MARATHON PIPE LINE LLC — Hazardous liquid — incident on 2002-04-29

Hazardous liquid incident in MADISON County, IL. Reported cause: 19. Reported consequences: 0 fatalities, 0 injuries, YES MID-CONTINENT SWEET CRUDE OIL released, $4,650,025 reported property damage. Operator-reported incident data submitted to PHMSA, generally within 30 days. Records may be supplemented or corrected and do not represent final agency causal findings.

Report number: 20020151.

Operator ID: 12127.

Reported incident date: 4/29/2002.

Cause detail: PIPE SEAM WELD

Cause detail: ON APRIL 29, 2002, THE PUMPS AT ROXANA STATION WERE SHUT DOWN AT 11:09 AM BY LOCAL PRESSURE SWITCHES THAT DETECTED LOW SUCTION PRESSURE. COMPUTATIONAL PIPELINE MONITORING (CPM)ALARMS ALSO IDENTIFIED THE RELEASE AT THE MARATHON ASHLAND PIPE LINE LLC (MAPL) CONTROL CENTER AND THE OZARK CONTROL CENTER. THE OPERATOR AT OZARK REACTED TO THE CPM ALARMS HE RECEIVED AND SHUT THE OZARK SYSTEM DOWN WITHIN 15 MINUTES. AERIAL PATROL WAS USED TO LOCATE THE RELEASE. THE EMERGENCY RESPONSE WAS INITIATED IN LESS THAN ONE HOUR FROM THE SHUTDOWN, AND APPROPRIATE AGENCY NOTIFICATIONS WERE MADE. MAPL AND CONTRACT PERSONNEL AND EQUIPMENT WERE DISPATCHED TO THE RELEASE SITE TO INITIATE OIL CONTAINMENT AND RECOVERY OPERATIONS. AN INTEGRATED INCIDENT COMMAND SYSTEM WAS SET-UP ON SITE. DURING THE APRIL 2002 EVENT, OIL FLOWED THROUGH AN UNDERGROUND FIELD TILE AND ENTERED INTO INDIAN CREEK. CONTAINMENT BOOMS WERE DEPLOYED AND EARTHEN CONTAINMENT STRUCTURES WERE INSTALLED TO CONTAIN THE OIL. THERE WERE NO IMPACTS TO WILDLIFE OR THE GENERAL PUBLIC. IMPACTED SOIL WAS COLLECTED AND TRANSPORTED TO A LANDFILL FOR PROPER DISPOSAL PER ILLINOIS EPA WASTE DISPOSAL REGULATIONS. THE FAILED SECTION OF PIPE HAS BEEN SENT TO A LABORATORY FOR METALLURGICAL ANALYSIS. PER ANALYSIS BY KIEFNER AND ASSOCIATES, IN A REPORT TITLED "INVESTIGATION OF CAUSE OF FAILURE THE FAILURE OF WOODPAT CRUDE OIL PIPELINE" DATED JULY 22, 2002, THE FAILURE WAS CAUSED BY HYDROGEN CRACK INITIATION AND PROPAGATION THROUGH THE HEAT AFFECTED ZONE OF THE ELECTRIC-RESISTANCE-WELDED (ERW) LONGITUDINAL SEAM OF THE PIPE. THE HYDROGEN CRACK WAS NOT PRESENT AT THE TIME OF ORIGINAL MANUFACTURE BUT APPEARS TO HAVE DEVELOPED WITH THE INTRODUCTION OF ATOMIC HYDROGEN INTO THE PIPELINE STEEL OVER TIME. THE LABORATORY REPORT WAS SENT UNDER SEPARATE COVER TO MR. IVAN HUNTOON, DIRECTOR, CENTRAL REGION, OFFICE OF PIPELINE SAFETY AUGUST 7, 2002. OPS OVERSIGHT OF THE EVENT CONTINUES PER CORRECTIVE ACTION ORDER CPF 3-2002-5007H. THE REGULATORY REMEDIATION HAS BEEN COMPLETED AND A NO FURTHER ACTION (NFA) LETTER DATED APRIL 2004 FROM THE ILLINOIS ENVIRONMENTAL PROTECTION AGENCY. IN DECEMBER 2005,MPL COMPLETED ITS ADDITIONAL REMEDIATION/RESTORATION BEYOND WHAT IS REGULATORY REQUIRED AT THE REQUEST OF LANDOWNERS. 4/20/2010 - UPDATED FOLLOWING QA/QC DATA QUALITY REVIEW. NAME OF HCA/HPA WAS SPELLED INCORRECTLY. WAS ROXANNE INSTEAD OF ROXANNA.

PHMSA trend classification: significant incident, not serious.

PHMSA standardized cause: MATERIAL FAILURE OF PIPE OR WELD — PIPE SEAM.

PHMSA indexed costs: $4,650,025 reported total cost, $3,020,308.506 in 1984 dollars, $7,438,090.304 in current-year dollars.

PHMSA trend flags, standardized causes, and indexed costs are analytical fields added to operator-reported incident data. They do not represent final agency causal findings.