Ind | Yes |
| Axial Recent Year | 2016 |
| Other Recent Year | 2016 |
| Has Hydrtst Conduc Before Ind | No |
| Direct Asmnt Conducted | No |
| Non Destructive Exam Ind | No |
| Preparer Name | E*** H***** |
| Preparer Title | Us Regulatory Compliance Specialist |
| Preparer Email | E**********@t**********.com |
| Preparer Telephone | 4024907253 |
| Prepared Date | 2017-01-25 00:00:00 |
| Authorizer Name | D** C******* |
| Authorizer Telephone | 7014831434 |
| Authorizer Title | Us Regulatory Compliance Engineer |
| Authorizer Email | D***********@t**********.com |
| Narrative | On 2 april, 2016, a release of oil was reported, and confirmed, at mp 411, or freeman ps+4. A contributing factor to the leak appears to be construction related, associated with a failed pipeline girth weld. Approximately 220 barrels of crude has been spilled; remediation is continuing at the time of this initial report. Preliminary and final metallurgical analysis have been performed. Integrity verification work has been conducted and completed. Rcfa: a metallurgical failure analysis of the weld was performed for transcanada by an independent third party approved by PHMSA . The failure analysis identified that the crack initiation and propagation mechanisms occurred at elevated temperature implying that the crack formed during the welding process. Evidence to support this statement includes high-temperature oxides found on the fracture surface and metallographic images appearing to show hot tearing in the vicinity of the main crack. The crack initiated at an isolated weld defect at the toe of the root of the weld at the 6 o'clock position along the inner diameter (id) of the girth weld and propagated through wall during the welding process. Overall, the leak was caused by a through-wall crack 3-11/16 inch long at the outer diameter (od) by 6.2 inch long at the id. Fracture surface erosion markings revealed two leak paths corresponding to the location of the leaks observed in the field and during laboratory testing. The length of the leak was small, measuring approximately 17% of the overall crack length at the od. It was postulated that the non-leaking area of the through-wall crack may have been too narrow for oil or water to flow. 20160823 update: corrected lat/long coordinates to proper format. 20161207 update: depth of cover updated, pipe seam type defined, costs reported, and rcfa updated (above). 20,428.52 tons of solid materials were removed from the site, and 1,174.25 tons of liquid wastes were disposed of. 20170125 update: changed volume to 400 barrels to match amount reported to nrc and other government agencies. |
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