Incident details
Operator, cause, commodity and consequences with raw source fields.
HL incident on 2025-06-12 — TX
Operator
Sunoco Pipeline L.p.
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)
$7,000
Incident datetime
2025-06-12 23:20
Report number
Location
TX
Narrative
On 6/12/25 at approximately 23:20, a local employee observed evidence of a potential gasoline release near the meter run manifold area at montello pump station. Gasoline was releasing from a failed densitometer pump seal on the 14-inch 12006 montello-bald eagle line segment. The densitometer was isolated to stop the leak. Approximately 5 barrels of gasoline was released. Local employees cleaned up released product and removed contaminated soil. The accident was repaired by replacing the densitometer pump. The failed densitometer pump is being sent to a third party lab for analysis. The cause of the accident is still under investigation. A supplemental report will be submitted once the investigation is completed. Supplemental & final: the investigation determined the cause of the accident was equipment failure which was attributed to the pump rebuild process by a 3rd party not being performed properly. The pump unit was rebuilt and had been in storage since october 2024 prior to reinstallation in the system in 2025. The failure and leakage of the mechanical seal occurred from not having the mechanical seal installed correctly. The shaft sleeve and set screws were not locked into the shaft resulting in the mechanical seal stationary assembly floating axially back and forth across the shaft. The working length for the seal as prescribed by flowserve was compromised. The elastomer bellows assembly was not supposed to slide on the shaft. Positive static seal between the bellows and the shaft, along with the free movement of the bellows means that there was no sliding action and can lead to shaft damage by fretting; however, no signs of fretting was found. Proper bellows position and attachment ensures that the seal will automatically compensate for normal shaft run-out and axial movements. To prevent reoccurrence, the failed unit was replaced with a unit compatible with the line's flow rate.
Detailed record list
Report Received Date
2025-07-09 00:00:00
Iyear
2025
Report Number
20250168
Supplemental Number
41513
Report Type
Supplemental Final
Operator Id
18718
Name
Sunoco Pipeline L.p.
Operator Street Address
1300 Main Street
Operator City Name
Houston
Operator State Abbreviation
TX
Operator Postal Code
77002
Local Datetime
2025-06-12 23:20:00
Time Zone
Eastern
Daylight Savings Ind
Yes
Location Latitude
40.3148
Location Longitude
-76.033875
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
5
Recovered Bbls
5
Fatality Ind
No
Fatal
0
Injury Ind
No
Injure
0
Accident Identifier
Local Operating Personnel, Including Contractors
Operator Type
Operator Employee
Incident Identified Datetime
2025-06-12 23:20:00
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
No
Shutdown Explain
Densitometer Was Isolated
Communication State Fed Ind
No
On Site Datetime
2025-06-12 23:20:00
Confirmed Discovery Datetime
2025-06-12 23:20:00
Nrc Rpt Num
Nrc Notification Not Required
Ignite Ind
No
Notify Qualified Indiv Ind
Yes
Qualified Indiv Notif Datetime
2025-06-12 23:20:00
Oil Spill Removal Org Ind
No
Num Pub Evacuated
0
Pipe Fac Name
Montello Pump Station
Segment Name
12001 - 14inch Montello-Bald Eagle
Onshore State Abbreviation
Pa
Onshore Postal Code
19608
Onshore City Name
Sinking Spring
Onshore County Name
Berks
Designated Location
Survey Station No.
Designated Name
0+00
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
Interstate
Item Involved
Other
Item Involved Details
Densitometer Pump Seal
Installation Year
2024
Manufactured Year
Unknown
Material Involved
Material Other Than Carbon Steel
Material Details
Densitometer Pump Seal
Release Type
Leak
Leak Type
Seal Or Packing
Wildlife Impact Ind
No
Soil Contamination
Yes
Long Term Assessment
No
Remediation Ind
Yes
Soil Remed Ind
Yes
Water Contam Ind
No
Could Be Hca
Yes
Commodity Reached Hca
Yes
High Pop Ind
Yes
High Pop Yes No
Yes
Usa Drinking Ind
Yes
Usa Drinking Yes No
Yes
Est Cost Oper Paid
0
Est Cost Gas Released
504
Est Cost Prop Damage
7000
Est Cost Emergency
600
Est Cost Environmental
5000
Est Cost Other
0
Prpty
13104
Num Persons Hosp Not Ovnght
0
Num Injured Treated By Emt
0
Num Resident Building Affctd
0
Num Business Building Affctd
0
Accident Psig
1036
Mop Psig
1040
Mop Cfr Section
Subpart E Pressure Test �195.406(A)(3)
Maop Established Date
2020-11-02 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
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
A review of the accident determined that there were no control room actions that contributed to the event.
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 Installation Ind
Yes
Eq Additional Other Ind
Yes
Eq Additional Other Details
Pump Rebuilding By 3rd Party Not Performed Properly.
Other Type
Unknown
Unknown Subtype
Still Under Investigation, Cause Of Accident To Be Determined* (*supplemental Report Required)
Io Not Installed Properly Ind
Yes
Preparer Name
T*** N*******
Preparer Title
Director - Dot Compliance
Preparer Email
T************@e*************.com
Preparer Telephone
713-989-7126
Prepared Date
2025-10-28 00:00:00
Authorizer Name
T*** N*******
Authorizer Telephone
713-989-7126
Authorizer Title
Director - Dot Compliance
Authorizer Email
T************@e*************.com
Narrative
On 6/12/25 at approximately 23:20, a local employee observed evidence of a potential gasoline release near the meter run manifold area at montello pump station. Gasoline was releasing from a failed densitometer pump seal on the 14-inch 12006 montello-bald eagle line segment. The densitometer was isolated to stop the leak. Approximately 5 barrels of gasoline was released. Local employees cleaned up released product and removed contaminated soil. The accident was repaired by replacing the densitometer pump. The failed densitometer pump is being sent to a third party lab for analysis. The cause of the accident is still under investigation. A supplemental report will be submitted once the investigation is completed. Supplemental & final: the investigation determined the cause of the accident was equipment failure which was attributed to the pump rebuild process by a 3rd party not being performed properly. The pump unit was rebuilt and had been in storage since october 2024 prior to reinstallation in the system in 2025. The failure and leakage of the mechanical seal occurred from not having the mechanical seal installed correctly. The shaft sleeve and set screws were not locked into the shaft resulting in the mechanical seal stationary assembly floating axially back and forth across the shaft. The working length for the seal as prescribed by flowserve was compromised. The elastomer bellows assembly was not supposed to slide on the shaft. Positive static seal between the bellows and the shaft, along with the free movement of the bellows means that there was no sliding action and can lead to shaft damage by fretting; however, no signs of fretting was found. Proper bellows position and attachment ensures that the seal will automatically compensate for normal shaft run-out and axial movements. To prevent reoccurrence, the failed unit was replaced with a unit compatible with the line's flow rate.
| Report Received Date | 2025-07-09 00:00:00 |
|---|---|
| Iyear | 2025 |
| Report Number | 20250168 |
| Supplemental Number | 41513 |
| Report Type | Supplemental Final |
| Operator Id | 18718 PHMSA Enforcement |
| Name | Sunoco Pipeline L.p. |
| Operator Street Address | 1300 Main Street |
| Operator City Name | Houston |
| Operator State Abbreviation | TX |
| Operator Postal Code | 77002 |
| Local Datetime | 2025-06-12 23:20:00 |
| Time Zone | Eastern |
| Daylight Savings Ind | Yes |
| Location Latitude | 40.3148 Google Maps OpenStreetMap |
| Location Longitude | -76.033875 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 | 5 |
| Recovered Bbls | 5 |
| Fatality Ind | No |
| Fatal | 0 |
| Injury Ind | No |
| Injure | 0 |
| Accident Identifier | Local Operating Personnel, Including Contractors |
| Operator Type | Operator Employee |
| Incident Identified Datetime | 2025-06-12 23:20:00 |
| 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 | No |
| Shutdown Explain | Densitometer Was Isolated |
| Communication State Fed Ind | No |
| On Site Datetime | 2025-06-12 23:20:00 |
| Confirmed Discovery Datetime | 2025-06-12 23:20:00 |
| Nrc Rpt Num | Nrc Notification Not Required NRC Report How to search |
| Ignite Ind | No |
| Notify Qualified Indiv Ind | Yes |
| Qualified Indiv Notif Datetime | 2025-06-12 23:20:00 |
| Oil Spill Removal Org Ind | No |
| Num Pub Evacuated | 0 |
| Pipe Fac Name | Montello Pump Station |
| Segment Name | 12001 - 14inch Montello-Bald Eagle |
| Onshore State Abbreviation | Pa |
| Onshore Postal Code | 19608 |
| Onshore City Name | Sinking Spring |
| Onshore County Name | Berks |
| Designated Location | Survey Station No. |
| Designated Name | 0+00 |
| 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 | Interstate |
| Item Involved | Other |
| Item Involved Details | Densitometer Pump Seal |
| Installation Year | 2024 |
| Manufactured Year | Unknown |
| Material Involved | Material Other Than Carbon Steel |
| Material Details | Densitometer Pump Seal |
| Release Type | Leak |
| Leak Type | Seal Or Packing |
| Wildlife Impact Ind | No |
| Soil Contamination | Yes |
| Long Term Assessment | No |
| Remediation Ind | Yes |
| Soil Remed Ind | Yes |
| Water Contam Ind | No |
| Could Be Hca | Yes |
| Commodity Reached Hca | Yes |
| High Pop Ind | Yes |
| High Pop Yes No | Yes |
| Usa Drinking Ind | Yes |
| Usa Drinking Yes No | Yes |
| Est Cost Oper Paid | 0 |
| Est Cost Gas Released | 504 |
| Est Cost Prop Damage | 7000 |
| Est Cost Emergency | 600 |
| Est Cost Environmental | 5000 |
| Est Cost Other | 0 |
| Prpty | 13104 |
| Num Persons Hosp Not Ovnght | 0 |
| Num Injured Treated By Emt | 0 |
| Num Resident Building Affctd | 0 |
| Num Business Building Affctd | 0 |
| Accident Psig | 1036 |
| Mop Psig | 1040 |
| Mop Cfr Section | Subpart E Pressure Test �195.406(A)(3) View CFR 49 §192 |
| Maop Established Date | 2020-11-02 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 | 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 | A review of the accident determined that there were no control room actions that contributed to the event. |
| 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 Installation Ind | Yes |
| Eq Additional Other Ind | Yes |
| Eq Additional Other Details | Pump Rebuilding By 3rd Party Not Performed Properly. |
| Other Type | Unknown |
| Unknown Subtype | Still Under Investigation, Cause Of Accident To Be Determined* (*supplemental Report Required) |
| Io Not Installed Properly Ind | Yes |
| Preparer Name | T*** N******* |
| Preparer Title | Director - Dot Compliance |
| Preparer Email | T************@e*************.com |
| Preparer Telephone | 713-989-7126 |
| Prepared Date | 2025-10-28 00:00:00 |
| Authorizer Name | T*** N******* |
| Authorizer Telephone | 713-989-7126 |
| Authorizer Title | Director - Dot Compliance |
| Authorizer Email | T************@e*************.com |
| Narrative | On 6/12/25 at approximately 23:20, a local employee observed evidence of a potential gasoline release near the meter run manifold area at montello pump station. Gasoline was releasing from a failed densitometer pump seal on the 14-inch 12006 montello-bald eagle line segment. The densitometer was isolated to stop the leak. Approximately 5 barrels of gasoline was released. Local employees cleaned up released product and removed contaminated soil. The accident was repaired by replacing the densitometer pump. The failed densitometer pump is being sent to a third party lab for analysis. The cause of the accident is still under investigation. A supplemental report will be submitted once the investigation is completed. Supplemental & final: the investigation determined the cause of the accident was equipment failure which was attributed to the pump rebuild process by a 3rd party not being performed properly. The pump unit was rebuilt and had been in storage since october 2024 prior to reinstallation in the system in 2025. The failure and leakage of the mechanical seal occurred from not having the mechanical seal installed correctly. The shaft sleeve and set screws were not locked into the shaft resulting in the mechanical seal stationary assembly floating axially back and forth across the shaft. The working length for the seal as prescribed by flowserve was compromised. The elastomer bellows assembly was not supposed to slide on the shaft. Positive static seal between the bellows and the shaft, along with the free movement of the bellows means that there was no sliding action and can lead to shaft damage by fretting; however, no signs of fretting was found. Proper bellows position and attachment ensures that the seal will automatically compensate for normal shaft run-out and axial movements. To prevent reoccurrence, the failed unit was replaced with a unit compatible with the line's flow rate. |
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