GENESIS FREE STATE PIPELINE, LLC

Incident Narrative

(10-15-2013) 6:05PM - 3"" DIAMETER ICE BALL IS SPOTTED ON ROW 8:30PM - UPSTREAM VALVE CLOSED. (10-16-2013) 7:00AM - DOWNSTREAM VALVE CLOSED. (10-20-2013) SEGMENT DE-PRESSURED AND LEAK SITE IS DUG UP. THE SUSPECTED LEAK POINT IN A JOINT WELD WAS X-RAYED AND THE LEAK WAS FOUND IN THE WELD. A 5' SECTION (2.5' ON EACH SIDE OF WELD) WAS CUT OUT. WHEN THE CUT-OUT WAS REMOVED, IT WAS NOTICED THAT THE PIPE HAD THE ORIGINAL X-RAY MARKINGS DESIGNATION OF A WELD REPAIR. IT WAS APPARENT FROM LOOKING AT THE WELD THAT IT HAD BEEN REPAIRED ORIGINALLY. THE INSIDE OF THE WELD SEAM SHOWS THE REPAIR WAS NOT DONE CORRECTLY. THE LEAK OCCURRED BECAUSE AN ORIGINAL GIRTH WELD THAT HAD TO BE REPAIRED WAS NOT DONE CORRECTLY. (10-21-2013) ALL REPAIRS ARE COMPLETED. PRETESTED PIPE WAS INSTALLED. ALL WELDS PASSED INSPECTIONS. (10-24-2013) THE SEGMENT IS PLACED BACK IN SERVICE. SUPPLEMENTAL A FAILURE ANALYSIS WAS PERFORMED BY PMI SPECIALISTS, INC.. THE ANALYSIS REPORT (FINAL - 11/18/2013) IS SUMMARIZED AS THUS: ""FROM THE APPEARANCE AND CROSS SECTION ANALYSIS, IT IS CLEAR THAT THE LEAK WAS CAUSED BY UNFILLED CAVITY IN THE ROOT PASS AND HAZ CRACKING FROM THE TOP. THE MAJOR REASON IS BECAUSE OF THE UNFILLED CAVITY IN THE ROOT PASS, WHICH CREATED A HUGE STRESS RISER ON THE PIPE INTERNAL SURFACE AND DECREASED THE EFFECTIVE WALL THICKNESS. SMALL CRACKS DEVELOPED ON THE BOTTOM OF THE ROOT CAVITY DURING SERVICE. WITH TIME, THEY MET WITH THE HAZ CRACKS FROM THE TOP, LEADING TO A THROUGH CRACK. THE UNFILLED CAVITY IN THE ROOT PASS IS CAUSED BY SLAG INCLUSION, WHICH WAS NOT PROPERLY CLEANED BEFORE THE REPAIR WELDING PROCEDURE. IN THIS CASE, MOST LIKELY, THE HAZ CRACKS WERE DUE TO INSUFFICIENT PREHEAT TEMPERATURE DURING REPAIR WELDING. SINCE THE CRACKS ARE SMALL, THEY WERE MISSED BY VISUAL EXAMINATION AND X-RAY. SUPPLEMENTAL - 1/21/2016 CORRECTION TO SMYS ENTRY (PART C, QUESTION 3C), ADDING APPROXIMATE VOLUME OF COMMODITY INTENTIONALLY RELEASED TO ATMOSPHERE TO PRIOR TO PIPE REPAIR (PART A, QUESTION 10), AND ADDING APPROXIMATE COST OF COMMODITY INTENTIONALLY RELEASED TO ATMOSPHERE (PART D, QUESTION 8D).