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Louisiana Refinery Accident Database

Marathon Ashland Petroleum (3165), Garyville

LDEQ Accident Report

Pollutants Released

Accident Classified As: Reportable Quantity

Cause of Problem: Human Factors

Unit 19 received a slug of rich amine, during the unit 15 start-up, causing the amine regenerator to slump and was unable to be removed from the stream. The amine, still rich with Hydrogen Sulfide, was then sent to the Fuel Gas Absorber tower and was unable to remove Hyrdogen Sulfide from the fuel gas. The fuel gas was then sent to the Fuel Gas Mixed Drum, which was supplying fuel gas to 22 sources. As a result, several heaters and boilers experienced an increase in Sulfur Dioxide above the maximum allowable permitted lbs/hr rate. A TAPROOT investigation concluded that the accident was caused by Human Performance (the 519 operator thought the board operator meant to close the spillback instead of the lean internal circulation) and Equipment Difficulty (steam trap system malfunctioned due to new Fuel Gas Project tie in). LDEQ conducted an Air Quality Compliance Incident Investigation Report in response to this accident.

Discharge Preventable - Yes

An internal lean amine circulation was left open causing the Lean Regenerator levels to drop rapidly. To prevent the unit from tripping due to low levels, the board operator increased the Rich Amine flow rapidly. This caused the amine regenerator to become upset. At the same time a Hydrogen Sulfide Analyzer malfunctioned due to steam in the tracer line. Because of the malfunctioning Hydrogen Sulfide analyzer, the board operator was unaware of increased Hydrogen Sulfide in the fuel gas system and did not take corrective action.

Notes/Remedial Actions

See Page 3 for very detailed list of point sources with names, unit numbers etc. The 60-day report recommends that the refinery revise the Unit 19 Start up procedure with more detailing events on when to use the internal lean circulation line while starting up Unit 15 with the appropriate line terminology, label lines accordingly, and retrain operators with the revisions. This report recommends additionally that the refinery evaluate the design of the existing steam tracing for the analyzer, and recommend proper mitigation. No report does not provide information of the the refinery's implementation of these recommendations. LDEQ Enforcement Division found that MPC failed to operate the lean amine circulation line in the closed position for the proper working order of the Lean Regenerator to control emissions by the facility. Facility will revise Unit start up procedures with operators.