Incident details
Operator, cause, commodity and consequences with raw source fields.
GTG incident on 2022-11-21 — MI
Operator
Consumers Energy Co
Cause
Incorrect Operation
Commodity
Natural Gas
Program
GTG
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$5,707
Incident datetime
2022-11-21 06:00
Report number
Location
MI
Narrative
On november 21, 2022, at approximately 06:00 hours, a station mechanic reporting to work at the consumers energy's freedom compressor station observed gas blowing at/near the condensate storage tank. Freedom compressor station is located at 12201 e. Pleasant lake road, manchester, (washtenaw county) michigan. The employee responded by utilizing isolation valve (30sdv-012) to stop the gas from blowing and began a preliminary investigation to determine the cause of the gas release. A review of the security footage and confirmation of historian data determined the release began on sunday, november 20, 2022, at approximately 05:48 hours. The initial investigation on november 21, 2022 determined the filter separator dump valve (30gv-528) did not close after the condensate dump operation and allowed gas to flow freely from the filter-separator to the condensate storage tank and release to atmosphere. Consumers energy personnel initiated an abnormal equipment alignment/configuration request (aec) to isolate the filter-separator condensate system to allow for manual operation. Further investigation determined the root cause of the release was due to the filter separator south sump level controller (lc_3001500). The level controller sent a pneumatic signal to the dump valve which opened the valve to initiate the condensate dump process. After the dump operation was complete, the signal to close the valve was not initiated (removed) causing the dump valve to remain open. On december 7, 2022, consumers energy (ce) personnel met with the local magnetrol level controller sales engineer to troubleshoot the level controller operation. During the investigation it was discovered the level adjustment knob was set at 1 which was lower than recommended for this operation. Station personnel proceeded to increase the level control set point while monitoring system response. After adjusting the level to a set point of 5, which was determined to be an acceptable level set point for operation. Ce personnel will continue to evaluating gas compression station level controllers and gas control notification methods to alarm in the event of gas release associated with pneumatic level control devices. The unit will remain in by-pass mode until the evaluation is completed and actions to mitigate are implemented. The evaluation of the level controller and gas control notification methods at the freedom compressor station was completed. As a result, low level liquid alarms as well as condensate tank acoustic monitoring were implemented. The aec was removed and the unit is no longer in by-pass mode, normal operation resumed on january 24, 2023. Ce has completed problem solving sessions regarding condensate drain system alarming and filter-separator commissioning/operational testing. Long-term countermeasures were generated with a plan to incorporate fleetwide.
Detailed record list
Report Received Date
2022-12-19 00:00:00
Iyear
2022
Report Number
20220133
Supplemental Number
38384
Report Type
Supplemental Final
Operator Id
2748
Name
Consumers Energy Co
Operator Street Address
One Energy Plaza
Operator City Name
Jackson
Operator State Abbreviation
MI
Operator Postal Code
49201
Local Datetime
2022-11-20 05:48:00
Time Zone
Eastern
Daylight Savings Ind
No
Location Latitude
42.207039
Location Longitude
-83.969183
Nrc Rpt Num
1353096
Nrc Rpt Datetime
2022-11-21 09:48:00
Additional Nrc Report Numbers
1353170
Commodity Released Type
Natural Gas
Unintentional Release
3560
Intentional Release
0
Accompanying Liquid
0
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Status When Identified
Normal Operation, Includes Pauses During Maintenance
Shutdown Due Accident Ind
No
Shutdown Explain
The Level-Controller And Dump Valve Was By-Passed (Manual Operation)
Communication State Fed Ind
No
Ignite Ind
No
Num Pub Evacuated
0
Incident Identified Datetime
2022-11-21 06:00:00
On Site Datetime
2022-11-21 06:00:00
On Off Shore
Onshore
Onshore State Abbreviation
Mi
Onshore Postal Code
48158
Onshore City Name
Manchester
Onshore County Name
Washtenaw
Designated Location
Not Applicable
Pipe Fac Name
Freedom Compressor Station
Segment Name
Filter-Separator Condensate System
Federal
No
Location Type
Operator-Controlled Property
Incident Area Type
Aboveground
Incident Area Subtype
Typical Aboveground Facility Piping Or Appurtenance
Crossing
No
Pipe Facility Type
Intrastate
System Part Involved
Onshore Compressor Station Equipment And Piping
Item Involved
Regulator/control Valve
Installation Year
2020
Manufactured Year
2018
Material Involved
Material Other Than Carbon Steel Or Plastic
Material Details
Level Controller
Release Type
Other
Release Type Details
Continuous Venting Due To The Level Controller Holding Dump Valve Open Allowing Natural Gas To Freely Flow From The Filter Separator To The Condensate Storage Tank Vent.
Class Location Type
Class 3 Location
Could Be Hca
Yes
Determination Method
Method2
Pir Radius
85
Heat Damage Ind
No
Non Heat Damage Ind
No
Est Cost Oper Paid
0
Est Cost Unintentional Release
20541
Est Cost Intentional Release
0
Est Cost Prop Damage
5707
Est Cost Emergency
68
Est Cost Other
0
Gas Cost In Mcf
5.77
Prpty
26316
Num Persons Hosp Not Ovnght
0
Num Injured Treated By Emt
0
Num Resident Building Affctd
0
Num Business Building Affctd
0
Wildlife Impact Ind
No
Accident Psig
668
Gas Flow In Pipe In Mcf
225
Mop Psig
960
Mop Cfr Section
192.619(A)(2)
Maop Established Date
2019-04-01 00:00:00
Maop Reversal Flow Ind
No
Accident Pressure
Pressure Did Not Exceed Maop
Pressure Restriction Ind
No
Gas Required Odorized Ind
No
Pipeline Function
Transmission System
Scada In Place Ind
Yes
Scada Operating Ind
Yes
Scada Functional Ind
No
Scada Detection Ind
Yes
Scada Conf Ind
No
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
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
As designed there were no alarm notifications sent to gas control
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 Other Ind
Yes
Operation Related Details
The Level Controller Was Not Calibrated During Commissioning Due To The Lack Of Condensate Liquid Needed To Appropriately Set The Functional Level.
Category Type
Commissioning
Operator Qualification Ind
No
Io No Procedure Ind
Yes
Preparer Name
C******* Q* K***
Preparer Title
Principal Engineer Technical Analyst
Preparer Email
C************@c********.com
Preparer Telephone
989-280-2963
Local Contact Name
C******* Q* K***
Local Contact Email
C************@c********.com
Local Contact Telephone
989-280-2963
Authorizer Name
J**** E* P****
Authorizer Title
Senior Manager Engineering
Authorizer Telephone
989-598-5031
Authorizer Email
J**********@c********.com
Narrative
On november 21, 2022, at approximately 06:00 hours, a station mechanic reporting to work at the consumers energy's freedom compressor station observed gas blowing at/near the condensate storage tank. Freedom compressor station is located at 12201 e. Pleasant lake road, manchester, (washtenaw county) michigan. The employee responded by utilizing isolation valve (30sdv-012) to stop the gas from blowing and began a preliminary investigation to determine the cause of the gas release. A review of the security footage and confirmation of historian data determined the release began on sunday, november 20, 2022, at approximately 05:48 hours. The initial investigation on november 21, 2022 determined the filter separator dump valve (30gv-528) did not close after the condensate dump operation and allowed gas to flow freely from the filter-separator to the condensate storage tank and release to atmosphere. Consumers energy personnel initiated an abnormal equipment alignment/configuration request (aec) to isolate the filter-separator condensate system to allow for manual operation. Further investigation determined the root cause of the release was due to the filter separator south sump level controller (lc_3001500). The level controller sent a pneumatic signal to the dump valve which opened the valve to initiate the condensate dump process. After the dump operation was complete, the signal to close the valve was not initiated (removed) causing the dump valve to remain open. On december 7, 2022, consumers energy (ce) personnel met with the local magnetrol level controller sales engineer to troubleshoot the level controller operation. During the investigation it was discovered the level adjustment knob was set at 1 which was lower than recommended for this operation. Station personnel proceeded to increase the level control set point while monitoring system response. After adjusting the level to a set point of 5, which was determined to be an acceptable level set point for operation. Ce personnel will continue to evaluating gas compression station level controllers and gas control notification methods to alarm in the event of gas release associated with pneumatic level control devices. The unit will remain in by-pass mode until the evaluation is completed and actions to mitigate are implemented. The evaluation of the level controller and gas control notification methods at the freedom compressor station was completed. As a result, low level liquid alarms as well as condensate tank acoustic monitoring were implemented. The aec was removed and the unit is no longer in by-pass mode, normal operation resumed on january 24, 2023. Ce has completed problem solving sessions regarding condensate drain system alarming and filter-separator commissioning/operational testing. Long-term countermeasures were generated with a plan to incorporate fleetwide.
| Report Received Date | 2022-12-19 00:00:00 |
|---|---|
| Iyear | 2022 |
| Report Number | 20220133 |
| Supplemental Number | 38384 |
| Report Type | Supplemental Final |
| Operator Id | 2748 PHMSA Enforcement |
| Name | Consumers Energy Co |
| Operator Street Address | One Energy Plaza |
| Operator City Name | Jackson |
| Operator State Abbreviation | MI |
| Operator Postal Code | 49201 |
| Local Datetime | 2022-11-20 05:48:00 |
| Time Zone | Eastern |
| Daylight Savings Ind | No |
| Location Latitude | 42.207039 Google Maps OpenStreetMap |
| Location Longitude | -83.969183 Google Maps OpenStreetMap |
| Nrc Rpt Num | 1353096 NRC Report How to search |
| Nrc Rpt Datetime | 2022-11-21 09:48:00 |
| Additional Nrc Report Numbers | 1353170 |
| Commodity Released Type | Natural Gas |
| Unintentional Release | 3560 |
| Intentional Release | 0 |
| Accompanying Liquid | 0 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Status When Identified | Normal Operation, Includes Pauses During Maintenance |
| Shutdown Due Accident Ind | No |
| Shutdown Explain | The Level-Controller And Dump Valve Was By-Passed (Manual Operation) |
| Communication State Fed Ind | No |
| Ignite Ind | No |
| Num Pub Evacuated | 0 |
| Incident Identified Datetime | 2022-11-21 06:00:00 |
| On Site Datetime | 2022-11-21 06:00:00 |
| On Off Shore | Onshore |
| Onshore State Abbreviation | Mi |
| Onshore Postal Code | 48158 |
| Onshore City Name | Manchester |
| Onshore County Name | Washtenaw |
| Designated Location | Not Applicable |
| Pipe Fac Name | Freedom Compressor Station |
| Segment Name | Filter-Separator Condensate System |
| Federal | No |
| Location Type | Operator-Controlled Property |
| Incident Area Type | Aboveground |
| Incident Area Subtype | Typical Aboveground Facility Piping Or Appurtenance |
| Crossing | No |
| Pipe Facility Type | Intrastate |
| System Part Involved | Onshore Compressor Station Equipment And Piping |
| Item Involved | Regulator/control Valve |
| Installation Year | 2020 |
| Manufactured Year | 2018 |
| Material Involved | Material Other Than Carbon Steel Or Plastic |
| Material Details | Level Controller |
| Release Type | Other |
| Release Type Details | Continuous Venting Due To The Level Controller Holding Dump Valve Open Allowing Natural Gas To Freely Flow From The Filter Separator To The Condensate Storage Tank Vent. |
| Class Location Type | Class 3 Location |
| Could Be Hca | Yes |
| Determination Method | Method2 |
| Pir Radius | 85 |
| Heat Damage Ind | No |
| Non Heat Damage Ind | No |
| Est Cost Oper Paid | 0 |
| Est Cost Unintentional Release | 20541 |
| Est Cost Intentional Release | 0 |
| Est Cost Prop Damage | 5707 |
| Est Cost Emergency | 68 |
| Est Cost Other | 0 |
| Gas Cost In Mcf | 5.77 |
| Prpty | 26316 |
| Num Persons Hosp Not Ovnght | 0 |
| Num Injured Treated By Emt | 0 |
| Num Resident Building Affctd | 0 |
| Num Business Building Affctd | 0 |
| Wildlife Impact Ind | No |
| Accident Psig | 668 |
| Gas Flow In Pipe In Mcf | 225 |
| Mop Psig | 960 |
| Mop Cfr Section | 192.619(A)(2) View CFR 49 §192 |
| Maop Established Date | 2019-04-01 00:00:00 |
| Maop Reversal Flow Ind | No |
| Accident Pressure | Pressure Did Not Exceed Maop |
| Pressure Restriction Ind | No |
| Gas Required Odorized Ind | No |
| Pipeline Function | Transmission System |
| Scada In Place Ind | Yes |
| Scada Operating Ind | Yes |
| Scada Functional Ind | No |
| Scada Detection Ind | Yes |
| Scada Conf Ind | No |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| 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 | As designed there were no alarm notifications sent to gas control |
| 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 Other Ind | Yes |
| Operation Related Details | The Level Controller Was Not Calibrated During Commissioning Due To The Lack Of Condensate Liquid Needed To Appropriately Set The Functional Level. |
| Category Type | Commissioning |
| Operator Qualification Ind | No |
| Io No Procedure Ind | Yes |
| Preparer Name | C******* Q* K*** |
| Preparer Title | Principal Engineer Technical Analyst |
| Preparer Email | C************@c********.com |
| Preparer Telephone | 989-280-2963 |
| Local Contact Name | C******* Q* K*** |
| Local Contact Email | C************@c********.com |
| Local Contact Telephone | 989-280-2963 |
| Authorizer Name | J**** E* P**** |
| Authorizer Title | Senior Manager Engineering |
| Authorizer Telephone | 989-598-5031 |
| Authorizer Email | J**********@c********.com |
| Narrative | On november 21, 2022, at approximately 06:00 hours, a station mechanic reporting to work at the consumers energy's freedom compressor station observed gas blowing at/near the condensate storage tank. Freedom compressor station is located at 12201 e. Pleasant lake road, manchester, (washtenaw county) michigan. The employee responded by utilizing isolation valve (30sdv-012) to stop the gas from blowing and began a preliminary investigation to determine the cause of the gas release. A review of the security footage and confirmation of historian data determined the release began on sunday, november 20, 2022, at approximately 05:48 hours. The initial investigation on november 21, 2022 determined the filter separator dump valve (30gv-528) did not close after the condensate dump operation and allowed gas to flow freely from the filter-separator to the condensate storage tank and release to atmosphere. Consumers energy personnel initiated an abnormal equipment alignment/configuration request (aec) to isolate the filter-separator condensate system to allow for manual operation. Further investigation determined the root cause of the release was due to the filter separator south sump level controller (lc_3001500). The level controller sent a pneumatic signal to the dump valve which opened the valve to initiate the condensate dump process. After the dump operation was complete, the signal to close the valve was not initiated (removed) causing the dump valve to remain open. On december 7, 2022, consumers energy (ce) personnel met with the local magnetrol level controller sales engineer to troubleshoot the level controller operation. During the investigation it was discovered the level adjustment knob was set at 1 which was lower than recommended for this operation. Station personnel proceeded to increase the level control set point while monitoring system response. After adjusting the level to a set point of 5, which was determined to be an acceptable level set point for operation. Ce personnel will continue to evaluating gas compression station level controllers and gas control notification methods to alarm in the event of gas release associated with pneumatic level control devices. The unit will remain in by-pass mode until the evaluation is completed and actions to mitigate are implemented. The evaluation of the level controller and gas control notification methods at the freedom compressor station was completed. As a result, low level liquid alarms as well as condensate tank acoustic monitoring were implemented. The aec was removed and the unit is no longer in by-pass mode, normal operation resumed on january 24, 2023. Ce has completed problem solving sessions regarding condensate drain system alarming and filter-separator commissioning/operational testing. Long-term countermeasures were generated with a plan to incorporate fleetwide. |
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