BP WEST COAST PRODUCTS L.L.C.

Incident Narrative

MAY 3 2011, 0945 HOURS TWO CONTRACT PERSONNEL ARRIVED AT BP MOBIL BOOSTER (MB) PUMP STATION TO PERFORM CALIBRATION CHECK OF HIGH PRESSURE SHUTDOWN SWITCH. PERSONNEL DISCOVERED JET FUEL LEAKING FROM PRESSURE SWITCH THAT WAS TO BE CALIBRATED. THE LINE WAS DOWN AND BLOCKED WITH APPROXIMATE 400PSIG ON THE LINE AT TIME OF DISCOVERY. JET FUEL WAS DRIPPING FROM THE PRESSURE SWITCH TO MB PUMP HOUSE FLOOR, ACCUMULATING IN CONCRETE CONTAINMENT SUMP. NO LEL WAS DETECTED WITH PORTABLE GAS DETECTION EQUIPMENT ON SITE. PERSONNEL CONTACTED BP PERSON IN CHARGE, THEREIN NOTIFYING BP OPERATIONS @ MARINE TERMINAL 2, BP OPERATIONS CONTROL CENTER, AND BP MAINTENANCE. THE CONTROL CENTER CONTACTED BP HSE FOR NOTIFICATION TO CAL EMA & CSFM. OES/STATE FIRE MARSHALL BOTH RECORDED THE INCIDENT UNDER THE 11-2744 NUMBER. BP CONTROL CENTER ALSO NOTIFIED TORRANCE FIRE DEPT. CONTRACT EMERGENCY RESPONSE PERSONNEL WERE DISPATCHED TO SITE FOR CLEAN UP. THE LEAK WAS NOT DETECTED BY BP SCADA, NO HIGH SUMP OR LEL) AND PRODUCT WAS CLEANED AND RECOVERED FROM SUMP AND FLOOR. PUMP SECURED, PRESSURE SWITCH ISOLATED, AND PERMITTED WORK PLAN DEVELOPED WITH REPAIR PLAN FOR MAY 3, 2011. THE PRESSURE SWITCH WAS REPLACED AND LINE RETURNED AT 2000 HOURS, MAY 3, 2011. THE PRESSURE SWITCH WAS SENT TO THE MANUFACTURER FOR A FAILURE ANALYSIS TO DETERMINE 'FIT FOR FUNCTION'. THE ASSESSMENT FROM THE MANUFACTURER WAS A FAILED DIAPHRAGM OF THE HIGH PRESSURE SWITCH MODEL # 646GZEM5. THIS SPECIFIC MODEL NUMBER CONTAINS A DIAPHRAGM CONSTRUCTED OF POLYIMIDE MATERIAL. THE MANUFACTURER RECOMMENDED MODEL NUMBER 646GZEM5-7030 WHICH CONTAINS A STAINLESS STEEL DIAPHRAGM AND GOLD CONTACTS FOR ROBUST USE WITH PETROLEUM BASED PRODUCTS. THE -7030 CONFIGURATION IS A COMBINATION OF TWO DASH NUMBERS; THE -7011 STAINLESS STEEL DIAPHRAGM AND -7008 GOLD CONTACTS. ADDITIONAL INVESTIGATION SUPPORTED MODEL NUMBERS PROPERLY INSTALLED IN THE FIELD ARE STAINLESS STEEL MATERIAL IDENTIFIED AS MODEL NUMBER 646GZE5-7011. MODEL NUMBER IDENTIFICATION FOR THE DIFFERENTIAL PRESSURE SWITCHES THAT FAILED IS 646DZE, THE POLYIMIDE DIAPHRAGM 646DZEM-7011, THE PRESSURE SWITCH WITH A STAINLESS STEEL DIAPHRAGM IS THE CORRECT MODEL IDENTIFCATION NUMBER. BP FIELD SEARCH WAS CONDUCTED AT EACH FACILITY TO IDENTIFIY ADDITIONAL PRESSURE SWITCHES, BOTH HIGH PRESSURE AND DIFFERENTIAL PRESSURE WITH POLYIMIDE DIAPHRAGMS THEREAFTER.