Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2016-06-20 — TX
Operator
Kuraray America, Inc.
Cause
Corrosion 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)
$80,000
Incident datetime
2016-06-20 15:00
Report number
Location
TX
Narrative
On 6/20/2016 at 15:00 contractor working in the facility notified company of a small puddle of liquid and the small of acetic acid near the pipeline. Pipeline was blocked in and the material confirmed to be 15% acetic acid. Tank trailers were delivered the next morning and the pipeline pigged empty into the trailers. Then the pipeline was flushed with water and pigged into tank trailer to clear the pipeline. The initial leak material and surrounding soil was excavated and placed in containment hydro excavation was utilized to remove all soil around the pipeline. All soil was removed and contained by 6/26/16. The leak detection began and the leak identified utilizing nitrogen pressure. The leaking weld did not leak until pressure exceeded 20 psig. Radiographic inspection confirmed weld corrosion and small pin hole breech. Pipe section was cut out and inside visual inspection indicated corrosion in the heat zone of the pipe weld. Cause no known at this time and additional testing underway. Pipe will be replaced, rt inspected and the pipeline hydro tested before returning to service. Failed weld has been sent to 3rd party laboratory for analysis. Initial evaluation of the event determined it was not a reportable accident but repair costs are now expected to exceed the $50,000 threshold for requiring reporting. A phone report was made as soon as costs were expected to exceed the reporting threshold.
Detailed record list
Report Received Date
2016-07-15 00:00:00
Iyear
2016
Report Number
20160226
Supplemental Number
21644
Report Type
Supplemental
Operator Id
39467
Name
Kuraray America, Inc.
Operator Street Address
2625 Bay Area Blvd 600
Operator City Name
Houston
Operator State Abbreviation
TX
Operator Postal Code
77058
Local Datetime
2016-06-20 15:00:00
Location Latitude
29.623347
Location Longitude
-95.04155
Commodity Released Type
Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions
Commodity Subtype
Other
Commodity Details
Acetic Acid
Unintentional Release Bbls
0.11
Recovered Bbls
0.11
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Contractor Working For The Operator
Incident Identified Datetime
2016-06-20 15:00:00
System Part Involved
Onshore Pipeline, Including Valve Sites
On Off Shore
Onshore
Shutdown Due Accident Ind
No
Shutdown Explain
Already Scheduled Down And Not In Use At The Time
On Site Datetime
2016-06-20 15:00:00
Nrc Rpt Datetime
2016-06-29 18:50:00
Nrc Rpt Num
1152043
Ignite Ind
No
Explode Ind
No
Upstream Valve Type Ind
Manual
Downstream Valve Type Ind
Manual
Num Pub Evacuated
0
Pipe Fac Name
Kuraray Poval To Lbc
Segment Name
Aa20760704
Onshore State Abbreviation
Tx
Onshore Postal Code
77507
Onshore City Name
Pasadena
Onshore County Name
Harris
Designated Location
Milepost/valve Station
Designated Name
Kuraray Eval
Federal
No
Location Type
Totally Contained On Operator-Controlled Property
Incident Area Type
Underground
Incident Area Subtype
Under Soil
Depth Of Cover
100
Crossing
No
Pipe Facility Type
Intrastate
Item Involved
Weld, Including Heat-Affected Zone
Weld Subtype
Other Butt Weld
Installation Year
2015
Material Involved
Material Other Than Carbon Steel
Material Details
316ss
Release Type
Leak
Leak Type
Pinhole
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
Yes
Commodity Reached Hca
No
Est Cost Oper Paid
0
Est Cost Gas Released
30
Est Cost Prop Damage
80000
Est Cost Emergency
40000
Est Cost Environmental
10000
Est Cost Other
0
Prpty
130030
Accident Psig
8
Mop Psig
340
Accident Pressure
Pressure Did Not Exceed Mop
Pressure Restriction Ind
No
Length Segment Isolated
9245
Internal Inspection Ind
Yes
Operation Complications Ind
Yes
Incompat Commod Ind
Yes
Pipeline Function
< 20% Smys Regulated Transmission
Scada In Place 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
Leak confirmed to be weld qc failure, pressure recorder never exceeded normal operating pressure while pipeline was in service.
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Corrosion Failure
Cause Details
Internal Corrosion
Internal External
Internal Corrosion
Int Visual Exam Results
Other
Int Visual Exam Details
Corrosion In Weld Heat Zone, Approx 5% Of Weld Area.
Int Corrosive Commodity Ind
Yes
Int Other Corrosion Ind
Yes
Int Corrosion Type Details
Still Evaluating Failure By 3rd Party Lab
Int Field Exam Basis Ind
Yes
Int Metallurgical Basis Ind
Yes
Int Other Loc Ind
Yes
Corrosion Location Details
Heat Zone Of Weld, Straight Pipe
Corrosion Inhibitors
No
Corrosion Lining
No
Cleaning Dewatering
No
Corrosion Coupons
No
Collected Data Ind
No
Has Hydrtst Conduc Before Ind
Yes
Hydrtst Most Rcnt Year
2015
Hydrtst Most Rcnt Pressure
425
Direct Asmnt Conducted
No
Non Destructive Exam Ind
Yes
Exm Radiography Rcnt Year
2014
Exm Radiography Rcnt Ind
Yes
Preparer Name
M**** O****
Preparer Title
Director - Project Engineering
Preparer Email
M**********@k******.com
Preparer Telephone
281-474-1509
Prepared Date
2016-08-29 00:00:00
Authorizer Name
M**** O****
Authorizer Telephone
281-474-1509
Authorizer Title
Directory - Project Engineering
Authorizer Email
M**********@k******.com
Narrative
On 6/20/2016 at 15:00 contractor working in the facility notified company of a small puddle of liquid and the small of acetic acid near the pipeline. Pipeline was blocked in and the material confirmed to be 15% acetic acid. Tank trailers were delivered the next morning and the pipeline pigged empty into the trailers. Then the pipeline was flushed with water and pigged into tank trailer to clear the pipeline. The initial leak material and surrounding soil was excavated and placed in containment hydro excavation was utilized to remove all soil around the pipeline. All soil was removed and contained by 6/26/16. The leak detection began and the leak identified utilizing nitrogen pressure. The leaking weld did not leak until pressure exceeded 20 psig. Radiographic inspection confirmed weld corrosion and small pin hole breech. Pipe section was cut out and inside visual inspection indicated corrosion in the heat zone of the pipe weld. Cause no known at this time and additional testing underway. Pipe will be replaced, rt inspected and the pipeline hydro tested before returning to service. Failed weld has been sent to 3rd party laboratory for analysis. Initial evaluation of the event determined it was not a reportable accident but repair costs are now expected to exceed the $50,000 threshold for requiring reporting. A phone report was made as soon as costs were expected to exceed the reporting threshold.
| Report Received Date | 2016-07-15 00:00:00 |
|---|---|
| Iyear | 2016 |
| Report Number | 20160226 |
| Supplemental Number | 21644 |
| Report Type | Supplemental |
| Operator Id | 39467 PHMSA Enforcement |
| Name | Kuraray America, Inc. |
| Operator Street Address | 2625 Bay Area Blvd 600 |
| Operator City Name | Houston |
| Operator State Abbreviation | TX |
| Operator Postal Code | 77058 |
| Local Datetime | 2016-06-20 15:00:00 |
| Location Latitude | 29.623347 Google Maps OpenStreetMap |
| Location Longitude | -95.04155 Google Maps OpenStreetMap |
| Commodity Released Type | Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions |
| Commodity Subtype | Other |
| Commodity Details | Acetic Acid |
| Unintentional Release Bbls | 0.11 |
| Recovered Bbls | 0.11 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Contractor Working For The Operator |
| Incident Identified Datetime | 2016-06-20 15:00:00 |
| System Part Involved | Onshore Pipeline, Including Valve Sites |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | No |
| Shutdown Explain | Already Scheduled Down And Not In Use At The Time |
| On Site Datetime | 2016-06-20 15:00:00 |
| Nrc Rpt Datetime | 2016-06-29 18:50:00 |
| Nrc Rpt Num | 1152043 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 | Kuraray Poval To Lbc |
| Segment Name | Aa20760704 |
| Onshore State Abbreviation | Tx |
| Onshore Postal Code | 77507 |
| Onshore City Name | Pasadena |
| Onshore County Name | Harris |
| Designated Location | Milepost/valve Station |
| Designated Name | Kuraray Eval |
| Federal | No |
| Location Type | Totally Contained On Operator-Controlled Property |
| Incident Area Type | Underground |
| Incident Area Subtype | Under Soil |
| Depth Of Cover | 100 |
| Crossing | No |
| Pipe Facility Type | Intrastate |
| Item Involved | Weld, Including Heat-Affected Zone |
| Weld Subtype | Other Butt Weld |
| Installation Year | 2015 |
| Material Involved | Material Other Than Carbon Steel |
| Material Details | 316ss |
| Release Type | Leak |
| Leak Type | Pinhole |
| 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 | Yes |
| Commodity Reached Hca | No |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 30 |
| Est Cost Prop Damage | 80000 |
| Est Cost Emergency | 40000 |
| Est Cost Environmental | 10000 |
| Est Cost Other | 0 |
| Prpty | 130030 |
| Accident Psig | 8 |
| Mop Psig | 340 |
| Accident Pressure | Pressure Did Not Exceed Mop |
| Pressure Restriction Ind | No |
| Length Segment Isolated | 9245 |
| Internal Inspection Ind | Yes |
| Operation Complications Ind | Yes |
| Incompat Commod Ind | Yes |
| Pipeline Function | < 20% Smys Regulated Transmission |
| Scada In Place 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 | Leak confirmed to be weld qc failure, pressure recorder never exceeded normal operating pressure while pipeline was in service. |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Corrosion Failure |
| Cause Details | Internal Corrosion |
| Internal External | Internal Corrosion |
| Int Visual Exam Results | Other |
| Int Visual Exam Details | Corrosion In Weld Heat Zone, Approx 5% Of Weld Area. |
| Int Corrosive Commodity Ind | Yes |
| Int Other Corrosion Ind | Yes |
| Int Corrosion Type Details | Still Evaluating Failure By 3rd Party Lab |
| Int Field Exam Basis Ind | Yes |
| Int Metallurgical Basis Ind | Yes |
| Int Other Loc Ind | Yes |
| Corrosion Location Details | Heat Zone Of Weld, Straight Pipe |
| Corrosion Inhibitors | No |
| Corrosion Lining | No |
| Cleaning Dewatering | No |
| Corrosion Coupons | No |
| Collected Data Ind | No |
| Has Hydrtst Conduc Before Ind | Yes |
| Hydrtst Most Rcnt Year | 2015 |
| Hydrtst Most Rcnt Pressure | 425 |
| Direct Asmnt Conducted | No |
| Non Destructive Exam Ind | Yes |
| Exm Radiography Rcnt Year | 2014 |
| Exm Radiography Rcnt Ind | Yes |
| Preparer Name | M**** O**** |
| Preparer Title | Director - Project Engineering |
| Preparer Email | M**********@k******.com |
| Preparer Telephone | 281-474-1509 |
| Prepared Date | 2016-08-29 00:00:00 |
| Authorizer Name | M**** O**** |
| Authorizer Telephone | 281-474-1509 |
| Authorizer Title | Directory - Project Engineering |
| Authorizer Email | M**********@k******.com |
| Narrative | On 6/20/2016 at 15:00 contractor working in the facility notified company of a small puddle of liquid and the small of acetic acid near the pipeline. Pipeline was blocked in and the material confirmed to be 15% acetic acid. Tank trailers were delivered the next morning and the pipeline pigged empty into the trailers. Then the pipeline was flushed with water and pigged into tank trailer to clear the pipeline. The initial leak material and surrounding soil was excavated and placed in containment hydro excavation was utilized to remove all soil around the pipeline. All soil was removed and contained by 6/26/16. The leak detection began and the leak identified utilizing nitrogen pressure. The leaking weld did not leak until pressure exceeded 20 psig. Radiographic inspection confirmed weld corrosion and small pin hole breech. Pipe section was cut out and inside visual inspection indicated corrosion in the heat zone of the pipe weld. Cause no known at this time and additional testing underway. Pipe will be replaced, rt inspected and the pipeline hydro tested before returning to service. Failed weld has been sent to 3rd party laboratory for analysis. Initial evaluation of the event determined it was not a reportable accident but repair costs are now expected to exceed the $50,000 threshold for requiring reporting. A phone report was made as soon as costs were expected to exceed the reporting threshold. |
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