Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2016-05-15 — TX
Operator
Phillips 66 Pipeline Llc
Cause
Equipment Failure
Commodity
Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$24,000
Incident datetime
2016-05-15 13:35
Report number
Location
TX
Narrative
During operation rounds employee discovered a leaking mixer on tank 1701 gearbox. Employee immediately controlled the spill with containment equipment and installed booms in the area. The tank mixer and all nearby sources of ignition were isolated as a safety pre-caution. Duty officer was notified of the incident. Emergency responders were dispatched to the terminal. Tank product was pumped down below of the mixer level, and the mixer was removed and tank returned to service. Jensen mixers was consulted to perform and rca of the mixer failure, the manufacturer concluded that the mixer failed due to "general wear and tear" due to the age of the mixer, (44 years old). From jensen report: the gearbox leaking gear oil out of the top pinion o-ring (there are clear signs this mixer was leaking out of the top). O-rings unfortunately fail over time, and we are taking steps to improve the service life of these. Since this mixer was installed/rebuilt, we have done away with the buna-n o-ring material which used to be standard in gearboxes, and we are now using double viton gflt o-rings in the top pinion. We have been doing this for about 2 years and we are seeing zero leaks. We believe this leaking (of gear oil) out of the top pinion, allowed a majority of the oil to leak out the top, the gearbox reservoir to dry up, and the gearbox to run hot and un-lubricated. From here the gearbox seized up, bearings failed, and when'.. #2) the mechanical seal failed, you could not rotate the mixer (or lock it off) because the main bearing was seized to the yoke. This further explains the ripped yoke ears which probably broke as a result of a pry bar being used to try and rotate the shaft, which could not turn.
Detailed record list
Report Received Date
2016-06-14 00:00:00
Iyear
2016
Report Number
20160181
Supplemental Number
21624
Report Type
Supplemental Final
Operator Id
31684
Name
Phillips 66 Pipeline Llc
Operator Street Address
2331 Citywest Blvd
Operator City Name
Houston
Operator State Abbreviation
TX
Operator Postal Code
77042
Local Datetime
2016-05-15 12:35:00
Location Latitude
29.715674
Location Longitude
-95.178747
Commodity Released Type
Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions
Commodity Subtype
Gasoline (Non-Ethanol)
Unintentional Release Bbls
3.61
Recovered Bbls
3.61
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
Incident Identified Datetime
2016-05-15 13:35:00
System Part Involved
Onshore Breakout Tank Or Storage Vessel, Including Attached Appurtenances
On Off Shore
Onshore
Shutdown Due Accident Ind
No
Shutdown Explain
Tank Was Isolated, Drained And Mixer Removed.
On Site Datetime
2016-05-15 13:45:00
Nrc Rpt Datetime
2016-05-15 14:45:00
Nrc Rpt Num
1147822
Ignite Ind
No
Explode Ind
No
Num Pub Evacuated
0
Pipe Fac Name
Pasadena Terminal
Segment Name
Tank 1701
Onshore State Abbreviation
Tx
Onshore Postal Code
77506
Onshore City Name
Pasadena
Onshore County Name
Harris
Designated Location
Milepost/valve Station
Designated Name
Tank 1701
Federal
No
Location Type
Totally Contained On Operator-Controlled Property
Incident Area Type
Tank, Including Attached Appurtenances
Crossing
No
Pipe Facility Type
Interstate
Item Involved
Tank/vessel
Tank Vessel Subtype
Mixer
Tank Type
Atmospheric
Installation Year
1972
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
Yes
High Pop Ind
Yes
High Pop Yes No
Yes
Est Cost Oper Paid
0
Est Cost Gas Released
350
Est Cost Prop Damage
24000
Est Cost Emergency
107000
Est Cost Environmental
7500
Est Cost Other
0
Est Cost Other Details
Cost Of Response, Cleanup, Tank Mixer Removal And Replacement.
Prpty
138850
Accident Psig
0
Mop Psig
0
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
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 discovered by operator conducting normal duties. The operator immediately notified local operators and initiated response and cleanup activities.
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Equipment Failure
Cause Details
Other Equipment Failure
Eq Failure Type
Other Equipment Failure
Failure Details
Tank Mixer Bearing Failure Resulting In Mixer Seal Leak.
Eq Additional Other Ind
Yes
Eq Additional Other Details
Wear And Tear Due To Age Of The Mixer
Preparer Name
J*** S*****
Preparer Title
Dot Coordinator
Preparer Email
J************@p**.com
Preparer Telephone
832-765-1858
Preparer Fax
918-977-8930
Prepared Date
2016-08-23 00:00:00
Authorizer Name
T*** F****
Authorizer Telephone
8327651632
Authorizer Title
Director Dot Compliance
Authorizer Email
M***********@p**.com
Narrative
During operation rounds employee discovered a leaking mixer on tank 1701 gearbox. Employee immediately controlled the spill with containment equipment and installed booms in the area. The tank mixer and all nearby sources of ignition were isolated as a safety pre-caution. Duty officer was notified of the incident. Emergency responders were dispatched to the terminal. Tank product was pumped down below of the mixer level, and the mixer was removed and tank returned to service. Jensen mixers was consulted to perform and rca of the mixer failure, the manufacturer concluded that the mixer failed due to "general wear and tear" due to the age of the mixer, (44 years old). From jensen report: the gearbox leaking gear oil out of the top pinion o-ring (there are clear signs this mixer was leaking out of the top). O-rings unfortunately fail over time, and we are taking steps to improve the service life of these. Since this mixer was installed/rebuilt, we have done away with the buna-n o-ring material which used to be standard in gearboxes, and we are now using double viton gflt o-rings in the top pinion. We have been doing this for about 2 years and we are seeing zero leaks. We believe this leaking (of gear oil) out of the top pinion, allowed a majority of the oil to leak out the top, the gearbox reservoir to dry up, and the gearbox to run hot and un-lubricated. From here the gearbox seized up, bearings failed, and when'.. #2) the mechanical seal failed, you could not rotate the mixer (or lock it off) because the main bearing was seized to the yoke. This further explains the ripped yoke ears which probably broke as a result of a pry bar being used to try and rotate the shaft, which could not turn.
| Report Received Date | 2016-06-14 00:00:00 |
|---|---|
| Iyear | 2016 |
| Report Number | 20160181 |
| Supplemental Number | 21624 |
| Report Type | Supplemental Final |
| Operator Id | 31684 PHMSA Enforcement |
| Name | Phillips 66 Pipeline Llc |
| Operator Street Address | 2331 Citywest Blvd |
| Operator City Name | Houston |
| Operator State Abbreviation | TX |
| Operator Postal Code | 77042 |
| Local Datetime | 2016-05-15 12:35:00 |
| Location Latitude | 29.715674 Google Maps OpenStreetMap |
| Location Longitude | -95.178747 Google Maps OpenStreetMap |
| Commodity Released Type | Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions |
| Commodity Subtype | Gasoline (Non-Ethanol) |
| Unintentional Release Bbls | 3.61 |
| Recovered Bbls | 3.61 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| Incident Identified Datetime | 2016-05-15 13:35:00 |
| System Part Involved | Onshore Breakout Tank Or Storage Vessel, Including Attached Appurtenances |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | No |
| Shutdown Explain | Tank Was Isolated, Drained And Mixer Removed. |
| On Site Datetime | 2016-05-15 13:45:00 |
| Nrc Rpt Datetime | 2016-05-15 14:45:00 |
| Nrc Rpt Num | 1147822 NRC Report How to search |
| Ignite Ind | No |
| Explode Ind | No |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Pasadena Terminal |
| Segment Name | Tank 1701 |
| Onshore State Abbreviation | Tx |
| Onshore Postal Code | 77506 |
| Onshore City Name | Pasadena |
| Onshore County Name | Harris |
| Designated Location | Milepost/valve Station |
| Designated Name | Tank 1701 |
| Federal | No |
| Location Type | Totally Contained On Operator-Controlled Property |
| Incident Area Type | Tank, Including Attached Appurtenances |
| Crossing | No |
| Pipe Facility Type | Interstate |
| Item Involved | Tank/vessel |
| Tank Vessel Subtype | Mixer |
| Tank Type | Atmospheric |
| Installation Year | 1972 |
| 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 | Yes |
| High Pop Ind | Yes |
| High Pop Yes No | Yes |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 350 |
| Est Cost Prop Damage | 24000 |
| Est Cost Emergency | 107000 |
| Est Cost Environmental | 7500 |
| Est Cost Other | 0 |
| Est Cost Other Details | Cost Of Response, Cleanup, Tank Mixer Removal And Replacement. |
| Prpty | 138850 |
| Accident Psig | 0 |
| Mop Psig | 0 |
| 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 | 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 discovered by operator conducting normal duties. The operator immediately notified local operators and initiated response and cleanup activities. |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Equipment Failure |
| Cause Details | Other Equipment Failure |
| Eq Failure Type | Other Equipment Failure |
| Failure Details | Tank Mixer Bearing Failure Resulting In Mixer Seal Leak. |
| Eq Additional Other Ind | Yes |
| Eq Additional Other Details | Wear And Tear Due To Age Of The Mixer |
| Preparer Name | J*** S***** |
| Preparer Title | Dot Coordinator |
| Preparer Email | J************@p**.com |
| Preparer Telephone | 832-765-1858 |
| Preparer Fax | 918-977-8930 |
| Prepared Date | 2016-08-23 00:00:00 |
| Authorizer Name | T*** F**** |
| Authorizer Telephone | 8327651632 |
| Authorizer Title | Director Dot Compliance |
| Authorizer Email | M***********@p**.com |
| Narrative | During operation rounds employee discovered a leaking mixer on tank 1701 gearbox. Employee immediately controlled the spill with containment equipment and installed booms in the area. The tank mixer and all nearby sources of ignition were isolated as a safety pre-caution. Duty officer was notified of the incident. Emergency responders were dispatched to the terminal. Tank product was pumped down below of the mixer level, and the mixer was removed and tank returned to service. Jensen mixers was consulted to perform and rca of the mixer failure, the manufacturer concluded that the mixer failed due to "general wear and tear" due to the age of the mixer, (44 years old). From jensen report: the gearbox leaking gear oil out of the top pinion o-ring (there are clear signs this mixer was leaking out of the top). O-rings unfortunately fail over time, and we are taking steps to improve the service life of these. Since this mixer was installed/rebuilt, we have done away with the buna-n o-ring material which used to be standard in gearboxes, and we are now using double viton gflt o-rings in the top pinion. We have been doing this for about 2 years and we are seeing zero leaks. We believe this leaking (of gear oil) out of the top pinion, allowed a majority of the oil to leak out the top, the gearbox reservoir to dry up, and the gearbox to run hot and un-lubricated. From here the gearbox seized up, bearings failed, and when'.. #2) the mechanical seal failed, you could not rotate the mixer (or lock it off) because the main bearing was seized to the yoke. This further explains the ripped yoke ears which probably broke as a result of a pry bar being used to try and rotate the shaft, which could not turn. |
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