Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2020-04-24 — TX
Operator
Epic Consolidated Operations, Llc
Cause
Incorrect Operation
Commodity
Crude Oil
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$0
Incident datetime
2020-04-24 05:00
Report number
Location
TX
Narrative
On april 24, 2020 at 5:00am, epic was in the process of commissioning a new tank. During the initial fill with crude the manway gasket on tank 3002 began to leak. Operations personnel on-site inspecting the tank while filling found the leak and took immediate action and sealed the leak by tightening several flange bolts at the leak location. Tank is operated at atmospheric pressure and there was no over-pressure of the tank. The site was made safe and the terminal operation personnel contacted the terminal operations supervisor and epic operations management was notified of the release. Ehs personnel were sent to the site and epic's post-accident procedure was used to determine the estimated release volume and damages. During this time release volume calculations were being performed per the o&m procedure and confirmed by epic operations. The discovery time was 9:30 am and was based on the estimated release volume of 3.551 bbls. Epic dispatched an environmental cleanup crew to the site to assist with the cleanup of the site. Cleanup was completed the same day and no further remediation is needed. After the cleanup was completed terminal operations ensured all other flange bolts in the facility were torqued correctly and did not find additional issues. Inspection records were reviewed and at the time of the manway cover installation new bolts, nuts, and gaskets were installed. It was discovered that an incorrect torque value was used by the torque crew potentially causing the leak. During installation 3/4-inch flange bolts with a torque value of 315 ft pounds were used, the toque value used was for an ansi/asme-rated flange for 'field condition non-lubricated' bolts per the chart in epic's torquing procedures. The field record shows that the bolts were new not field condition(used), and the correct value for a new bolt with lubrication is 150 ft pounds per the torquing procedure using the ansi/asme torque values. Epic's torque value for the shell manways is 250 ft pounds, however this specification cannot be found in the procedure or records. The 250 ft pound torque value was verbally given by facility construction personnel. To mitigate re-occurrence of a similar accident epic will revise the torquing procedure to include torquing guidance for break tank manway flanges. In addition, all bolts in the terminal were inspected and no issues were found during the inspections.
Detailed record list
Report Received Date
2020-05-18 00:00:00
Iyear
2020
Report Number
20200141
Supplemental Number
34223
Report Type
Supplemental Final
Operator Id
39785
Name
Epic Consolidated Operations, Llc
Operator Street Address
18615 Tuscany Stone, Suite 300
Operator City Name
San Antonio
Operator State Abbreviation
TX
Operator Postal Code
78258
Local Datetime
2020-04-24 05:00:00
Location Latitude
27.8294937
Location Longitude
-97.6138882
Commodity Released Type
Crude Oil
Unintentional Release Bbls
3
Recovered Bbls
1
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
2020-04-24 05:00:00
System Part Involved
Onshore Breakout Tank Or Storage Vessel, Including Attached Appurtenances
On Off Shore
Onshore
Shutdown Due Accident Ind
No
Shutdown Explain
Release Was From The Manway Of A Breakout Tank.
On Site Datetime
2020-04-24 05:00:00
Nrc Rpt Num
Nrc Notification Not Required
Ignite Ind
No
Explode Ind
No
Num Pub Evacuated
0
Pipe Fac Name
Robstown Terminal
Segment Name
Breakout Tank 3002
Onshore State Abbreviation
Tx
Onshore Postal Code
78380
Onshore City Name
Not Within A Municipality
Onshore County Name
Nueces
Designated Location
Milepost/valve Station
Designated Name
Terminal
Federal
No
Location Type
Totally Contained On Operator-Controlled Property
Incident Area Type
Tank, Including Attached Appurtenances
Crossing
No
Pipe Facility Type
Intrastate
Item Involved
Flange Assembly
Tank Type
Atmospheric
Installation Year
2020
Material Involved
Carbon Steel
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
No
Est Cost Oper Paid
0
Est Cost Gas Released
75
Est Cost Prop Damage
0
Est Cost Emergency
1500
Est Cost Environmental
500
Est Cost Other
0
Prpty
2075
Accident Psig
10
Mop Psig
10
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 occurred on the tank manway during initial fill to commission the tanks floating roof.
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Incorrect Operation
Cause Details
Equipment Not Installed Properly
Operation Type
Equipment Not Installed Properly
Related Inadequate Proc Ind
Yes
Category Type
Commissioning
Operator Qualification Ind
No
Preparer Name
C**** W*******
Preparer Title
Sr. Pipeline Compliance Professional
Preparer Email
C*************@f*************.net
Preparer Telephone
806-759-6499
Prepared Date
2020-09-03 00:00:00
Authorizer Name
D***** V** D****
Authorizer Telephone
210-840-6622
Authorizer Title
Director Of Operations
Authorizer Email
D**************@e******.com
Narrative
On april 24, 2020 at 5:00am, epic was in the process of commissioning a new tank. During the initial fill with crude the manway gasket on tank 3002 began to leak. Operations personnel on-site inspecting the tank while filling found the leak and took immediate action and sealed the leak by tightening several flange bolts at the leak location. Tank is operated at atmospheric pressure and there was no over-pressure of the tank. The site was made safe and the terminal operation personnel contacted the terminal operations supervisor and epic operations management was notified of the release. Ehs personnel were sent to the site and epic's post-accident procedure was used to determine the estimated release volume and damages. During this time release volume calculations were being performed per the o&m procedure and confirmed by epic operations. The discovery time was 9:30 am and was based on the estimated release volume of 3.551 bbls. Epic dispatched an environmental cleanup crew to the site to assist with the cleanup of the site. Cleanup was completed the same day and no further remediation is needed. After the cleanup was completed terminal operations ensured all other flange bolts in the facility were torqued correctly and did not find additional issues. Inspection records were reviewed and at the time of the manway cover installation new bolts, nuts, and gaskets were installed. It was discovered that an incorrect torque value was used by the torque crew potentially causing the leak. During installation 3/4-inch flange bolts with a torque value of 315 ft pounds were used, the toque value used was for an ansi/asme-rated flange for 'field condition non-lubricated' bolts per the chart in epic's torquing procedures. The field record shows that the bolts were new not field condition(used), and the correct value for a new bolt with lubrication is 150 ft pounds per the torquing procedure using the ansi/asme torque values. Epic's torque value for the shell manways is 250 ft pounds, however this specification cannot be found in the procedure or records. The 250 ft pound torque value was verbally given by facility construction personnel. To mitigate re-occurrence of a similar accident epic will revise the torquing procedure to include torquing guidance for break tank manway flanges. In addition, all bolts in the terminal were inspected and no issues were found during the inspections.
| Report Received Date | 2020-05-18 00:00:00 |
|---|---|
| Iyear | 2020 |
| Report Number | 20200141 |
| Supplemental Number | 34223 |
| Report Type | Supplemental Final |
| Operator Id | 39785 PHMSA Enforcement |
| Name | Epic Consolidated Operations, Llc |
| Operator Street Address | 18615 Tuscany Stone, Suite 300 |
| Operator City Name | San Antonio |
| Operator State Abbreviation | TX |
| Operator Postal Code | 78258 |
| Local Datetime | 2020-04-24 05:00:00 |
| Location Latitude | 27.8294937 Google Maps OpenStreetMap |
| Location Longitude | -97.6138882 Google Maps OpenStreetMap |
| Commodity Released Type | Crude Oil |
| Unintentional Release Bbls | 3 |
| Recovered Bbls | 1 |
| 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 | 2020-04-24 05:00:00 |
| System Part Involved | Onshore Breakout Tank Or Storage Vessel, Including Attached Appurtenances |
| On Off Shore | Onshore |
| Shutdown Due Accident Ind | No |
| Shutdown Explain | Release Was From The Manway Of A Breakout Tank. |
| On Site Datetime | 2020-04-24 05:00:00 |
| 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 | Robstown Terminal |
| Segment Name | Breakout Tank 3002 |
| Onshore State Abbreviation | Tx |
| Onshore Postal Code | 78380 |
| Onshore City Name | Not Within A Municipality |
| Onshore County Name | Nueces |
| Designated Location | Milepost/valve Station |
| Designated Name | Terminal |
| Federal | No |
| Location Type | Totally Contained On Operator-Controlled Property |
| Incident Area Type | Tank, Including Attached Appurtenances |
| Crossing | No |
| Pipe Facility Type | Intrastate |
| Item Involved | Flange Assembly |
| Tank Type | Atmospheric |
| Installation Year | 2020 |
| Material Involved | Carbon Steel |
| 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 | No |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 75 |
| Est Cost Prop Damage | 0 |
| Est Cost Emergency | 1500 |
| Est Cost Environmental | 500 |
| Est Cost Other | 0 |
| Prpty | 2075 |
| Accident Psig | 10 |
| Mop Psig | 10 |
| 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 occurred on the tank manway during initial fill to commission the tanks floating roof. |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Incorrect Operation |
| Cause Details | Equipment Not Installed Properly |
| Operation Type | Equipment Not Installed Properly |
| Related Inadequate Proc Ind | Yes |
| Category Type | Commissioning |
| Operator Qualification Ind | No |
| Preparer Name | C**** W******* |
| Preparer Title | Sr. Pipeline Compliance Professional |
| Preparer Email | C*************@f*************.net |
| Preparer Telephone | 806-759-6499 |
| Prepared Date | 2020-09-03 00:00:00 |
| Authorizer Name | D***** V** D**** |
| Authorizer Telephone | 210-840-6622 |
| Authorizer Title | Director Of Operations |
| Authorizer Email | D**************@e******.com |
| Narrative | On april 24, 2020 at 5:00am, epic was in the process of commissioning a new tank. During the initial fill with crude the manway gasket on tank 3002 began to leak. Operations personnel on-site inspecting the tank while filling found the leak and took immediate action and sealed the leak by tightening several flange bolts at the leak location. Tank is operated at atmospheric pressure and there was no over-pressure of the tank. The site was made safe and the terminal operation personnel contacted the terminal operations supervisor and epic operations management was notified of the release. Ehs personnel were sent to the site and epic's post-accident procedure was used to determine the estimated release volume and damages. During this time release volume calculations were being performed per the o&m procedure and confirmed by epic operations. The discovery time was 9:30 am and was based on the estimated release volume of 3.551 bbls. Epic dispatched an environmental cleanup crew to the site to assist with the cleanup of the site. Cleanup was completed the same day and no further remediation is needed. After the cleanup was completed terminal operations ensured all other flange bolts in the facility were torqued correctly and did not find additional issues. Inspection records were reviewed and at the time of the manway cover installation new bolts, nuts, and gaskets were installed. It was discovered that an incorrect torque value was used by the torque crew potentially causing the leak. During installation 3/4-inch flange bolts with a torque value of 315 ft pounds were used, the toque value used was for an ansi/asme-rated flange for 'field condition non-lubricated' bolts per the chart in epic's torquing procedures. The field record shows that the bolts were new not field condition(used), and the correct value for a new bolt with lubrication is 150 ft pounds per the torquing procedure using the ansi/asme torque values. Epic's torque value for the shell manways is 250 ft pounds, however this specification cannot be found in the procedure or records. The 250 ft pound torque value was verbally given by facility construction personnel. To mitigate re-occurrence of a similar accident epic will revise the torquing procedure to include torquing guidance for break tank manway flanges. In addition, all bolts in the terminal were inspected and no issues were found during the inspections. |
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