CAPROCK PERMIAN CRUDE LLC

Incident Narrative

CAPROCK PERMIAN CRUDE, LLC STAMPEDE TERMINAL IS LOCATED 22.2 MILES NORTH OF PECOS, TEXAS OFF US HWY 285. A REEVES COUNTY DEPUTY SHERIFF DISCOVERED CRUDE OIL LEAKING INTO A BAR DITCH ADJACENT TO US HWY 285. THE DEPUTY CALLED THE EMERGENCY PHONE NUMBER POSTED ON THE FACILITY SIGN. THE CALL WAS RECEIVED BY THE EMERGENCY PHONE NUMBER ANSWERING SERVICE AND FORWARDED TO GAS PLANT OPERATORS LOCATED AT EAGLE CLAW MIDSTREAM VENTURES, LLC EAST TOYAH GAS PLANT. THE CALL WAS RECEIVED AT APPROXIMATELY 4:45 PM AND THE DIRECTOR OF FIELD OPERATIONS WAS CONTACTED IMMEDIATELY. AN INSTRUMENT CONTROLS TECHNICIAN SHUT DOWN PUMPS AT THE FACILITY REMOTELY AT APPROXIMATELY 4:54 PM. FIELD PERSONNEL WERE DISPATCHED TO THE TERMINAL, ARRIVING AT APPROXIMATELY 5:30 PM. FIELD PERSONNEL DISCOVERED A FLANGE CONNECTING A PUMP CASING TO SUCTION PIPING HAD SEPARATED AND WAS LEAKING OIL. THE PERSONNEL ISOLATED AND STOPPED THE LEAK BY CLOSING MANUAL VALVES IMMEDIATELY UPSTREAM AND DOWNSTREAM OF THE PUMP. DURING THE TIME IMMEDIATELY AFTER CALLING THE COMPANY EMERGENCY NUMBER AND PRIOR TO THE ARRIVAL OF COMPANY PERSONNEL THE DEPUTY SHERIFF CALLED LONE STAR HAZMAT RESPONSE. THEIR RESPONSE TEAM ARRIVED AND CONSTRUCTED DIRT BERMS TO CONTAIN THE SPILL WITHIN THE HIGHWAY BAR DITCH AND A CONCRETE CULVERT. THE DEPUTY SHERIFF AND HAZMAT TEAM DETERMINED IT WAS NOT NECESSARY TO CLOSE THE HIGHWAY. THE INITIAL DETERMINATION OF THE CAUSE OF THIS SPILL IS THAT A MECHANICAL COUPLING BETWEEN THE PUMP MOTOR AND PUMP FAILED, BUT DID NOT SHEAR AS DESIGNED. RESULTING VIBRATION FROM THE COUPLING FAILURE CAUSED FLANGE BOLTS CONNECTING THE PUMP TO PUMP SUCTION PIPING TO COME LOOSE. THE ORIGIN OF THE LEAK IS FROM THIS FLANGE. (SEE DRAWING #4 AND PHOTO #5 OF FLANGE 57 ATTACHED) AFTER CHECKING OTHER PUMP MOTOR / PUMP COUPLINGS AND THE TORQUE OF PUMP SUCTION FLANGE BOLTS, OTHER PUMPS AT THIS TERMINAL WERE RETURNED TO SERVICE. THE PUMP ASSOCIATED WITH THIS LEAK REMAINS OUT OF SERVICE AT THIS TIME. THESE CORRECTIVE ACTIONS ARE BEING MADE: 1. REPLACE FAILED COUPLING WITH ALTERNATIVE BRAND/DESIGN NOTE: REVISED CORRECTIVE ACTION: EAGLECLAW DOES NOT CONSIDER VIBRATION FROM MOTOR OR PUMP AS A CAUSAL FACTOR IN THE FAILURE OF THE COUPLING. AFTER INSTALLATION OF NEW COUPLING HALVES AND ATTEMPTING TO ALIGN MOTOR AND PUMP BUT FAILING TO BE ABLE TO DO, IT IS DETERMINED BY SERVICE PERSONNEL THAT STRESS FROM INLET PIPING HAD CAUSED THE PUMP TO BECOME MISALIGNED WITH THE MOTOR, CAUSING THE COUPLING TO FAIL. THIS PUMP REMAINS OUT OF SERVICE WHILE WORK NECESSARY TO CORRECT INLET PIPING ALIGNMENT WITH THE PUMP IS PERFORMED. A. IF OTHER PUMPS ONSITE SHARE THE SAME BRAND COUPLING AS THE PUMP THAT FAILED ON 1/1/20 REPLACE THOSE COUPLINGS AS WELL. REVISED CORRECTIVE ACTION: THE VENDOR OF VARIOUS PUMP COUPLINGS AND SERVICE PERSONNEL PERFORMING PUMP ALIGNMENTS RECOMMEND NOT CHANGING THE COUPLING BRAND. ALIGNMENT OF OTHER PUMPS WAS CHECKED, PUMPS REALIGNED WHERE NECESSARY AND THE PUMPS RETURNED TO SERVICE. SERVICE LIFE OF THIS COUPLING BRAND (REXNORD OMEGA) IS EXPECTED TO BE 10 YEARS. THE CONDITION OF THE COUPLINGS NOT REPLACED IS REPORTED TO BE SATISFACTORY. 2. INSTALL VIBRATION TRANSMITTERS AND SHUTDOWNS ON PUMPS.UPDATE: THIS CORRECTIVE ACTION IS COMPLETE. 3. BERM THE EAST SIDE OF LOCATION TO PREVENT ANY FUTURE OIL OR WATER SPILLS FROM ENTERING TXDOT ROW (NORTH SIDE OF LOCATION). UPDATE: THIS CORRECTIVE ACTION IS COMPLETE. UPDATED NRC REPORT NUMBER IS: 1270368