Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2023-11-08 — TX
Operator
Epic Consolidated Operations, Llc
Cause
Equipment Failure
Commodity
Crude Oil
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$15,765
Incident datetime
2023-11-08 00:00 UTC
Report number
Location
TX
Narrative
Upton pump station experienced a seal failure on pump 3110 discharging 1.71 bbls of crude oil. Operator was on location and noticed oil release. Operator contacted control room to remotely shut off pump 3110. Inlet and outlet valves were isolated. Qualified individuals and supervisor were notified. Safety was notified, spill response trailer was deployed and vacuum truck was requested to recover liquids. Cleanup crew arrived onsite to contain and cleanup spill. An investigation confirmed the root cause was the seal catastrophically failed, showing deep grooving as evidence of a manufacturing defect. The seal was installed in 2023, but manufactured in 2019 per john crane mechanical drawing specifications. Further investigation showed that the disaster bushing stabilizing pin did not properly align back onto the pin slot allowing bushing to break immediately and was stuck into one position causing further damage to the sleeve. The failure was not a result of improper installation. The result of the failure was mechanical in nature. A change was implemented in work order system in relation to seal replacements to require the following process: 1. Visual inspection of seal faces. Were seal faces visually inspected (y/n), and a follow-up question will automatically generate to ask why visual inspection was not performed if "n" is selected. 2. Abnormalities. Were any abnormalities found (y/n), and a follow-up question will generate to describe abnormalities if "y" is selected. 3. Visual inspection pass. A final question will ask if seal passed visual inspection and if it fails, a corrective action work order will be generated with a link to the original work order to follow up. As an additional corrective action, operator will change the single bushing seal set to a double bushing seal set along with installing a pressure indicating transmitter to identify abnormal seal pressure and detect seal anomalies. The logic will shut the pump down on abnormal pressure readings. This will further mitigate the risk associated with seal anomalies.
Detailed record list
Report Received Date
2023-11-08 00:00:00
Iyear
2023
Report Number
20230264
Supplemental Number
39044
Report Type
Supplemental
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
Time Zone
Central
Daylight Savings Ind
No
Location Latitude
31.53102
Location Longitude
-101.93209
Commodity Released Type
Crude Oil
Unintentional Release Bbls
1.71
Recovered Bbls
1.33
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
System Part Involved
Onshore Pump/meter Station Equipment And Piping
On Off Shore
Onshore
Status When Identified
Normal Operation, Includes Pauses Between Batches And During Maintenance
Shutdown Due Accident Ind
Yes
Communication State Fed Ind
No
Nrc Rpt Num
Nrc Notification Not Required
Ignite Ind
No
Notify Qualified Indiv Ind
Yes
Oil Spill Removal Org Ind
No
Num Pub Evacuated
0
Pipe Fac Name
24" Crane To Benedum
Segment Name
104
Onshore State Abbreviation
Tx
Onshore Postal Code
79755
Onshore City Name
Midkiff
Onshore County Name
Upton
Designated Location
Milepost
Designated Name
Fm2401&tx349
Federal
No
Location Type
Totally Contained On Operator-Controlled Property
Incident Area Type
Aboveground
Incident Area Subtype
Other
Incident Area Details
Pump Station
Crossing
No
Pipe Facility Type
Intrastate
Item Involved
Pump
Pump Type
Centrifugal
Pump Service Type
Mainline
Installation Year
2023
Manufactured Year
2019
Material Involved
Material Other Than Carbon Steel
Material Details
316ss
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
No
Commodity Reached Hca
No
Est Cost Oper Paid
0
Est Cost Gas Released
35
Est Cost Prop Damage
15765
Est Cost Emergency
0
Est Cost Environmental
2100
Est Cost Other
0
Est Cost Other Details
No Property Damages, Only Cost To Replace Seal And Cleanup Expense.
Prpty
17900
Num Persons Hosp Not Ovnght
0
Num Injured Treated By Emt
0
Num Resident Building Affctd
0
Num Business Building Affctd
0
Accident Psig
248
Mop Psig
1440
Mop Cfr Section
Component Design Pressure �195.406(A)(2)
Maop Established Date
2020-01-01 00:00:00
Maop Reversal Flow Ind
No
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
Yes
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
This was a catastrophic seal failure. The control room did receive an alarm indicating failure and remotely shut off the pumps.
Employee Drug Test Ind
No
Contractor Drug Test Ind
No
Cause
Equipment Failure
Cause Details
Pump Or Pump-Related Equipment
Eq Failure Type
Pump Or Pump-Related Equipment
Other Pump Ind
Seal/packing Failure
Additional Defect Ind
Yes
Eqf Pump Equipment Ind
Yes
Preparer Name
J******* M*********
Preparer Title
Consultant
Preparer Email
J**************@f*************.net
Preparer Telephone
405-570-7089
Prepared Date
2024-01-05 00:00:00
Local Contact Name
B*** T*****
Local Contact Email
B**********@e******.com
Local Contact Telephone
210-215-3361
Authorizer Name
G***** C******
Authorizer Telephone
210-587-6004
Authorizer Title
Vice President Operations
Authorizer Email
G*******@e******.com
Narrative
Upton pump station experienced a seal failure on pump 3110 discharging 1.71 bbls of crude oil. Operator was on location and noticed oil release. Operator contacted control room to remotely shut off pump 3110. Inlet and outlet valves were isolated. Qualified individuals and supervisor were notified. Safety was notified, spill response trailer was deployed and vacuum truck was requested to recover liquids. Cleanup crew arrived onsite to contain and cleanup spill. An investigation confirmed the root cause was the seal catastrophically failed, showing deep grooving as evidence of a manufacturing defect. The seal was installed in 2023, but manufactured in 2019 per john crane mechanical drawing specifications. Further investigation showed that the disaster bushing stabilizing pin did not properly align back onto the pin slot allowing bushing to break immediately and was stuck into one position causing further damage to the sleeve. The failure was not a result of improper installation. The result of the failure was mechanical in nature. A change was implemented in work order system in relation to seal replacements to require the following process: 1. Visual inspection of seal faces. Were seal faces visually inspected (y/n), and a follow-up question will automatically generate to ask why visual inspection was not performed if "n" is selected. 2. Abnormalities. Were any abnormalities found (y/n), and a follow-up question will generate to describe abnormalities if "y" is selected. 3. Visual inspection pass. A final question will ask if seal passed visual inspection and if it fails, a corrective action work order will be generated with a link to the original work order to follow up. As an additional corrective action, operator will change the single bushing seal set to a double bushing seal set along with installing a pressure indicating transmitter to identify abnormal seal pressure and detect seal anomalies. The logic will shut the pump down on abnormal pressure readings. This will further mitigate the risk associated with seal anomalies.
| Report Received Date | 2023-11-08 00:00:00 |
|---|---|
| Iyear | 2023 |
| Report Number | 20230264 |
| Supplemental Number | 39044 |
| Report Type | Supplemental |
| 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 |
| Time Zone | Central |
| Daylight Savings Ind | No |
| Location Latitude | 31.53102 Google Maps OpenStreetMap |
| Location Longitude | -101.93209 Google Maps OpenStreetMap |
| Commodity Released Type | Crude Oil |
| Unintentional Release Bbls | 1.71 |
| Recovered Bbls | 1.33 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| System Part Involved | Onshore Pump/meter Station Equipment And Piping |
| On Off Shore | Onshore |
| Status When Identified | Normal Operation, Includes Pauses Between Batches And During Maintenance |
| Shutdown Due Accident Ind | Yes |
| Communication State Fed Ind | No |
| Nrc Rpt Num | Nrc Notification Not Required NRC Report How to search |
| Ignite Ind | No |
| Notify Qualified Indiv Ind | Yes |
| Oil Spill Removal Org Ind | No |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | 24" Crane To Benedum |
| Segment Name | 104 |
| Onshore State Abbreviation | Tx |
| Onshore Postal Code | 79755 |
| Onshore City Name | Midkiff |
| Onshore County Name | Upton |
| Designated Location | Milepost |
| Designated Name | Fm2401&tx349 |
| Federal | No |
| Location Type | Totally Contained On Operator-Controlled Property |
| Incident Area Type | Aboveground |
| Incident Area Subtype | Other |
| Incident Area Details | Pump Station |
| Crossing | No |
| Pipe Facility Type | Intrastate |
| Item Involved | Pump |
| Pump Type | Centrifugal |
| Pump Service Type | Mainline |
| Installation Year | 2023 |
| Manufactured Year | 2019 |
| Material Involved | Material Other Than Carbon Steel |
| Material Details | 316ss |
| 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 | No |
| Commodity Reached Hca | No |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 35 |
| Est Cost Prop Damage | 15765 |
| Est Cost Emergency | 0 |
| Est Cost Environmental | 2100 |
| Est Cost Other | 0 |
| Est Cost Other Details | No Property Damages, Only Cost To Replace Seal And Cleanup Expense. |
| Prpty | 17900 |
| Num Persons Hosp Not Ovnght | 0 |
| Num Injured Treated By Emt | 0 |
| Num Resident Building Affctd | 0 |
| Num Business Building Affctd | 0 |
| Accident Psig | 248 |
| Mop Psig | 1440 |
| Mop Cfr Section | Component Design Pressure �195.406(A)(2) View CFR 49 §192 |
| Maop Established Date | 2020-01-01 00:00:00 |
| Maop Reversal Flow Ind | No |
| 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 | Yes |
| 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 | This was a catastrophic seal failure. The control room did receive an alarm indicating failure and remotely shut off the pumps. |
| Employee Drug Test Ind | No |
| Contractor Drug Test Ind | No |
| Cause | Equipment Failure |
| Cause Details | Pump Or Pump-Related Equipment |
| Eq Failure Type | Pump Or Pump-Related Equipment |
| Other Pump Ind | Seal/packing Failure |
| Additional Defect Ind | Yes |
| Eqf Pump Equipment Ind | Yes |
| Preparer Name | J******* M********* |
| Preparer Title | Consultant |
| Preparer Email | J**************@f*************.net |
| Preparer Telephone | 405-570-7089 |
| Prepared Date | 2024-01-05 00:00:00 |
| Local Contact Name | B*** T***** |
| Local Contact Email | B**********@e******.com |
| Local Contact Telephone | 210-215-3361 |
| Authorizer Name | G***** C****** |
| Authorizer Telephone | 210-587-6004 |
| Authorizer Title | Vice President Operations |
| Authorizer Email | G*******@e******.com |
| Narrative | Upton pump station experienced a seal failure on pump 3110 discharging 1.71 bbls of crude oil. Operator was on location and noticed oil release. Operator contacted control room to remotely shut off pump 3110. Inlet and outlet valves were isolated. Qualified individuals and supervisor were notified. Safety was notified, spill response trailer was deployed and vacuum truck was requested to recover liquids. Cleanup crew arrived onsite to contain and cleanup spill. An investigation confirmed the root cause was the seal catastrophically failed, showing deep grooving as evidence of a manufacturing defect. The seal was installed in 2023, but manufactured in 2019 per john crane mechanical drawing specifications. Further investigation showed that the disaster bushing stabilizing pin did not properly align back onto the pin slot allowing bushing to break immediately and was stuck into one position causing further damage to the sleeve. The failure was not a result of improper installation. The result of the failure was mechanical in nature. A change was implemented in work order system in relation to seal replacements to require the following process: 1. Visual inspection of seal faces. Were seal faces visually inspected (y/n), and a follow-up question will automatically generate to ask why visual inspection was not performed if "n" is selected. 2. Abnormalities. Were any abnormalities found (y/n), and a follow-up question will generate to describe abnormalities if "y" is selected. 3. Visual inspection pass. A final question will ask if seal passed visual inspection and if it fails, a corrective action work order will be generated with a link to the original work order to follow up. As an additional corrective action, operator will change the single bushing seal set to a double bushing seal set along with installing a pressure indicating transmitter to identify abnormal seal pressure and detect seal anomalies. The logic will shut the pump down on abnormal pressure readings. This will further mitigate the risk associated with seal anomalies. |
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