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EPIC CONSOLIDATED OPERATIONS, LLC

hazardous_liquid Incident —

Incident Information

Report Date—
OperatorEPIC CONSOLIDATED OPERATIONS, LLC
Commodity—
Pipeline Typehazardous_liquid

Location

State
Coordinates31.53102, -101.93209

Cause

CauseEQUIPMENT FAILURE
Subcause—

Casualties

Fatalities0
Injuries0

Costs

Property Damage—
Lost Commodity—
Public/Private Damage—
Emergency Response—
Environmental Remediation—
Other Costs—

Location Map

Incident 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.

About This Pipeline Incident

Pipeline incident data is reported to the Pipeline and Hazardous Materials Safety Administration (PHMSA). All significant incidents involving fatalities, injuries, or property damage over $50,000 must be reported.

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