Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2019-07-31 — TX
Operator
Equistar Chemicals, L.p.
Cause
Equipment Failure
Commodity
Hvl Or Other Flammable Or Toxic Fluid Which Is A Gas At Ambient Conditions
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$3
Incident datetime
2019-07-31 07:20
Report number
Location
TX
Narrative
Lyondellbasell equistar maintenance technicians were reporting to stratton ridge for routine inspections. Upon arrival at 7:20 a.M. They saw what appeared to be ethylene vapors coming from the door to one of the filters. Upon opening the door, they noticed an ice ball had formed around the 3/4 inch o-ring gasket and filter cabinet door and a vapor cloud emitting from the ice ball. They immediately swapped filters and blocked in the filter that had the leak and started depressuring the system. A call was made to the control room at 7:28 a.M. After discussions with field technician and engineer, it was determined that we would exceed the 5 gallon reportable quantities threshold. This is a regulated intrastate pipeline in brazoria county. After the system was depressured and repairs were made it was determined that the leak was from the 3/4 inch o-ring on the filter. Repairs were made and system is back to normal. Preliminary investigation findings: our investigation's preliminary finding determined the leak was due to failure of an o-ring gasket on an orifice plug in a filter door mechanism. The failure of the gasket was due to material degradation resulting from the age of the gasket combined with exposure to atmospheric conditions and ethylene service and possibly mechanical stress due to possible reuse of the gasket. Our existing maintenance procedure for inspection and replacement of ethylene filter elements doesn't specify inspection and replacement of orifice plug gaskets of this type. Plan to prevent recurrence: in this instance, the plug with the o-ring gasket was replaced with a capped section of pipe with full threading where it connects to the filter housing. The investigation will also recommend updating the maintenance procedure to include a specification for replacing gaskets on similar orifice plugs.
Detailed record list
Report Received Date
2019-08-29 00:00:00
Iyear
2019
Report Number
20190269
Supplemental Number
33238
Report Type
Supplemental Final
Operator Id
25146
Name
Equistar Chemicals, L.p.
Operator Street Address
16055 Space Center Blvd. Suite 350
Operator City Name
Houston
Operator State Abbreviation
TX
Operator Postal Code
77062
Local Datetime
2019-07-31 07:20:00
Location Latitude
29.041033
Location Longitude
-95.366683
Commodity Released Type
Hvl Or Other Flammable Or Toxic Fluid Which Is A Gas At Ambient Conditions
Commodity Subtype
Other Hvl
Commodity Details
Ethylene
Unintentional Release Bbls
0.18
Intentional Release Bbls
12.6
Recovered Bbls
0
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
Incident Identified Datetime
2019-07-31 07:20:00
System Part Involved
Onshore Pump/meter Station Equipment And Piping
On Off Shore
Onshore
Shutdown Due Accident Ind
No
Shutdown Explain
No Need To Shut Down. Isolated Equipment And Replaced Faulty Part.
On Site Datetime
2019-07-31 07:20:00
Nrc Rpt Datetime
2019-07-31 08:55:00
Nrc Rpt Num
1253740
Ignite Ind
No
Explode Ind
No
Num Pub Evacuated
0
Pipe Fac Name
5*************************@ **************
Segment Name
Cb03_sr To Chocolate Bayou Pes Id # 550448
Onshore State Abbreviation
Tx
Onshore Postal Code
77531
Onshore City Name
Clute
Onshore County Name
Brazoria
Designated Location
Survey Station No.
Designated Name
974+32
Federal
No
Location Type
Originated On Operator-Controlled Property, But Then Flowed Or Migrated Off The Property
Incident Area Type
Aboveground
Incident Area Subtype
Typical Aboveground Facility Piping Or Appurtenance
Crossing
No
Pipe Facility Type
Intrastate
Item Involved
Auxiliary Piping (E.g. Drain Lines)
Installation Year
2010
Material Involved
Material Other Than Carbon Steel
Material Details
Gasket, Soft Good
Release Type
Leak
Leak Type
Seal Or Packing
Wildlife Impact Ind
No
Soil Contamination
No
Long Term Assessment
No
Remediation Ind
No
Water Contam Ind
No
Could Be Hca
Yes
Commodity Reached Hca
Yes
Usa Drinking Ind
Yes
Usa Drinking Yes No
Yes
Usa Ecological Ind
Yes
Usa Ecological Yes No
Yes
Est Cost Oper Paid
0
Est Cost Gas Released
0
Est Cost Prop Damage
3
Est Cost Emergency
0
Est Cost Environmental
0
Est Cost Other
0
Prpty
3
Accident Psig
1308
Mop Psig
2160
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
Failure on a non-automated component, no controller action.
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Equipment Failure
Cause Details
Non-Threaded Connection Failure
Eq Failure Type
Non-Threaded Connection Failure
Other Non Threaded Ind
O-Ring
Additional Breakdown Ind
Yes
Preparer Name
S**** T******
Preparer Title
Compliance Specialist
Preparer Email
S************@l**.com
Preparer Telephone
281-709-0712
Prepared Date
2020-01-28 00:00:00
Authorizer Name
M****** C*****
Authorizer Telephone
281 709 0626
Authorizer Title
Technical Manager
Authorizer Email
M*************@l**.com
Narrative
Lyondellbasell equistar maintenance technicians were reporting to stratton ridge for routine inspections. Upon arrival at 7:20 a.M. They saw what appeared to be ethylene vapors coming from the door to one of the filters. Upon opening the door, they noticed an ice ball had formed around the 3/4 inch o-ring gasket and filter cabinet door and a vapor cloud emitting from the ice ball. They immediately swapped filters and blocked in the filter that had the leak and started depressuring the system. A call was made to the control room at 7:28 a.M. After discussions with field technician and engineer, it was determined that we would exceed the 5 gallon reportable quantities threshold. This is a regulated intrastate pipeline in brazoria county. After the system was depressured and repairs were made it was determined that the leak was from the 3/4 inch o-ring on the filter. Repairs were made and system is back to normal. Preliminary investigation findings: our investigation's preliminary finding determined the leak was due to failure of an o-ring gasket on an orifice plug in a filter door mechanism. The failure of the gasket was due to material degradation resulting from the age of the gasket combined with exposure to atmospheric conditions and ethylene service and possibly mechanical stress due to possible reuse of the gasket. Our existing maintenance procedure for inspection and replacement of ethylene filter elements doesn't specify inspection and replacement of orifice plug gaskets of this type. Plan to prevent recurrence: in this instance, the plug with the o-ring gasket was replaced with a capped section of pipe with full threading where it connects to the filter housing. The investigation will also recommend updating the maintenance procedure to include a specification for replacing gaskets on similar orifice plugs.
| Report Received Date | 2019-08-29 00:00:00 |
|---|---|
| Iyear | 2019 |
| Report Number | 20190269 |
| Supplemental Number | 33238 |
| Report Type | Supplemental Final |
| Operator Id | 25146 PHMSA Enforcement |
| Name | Equistar Chemicals, L.p. |
| Operator Street Address | 16055 Space Center Blvd. Suite 350 |
| Operator City Name | Houston |
| Operator State Abbreviation | TX |
| Operator Postal Code | 77062 |
| Local Datetime | 2019-07-31 07:20:00 |
| Location Latitude | 29.041033 Google Maps OpenStreetMap |
| Location Longitude | -95.366683 Google Maps OpenStreetMap |
| Commodity Released Type | Hvl Or Other Flammable Or Toxic Fluid Which Is A Gas At Ambient Conditions |
| Commodity Subtype | Other Hvl |
| Commodity Details | Ethylene |
| Unintentional Release Bbls | 0.18 |
| Intentional Release Bbls | 12.6 |
| Recovered Bbls | 0 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| Incident Identified Datetime | 2019-07-31 07:20:00 |
| System Part Involved | Onshore Pump/meter Station Equipment And Piping |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | No |
| Shutdown Explain | No Need To Shut Down. Isolated Equipment And Replaced Faulty Part. |
| On Site Datetime | 2019-07-31 07:20:00 |
| Nrc Rpt Datetime | 2019-07-31 08:55:00 |
| Nrc Rpt Num | 1253740 NRC Report How to search |
| Ignite Ind | No |
| Explode Ind | No |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | 5*************************@ ************** |
| Segment Name | Cb03_sr To Chocolate Bayou Pes Id # 550448 |
| Onshore State Abbreviation | Tx |
| Onshore Postal Code | 77531 |
| Onshore City Name | Clute |
| Onshore County Name | Brazoria |
| Designated Location | Survey Station No. |
| Designated Name | 974+32 |
| Federal | No |
| Location Type | Originated On Operator-Controlled Property, But Then Flowed Or Migrated Off The Property |
| Incident Area Type | Aboveground |
| Incident Area Subtype | Typical Aboveground Facility Piping Or Appurtenance |
| Crossing | No |
| Pipe Facility Type | Intrastate |
| Item Involved | Auxiliary Piping (E.g. Drain Lines) |
| Installation Year | 2010 |
| Material Involved | Material Other Than Carbon Steel |
| Material Details | Gasket, Soft Good |
| Release Type | Leak |
| Leak Type | Seal Or Packing |
| Wildlife Impact Ind | No |
| Soil Contamination | No |
| Long Term Assessment | No |
| Remediation Ind | No |
| Water Contam Ind | No |
| Could Be Hca | Yes |
| Commodity Reached Hca | Yes |
| Usa Drinking Ind | Yes |
| Usa Drinking Yes No | Yes |
| Usa Ecological Ind | Yes |
| Usa Ecological Yes No | Yes |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 0 |
| Est Cost Prop Damage | 3 |
| Est Cost Emergency | 0 |
| Est Cost Environmental | 0 |
| Est Cost Other | 0 |
| Prpty | 3 |
| Accident Psig | 1308 |
| Mop Psig | 2160 |
| 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 | Failure on a non-automated component, no controller action. |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Equipment Failure |
| Cause Details | Non-Threaded Connection Failure |
| Eq Failure Type | Non-Threaded Connection Failure |
| Other Non Threaded Ind | O-Ring |
| Additional Breakdown Ind | Yes |
| Preparer Name | S**** T****** |
| Preparer Title | Compliance Specialist |
| Preparer Email | S************@l**.com |
| Preparer Telephone | 281-709-0712 |
| Prepared Date | 2020-01-28 00:00:00 |
| Authorizer Name | M****** C***** |
| Authorizer Telephone | 281 709 0626 |
| Authorizer Title | Technical Manager |
| Authorizer Email | M*************@l**.com |
| Narrative | Lyondellbasell equistar maintenance technicians were reporting to stratton ridge for routine inspections. Upon arrival at 7:20 a.M. They saw what appeared to be ethylene vapors coming from the door to one of the filters. Upon opening the door, they noticed an ice ball had formed around the 3/4 inch o-ring gasket and filter cabinet door and a vapor cloud emitting from the ice ball. They immediately swapped filters and blocked in the filter that had the leak and started depressuring the system. A call was made to the control room at 7:28 a.M. After discussions with field technician and engineer, it was determined that we would exceed the 5 gallon reportable quantities threshold. This is a regulated intrastate pipeline in brazoria county. After the system was depressured and repairs were made it was determined that the leak was from the 3/4 inch o-ring on the filter. Repairs were made and system is back to normal. Preliminary investigation findings: our investigation's preliminary finding determined the leak was due to failure of an o-ring gasket on an orifice plug in a filter door mechanism. The failure of the gasket was due to material degradation resulting from the age of the gasket combined with exposure to atmospheric conditions and ethylene service and possibly mechanical stress due to possible reuse of the gasket. Our existing maintenance procedure for inspection and replacement of ethylene filter elements doesn't specify inspection and replacement of orifice plug gaskets of this type. Plan to prevent recurrence: in this instance, the plug with the o-ring gasket was replaced with a capped section of pipe with full threading where it connects to the filter housing. The investigation will also recommend updating the maintenance procedure to include a specification for replacing gaskets on similar orifice plugs. |
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