Some of the 2020 LOPC events in chemical processes in Alberta

Here is a listing of just some of the Loss of Primary Containment (LOPC) events involving pressure equipment unsafe conditions, accidents, and fires that have been reported to and investigated by ABSA.  This information is provided to make people aware of the general nature of pressure equipment unsafe conditions, accidents, and fires. The intent is to heighten the awareness of the general public of the hazards of pressure equipment in an effort to prevent injury.

Note: “Loss of Containment” as used in this report refers to the loss of any amount of process fluid from the pressure equipment.

Date Reported

Injuries

Fatalities

Description

Loss of Containment

2021-01-15

0

0

A leak was discovered on the nozzle to shell weld of hydrogen cooler. The leak was determined to be the result of chloride stress corrosion cracking.

Yes

2020-12-17

0

0

Ammonia leak discovered at an ice plant. The leak was determined to be the result of a cracked gasket on a flanged piping connection from the compressor.

Yes

2020-12-02

0

0

A leak in a compressor building was discovered due to a through wall crack at a piping butt weld. The crack was a result of fatigue due to vibration during service.

Yes

2020-10-31

0

0

A natural gas leak was discovered in a compressor building. The leak was from a cracked relief valve body caused by fatigue from vibration during service.

Yes

2020-10-29

0

0

A fire was caused by a leak at a dissimilar metal weld in a steam methane reformer furnace tube.

Yes

2020-10-28

0

0

A heat exchanger was shut down after observed process fluid collecting on the ground below a shell and tube heat exchanger. The leak was from a through-wall crack that originated at a baffle in the channel head.

Yes

2020-10-26

0

0

Failure of a section of 0.5 inch process piping from the discharge of a drain booster pump resulted in a loss of containment. The failure was a result of fatigue cracking from excessive vibration during service.

Yes

2020-10-22

0

0

Operators discovered a pinhole leak from a on a 2 inch process piping line at a flange to pipe weld. The pinhole was due to internal corrosion.

Yes

2020-10-22

0

0

Operations personnel discovered leaking produced water from the transfer piping that conveys water from the separator vessel to the storage/disposal tank at a well head. The leak was a result of internal corrosion.

Yes

2020-10-16

0

0

A crack at an inlet nozzle of a heat exchanger resulted in a small fire in a chemical processing facility. The crack is believed to be the result of creep induced damage.

Yes

2020-10-09

0

0

Operators discovered a leak from a pipe nipple on the upper shell of a glycol contactor. The leak was caused by a through wall crack in the threads of the nipple due to vibration during service.

Yes

2020-10-02

0

0

A fire was caused by a leak at a dissimilar metal weld in a steam methane reformer furnace tube.

Yes

2020-09-28

0

0

Operators responded to a H2S alarm at a produced water pumping station and discovered a leak from the bottom head of a water filter that was in operation. The leak was a result of internal corrosion due to breach of the internal coating.

Yes

2020-09-25

0

0

A fire underneath an heat exchanger at a sour gas processing facility was reported. The fire resulted from a leaking drain valve which allowed excess hydrocarbon to accumulate in the spill containment receptacle.

Yes

2020-09-23

0

0

A pinhole leak was discovered on propane inlet piping to a process chiller. The pinhole is believed to be a result of external damage due to corrosion under insulation.

Yes

2020-09-21

0

0

Operations discovered a leak from underneath the insulation of a process piping system. The leak is believed to be caused by internal corrosion associated with the process.

Yes

2020-09-18

0

0

Leak discovered in the bottom cone of a sand separator vessel. The leak was a result of localized internal wall thinning due to erosion.

Yes

2020-09-16

0

0

A pinhole leak was discovered on a process piping system. Pinhole was a result of internal corrosion.

Yes

2020-09-04

0

0

A leak was discovered from a compressor discharge bottle. The leak was a result of a through wall crack, due to vibration, on the inlet nozzle repad to shell weld.

Yes

2020-09-03

0

0

A Pinhole leak discovered in the drain line of a sour service separator due to corrosion.

Yes

2020-09-01

0

0

A block valve packing failure resulted in a loss of containment of liquid nitrogen at a tank offloading station. The valve packing failed due to a lack of regular maintenance.

Yes

2020-09-01

0

0

A gasket failure on the gage glass of a carbon monoxide (CO) boiler drum resulted in a loss of containment.

Yes

2020-09-01

0

0

A pinhole leak was discovered in a check valve of a process piping system. The pinhole was a result of internal corrosion.

Yes

2020-09-01

0

0

A gasket failure at a pressure control valve on a process piping system resulted in a loss of containment of natural gas.

Yes

2020-08-26

0

0

A pinhole leak was discovered in a light naphtha piping system. The pinhole was a result of internal corrosion.

Yes

2020-08-21

0

0

A pinhole leak was discovered in a 2 inch condensate piping elbow. The pinhole was due to internal corrosion and erosion.

Yes

2020-08-21

1

0

An operator was burned by a flash fire while bleeding hydrocarbon condensate into a pail.

No

2020-08-21

0

0

A leak was discovered from an interstage scrubber in a compressor building. The leak was a result of a cracked pipe nipple on the drain of the sight glass, due to vibration and over torqueing of the pipe nipple during installation.

Yes

2020-08-20

0

0

Operators discovered a leak from a nozzle on a process vessel due to internal corrosion.

Yes

2020-08-20

0

0

A loss of containment was reported from a hot oil heater due to localized overheating causing several tubes to fail.

Yes

2020-08-17

0

0

Operators discovered a leak from an instrument air receiver. The leak was a result of a through wall crack, due to vibration, at the weld of a support leg.

Yes

2020-08-13

0

0

Operators discovered a leak at a process gas exchanger nozzle weld. The leak was a result of cracking due to suspected vibration during service.

Yes

2020-08-12

0

0

Overpressure of process piping caused a loss of containment from several bolted connections. The overpressure condition was due to a passing block valve which resulted in an inability to isolate the pressure source during maintenance.

Yes

2020-08-07

0

0

An explosion in a compressor building and subsequent fire resulted from the failure of a braided hose connection allowing hydrocarbon to leak.

Yes

2020-08-06

0

0

An operator discovered a leak from an air dryer during routine rounds. The leak was a result of continuous vibration while the dryer was in operation.

Yes

2020-08-05

0

0

Erosion inside the nozzle of a process vessel resulted in a loss of containment.

Yes

2020-08-05

0

0

A through wall crack in the threads of a pipe nipple beneath the second stage discharge safety valve resulted in a loss of containment in a compressor package building. The crack was a result of fatigue due to excessive vibration during operation.

Yes

2020-08-01

0

0

Operators discovered a leak at a process gas exchanger nozzle weld. The leak was a result of cracking due to suspected vibration during service.

No

2020-07-27

0

0

An operator discovered a pinhole leak on the bottom head of a process vessel. The pinhole was a result of internal corrosion.

Yes

2020-07-20

0

0

Steam outlet piping from a depropanizer oil coalescer vessel was discovered to have ruptured. It is unknown when this failure occurred as the line is used infrequently, but the owner suspects it was a result of freezing.

Yes

2020-07-15

0

0

Operators discovered a hydrogen sulphide leak from a compressor discharge bottle. Upon investigation it was determined that a nozzle had cracked at the weld to shell joint due to excessive vibration.

Yes

2020-06-22

0

0

A loss of containment was reported due to a crack in the threaded area of a fitting attached to a recycle valve on a compressor package. The crack was a result of fatigue due to excessive vibration during operation.

Yes

2020-06-18

0

0

Leak discovered at the weld neck of the inlet flange of an aerial cooler. The leak was a result of a small crack that had formed due to continuous vibratory service.

Yes

2020-06-15

0

0

Pinhole leak discovered in a socket weld of piping attached to float column in an acid gas compressor package.

Yes

2020-06-10

0

0

Operator discovered a steam leak from the vent line of a heater at a pulp mill. The leak was caused by a crack in the vent line as a result of fatigue from vibration service.

Yes

2020-06-10

0

0

Loss of containment reported due to a failed steam hose at the coupling. Investigation revealed that the hose material had become brittle due to age and constant usage.

Yes

2020-06-04

0

0

Operators discovered a leak from a compressor discharge bottle due to a crack located at the toe of a nozzle to shell weld. The crack was a result of fatigue due to vibration service.

Yes

2020-06-02

0

0

A through wall crack was discovered in a nozzle of a stainless steel vessel. The owner believes the crack was a result of fatigue due to vibration.

Yes

2020-05-25

0

0

Pinhole leak discovered on compressor piping due to corrosion.

Yes

2020-05-25

0

0

Excess water not drained from a process piping system froze causing the flanged connections to leak and permanently deform the piping. The water in the system was allowed to freeze due to a failure of the building’s heating system.

Yes

2020-05-20

0

0

A loss of containment was reported from an internally coated process filter vessel due to internal corrosion. It was determined that cracking in the coating allowed process fluid to contact the vessel wall and cause the corrosion.

Yes

2020-05-19

0

0

Pinhole leak discovered on an air cooled heat exchanger due to corrosion.

Yes

2020-05-12

0

0

A process heater coil exceeded its design temperatures due to a deviation from operating procedure.

No

2020-05-08

0

0

A leak was discovered from a fluidized bed boiler. The leak was determined to be caused by a cracked attachment weld due to fatigue.

Yes

2020-05-05

0

0

Operators discovered a process water leak at a flanged connection on a piping system. The leak was determined to have been caused by loosening of the flange bolts due to water hammer.

Yes

2020-04-29

0

0

Steam tracing piping failed due to corrosion.

Yes

2020-04-23

0

0

Pinhole leak discovered in a 3/4 inch drain nozzle as a result of corrosion.

Yes

2020-04-21

0

0

Weld defect in an ammonia refrigeration heat exchanger coil resulted in a release.

Yes

2020-04-17

0

0

A steam leak from a weld was discovered in a steam coil associated with an emulsion cooler. The leak is believed to have resulted from a manufacturing defect during welding.

Yes

2020-04-15

0

0

Through wall crack discovered on coke drum as a result of cyclic thermal fatigue.

Yes

2020-04-14

0

0

Pinhole leak discovered in a 4 inch piping spool containing crude oil caused by erosion.

Yes

2020-04-13

0

0

Pipe nipple connected to ball valve failed due to vibration and misalignment causing a release of hydrocarbon and subsequent fire in the compressor building.

Yes

2020-04-10

0

0

Failure of steam trap piping due to freezing. The freezing was a result of failed heat tracing.

Yes

2020-04-09

0

0

Failed fuel gas pressure regulator vented gas which combusted.

No

2020-04-08

0

0

A nitrogen hose burst from overpressure after being inadvertently left connected to a process vessel resulting in a release of sour gas.

Yes

2020-04-08

0

0

Loss of containment of hydrocarbon from 2 inch branch connection of process piping. Cause determined to be stress corrosion cracking (SCC).

Yes

2020-04-07

0

0

Unintentional release of hydrocarbon due to corroded vent valve on flare header.

Yes

2020-04-07

0

0

Corrosion in the oil side of a cooler resulted in release of oil.

Yes

2020-04-06

0

0

Corrosion of a pipe nipple in a leach unit resulted in a loss of containment. The material used for the pipe nipple was incorrect and not suitable for the intended service.

Yes

2020-04-04

0

0

Ruptured tube on an aerial cooler resulting in a hydrocarbon leak. The tube failure was due to freezing.

Yes

2020-04-03

0

0

Release of refrigerant due to fretting of a braided hose against the compressor piping.

Yes

2020-04-01

0

0

Through wall crack discovered on 1 inch piping to a pressure gauge on the water makeup system. Water hammer is believed to be the most probable cause.

Yes

2020-03-30

0

0

Isolated pressure piping line found frozen as a result of the heat tracing not activated. No loss of containment.

No

2020-03-30

0

0

Pinhole leak discovered in process piping due to corrosion.

Yes

2020-03-29

0

0

Gasket failure in a bolted connection on a process vessel led to a loss of containment.

Yes

2020-03-29

0

0

Valve failure discovered in piping system. The failure is believed to have been caused by fatigue due to excessive vibration.

Yes

2020-03-26

0

0

Process piping line failure discovered due to freezing. The freezing was caused by heat tracing failure.

Yes

2020-03-25

0

0

A suspected leak on the fuel gas supply piping resulted in a fire in the compressor building.

Yes

2020-03-23

0

0

Steam piping to deaerator failed due to freezing. The freezing was a result of unusually cold ambient temperatures.

Yes

2020-03-20

0

0

A flame was discovered from an inadequately bolted connection to a process vessel.

Yes

2020-03-19

0

0

Pinhole leak discovered on an elbow between the steam trap and blowdown tank due to erosion.

Yes

2020-03-18

0

0

Tube failure on an air cooled heat exchanger. The failure was a result of mechanical damage due to hydrates in the system.

Yes

2020-03-18

0

0

An air cooled heat exchanger overpressured during purging due to the vent line valve being closed. No loss of containment.

No

2020-03-18

0

0

Valve stem packing failure resulting in a release of hydrocarbon.

Yes

2020-03-17

0

0

Boiler tube leak as a result of under-deposit corrosion.

Yes

2020-03-16

3

0

During maintenance on a process piping system, an unintentional release of naphtha and hydrocarbon resulted in a fire. The release was caused by a deviation from maintenance procedures.

Yes

2020-03-12

0

0

Failure of drain piping from particle filter due to freezing. The freezing was a result of failure of the heat tracing.

No

2020-03-11

0

0

Following maintenance activities, process fluid was reintroduced to the tube side of a heat exchanger, but the shell side was still blocked in, causing pressure build up in the shell side until the outlet valve lost containment at its inlet flange.

Yes

2020-03-11

0

0

Pinhole leak discovered on a water drain line from an oil treater.

Yes

2020-03-09

0

0

Incorrectly assembled drain tubing on a fuel gas scrubber leaked gas resulting in a fire.

Yes

2020-03-09

0

0

A firetube in an oil treater failed due to localized overheating.

Yes

2020-03-08

0

0

A process high temperature excursion resulted in loosening of a flanged joint, allowing flammable process fluid to leak resulting in a fire.

Yes

2020-03-04

0

0

Pinhole leak discovered in weld on the return elbow of an economizer.

Yes

2020-03-04

0

0

Brittle weld failure on a steam line due to incorrect material used in piping modifications which took place in 2006.

Yes

2020-03-04

0

0

Compressor package overpressured due to blocked in pressure relief device.

No

2020-03-03

0

0

Excess scale caused localized overheating leading to failure on the fire tube of a free water knockout vessel.

Yes

2020-03-03

0

0

Ammonia leak reported due to a gasket failure.

Yes

2020-03-02

0

0

Instument tubing failure due to fatigue resulted in a fire.

Yes

2020-03-02

0

0

Through wall crack discovered on coke drum as a result of cyclic thermal fatigue.

Yes

2020-03-02

0

0

Freezing of process fluid in a piping associated with the humidification system of a furnace resulted in a failure and release of humidified ethane.

Yes

2020-03-01

0

0

A firetube in an oil treater failed due to localized overheating resulting in a fire.

Yes

2020-02-29

0

0

Failure of steam coil due to freezing. The freezing was a result of failed heat tracing.

Yes

2020-02-29

0

0

Loss of containment due to damaged lining resulting in corrosion in sulfuric acid piping.

Yes

2020-02-28

0

0

Pinhole leak discovered in an economizer tube resulting in a loss of containment.

Yes

2020-02-27

0

0

Freezing damage caused to an air cooled heat exchanger due to failed heat tracing. The heat exchanger was damaged beyond repair and will be replaced.

No

2020-02-26

0

0

An operator heard a gas leak from the cooler. The compressor was immediately shut down to isolate the leak. After a further inspection by the owner a pin-hole was found on one tube.

Yes

2020-02-25

0

0

A failed pipe nipple resulted in an ammonia leak in a refrigeration plant. The pipe nipple is believed to have had an existing defect in the threaded portion resulting in eventual failure.

Yes

2020-02-25

0

0

Tube failure in an air cooled heat exchanger resulted in a loss of containment. Flow accelerated corrosion (FAC) is believed to be the probable cause.

Yes

2020-02-25

0

0

Failure of a steam line as a result of freezing. In adequate draining of the line allowed the remaining condensate to freeze.

Yes

2020-02-24

0

0

Isolation valve passing liquid into steam piping and subsequently freezing causing the pipe to fail.

Yes

2020-02-23

0

0

Freezing failure of a piping elbow due to an abandoned dead leg.

Yes

2020-02-21

0

0

Pinhole leak discovered in produced water piping. Owner suspects bacterial corrosion to be a likely cause.

Yes

2020-02-21

0

0

Through wall crack discovered on well injector steam line check valve, due to freezing. Freezing was a result of the steam isolation valve passing and allowing condensation to form in the check valve.

Yes

2020-02-20

0

0

Loss of containment due to pinhole and crack in emulsion inlet piping during warmup and preparation. System had been sitting stagnant for over four years prior to startup.

Yes

2020-02-20

0

0

Loss of containment at flange gasket on process vessel due to incorrect bolt tightening.

Yes

2020-02-19

0

0

Boiler feed water piping system overpressured. No damage apparent or loss of containment.

No

2020-02-18

0

0

Pinhole leak discovered in 90° elbow of drain pipe on a separator.

Yes

2020-02-18

0

0

Loose restraint caused contact and wear on tubes resulting in vapor/steam observed from an inspection access door.

Yes

2020-02-10

0

0

Loss of containment at weld on process line connecting to a vessel. Owner determined that the loss of containment was a result of a crack caused by fatigue.

Yes

2020-02-04

0

0

Freezing of water line due to failed heat tracing.

Yes

2020-02-04

0

0

Boiler feed water low flow bypass piping spool developed a leak due to erosion.

Yes

2020-02-03

0

0

Several tubes on aerial cooler failed due to freezing while cooler was out of service.

Yes

2020-02-02

0

0

Loss of containment due to weld failure at return bend of economizer.

Yes

2020-01-30

0

0

A leak was discovered in a high pressure steam piping system. The pipe was found to have a through wall crack as the result of service induced deterioration.

Yes

2020-01-30

0

0

Hot spot discovered in a methane reformer furnace tube. No loss of containment, tube repaired.

No

2020-01-29

0

0

Freezing at dead leg of condensate return line due to insufficient heat tracing.

Yes

2020-01-27

0

0

Loss of containment due to pinhole on catalyst transfer line. Pinhole was determined to be a result of damaged refractory that resulted in localized erosion.

Yes

2020-01-24

0

0

Boiler feed water blowdown piping failed due to freezing. The freezing was a result of extreme cold ambient conditions.

Yes

2020-01-23

0

0

Pinhole leak in discharge elbow of process vessel due to localized wall thining.

Yes

2020-01-22

0

0

Operators observed smoke and steam vapor issuing from a pressure vessel. Upon further inspection, a through wall crack approximately 30 inch long was found at a circumferential weld.

Yes

2020-01-22

0

0

A tube bundle was removed from a heat exchanger for inspection and maintenance. The bundle was fouled with a substance that caught upon initial removal.

No

2020-01-22

0

0

A pair of air cooled heat exchangers were found to have several split tubes due to freezing. The exchangers were in intermittent service and the owner has determined that they were not isolated correctly.

Yes

2020-01-22

0

0

Pipe nipple failure due to a combination of vibration and cold temperatures resulted in a release of propane to atmosphere.

Yes

2020-01-21

0

0

Liquids accumulated in a compressed gas cooler the tube and froze causing the tube to fail.

Yes

2020-01-21

0

0

Mobile compressor package destroyed due to fire. The owner believes that the cause of the fire may have been as a result of cracked exhaust pipe inside the compressor trailer.

Yes

2020-01-21

0

0

Liquids accumulated in a compressed gas cooler the tube and froze causing the tube to fail.

Yes

2020-01-20

0

0

Operators discovered a small steam leak under the insulation at a pressure vessel nozzle. It was determined that internal erosion resulted in a breach of the pressure envelope.

Yes

2020-01-20

0

0

Freezing of water line from inlet separator due to failed heat tracing.

Yes

2020-01-18

0

0

Process upset due to failure of rotating equipment resulted in excess liquid and pressure in the system. The fluid released by the PSV contained excess liquid, which accumulated and ignited.

Yes

2020-01-18

0

0

Freezing of steam trap due to failed heat tracing.

No

2020-01-18

0

0

Leaking valve due to failed bonnet gasket. The owner suspects a previously undetected freezing event was the most probable cause.

Yes

2020-01-18

0

0

Freezing of pressure piping line to flow meter due to failed heat tracing.

No

2020-01-16

0

0

Truck hit an oil supply line causing loss of containment.

Yes

2020-01-16

1

0

Operator burned with hot water while draining a filter pot. Second degree burns required hospitalization and surgery.

Yes

2020-01-16

0

0

Pressure vessel sight glass gasket failed resulting in significant fluid loss. Emergency procedures were initiated to contain leak without further damage.

Yes

2020-01-15

0

0

Ammonia leak reported at a load out station. Leak determined be the result of gasket failure at a flanged piping connection.

Yes

2020-01-14

0

0

Freezing of slurry inlet line due to failed heat tracing.

No

2020-01-12

0

0

Leak on process piping due to wall thinning as a result of unanticipated in-service corrosion.

Yes

2020-01-11

0

0

Loss of containment from pinhole at the socket weld connecting a globe valve to steam supply line. The pinhole is believed to be caused by steam erosion.

Yes

2020-01-11

0

0

The discharge piping of a safety valve was found to be frozen. The freezing was a result of a small ammount of water unintentionally passing through the safety valve.

No

2020-01-10

0

0

Freezing of a froth condensate drain line caused a gasket failure resulting in a loss of containment. The freezing was caused by failure of heat tracing.

Yes

2020-01-07

0

0

Through wall crack in air receiver resulted in a loss of containment. The crack appears to have initiated at a saddle support weld and propagated into the shell material, most likely as a result of vibration service.

Yes

2020-01-07

0

0

A pinhole leak was discovered on the bridle to inlet separator as a result of a high LEL alarm. The pinhole is believed to be caused by microbial corrosion.

Yes

2020-01-06

0

0

A pinhole leak was discovered on a piping system. The pinhole was attributed to corrosion.

Yes

2020-01-03

0

0

Nipple at inlet of PSV leaking from a crack in the threads. Crack believed to be a result of vibration due to broken discharge piping support.

Yes

2020-01-03

0

0

Unplanned plant shutdown, due to power outage, caused freezing in piping and exchangers.

No

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