EXPRESS HOLDINGS (USA), LLC

Incident Narrative

ON FEBRUARY 13, 2024, A PIPE REPLACEMENT PROJECT WAS BEING COMPLETED ON THE TANK DRAIN LINE AT CASPER TERMINAL AT TANK 411. THE TANK LINE WAS DRAINED, COLD CUT AND A LANSAS AIR BAG WAS UTILIZED FOR VAPOR ISOLATION TO WELD A FLANGE ONTO A DOUBLE 45-DEGREE FITTING LEADING TO A 24""X10"" TEE IN THE TANK LINE. THE LANSAS AIR BAG WAS PLACED INTO THE PIPING WITH THE SETBACK IN COMPLIANCE WITH THE OPERATIONS AND MAINTENANCE MANUAL. AS THE WELDERS WERE WELDING THE FLANGE ONTO THE PIPE, A WORKER NOTICED A DROP IN PRESSURE ON THE AIRBAG TO 18 PSIG. AT APPROXIMATELY 1:10 PM MST, A SMALL FLAME EJECTED FROM THE PIPE. THE PERSON IN CHARGE OF WORK LOOKED INSIDE OF THE PIPE AND SAW A FIRE AT THE 10 O'CLOCK POSITION IN THE PIPE AND ALERTED THE FIRE WATCH WHO EXTINGUISHED THE FIRE. NO ONE WAS INJURED, NO CRUDE OIL WAS RELEASED, AND NO PROPERTY WAS DAMAGED AS A RESULT OF THE FIRE. THE NRC WAS NOTIFIED OF THE VAPOR IGNITION ON FEBRUARY 13, 2024, AT 4:20 PM MST (NRC# 1391496). A 48-HOUR UPDATE TO THE NRC WAS MADE ON FEBRUARY 15, 2024, AT 1:41 PM MST (NRC# 1391646). THE RESULTS OF THE INVESTIGATION DETERMINED THAT THE LANSAS AIR BAG EXTENDED BEYOND THE 10"" NOMINAL PIPE SIZE AND INTO THE 24""X10"" TEE. THIS EXTENSION BEYOND THE NOMINAL PIPE SIZE FOR THE TOOL IS NOT AN ACCEPTABLE PRACTICE PER THE MANUFACTURER'S SAFETY INSTRUCTIONS FOR PROPER USE. DURING THE PROCESS OF COMPLETING THE WELD, ON THE FINAL PASS, A PSI DROP ON THE PNEUMATIC VAPOR ISOLATION TOOL WAS OBSERVED. THIS IS WHEN IT IS BELIEVED THAT THE LANSAS AIR BAG MOVED FROM WITHIN THE NOMINAL 10"" PIPING AND INTO THE NOMINAL 24"" PORTION OF THE TEE WHERE THE SIZE OF THE ISOLATION TOOL WAS NOT ADEQUATE TO PREVENT VAPORS FROM ENTERING THE AREA HOT WORK WAS TAKING PLACE. IN ADDITION TO THE LANSAS AIR BAG MOVING INTO THE NOMINAL 24"" PORTION OF THE PIPE, THE MUD THAT WAS PLACED ON THE FACE OF THE TOOL WAS DAMAGED BY THE TOOL MOVEMENT AND THE AIR HOSE CONNECTED TO THE LANSAS AIR BAG. THE VAPOR ISOLATION BARRIER FAILED DURING THE WELDING PROCESS AND RESULTED IN A FLASH FIRE. THE TANK LINE WAS RETURNED TO SERVICE ON FEBRUARY 21, 2024, AFTER FINISHING THE WELD BY UTILIZING AN INERT ATMOSPHERE. THERE WAS NO PRODUCT RELEASED, ONLY VAPORS. THE PHMSA PORTAL DOES NOT RECOGNIZE VOLUMES LESS THAN 0.1 BARRELS THEREFORE THAT IS THE VOLUME ENTERED IN PART A7.