EQUIPMENT PERFORMANCE SPILL PREVENTION AND PIPING KEVIN HENDERSON

Transcription

1 EQUIPMENT PERFORMANCE SPILL PREVENTION AND PIPING KEVIN HENDERSON 20 th ANNUAL NATIONAL TANKS CONFERENCE March 17-19, 2008 ATLANTA, GEORGIA

2 SPILL BUCKETS: OPW 1 PETRO STOPPING CENTER JACKSON, MS Six 20,000 gallon tanks installed May 1999 One regular tank One premium tank Four diesel tanks all manifolded together Direct and remote fills for all six tanks (12 buckets)

3 Petro Stopping Center Jackson, MS DOUBLE-WALLED TANKS & PIPING Interstitial Monitoring Tanks Hydrostatic Piping Electronic sump sensors - Mechanical leak detectors No indication of any suspected release with the release detection systems utilized by owner/operator (no alarms). Observation wells installed at each corner of the tank bed but not utilized (never checked).

4 Petro Stopping Center Jackson, MS

5 Petro Stopping Center Jackson, MS

6 Inspected in May 2007

7 OPW 1

8 OPW 1

9 OPW 1

10 OPW 1

11 OPW 1

12 OPW 1

13 OPW 1

14 OPW 1

15 OPW 1

16 OPW 1

17 OPW 1

18 Duratuff OPW 1

19 Petro Stopping Center Jackson, MS 4800 Gallons Recovered

20 What s Wrong With This Picture?

21 Ball Float Valves

22 Flex Connectors

23 PIPING: APT XP The Pantry - Flowood, MS STORE REGULAR R-1 R-2 PREMIUM P-1 P Originally piped with Western flex pipe in rigid PVC electrical conduit May R-2 replaced July 2006 by Contractor A because fuel found dripping from conduit into STP sump. R-1, P-1 and P-2 replaced March 2007 by Contractor B.

24 APT - XP

25 APT XP Dispenser Premium

26 APT XP Dispenser 9-10 Premium

27 APT XP Dispenser 9-10 Premium

28 APT XP Dispenser 1-2 Premium

29 APT XP Dispenser 9-10 Premium 28 feet between dispensers 6 inches cut off pipe to get riser lined-up underneath dispenser 9-10 Represents 1.8 % swell rate

30 APT XP R-1 (installed July 2006) and R-2 (installed March 2007) have not significantly swelled. P-1 installed March 2007 has swollen enough to crack shear valve at termination dispenser (1-2) at least once. No length had to be cut off this pipe. P-2 installed March 2007 has swollen significantly: Shear valve at terminating dispenser (9-10) has been broken at least twice. 6 inches cut off the length of this pipe. Shear valve at dispenser cracked at least once.

31 PIPING: UPP EXTRA MURPHY OIL -GREENWOOD, MS Installed October 2005 Passed precision tightness testing Brought into use June 2006 Leak Reported July 2006

32 Leaking Coupling UPP EXTRA Murphy Oil Greenwood, MS Coupling Already Replaced 3rd Coupling Not Leaking (out of picture frame)

33 UPP EXTRA Murphy Oil Greenwood, MS Secondary to Primary Termination Fitting Primary Piping Welding Sockets Coupling Welding Indicators Termination Fitting Leaking Coupling - Note fuel within sockets of welding pins.

34 UPP EXTRA Murphy Oil Greenwood, MS Coupling Pipe Termination Fitting

35

36 PetroTechnik Analysis on reported leakage of fuel through welding pins

37 Analysis of the sample received Pressure test on the sample could not replicate the leak through the welding pins The sample was subjected to X-Ray, and the result highlighted two important facts: Pipe and termination fitting were not fully inserted The assembly was exposed to bending stress during welding

38 Incomplete insertion

39 X-ray: Resistor displacement induced by welding under stress

40 Conclusions The assembly was exposed to external loads and partial insertion of either the pipe or fitting prior and during electrofusion. Both the partial insertion and external loading resulted in the molten material moving into the bore of the welding coupler. Molten material was forced out of the fusion area to form material tongues. This movement of molten material has resulted in unsatisfactory fusion welds. The movement of molten material has also resulted in the exposure of the welding coil. Thus the cause of the assembly failure is due to poor installation with the pipe and fitting not fully inserted squarely and also the assembly exposed to external forces prior to, during and after electrofusion. The x-ray results of the original Murphy sample conclude the original findings that poor installation of pipe and fitting was the cause of the assembly failure.

41 Actioned Review of installation manuals and documentation emphasizing the critical steps Efficiently communicate this information to installers Post the revised installation manual on Murphy Oil s web site Petrotechnik is progressively recertifying contractors in line the Murphy new site build program

42 UPP EXTRA MURPHY OIL - INDIANOLA, MS Installed October 2005 Passing precision tightness test results Inspected May 2007

43 UPP EXTRA Murphy Oil Indianola, MS Premium Sump

44 UPP EXTRA Murphy Oil Indianola, MS Regular Sump

45 UPP EXTRA Murphy Oil Indianola, MS

46 ENVIRON GeoFlex

47 ENVIRON GeoFlex+Plus

48 ENVIRON GeoFlex+Plus

49 KEVIN HENDERSON