PHILLIPS 66 PIPELINE LLC

Incident Narrative

AT 21:17 (ON 3/20/2016) THE CONTROL CENTER RECEIVED A SEAL FAIL ALARM ON THE WT-10 MAINLINE PUMP AT THE PEP STATION. THE PUMP UNIT WAS STOPPED AND THE PEP INJECTION SITE WAS SHUTDOWN. THE ON CALL FIELD PERSONNEL WAS CONTACTED TO RESPOND. AT 21:24 THE CONTROL CENTER RECEIVED A SUMP LEVEL HIGH ALARM, AND AT 21:30 RECEIVED SUMP LEVEL HIGH HIGH ALARM. FIELD PERSONNEL ARRIVED ON-SITE AT 10:15 PM AND FOUND BOTH THE INBOARD AND OUTBOARD SEALS LEAKING ON THE MAINLINE PUMP AND SUMP HAD OVER FILLED. THE PUMP WAS ISOLATED AND LOCKED OUT FOR SEAL REPLACEMENT. OIL WAS ON THE GROUND BY THE MAINLINE PUMP, AROUND THE SUMP AND THE SUMP PIPING BY THE PD PUMP. 1.34BBLS OF CRUDE WAS ESTIMATED TO HAVE BEEN SPILLED TO THE GROUND. THE SPILLED OIL WAS RECOVERED AND THE CONTAMINATED SOIL REMOVED FOR DISPOSAL. THE SEALS FOR THE PEP STATION MAINLINE PUMP WERE REPLACED WITH A NEW SEALS AND THE UNIT WAS RESTARTED AS NEEDED FOR OPERATION OF THE PIPELINE. THE FAILED SEALS HAVE BEEN SENT TO JOHN CRANE FOR ANALYSIS TO DETERMINE THE CAUSE OF THE FAILURE AND ANY REQUIRED CORRECTIVE ACTIONS TO PREVENT REOCCURRENCE. A FINAL REPORT WILL BE SUBMITTED WHEN THE SEAL FAILURE ANALYSIS IS COMPLETED. THE SEAL FAILURE ANALYSIS WAS COMPLETED AND THE CAUSE OF THE SEAL FAILURE WAS DETERMINED TO BE THAT THE GLAND BOLTS WERE NOT TORQUED TO SPECIFICATION WHEN THE SEALS WERE INSTALLED. THE SEALS WHICH FAILED WERE INSTALLED IN 2012 AND 2013 RESPECTIVELY. THE PHILLIPS 66 EMPLOYEE WHO INSTALLED BOTH THE SEALS HAS SINCE RETIRED. IN ADDITION, THE MECHANIC IN THE AREA COMPLETED MECHANICAL SEAL BASICS TRAINING ON 3/31/2015. THEREFORE NO ADDITIONAL SEAL TRAINING WILL BE CONDUCTED. A CONTRIBUTING CAUSE TO THE SPILL WAS ALSO FOUND TO BE THAT THE MOTOR OPERATED VALVE (MOV) ON THE PUMP SUCTION DID NOT CLOSE 100%, WHICH ALLOWED THE SEALS TO LEAK AT A GREAT RATE (AFTER FAILURE). IN ORDER TO PREVENT THIS IN THE FUTURE, THE TORQUE SETTING ON THE PUMP SUCTION MOV WAS INCREASED FROM 40% OF MAXIMUM TO 80% OF MAXIMUM.