Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2022-11-21 — KS
Operator
Flint Hills Resources, Lc
Cause
Incorrect Operation
Commodity
Crude Oil
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$0
Incident datetime
2022-11-21 09:24
Report number
Location
KS
Narrative
Root cause investigation has been completed with no changes to the original report. 11-21-2022 at approx. 09:15 fhr personnel arrived at helena station to perform a routine overpressure safety device inspection. At approx. 09:24, while performing the inspection, one of the downstream valves was closed in error and caused an overpressure of station piping and equipment. Once the onsite fhr personnel saw the overpressure incident they notified the pipeline control center who shut down the incoming flow at 09:28 and isolated the trap valves upstream of the area at the station at 09:28. Fhr personnel continued to further isolated the area downstream while the pipeline control center closed an additional downstream valve at 09:48 and allowed the isolated area to drain down. Fhr operations replaced the relief device and the o-rings on the strainer. The pipeline segment was restarted on 11-22-2022 at 17:00. Fhr performed a root cause analysis, which determined that (1) the flex flo regulator valve (relief device) was under designed for current operating conditions, and (2) fhr personnel failed to place control valve in manual before performing the overpressure safety device inspection. To prevent recurrence, fhr automation has added programming changes to the plc that will not allow the control valve to fully close to keep an open flow path.
Detailed record list
Report Received Date
2022-12-21 00:00:00
Iyear
2022
Report Number
20220290
Supplemental Number
38002
Report Type
Supplemental Final
Operator Id
22855
Name
Flint Hills Resources, Lc
Operator Street Address
4111 East 37th Street North
Operator City Name
Wichita
Operator State Abbreviation
KS
Operator Postal Code
67220
Local Datetime
2022-11-21 09:24:00
Time Zone
Central
Daylight Savings Ind
No
Location Latitude
28.937256
Location Longitude
-97.798827
Commodity Released Type
Crude Oil
Unintentional Release Bbls
36
Recovered Bbls
30
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
Incident Identified Datetime
2022-11-21 09:24:00
System Part Involved
Onshore Pipeline, Including Valve Sites
On Off Shore
Onshore
Status When Identified
Normal Operation, Includes Pauses Between Batches And During Maintenance
Shutdown Due Accident Ind
Yes
Shutdown Datetime
2022-11-21 09:28:00
Restart Datetime
2022-11-22 17:00:00
Communication State Fed Ind
No
On Site Datetime
2022-11-21 09:24:00
Confirmed Discovery Datetime
2022-11-21 09:24:00
Nrc Rpt Datetime
2022-11-21 10:27:00
Nrc Rpt Num
1353103
Additional Nrc Report Numbers
1353228
Ignite Ind
No
Upstream Action Taken
Valve Closure
Upstream Valve Close Datetime
2022-11-21 09:28:00
Upstream Valve Type Ind
Remotely Controlled
Downstream Action Taken
Valve Closure
Downstream Vlv Close Datetime
2022-11-21 09:48:00
Downstream Valve Type Ind
Remotely Controlled
Notify Qualified Indiv Ind
Yes
Qualified Indiv Notif Datetime
2022-11-21 10:00:00
Oil Spill Removal Org Ind
Yes
Osro Activated Datetime
2022-11-21 10:40:00
Osro Arrived On Site Dt
11/21/2022 14:00
Num Pub Evacuated
0
Pipe Fac Name
Helena Receipt Station
Segment Name
Ecleto To Helena, 12"
Onshore State Abbreviation
Tx
Onshore Postal Code
78118
Onshore City Name
Karnes City
Onshore County Name
Karnes
Designated Location
Survey Station No.
Designated Name
493+65
Federal
No
Location Type
Totally Contained On Operator-Controlled Property
Incident Area Type
Aboveground
Incident Area Subtype
Typical Aboveground Facility Piping Or Appurtenance
Crossing
No
Pipe Facility Type
Intrastate
Item Involved
Filter/strainer/separator
Installation Year
2017
Manufactured Year
2013
Material Involved
Carbon Steel
Release Type
Leak
Leak Type
Other
Leak Type Other
Strainer Overpressured
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
No
Est Cost Oper Paid
0
Est Cost Gas Released
2880
Est Cost Prop Damage
0
Est Cost Emergency
100945
Est Cost Environmental
0
Est Cost Other
0
Prpty
103825
Num Persons Hosp Not Ovnght
0
Num Injured Treated By Emt
0
Num Resident Building Affctd
0
Num Business Building Affctd
0
Accident Psig
650
Mop Psig
285
Mop Cfr Section
Component Design Pressure �195.406(A)(2)
Maop Established Date
2017-10-07 00:00:00
Maop Reversal Flow Ind
No
Accident Pressure
Pressure Exceeded 110% Of Mop
Pressure Restriction Ind
No
Length Segment Isolated
1000
Internal Inspection Ind
No
Other Restrictions Ind
Yes
Operation Complications 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
Yes, specify investigation result(s): (select all that apply)
Invest Schedule Ind
Yes
Invest No Control Room Ind
Yes
Invest No Controller Ind
Yes
Employee Drug Test Ind
Yes
Contractor Drug Test Ind
No
Num Employees Tested
1
Num Employees Failed
0
Cause
Incorrect Operation
Cause Details
Pipeline Or Equipment Overpressured
Operation Type
Pipeline Or Equipment Overpressured
Related Other Ind
Yes
Operation Related Details
Relief Device Failed
Category Type
Routine Maintenance
Operator Qualification Ind
Yes
Qualified Individuals
Yes, They Were Qualified For The Task(S)
Io Equipment Overpressure Ind
Yes
Io Follow Procedure Ind
Yes
Preparer Name
M**** T*****
Preparer Title
Sr Compliance Specialist
Preparer Email
M***********@f**.com
Preparer Telephone
409-273-9482
Prepared Date
2023-05-02 00:00:00
Local Contact Name
M**** T*****
Local Contact Email
M***********@f**.com
Local Contact Telephone
409-273-9482
Authorizer Name
M**** T*****
Authorizer Telephone
409-273-9482
Authorizer Title
Sr Compliance Specialist
Authorizer Email
M***********@f**.com
Narrative
Root cause investigation has been completed with no changes to the original report. 11-21-2022 at approx. 09:15 fhr personnel arrived at helena station to perform a routine overpressure safety device inspection. At approx. 09:24, while performing the inspection, one of the downstream valves was closed in error and caused an overpressure of station piping and equipment. Once the onsite fhr personnel saw the overpressure incident they notified the pipeline control center who shut down the incoming flow at 09:28 and isolated the trap valves upstream of the area at the station at 09:28. Fhr personnel continued to further isolated the area downstream while the pipeline control center closed an additional downstream valve at 09:48 and allowed the isolated area to drain down. Fhr operations replaced the relief device and the o-rings on the strainer. The pipeline segment was restarted on 11-22-2022 at 17:00. Fhr performed a root cause analysis, which determined that (1) the flex flo regulator valve (relief device) was under designed for current operating conditions, and (2) fhr personnel failed to place control valve in manual before performing the overpressure safety device inspection. To prevent recurrence, fhr automation has added programming changes to the plc that will not allow the control valve to fully close to keep an open flow path.
| Report Received Date | 2022-12-21 00:00:00 |
|---|---|
| Iyear | 2022 |
| Report Number | 20220290 |
| Supplemental Number | 38002 |
| Report Type | Supplemental Final |
| Operator Id | 22855 PHMSA Enforcement |
| Name | Flint Hills Resources, Lc |
| Operator Street Address | 4111 East 37th Street North |
| Operator City Name | Wichita |
| Operator State Abbreviation | KS |
| Operator Postal Code | 67220 |
| Local Datetime | 2022-11-21 09:24:00 |
| Time Zone | Central |
| Daylight Savings Ind | No |
| Location Latitude | 28.937256 Google Maps OpenStreetMap |
| Location Longitude | -97.798827 Google Maps OpenStreetMap |
| Commodity Released Type | Crude Oil |
| Unintentional Release Bbls | 36 |
| Recovered Bbls | 30 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| Incident Identified Datetime | 2022-11-21 09:24:00 |
| System Part Involved | Onshore Pipeline, Including Valve Sites |
| On Off Shore | Onshore |
| Status When Identified | Normal Operation, Includes Pauses Between Batches And During Maintenance |
| Shutdown Due Accident Ind | Yes |
| Shutdown Datetime | 2022-11-21 09:28:00 |
| Restart Datetime | 2022-11-22 17:00:00 |
| Communication State Fed Ind | No |
| On Site Datetime | 2022-11-21 09:24:00 |
| Confirmed Discovery Datetime | 2022-11-21 09:24:00 |
| Nrc Rpt Datetime | 2022-11-21 10:27:00 |
| Nrc Rpt Num | 1353103 NRC Report How to search |
| Additional Nrc Report Numbers | 1353228 |
| Ignite Ind | No |
| Upstream Action Taken | Valve Closure |
| Upstream Valve Close Datetime | 2022-11-21 09:28:00 |
| Upstream Valve Type Ind | Remotely Controlled |
| Downstream Action Taken | Valve Closure |
| Downstream Vlv Close Datetime | 2022-11-21 09:48:00 |
| Downstream Valve Type Ind | Remotely Controlled |
| Notify Qualified Indiv Ind | Yes |
| Qualified Indiv Notif Datetime | 2022-11-21 10:00:00 |
| Oil Spill Removal Org Ind | Yes |
| Osro Activated Datetime | 2022-11-21 10:40:00 |
| Osro Arrived On Site Dt | 11/21/2022 14:00 |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Helena Receipt Station |
| Segment Name | Ecleto To Helena, 12" |
| Onshore State Abbreviation | Tx |
| Onshore Postal Code | 78118 |
| Onshore City Name | Karnes City |
| Onshore County Name | Karnes |
| Designated Location | Survey Station No. |
| Designated Name | 493+65 |
| Federal | No |
| Location Type | Totally Contained On Operator-Controlled Property |
| Incident Area Type | Aboveground |
| Incident Area Subtype | Typical Aboveground Facility Piping Or Appurtenance |
| Crossing | No |
| Pipe Facility Type | Intrastate |
| Item Involved | Filter/strainer/separator |
| Installation Year | 2017 |
| Manufactured Year | 2013 |
| Material Involved | Carbon Steel |
| Release Type | Leak |
| Leak Type | Other |
| Leak Type Other | Strainer Overpressured |
| 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 | No |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 2880 |
| Est Cost Prop Damage | 0 |
| Est Cost Emergency | 100945 |
| Est Cost Environmental | 0 |
| Est Cost Other | 0 |
| Prpty | 103825 |
| Num Persons Hosp Not Ovnght | 0 |
| Num Injured Treated By Emt | 0 |
| Num Resident Building Affctd | 0 |
| Num Business Building Affctd | 0 |
| Accident Psig | 650 |
| Mop Psig | 285 |
| Mop Cfr Section | Component Design Pressure �195.406(A)(2) View CFR 49 §192 |
| Maop Established Date | 2017-10-07 00:00:00 |
| Maop Reversal Flow Ind | No |
| Accident Pressure | Pressure Exceeded 110% Of Mop |
| Pressure Restriction Ind | No |
| Length Segment Isolated | 1000 |
| Internal Inspection Ind | No |
| Other Restrictions Ind | Yes |
| Operation Complications 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 | Yes, specify investigation result(s): (select all that apply) |
| Invest Schedule Ind | Yes |
| Invest No Control Room Ind | Yes |
| Invest No Controller Ind | Yes |
| Employee Drug Test Ind | Yes |
| Contractor Drug Test Ind | No |
| Num Employees Tested | 1 |
| Num Employees Failed | 0 |
| Cause | Incorrect Operation |
| Cause Details | Pipeline Or Equipment Overpressured |
| Operation Type | Pipeline Or Equipment Overpressured |
| Related Other Ind | Yes |
| Operation Related Details | Relief Device Failed |
| Category Type | Routine Maintenance |
| Operator Qualification Ind | Yes |
| Qualified Individuals | Yes, They Were Qualified For The Task(S) |
| Io Equipment Overpressure Ind | Yes |
| Io Follow Procedure Ind | Yes |
| Preparer Name | M**** T***** |
| Preparer Title | Sr Compliance Specialist |
| Preparer Email | M***********@f**.com |
| Preparer Telephone | 409-273-9482 |
| Prepared Date | 2023-05-02 00:00:00 |
| Local Contact Name | M**** T***** |
| Local Contact Email | M***********@f**.com |
| Local Contact Telephone | 409-273-9482 |
| Authorizer Name | M**** T***** |
| Authorizer Telephone | 409-273-9482 |
| Authorizer Title | Sr Compliance Specialist |
| Authorizer Email | M***********@f**.com |
| Narrative | Root cause investigation has been completed with no changes to the original report. 11-21-2022 at approx. 09:15 fhr personnel arrived at helena station to perform a routine overpressure safety device inspection. At approx. 09:24, while performing the inspection, one of the downstream valves was closed in error and caused an overpressure of station piping and equipment. Once the onsite fhr personnel saw the overpressure incident they notified the pipeline control center who shut down the incoming flow at 09:28 and isolated the trap valves upstream of the area at the station at 09:28. Fhr personnel continued to further isolated the area downstream while the pipeline control center closed an additional downstream valve at 09:48 and allowed the isolated area to drain down. Fhr operations replaced the relief device and the o-rings on the strainer. The pipeline segment was restarted on 11-22-2022 at 17:00. Fhr performed a root cause analysis, which determined that (1) the flex flo regulator valve (relief device) was under designed for current operating conditions, and (2) fhr personnel failed to place control valve in manual before performing the overpressure safety device inspection. To prevent recurrence, fhr automation has added programming changes to the plc that will not allow the control valve to fully close to keep an open flow path. |
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