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Louisiana Refinery Accident Database

Valero (1238), Meraux

LDEQ Accident Report

Pollutants Released

Accident Classified As: Below Reportable Quantity (BRQ)

Cause of Problem: Equipment Failure

Multiple issues involving the Flue Gas Cooler and Cat Cracker throughout the week caused periodic flaring, which resulted in noise, smoke, and odors. Noise Cause: The flue gas cooler on the Cat Cracker began experiencing an increase in pressure drop across its super heater section during the last week of November. It is believed that this increased pressure drop across the super heater section has resulted in deposits of salts in the super heater tubes and resulted in an increase in the operating pressure in the steam drum causing the excess noise. The pressure relief valves on the steam drum have vented periodically to protect the steam drum and maintain safe operation. The relief valve events are the source of the recent noise complaints. Flaring: the Cat Cracker wet gas compressor tripped off line resulting in a total shutdown of the Cat Cracker and flaring. A malfunction in the speed controls on the compressor is suspected as a cause.

Discharge Preventable - No Information Given

Notes/Remedial Actions

LDEQ received seven complaints regarding smoke, odors, noice, and vibrations from the Valero Mereaux Refinery. No RQ's were exceeded, but some permit limits were exceeded and will therefore be reported on the semiannual deviation reports. Corrective actions were implemented to prevent similar issues. Complaint reports included: 12/2 smells emanating from Meraux refinery caused headache, smells like burning fuel. South flare in use with deep, dark orange colors and trailing black smoke. The refinery noise has been in the home for the last few nights. 12/3 a constant high pitched tone in the house, large flame from both flare with smoke. 12/4 very strong possibly sulfur odor infiltrated home and can not be removed, so bad that it is making us nauseous, the odors have never been to this degree within our residence. 12/4 smell is stronger as approach refinery. It is a burnt gas smell. Very nasty around Ventura and further east, closer to refinery. 12/4 very loud medium to high pitched constant humming emanating from the valero Meraux refinery, can be heard in home over sound from television. 12/5 Rotten egg odors have been increasing over the last 2-3 days. 12/5 report of an odor of sulfur dioxide coming from a plant making resident sick. 12/9 extremely loud steam release this morning for about four minutes. Noise Corrective Actions: Cat Cracker operating conditions have been adjusted in an effort to reduce the steam make from the flue gas cooler. These actions include reducing Cat Cracker charge rate and adjusting unit operations to minimize regenerator temperature. The operating pressure has been lowered on a portion of the refinery steam system to minimize steam drum pressure on the flue gas cooler. Modifications were made to the system to allow steam condensate to be injected upstream of the super heater section in an effort to rid salt deposits. A super heater bypass line was designed and installed.