MOTIVA ENTERPRISE LLC

Incident Narrative

OPERATORS FOUND A SMALL AMOUNT OF DARK OIL ON THE GROUND AT THE 7TH STREET TANK FARM. A MAINTENANCE CREW BEGAN EXCAVATING. AT ~16:30 (THURSDAY, 8/29), FOLLOWING STAIN, CREW NOTICED A SMALL AMOUNT OF OIL BUBBLING EVERY FEW SECONDS ~30 FEET AWAY FROM THE INITIAL FINDING, CLOSE TO WHERE THE 16"" DOCK LINE RUNS UNDERGROUND. TO PREVENT THE LEAK FROM POTENTIALLY WORSENING, THE CREW STOPPED DIGGING AND PLANS TO FLUSH (WITH LIGHT-CYCLE GAS OIL) AND DEPRESSURE THE LINE WERE INITIATED. EXCAVATION CONTINUED FRIDAY MORNING. ~30 FEET OF THE LINE WAS EXPOSED IN DIFFERENT AREAS, BUT NO OBVIOUS LEAK SOURCE WAS IDENTIFIED. WITH A VIABLE BACKUP LINE AVAILABLE, STOPPED DIGGING FOR THE WEEKEND AND INITIATED A PLAN TO FLUSH THE LINE CLEAR WITH FIREWATER SATURDAY MORNING. ON TUESDAY (3 SEPT) GREEN DYE WAS INJECTED AND THE LINE PRESSURED-UP TO 50 PSIG. A CRACK IN A CIRCUMFERENTIAL WELD OF A 45-DEGREE ELBOW WAS EVENTUALLY IDENTIFIED AS THE LEAK LOCATION. IMMEDIATE MITIGATION PLAN WAS TO MAKE A TEMPORARY REPAIR BY INSTALLING AN ENGINEERED BOLTED ENCLOSURE DUE TO THE PLAN TO ASSESS THE ENTIRE PIPELINE USING ILI TECHNOLOGY SCHEDULED FOR 2020. PERMANENT REPAIR BY REPLACING THE FAILED SECTION WAS PLANNED POST ILI ACTIVITIES. HOWEVER, THE ENGINEERED BOLTED ENCLOSURE WOULD NOT SEAL. THEREFORE, ~10 LINEAR FEET OF PIPING AND (2) 45-DEGREE ELBOWS WERE REMOVED AND REPLACED. ALL REPLACED PIPING AND FITTINGS WERE SAND BLASTED AND RE-COATED USING SP-2888 (EPOXY-URETHANE COATING). AFTER ALL REPAIRS WERE MADE, A HYDROTEST WAS PERFORMED ON 100% OF THE PIPELINE. THE FOLLOWING NONDESTRUCTIVE EXAMINATIONS WERE ALSO PERFORMED: A. 100% VISUAL ANALYSIS B. 100% RADIOGRAPHIC TESTING C. 10% DYE PENETRANT TESTING PEI ENGINEER AND PEI CORROSION AND MATERIALS SPECIALIST DEVELOPED A PLAN TO DETERMINE THE CAUSE OF THE FAILURE OF THE PIPING. THE PLAN WAS TO RECEIVE THE FAILED SECTION OF THE PIPE, TAKE AS-RECEIVED PHOTOS, BLAST THE FAILED SECTION (INTERNAL AND EXTERNAL), PERFORM VISUAL ANALYSIS AND DYE PENETRANT EXAMINATION IN THE AREA OF THE LEAK LOCATION. AFTER VISUAL ANALYSIS, DYE PENETRANT TESTING WAS PERFORMED TO DETERMINE THE EXTENT OF CRACKING IN THE LEAK LOCATION AS WELL AS SIMILAR LOCATIONS IN THE AREA OF THE CIRCUMFERENTIAL WELD. TESTING INDICATED THE CRACK WAS ISOLATED TO THE AREA OF THE LEAK LOCATION. NO OTHER CRACKING WAS FOUND. IT WAS OBSERVED THAT THERE WAS A DEFECTIVE WELD IN THE AREA OF THE LEAK LOCATION RESULTING IN A STRESS RISER FROM WHICH A LONGITUDINAL CRACK PROPAGATED. THE LONGITUDINAL CRACK PROPAGATED DUE TO CIRCUMFERENTIAL STRESS THAT MAY HAVE BEEN CAUSED BY ONE OR MORE OF THE FOLLOWING CAUSES: A. BENDING STRESS DUE TO MISALIGNMENT. B. OUT-OF-ROUNDNESS EXHIBITED BY SIGNIFICANT HIGH-LOW. C. HOOP STRESS GENERATED BY NORMAL OPERATING PRESSURE. TO ENSURE THE INTEGRITY OF THE 16"" DOCK LINE, MOTIVA HAS THE FOLLOWING CURRENT PLAN IN PLACE: 1. ILI (INLINE INSPECTION) IN 2020. 2. PERFORM HYDROSTATIC TEST IN CONJUNCTION WITH ILI. 3. PERFORM INTEGRITY RISK ASSESSMENTS EVERY 5 YEARS. 4. PERFORM ATMOSPHERIC CORROSION INSPECTIONS EVERY 3 YEARS. 5. CATHODIC PROTECTION MONITORED BI-MONTHLY RECTIFIER TEST. 6. CATHODIC PROTECTION ANNUAL POTENTIAL SURVEYS.