Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2024-11-27 — KS
Operator
Flint Hills Resources, Lc
Cause
Equipment Failure
Commodity
Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions
Program
HL
Damage and Injuries
0 fatalities
0 injuries
Property damage (nominal)
$555,000
Incident datetime
2024-11-27 00:00 UTC
Report number
Location
KS
Narrative
02/03/2025-final report update-the investigation determined that the incident was an isolated failure of the auxiliary relay. _________________________________________________________________________________� on october 31, 2024, at 19:47, an alarm on the unit 3 pump at flint hills resources' (fhr) waco pump station, initiated a shutdown/lockout sequence which shut down the unit 3 pump and associated valves. An fhr operator was enroute for an unrelated reason and arrived at the site at 20:48. The operator was asked to check the unit 3 pump as a follow up to the alarm. The operator observed smoke coming from the unit 3 pump, which was still running. The operator activated the pump station esd which shut down two additional pumps and closed the remaining station bypass valves. However, the unit 3 pump continued to run and ultimately caught on fire. 911 was notified and the local fire department responded. The fire was extinguished by approximately 21:54. After the fire was extinguished, gasoline was observed in the pump skid and on the ground. The gasoline was contained and once the area was safe to enter, excavation of the contaminated soil began. Product was collected in a roll-off box and cleanup was complete by november 1. Through investigation it was identified that when the unit 3 pump shutdown/lockout alarm occurred, all valves closed as expected, however, the motor/pump continued to run causing an overheating scenario resulting in fire and failure of the pump and motor. When inspecting the switchgear that controls the pump 3 motor, a control relay (mx relay) was observed in the closed position and could not mechanically move to the open position. The failed relay allowed the motor to continue to operate without flow of product contributing to the pump overheating and ultimately catching on fire.
Detailed record list
Report Received Date
2024-11-27 00:00:00
Iyear
2024
Report Number
20240283
Supplemental Number
40470
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
Time Zone
Central
Daylight Savings Ind
No
Location Latitude
32.922149
Location Longitude
-97.115972
Commodity Released Type
Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions
Commodity Subtype
Gasoline (Non-Ethanol)
Unintentional Release Bbls
0.71
Recovered Bbls
0.71
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
Yes
Party Initiated Communication
Operator
Nrc Rpt Num
1415268
Additional Nrc Report Numbers
1415361
Ignite Ind
Yes
How Extinguished
Local/state/federal Emergency Responder
Consumed By Fire In Barrels
0
Explode Ind
No
Notify Qualified Indiv Ind
Yes
Oil Spill Removal Org Ind
Yes
Osro Arrived On Site Dt
10/31/2024 23:13
Num Pub Evacuated
0
Pipe Fac Name
Waco Pump Station
Segment Name
Waco To Waco Remote (Tpl2)
Onshore State Abbreviation
Tx
Onshore Postal Code
76705
Onshore City Name
Waco
Onshore County Name
Mclennan
Designated Location
Milepost
Designated Name
108.7
Federal
Yes
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
Pump
Pump Type
Centrifugal
Pump Service Type
Mainline
Installation Year
1989
Manufactured Year
Unknown
Material Involved
Carbon Steel
Release Type
Other
Release Type Details
Fire
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
Yes
High Pop Ind
Yes
High Pop Yes No
Yes
Est Cost Oper Paid
0
Est Cost Gas Released
60
Est Cost Prop Damage
555000
Est Cost Emergency
63600
Est Cost Environmental
0
Est Cost Other
0
Prpty
618660
Num Persons Hosp Not Ovnght
0
Num Injured Treated By Emt
0
Num Resident Building Affctd
0
Num Business Building Affctd
0
Accident Psig
1291
Mop Psig
1440
Mop Cfr Section
Component Design Pressure �195.406(A)(2)
Maop Established Date
2012-04-27 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
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
It was determined that neither controller actions, nor control room issues contributed to the accident.
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
Other
Other Pump Details
Auxiliary Relay
Eq Additional Other Ind
Yes
Eq Additional Other Details
Isolated Failure Of Auxiliary Relay
Preparer Name
M***** P****
Preparer Title
Compliance Support Specialist
Preparer Email
M***********@f**.com
Preparer Telephone
361-242-8781
Prepared Date
2025-02-03 00:00:00
Authorizer Name
S*** M******
Authorizer Telephone
361-242-0288
Authorizer Title
Senior Compliance Specialist
Authorizer Email
S***********@f**.com
Narrative
02/03/2025-final report update-the investigation determined that the incident was an isolated failure of the auxiliary relay. _________________________________________________________________________________� on october 31, 2024, at 19:47, an alarm on the unit 3 pump at flint hills resources' (fhr) waco pump station, initiated a shutdown/lockout sequence which shut down the unit 3 pump and associated valves. An fhr operator was enroute for an unrelated reason and arrived at the site at 20:48. The operator was asked to check the unit 3 pump as a follow up to the alarm. The operator observed smoke coming from the unit 3 pump, which was still running. The operator activated the pump station esd which shut down two additional pumps and closed the remaining station bypass valves. However, the unit 3 pump continued to run and ultimately caught on fire. 911 was notified and the local fire department responded. The fire was extinguished by approximately 21:54. After the fire was extinguished, gasoline was observed in the pump skid and on the ground. The gasoline was contained and once the area was safe to enter, excavation of the contaminated soil began. Product was collected in a roll-off box and cleanup was complete by november 1. Through investigation it was identified that when the unit 3 pump shutdown/lockout alarm occurred, all valves closed as expected, however, the motor/pump continued to run causing an overheating scenario resulting in fire and failure of the pump and motor. When inspecting the switchgear that controls the pump 3 motor, a control relay (mx relay) was observed in the closed position and could not mechanically move to the open position. The failed relay allowed the motor to continue to operate without flow of product contributing to the pump overheating and ultimately catching on fire.
| Report Received Date | 2024-11-27 00:00:00 |
|---|---|
| Iyear | 2024 |
| Report Number | 20240283 |
| Supplemental Number | 40470 |
| 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 |
| Time Zone | Central |
| Daylight Savings Ind | No |
| Location Latitude | 32.922149 Google Maps OpenStreetMap |
| Location Longitude | -97.115972 Google Maps OpenStreetMap |
| Commodity Released Type | Refined And/or Petroleum Product (Non-Hvl) Which Is A Liquid At Ambient Conditions |
| Commodity Subtype | Gasoline (Non-Ethanol) |
| Unintentional Release Bbls | 0.71 |
| Recovered Bbls | 0.71 |
| 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 | Yes |
| Party Initiated Communication | Operator |
| Nrc Rpt Num | 1415268 NRC Report How to search |
| Additional Nrc Report Numbers | 1415361 |
| Ignite Ind | Yes |
| How Extinguished | Local/state/federal Emergency Responder |
| Consumed By Fire In Barrels | 0 |
| Explode Ind | No |
| Notify Qualified Indiv Ind | Yes |
| Oil Spill Removal Org Ind | Yes |
| Osro Arrived On Site Dt | 10/31/2024 23:13 |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Waco Pump Station |
| Segment Name | Waco To Waco Remote (Tpl2) |
| Onshore State Abbreviation | Tx |
| Onshore Postal Code | 76705 |
| Onshore City Name | Waco |
| Onshore County Name | Mclennan |
| Designated Location | Milepost |
| Designated Name | 108.7 |
| Federal | Yes |
| 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 | Pump |
| Pump Type | Centrifugal |
| Pump Service Type | Mainline |
| Installation Year | 1989 |
| Manufactured Year | Unknown |
| Material Involved | Carbon Steel |
| Release Type | Other |
| Release Type Details | Fire |
| 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 | Yes |
| High Pop Ind | Yes |
| High Pop Yes No | Yes |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 60 |
| Est Cost Prop Damage | 555000 |
| Est Cost Emergency | 63600 |
| Est Cost Environmental | 0 |
| Est Cost Other | 0 |
| Prpty | 618660 |
| Num Persons Hosp Not Ovnght | 0 |
| Num Injured Treated By Emt | 0 |
| Num Resident Building Affctd | 0 |
| Num Business Building Affctd | 0 |
| Accident Psig | 1291 |
| Mop Psig | 1440 |
| Mop Cfr Section | Component Design Pressure �195.406(A)(2) View CFR 49 §192 |
| Maop Established Date | 2012-04-27 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 | 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 | It was determined that neither controller actions, nor control room issues contributed to the accident. |
| 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 | Other |
| Other Pump Details | Auxiliary Relay |
| Eq Additional Other Ind | Yes |
| Eq Additional Other Details | Isolated Failure Of Auxiliary Relay |
| Preparer Name | M***** P**** |
| Preparer Title | Compliance Support Specialist |
| Preparer Email | M***********@f**.com |
| Preparer Telephone | 361-242-8781 |
| Prepared Date | 2025-02-03 00:00:00 |
| Authorizer Name | S*** M****** |
| Authorizer Telephone | 361-242-0288 |
| Authorizer Title | Senior Compliance Specialist |
| Authorizer Email | S***********@f**.com |
| Narrative | 02/03/2025-final report update-the investigation determined that the incident was an isolated failure of the auxiliary relay. _________________________________________________________________________________� on october 31, 2024, at 19:47, an alarm on the unit 3 pump at flint hills resources' (fhr) waco pump station, initiated a shutdown/lockout sequence which shut down the unit 3 pump and associated valves. An fhr operator was enroute for an unrelated reason and arrived at the site at 20:48. The operator was asked to check the unit 3 pump as a follow up to the alarm. The operator observed smoke coming from the unit 3 pump, which was still running. The operator activated the pump station esd which shut down two additional pumps and closed the remaining station bypass valves. However, the unit 3 pump continued to run and ultimately caught on fire. 911 was notified and the local fire department responded. The fire was extinguished by approximately 21:54. After the fire was extinguished, gasoline was observed in the pump skid and on the ground. The gasoline was contained and once the area was safe to enter, excavation of the contaminated soil began. Product was collected in a roll-off box and cleanup was complete by november 1. Through investigation it was identified that when the unit 3 pump shutdown/lockout alarm occurred, all valves closed as expected, however, the motor/pump continued to run causing an overheating scenario resulting in fire and failure of the pump and motor. When inspecting the switchgear that controls the pump 3 motor, a control relay (mx relay) was observed in the closed position and could not mechanically move to the open position. The failed relay allowed the motor to continue to operate without flow of product contributing to the pump overheating and ultimately catching on fire. |
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