My two cents worth:
I've hunted with percussion rifles for many years and have generally left my hunting load in the rifle until I was lucky enough to get a shot at an animal or until I knew my season was over; some years I've left it loaded until the next summer. Only once has my rifle failed to fire for me on a first cap and that was after a couple of days of sitting totally exposed in some of the most miserable heavy wet snow, rain and fog; you know the kind of weather that only a moron would sit out in. A little powder dribbled in under the nipple and she fired with authority on the next cap.
As many have already stated it is important to be sure that before you drop your hunting load that your breech, fire channel and nipple are cleaned of whatever preservative (oil) may be there. My practice is to dry patch with the nipple removed; pipe cleaner to the fire channel and dry and blow out the nipple. I have no problem with others having their own methods that differ.
In my one and only fail to fire mentioned above I feel confident that exposure to the crappy weather was the source of the cause of the failure to fire; so, my powder was wet from water not oil. The main charge went off as normal when the extra powder was dribbled in under the nipple leading me to assume that only the powder immediately under the nipple and into the fire channel had been dampened. Could I have done some things that may have prevented that? Sure, but, I don't want to go down that path at this time because Crew Chief didn't mention anything in his post about extreme weather conditions.
What I'm curious about with your experience Crew Chief is that you stated that on your second attempt adding more powder under the nipple
so I could at least get the ball out but it only pushed it about have way out
you only got the load half way out of the barrel; so obviously the main charge did not go off. You said you pulled the ball, so I'll assume that you were using a patched round ball. You didn't mention your powder load, but, since you were hunting I'd assume somewhere between 65-100 grains; that's a lot of powder to totally contaminate with either breech oil or patch lube. What did the powder look like when you dumped it out?