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Chalmette Refining (1376), Chalmette
Causal Factor: Equipment Failure
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| No LDEQ Reported 2005-12-18 | Coker 2 Wet Gas Compressor K8101 | Cause: Compressor went into high alarm for high vibration. It was determined that the vibration probe had provided a false alarm due to a faulty connection.
Coker 2 Wet Gas Compressor K8101 went into alarm for high vibration on 12/18/2005. Followup: No Notes: This is a letter rescining the notification made relative to Hydrogen Sulfide (H2S). Upon further review, the total amount of H2S is estimated to be less than the reportable quantity (RQ= 100 lbs). Chalmette refinery estimates that approximately 70 lbs of H2S was released to the atmosphere during the 12/18/05 event. In order to avoid equipment damage and associated emissions, refinery personnel shut down the machine in order to evaluate and develop a repair strategy. The vibration probe was repaired and the machine was put back in service, ending the incident. Instrument and electrical connections directly related to K8101 were double checked for proper connections in order to avoid a recurrence due to the same root cause. It was determined that the vibration probe had provided a false alarm due to a faulty connection. The vibration probe was repaired and the machine was put back in service, ending the incident. Instrument and electrical connections directly related to K8101 were double checked for proper connections in order to avoid a recurrence due to the same root cause. Although the facility claims that this was a false alarm, there must have been some type of equipment failure to result in the release of 26,127 lbs of sulfur dioxide. The incident released 26,127 lbs of S02, which exceeds the reportable quantity for S02 (RQ= 500 lbs). | Nitric Oxide: 254.0 pounds Nitrogen Dioxide: 28.0 pounds Sulfur Dioxide: 26,127.0 pounds Hydrogen Sulfide: 70.0 pounds |
| 84474 2005-12-10 | Wet Gas Compressor K8101 | Cause: Coker 2 Wet Gas Compressor K8101 shutdown on multiple occasion for uncertain reasons. On December 13, 2005 it was determined that some shutdown relay wiring on K8101 had become less secure than required for consistent operations. Followup: No Notes: Chalmette Refinery notified the office regarding a release of Nitric Oxide, Nitrogen Dioxide, Sulfur Dioxide, and Hydrogen Sulfide on December 10,12, and 13. This is a notification by CRLLC rescinding the notification made relative to Hydrogen Sulfide (H2S). Upon further review, the total amount of Hydrogen Sulfide is estimated to be less than the reportable quantity. The RQ for H2S is 100 pounds. Chalmette Refinery estimates that approximately 25 pounds of H2S was released to the atmosphere during the combination of the events. The incident occurred on four separate occasions, during three days. Due to incremental emissions caused by downtime of K8101, the compressor was re-started as quickly as possible during the trips on 12/10 and 12/12. On 12/12, when the compressor once again tripped, the machine was left off-line and refinery instrument and electrical resources were mobilized to conduct more extensive evaluation of the machine before re-start. Coker 2 rates were reduced in order to reduce emissions. It was determined on 12/13/05 that some shutdown relay wiring on K8101 had become less secure than required for consistent operations. The wiring was reinstalled, and the machine was re-started ending the incident. The machine was left off-line until refinery instrument and electrical resources could be mobilized to conduct more extensive evaluation of the machine before re-start. K8101 was repaired in order to minimize recurrence due to the same root cause. Sulfur Dioxide, Nitric Oxide and Nitrogen Dioxide released to atmosphere through the refinery No. 1 flare. | Nitric Oxide: 91.0 pounds Nitrogen Dioxide: 10.0 pounds Sulfur Dioxide: 9,361.0 pounds Hydrogen Sulfide: 25.0 pounds |
| 84073 2005-11-23 | No. 2 Coker Wet Gas Compressor | Cause: The wet gas compressor shut down due to the axial thrust alarm, resulting in emissions from the No. 1 Flare. Following investigation, refinery personnel believe the Wet Gas Compressor shut down due to a momentary loss of lube oil. Followup: No Notes: In an effort to stop the release, the compressor was restarted, but the alarm remained. Following determination by refinery personnel that maintenance was required on the compressor, K-8101 was taken out of service and sent out for repair. A variance was applied for with the LDEQ to authorize the emissions associated with the compressor maintenance. The variance was approved on November 29, 2005, ending this release. | Compressed Flammable Gas: 10,509.0 pounds Hydrogen Sulfide: 685.0 pounds Nitric Oxide: 2,490.0 pounds Nitrogen Dioxide: 277.0 pounds Sulfur Dioxide: 255,680.0 pounds |
| 84013 2005-11-21 | Sulfur Recovery Unit Thermal Oxidizer Stack | Cause: Refinery personnel diverted acid gas from Train I of the SRU due to mechanical issues on the unit. Diverting the acid gas resulted in Sulfur Dioxide emissions from the Thox stack in excess of the permit limit, resulting in a reportable release. Followup: No Notes: Sulfur dioxide to atmosphere through the SRU Thox Stack. | Sulfur Dioxide: 8,632.0 pounds |
| 83924 2005-11-17 | Hydrodesulphurization (HDS) Unit Fans | Cause: Leak on the HDS Unit fans caused spill to the ground. Emissions resulted from the spill to the ground, the release to the atmosphere and from the unit de-pressure to the No. 2 flare. Followup: Yes Notes: At approximately 04:07 hours on 11/17/05, refinery personnel discovered a leak on the Hydrodesulphurization (HDS) Unit fin-fans. Approximately 9.3 barrels of Distillate range material spilled to the ground. Emissions resulted from the spill to the ground, the release to the atmosphere, and from the unit de-pressure to the no. 2 flare. Chalmette Refinery rescinded the 11/17/05 notifications for NO, NO2, VOC, SO2 and H2S since the estimated amounts were less than the reportable quantity of 10lbs. They estimate that approximately 1.93 and 0.21 pounds of Nitric Oxide (NO) and Nitrogen Dioxide (nO2), respectively, were released to the atmosphere during the 11/17/05 event. Therefore, notification for Nitrous Oxides (NOx) was not required. Calculations performed after the incident indicated that a greater than reportable quantity of oil was spilled to the ground during this incident, and as such, emissions calculations for the oil spill are included in the follow-up report. Hydrogen Sulfide and Compressed Flammable Gas/Non-speciated VOCs released to atmosphere through the leak; Sulfur Dioxide and compressed flammable gas/non-speciated VOCs released to atmosphere through the NO. 2 flare; oil spill to ground with VOC volatilization to atmosphere. The HDS Unit was shutdown and de-pressured to the no. 2 flare to minimize the impact of the leak. A pipe clamp was installed, stopping the leak. Liquid released from the leak was contained and recovered. Soils that appeared to have come in contact with spilled slop oil were removed for off site disposal. | Hydrogen Sulfide: 274.0 pounds Oil: 2,765.0 pounds Sulfur Dioxide: 783.0 pounds Volatile Organic Compounds (VOCs): 3,681.0 pounds Volatile Organic Compounds (VOCs): 9.3 pounds |
| 83685 2005-11-07 | Tank 72 (D-72) | Cause: During periodic rounds and gauging of tank 72 (D-72), refinery operations personnel observed slop oil overflowing from tank 72. It was determined that the tank had experienced an unanticipated sure in inventory between manual gauging events. The release was caused by the unanticipated malfunction of tank gauge equipment. Followup: Yes Notes: Chalmette Refining reported a release of oil (Slop Oil) and Benzene on 1/7/05. Calculations performed after the incident indicate the greater than a reportable quantity of Volatile Organic Compounds (VOCs) was also released during this incident, as such, emissions calculations for VOCs are included in this follow-up report. Hurricane Katrina caused damage to the electronic tank gauge (telepulse) system for tank 72 (D-72). As mitigation step, periodic manual gauging of D-72 was implemented based on anticipated tank inventory movement. At approximately 2345 hours on 11/7/05 during periodic rounds and gauging of tank 72, refinery operations personnel observed slop oil overflowing from tank 72. It was determined that the tank had experienced an unanticipated surge in inventory between manual gauging events. Since the tank receives inventory from multiple sources the reason for the unexpected increase in inventory was no immediately evident. Oil (as slop oil) released from refinery tank 72 (D-72) via overflow. Slop oil and water was released to the carthen tank containment dike. A portion of the slop oil components evaporated to the air. Transfer to tank the was stopped ending the incident. Transfer out of the tank to the other storage was initiated, lowering the level. Vacuum Trucks were dispatched in order to recover released liquids. The electronic tank gauge for tank 72 has been repaired and placed back in service. Liquid released was contained within the tank dike area and recovered via vacuum truck. Refinery personnel have begun removing soils that appear to have come in contact with spilled slop oil and will remove all stained soil for off site disposal. Currently, migration outside of the tank dike or to groundwater is not suspected. Released liquids that did not volatilize were contained within the tank dike area. Liquids were recovered via vacuum truck and placed into refinery tankage for re-processing. Excavated soils are being placed in roll-off containers, characterized and properly disposed of. | Benzene: 11.5 pounds Oil: 44,782.0 pounds Volatile Organic Compounds (VOCs): 1,862.0 pounds |
| 83087 2005-10-13 | Flare No. 2 | Cause: #2 flare was smoking. In an attempt to reduce the smoke, the flare steam was engaged. Repairs to the flare steam system from the Hurricane Katrina shutdown were still ongoing. The steam was engaged with allowance for draining the lines of condensate prior to putting the steam to the flare.. there was some water carryover, resulting in intermittent steam and a surge of steam which extinguished the flare and pilots. Followup: No Notes: This letter is in regard to calls made by the Chalmette Refinery, notifying of a release of compressed flammable gas/volatile organic compounds (VOCs) on 10/13/05.At 15:00, the #2 flare was smoking. In an attempt to reduce the smoke, the flare steam was engaged. Repairs to the flare steam system from the Hurricane Katrina shutdown were still ongoing. The steam was engaged with allowance for draining the lines of condensate prior to putting the steam to the flare. There was some water carryover, resulting in intermittent steam and a surge of steam which extinguished the flare and pilots. Initial investigation indicated that too few drains were present on the steam line to eliminate the quantity of water created, and there were leaking isolation valved on the steam line. Chalmette will establish review the procedure for commissioning steam to the flare after shutdown to ensure that the line is drained prior to putting steam to the tip of the flare and that the line is checked for valve leaks and pluggings. affected refinery personnel will be trained regarding updates to applicable procedures. The refinery anticipates that these measures will minimize the likelihood of a recurrence of an incident due to the same root cause in the future. The flare was re-lit and the steam was adjusted and stabilized, ending the incident. Initial investigation indicates that too few drains were present on the steam line to eliminate the quality of water created, and there were leaking isolation valves onthe steam line. CRLLC will establish and review the procedure for commissioning steam to the flare after shutdown and will train affected personnel for updated procedures. These measurements should minimize the likelihood of a recurrence | Volatile Organic Compounds (VOCs): 4,800.0 pounds |
| 81795 2005-08-27 | FCC Debutanizer Overhead Condenser | Cause: Condenser overpressured due to a failure with the FCC debutanizer overhead condenser, resulting in flaring and a small ground fire. Followup: No Notes: For the FCC, the tower was returned to normal pressure and the pressure transmitter on the overhead condenser was repaired. The small ground fire was extinguished. This follow-up letter was delayed due to Hurricane Katrina This is a letter rescinding the 8/27/2005 notification for Sulfur Dioxide (S02), Hydrogen Sulfide (H2S), Nitrogen Dioxide (NO2), and Hydrocarbons (non-speciated VOCs). Upon further review, the total amounts were estimated to be less than reportable quantities. Nitric oxide was released to the atmosphere through the refinery Number 1 flare. | Nitric Oxide: 74.0 |
| 81586 2005-08-23 | LPG compressor K-9200 | Cause: At 7:52am on 8/23/2005, the LPG compressor, K-9200, tripped on high suction drum level due to a problem with the suction drum instrumentation, causing the fuel system to overpressure to the #2 flare. Nitric oxide was released to the atmosphere through the no.2 flare.
An unexpected increase in fuel pressure caused fuel system to divert to the #2 Flare. Followup: No Notes: The suction drum instrumentation was repaired and the compressor was restarted. The instrumentation causing the compressor trip was repaired in order to prevent recurrence. This letter has been delayed due to Hurricane Katrina. The event is considered as reasonably unforeseeable, and qualifies as an upset. No further action warranted at this time. | Nitric Oxide: 20.0 pounds |
| 81244 2005-08-12 | No information given | Cause: Leaking relief valve released naphtha. Followup: No Notes: BELOW REPORTABLE QUANTITIES. Chalmette Refining rescinded its notification after further review since it was determined that the event that prompted notification was not a reportable event as the amount released was below reportable quantities. | Volatile Organic Compounds (VOCs): 36.0 pounds |
| 81112 2005-08-08 | Sulfur Recovery Unit Pit Blower K8053 | Cause: Refinery personnel identified unacceptable levels of SRU vibration in Pit Blower K8053. The blower was shut down for repairs Followup: No Notes: Bearing wear was determined to be the cause of the vibration and shutdown of K8053. Repairs were progressed continuously and K8053 was placed back in service. | Hydrogen Sulfide: 126.0 pounds |
| 80549 2005-07-14 | closed cooling water tower | Cause: Leaking heat exchanger. Contamination of closed water cooling system by hydrocarbon, released via evaporation through cooling tower Followup: No Notes: E1288 isolated as the source of the hydrocarbon, repaired or replaced before returned to service. | Xylene: 1,307.0 pounds |
| 80502 2005-07-13 | Transformer power outage - emitted at No. 2 Flare | Cause: Loss of a refinery power transformer resulted in unplanned shut-down of coker 1, resulting in flaring to no. 2 Followup: No Notes: Backup transformer was placed in service to replace the one that failed. | Nitric Oxide: 266.0 pounds Nitrogen Dioxide: 29.0 pounds Sulfur Dioxide: 1,096.0 pounds |
| 79977 2005-06-20 | No. 2 Flare | Cause: The LPG compressor tripped; the alarm panel showed a high suction drum level. Upon investigation no high drum was detected. The machine was restarted and tripped again on a high level indication. A this time the high level alarm was calibrated by the operators and again restarted. Followup: No Notes: The level in the suction drum was checked and upon tripping a second time the operators checked the high level shutdowm switch chamber for liquid. Finding none, the machine was restarted. | Nitric Oxide: 11.4 pounds |
| No LDEQ Reported 2005-06-01 | C8901 - meter station sump vessel | Cause: Sump vent overfilled due to a failed check valve which allowed pressure from the discharge pump on a common discharge pipe to back pressure in sump vent C8901 Followup: No Notes: BELOW REPORTABLE QUANTITIES. All draining and pumping of vessels on the Dock 2 meter platform was stopped. Personnel attempted to capture the overflow with buckets. Hard boom was deployed in order to capture the sheen. Absorbent materials were used in order to clean up the sheen and residual diesel. | Diesel Fuel: 21.3 pounds |
| 79008 2005-05-11 | K7402 No. 2 Crude Unit Thermal Oxidizer Stack on the API | Cause: Gas oil tower overhead compressor tripped. The bypass was a result of a mechanical malfunction of the flame arrestor. Attempts to restart were impeded by plugging on the pilot gas line. LDEQ report adds that the Gas Oil Tower overhead compressor tripped on high knock-out-drum level. Followup: No Notes: Below reportable quantities. Appropriate maintenance and preventive maintenance were followed in order to minimize plugging on the flame arrestor. | Sulfur Dioxide: 189.0 pounds Volatile Organic Compounds (VOCs): 2.0 pounds |
| 78760 2005-05-02 | K7702 Cat Feed Hydrotreater | Cause: Cat Feed Hydrotreater make-up compressor automatically shut down due to thermal overload. The shutdown caused excess acid gas loading at the refinery Sulfur Recovery Unit (SRU) which lead to increased Sulfur Dioxide emission from the SRU Thermal Oxidizer (THOX) Followup: No Notes: K7702 was restarted and SRU and CFHT operations were stabilized and efforts were made to reduce SRU THOX Sulfur Dioxide concentrations | Sulfur Dioxide: 856.0 pounds |
| 78674 2005-04-29 | Coke drum | Cause: Coke drum got too hot, causing gases to be sent to flare Followup: No Notes: Below reportable quantities. LDEQ notes that the event that prompted the call was part of a Continuous Release Report filed October 14, 2002. | |
| 78361 2005-04-19 | K-401 (waste gas compressor number 2) | Cause: Waste gas compressor number 2 (K-401) automatically shut down, automatically diverting waste gas to the flare system. Followup: No Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize total amount of waste being sent to the flare. Same language about doing an investigation to understand the underlying cause and prevent future incidents. | Carbon Monoxide: 19.0 pounds Hydrocarbon: 12.0 pounds Hydrogen Sulfide: 3.0 pounds Nitric Oxide: 3.0 pounds Particulate Matter 10: 1.0 pounds Sulfur Dioxide: 970.0 pounds |
| 78345 2005-04-18 | No information given | Cause: Compressor tripped offline Followup: No Notes: Below reportable quantities | Sulfur Dioxide: 332.0 pounds |
| 78341 2005-04-17 | K-401 (waste gas compressor number 2) | Cause: Waste gas compressor number 2 (K-401) automatically shut down, automatically diverting waste gas to the flare system. Followup: No Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize total amount of waste being sent to the flare. | Carbon Monoxide: 14.0 pounds Hydrocarbon: 9.0 pounds Hydrogen Sulfide: 2.0 pounds Nitric Oxide: 2.0 pounds Particulate Matter 10: 1.0 pounds Sulfur Dioxide: 707.0 pounds |
| 78226 2005-04-13 | K-401 (waste gas compressor number 2) | Cause: Waste gas compressor number 2 (K-401) automatically shut down, automatically diverting waste gas to the flare system. Followup: No Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize total amount of waste being sent to the flare. Letter rescinds report of nitric oxide because below reportable quantity. | Nitric Oxide: 7.0 pounds Sulfur Dioxide: 2,161.0 pounds Carbon Monoxide: 42.0 pounds Hydrocarbon: 27.0 pounds Hydrogen Sulfide: 6.0 pounds Nitrogen Dioxide: 1.0 pounds Particulate Matter 10: 2.0 pounds |
| 78042 2005-04-06 | K-402 (Refinery waste gas compressor number 3) | Cause: K-402 unexpectedly shut down. Shortly after shutdown, refinery personnel identified the cause of the shutdown as a malfunction of the compressor motor ignition system. Followup: No Notes: The compressor motor was repaired and the compressor restarted, ending the incident. | Carbon Monoxide: 651.0 pounds Hydrocarbon: 422.0 pounds Hydrogen Sulfide: 90.0 pounds Nitric Oxide: 108.0 pounds Nitrogen Dioxide: 12.0 pounds Particulate Matter 10: 27.0 pounds Sulfur Dioxide: 33,873.0 pounds |
| 77936 2005-03-31 | K-400 (Refinery waste gas compressor number 1) | Cause: Refinery waste gas compressor number 1 (K-400) unexpectedly shut down. Refinery waste gas automatically diverted to the flare system. Followup: No Notes: Adjustments made to the fuel/air mixture and K-400 restarted. | Carbon Monoxide: 14.0 pounds Hydrocarbon: 9.0 pounds Hydrogen Sulfide: 2.0 pounds Nitric Oxide: 2.0 pounds Particulate Matter 10: 1.0 pounds Sulfur Dioxide: 706.0 pounds |
| 77649 2005-03-16 | No information given | Cause: Waste gas compressor number 2 (K-401) automatically shut down due to a high temperature. Followup: No Notes: Letter rescinds verbal report because incident was not reportable. No release to atmosphere. | Carbon Monoxide: 42.0 pounds Hydrocarbon: 27.0 pounds Hydrogen Sulfide: 2.0 pounds Nitric Oxide: 7.0 pounds Nitrogen Dioxide: 1.0 pounds Particulate Matter 10: 2.0 pounds Sulfur Dioxide: 888.0 pounds |
| 76355 2005-01-22 | K-406 (waste gas compressor number 4) | Cause: Waste gas compressor number 4 (K-406) unexpectedly shut down. Waste gas was automatically diverted to refinery safety flare system. Followup: No Notes: Rescinding notification for NO2. The refinery waste gas system and refinery operations were adjusted in order to minimize the amount of waste gas being sent to the flare. Sweet streams were routed to the flare in order to minimize sour gas flaring. K-406 was removed from service on 01/27/05 to complete an evaluation of the machine and perform other maintenance. Additional emissions listed in the Summary of Emissions were not mentioned in the report. This incident is related to incident # 76362.(There are two hand-written incident numbers, T76377 & T76382, on the PDF, but LABB believes they are not related to this event). | Carbon Monoxide: 138.0 pounds Hydrocarbon: 90.0 pounds Hydrogen Sulfide: 12.2 pounds Nitric Oxide: 23.0 pounds Nitrogen Dioxide: 2.5 pounds Particulate Matter 10: 5.8 pounds Sulfur Dioxide: 4,543.0 pounds |
| 76033 2005-01-06 | K-406 (waste gas compressor number 4) | Cause: K-406 unexpectedly shut down and waste gas was automatically diverted to refinery safety flare system. Followup: No Notes: Sweet streams (lower Sulfur content) were routed to the flare to minimize sour gas flaring. Process unit output was adjusted in order to minimize the total amount of waste gas being sent to the flare. Shortly after shutdown, personnel re-started K-406 restoring the systems ability to process available refinery waste gas streams, ending the incident. | Carbon Monoxide: 14.0 pounds Hydrocarbon: 9.0 pounds Hydrogen Sulfide: 2.0 pounds Nitric Oxide: 2.0 pounds Particulate Matter 10: 1.0 pounds Sulfur Dioxide: 726.0 pounds |
| 92383 2006-12-01 | AE-AOA-05-0109 EPN 28 | Cause: WGC (K-8101) tripped due to low seal Oil pressure. Main pump was shut down due to erratic operation due to wet steam. WGC restarted ending incidend. Liquid level indicator in the GRU condensate drum was not working. Followup: No Notes: put in work order for liquid level indicator. | Sulfur Dioxide: 722.0 pounds Nitrogen Oxide: 7.0 pounds |
| 92158 2006-11-18 | #1 Flare - AE-AOA-05-0109 EPN 28 | Cause: WGC K-406 tripped due to high vibrations. The shutdown caused the pressure in the WGS to increase and hydrocarbon gas with Hydrogen Sulfide was routed to the number 1 flare Followup: No Notes: cause of vibration is unknown at this time. K-406 will be inspected for damage. | Sulfur Dioxide: 4,607.0 pounds Nitrogen Oxide: 15.0 pounds |
| 92095 2006-11-15 | AE-AOA-05-0109 EPN 28 | Cause: FCC tripped due to a blown fuse and a malfunctioning component within the FCC multi lin and fuse system. A second mechanical failure (currently under investigation) dropped the remaining voltage to below the sct point. Followup: No Notes: Investigation ongoing. Unit feed rates reduced to a minimum and reactor severity was reduced. In addition, moves were made to minimize the main fractionators overhead receiver pressure. Process gas was routed to the #1 Flare while troubleshooting was performed. | Nitrogen Dioxide: 42.0 pounds Nitrogen Oxide: 374.0 pounds Volatile Organic Compounds: 1,429.0 pounds Sulfur Dioxide: 8,190.0 pounds |
| 91727 2006-10-29 | AE-AOA-05-0109 EPN 28 | Cause: mechanical failure in the check valve servicing the K-7702 Compressor. Make-up Discharge Check Valve mechanically failed and allowed the system to pressure back into the compressor. The resulting surge in pressure to the compressor caused the pressure safety valve on the first and second stage to relieve. Followup: No Notes: PSV was isolated until it rescated and lined back up to the compressor. During the next turnaround on the CFHT or shutdown, the valve for the K-7702 compressor will be replaced. | Nitrogen Oxide: 24.0 pounds |
| 88847 2006-06-23 | Emergency Flare System - AE-AOA-05-0109 EPN 28 | Cause: chiller malfunction. excess flare volume identified, search to identify source, as D9007 sphere as having relieved pressure to the emergency flare system. Sphere's chiller (ME9002) malfunctioned, heated up and overpressured. Followup: No Notes: sphere chiller was restarted which ended flaring. | Nitric Oxide: 19.0 pounds |
| 88694 2006-06-18 | No information given | Cause: malfunction on fuel drum Followup: No Notes: Letter written to rescind notification of 6/18/6 | |
| 88492 2006-06-11 | #2 Flare - AE-AOA-05-0109 EPN 29 | Cause: thermal overload from direct sunlight, automatic shut down of WGC Followup: No Notes: temporary roof installed over the motor starter / thermal load protection system. This will prevent direct sunlight from contributing to excess temperature on the thermal over arm protection system. | Nitric Oxide: 29.0 pounds Sulfur Dioxide: 2,926.0 pounds |
| 88381 2006-06-07 | Flare | Cause: off gas compressor tripped on overload and released to flare Followup: No Notes: Letter written to rescind notification of 6/7/06 | Sulfur Dioxide: 288.0 pounds |
| 88280 2006-06-02 | No information given | Cause: malfunction in a control valve causes a clearing incident Followup: No Notes: DEQ report with no corresponding letter from CRLLC | 0 Nitric Oxide: 8.0 pounds |
| 87647 2006-05-04 | Flare No. 1 AE-AOA-05-0109 | Cause: malfunctioning chiller, bad coil (report not legible). Release from Flare No. 1 Followup: No Notes: sphere chiller was switched, which ended flaring. | Nitrogen Oxide: 35.0 pounds |
| 87269 2006-04-19 | No information given | Cause: coker compressor failed Followup: No Notes: Letter states that emissions were BRQ | Sulfur Dioxide: 346.0 pounds |
| 86835 2006-03-29 | AE-AOA-05-0109 | Cause: Plant de-ethanizer tower (2410) relieved pressure to the emergency flare system after that propane treater (C7402) had plugged causing backpressure on the system leading to venting to emergency flare system. Release from Flare no. 2. Followup: No Notes: the refinery has initiated an investigation, appropriate measures will be taken in order to prevent a recurrence due to the same cause. | Nitric Oxide: 25.0 pounds Sulfur Dioxide: 472.0 pounds |
| 86817 2006-02-28 | NA | Cause: unanticipated failure cause a leak in instrument piping on a sight glass at the Sour Water Stripper Unit. The unanticipated leak caused the release of stripper overhead gasses to the atmosphere. Followup: No Notes: Piping was repaired and unit was returned to service. A review of the Sour Water Stripper Unit condensate flush piping will be conducted. | Hydrogen Sulfide: 139.0 pounds |
| 85863 2006-02-15 | Tank 75 Roof Vent | Cause: Small fire from a tank vent. Fire originated at the roof of tank 75. Followup: No Notes: Letter written to rescind notification of 2/14/06. Extinguished immediately. | |
| 100252 2008-10-16 | None Reported | Cause: relief valve failed on an operating unit Followup: No Notes: Letter states that no RQ's were exceeded | |
| 101836 2007-12-19 | #1 Flare | Cause: #4 Waste Gas system shut down because of misalignment of a sensor and magnetic pick-up. CRLLC technicians also found a bad bearing for the cam shaft idler sprocket. Followup: No Notes: Operators immediately tried to start a second compressor. Restarted the shutdown compressor and removed gas flow from flare, ending event. | Sulfur Dioxide: 1,955.0 pounds |
| 101150 2007-11-18 | #1 Flare | Cause: HGO Pump around failed, causing a shut down of #2 Coker Off Gas Compressor Followup: No Notes: Operators established the HGO Pump Around before restarting the K-8101 Compressor. When compressor restarted, gas flow removed from flare, ending incident. | Sulfur Dioxide: 4,484.0 pounds |
| 100171 2007-10-14 | #2 Flare | Cause: #2 crude unit prefractionator tower reflux pump tripped Followup: No Notes: Letter states that no RQ's were exceeded | |
| 99603 2007-09-19 | Hydro-cracker HCU Unit First Stage Reactor | Cause: Hydro-cracker HCU Unit First Stage Reactor malfunction Followup: No Notes: Letter states that no RQ's were exceeded | |
| 99116 2007-09-03 | No information given | Cause: SRU unit, train 1, pit blower K8003 suffered equipment failure. Followup: No Notes: Letter states that no RQ's were exceeded | |
| 97329 2007-06-22 | Number 2 Flare No information given | Cause: chain operator on the sour waste gas block valve on the #3 Deoctane Overhead Off-Gas Line failed allowing waste gas to go to flare Followup: No Notes: CRLLC repaired the malfunctioned chain operator on the #3 Deoctane Overhead Off-Gas sour waste gas block valve. | Sulfur Dioxide: 509.0 pounds Sulfur Dioxide: 495.0 pounds |
| 96641 2007-05-30 | Number 1 Flare | Cause: failure of the central processing unit within the ignition control system for the engine driver for K-402. Followup: No Notes: Central Processing Unit within the ignition control system was replaced | Sulfur Dioxide: 8,132.0 pounds |
| 95928 2007-05-05 | No information given | Cause: new flare gas recovery system that the compressor tripped on Followup: No Notes: Letter written to rescind notification of 5/5 concerning release of SO2. File includes flare assessment report for month of April. | |
| 93240 2007-01-11 | #2 Flare | Cause: #2 prefractionator tower bottoms level controller malfunctioned causing resulted in venting to #2 flare Followup: No Notes: Refinery has issued a work order to repair the Prefractionator Tower bottoms level controller (741C012) | Sulfur Dioxide: 822.0 pounds |
| 93101 2007-01-07 | Sulfur Recovery Unit | Cause: the governor control arm was sticking which caused a problem with the blower. Followup: No Notes: Initial report indicates emissions were: SO2 - 500 lbs and H2S - 100 lbs, but letter from Chalmette states that further investigation indicates amt released of both substances was 0 lbs. Follow-up letter adjusts emissions to numbers listed here. | Sulfur Dioxide: 433.0 pounds Hydrogen Sulfide: 8.0 pounds |
| 93102 2007-01-06 | Exchanger E2321 on 2nd Stage Effluent Cooler of Hydrocracker Unit | Cause: leak in the tube sheet on the E2321 Exchanger Followup: No Notes: CRLLC will replace Exchanger E2321 with an upgraded new exchanger. | Volatile Organic Compounds: 50.0 pounds Light Oil: 49.0 gallons |
| 110493 2008-10-30 | Sulfur Recovery unit THOX stack | Cause: lost a burner during start up of THOX Followup: No Notes: Letter states that emissions were BRQ. | |
| 108882 2008-09-11 | No information given | Cause: pressure safety valve released Followup: No Notes: No Information Given | |
| 106153 2008-06-04 | Chemical loading rack | Cause: sump at chemical loading rack has a crack Followup: No Notes: Upon discovery, released liquids were recovered via vacuum truck for appropriate reprocessing. Liquids recovered for reprocessing. Soil impacted removed for proper disposal. | Xylene: 6.0 pounds |
| 106122 2008-06-03 | Train 1 Reaction furnace | Cause: hairline crack in a weld where the side port nozzle enters the Train 1 Reaction furnace. SRU operations were adjusted to minimize emissions from this crack. Followup: No Notes: Inspectors analyzed the area of the leak and a repair plan has been initiated. SRU operations were adjusted to minimize emissions. | Hydrogen Sulfide: 222.0 pounds |
| 103437 2008-02-26 | No information given | Cause: power failure in FCC Unit Followup: No Notes: Letter states that emissions were BRQ. | |
| 102542 2008-01-24 | Frac Tank | Cause: two hoses draining wash water from a Frac Tank to the industrial sewer system allowed wash water to seep through the sides Followup: No Notes: Upon discovery, draining activities were suspended. Released liquids were recovered via vacuum truck and properly containerized for dispsal. | Wash Water: 50.0 gallons |
| 102088 2008-01-04 | No information given | Cause: Vacuum compressor at #1 crude tripped Followup: No Notes: Letter states that emissions were BRQ. | |
| 126929 2010-10-07 | FLARE | Cause: LDEQ states that there was leak in the flare system. Followup: No Notes: No Information Given. LDEQ Report included. No Refinery Letter. | |
| 120686 2010-01-10 | TANK 56; fast loop sampling pump G3832 | Cause: Leaking gasoline blend pump. Gasoline release adjacent to Tank 56. Followup: No Notes: Liquid removed with vacuum truck, contaminated soil removed & disposed of. Report stated that no groundwater impact or health effects were identified as a result of incident. | Gasoline: 147.0 gallons Volatile Organic Compounds (VOCs): 512.0 pounds |
| 120629 2010-01-08 | SOX scrubber | Cause: Fluid Catalytic Cracking (FCC) SOX scrubber circulating water pumps failed due to catalyst pluggage. Followup: No Notes: RQ. had difficulty dislodging the catalyst--tried switching pumps off & on, using portable air compressor, increased grid wash, FCC charge rate decreased continuing to monitor performance of SOX scrubber | Sulfur Dioxide: 1,956.0 pounds |
| 135522 2011-11-29 | Unspecified valve | Cause: Packing leak on valve. Followup: No Notes: Chalmette Refining provided a courtesy notification to the LDEQ regarding a release of Hydrogen Fluoride on November 29, 2011. After further review, there were no RQ exceedances or permit violations as a result of this event. | Hydrogen Flouride: 10.0 pounds |
| 135438 2011-11-20 | #1 Flare | Cause: The flare gas machines lost its pumping ability. The stages on the #1 flare overpressured and burned the gas into the atmosphere. The cause is under investigation. Followup: No Notes: Chalmette Refining provided a courtesy notification to your office regarding a release of Sulfur Dioxide on November 20, 2011. After further review, there were no RQ exceedances or permit violations as a result of this event. | |
| 135184 2011-11-09 | Flare: Flare No. 1 | Cause: The low pressure side waste gas compressor shutdown due to a fuel control valve failure. This routed the low pressure side waste gas to the Flare Gas Management (FGM) system. Followup: No Notes: The fuel control valve was repaired. The low pressure side waste gas compressor was restarted, and the stream was removed from the FGM system. The seal water on the FGM compressors was changed out. There is no SPOC report and no LDEQ report in the file. | Sulfur Dioxide: 5,484.0 pounds |
| 134471 2011-10-10 | FLARE-No. 1 Flare; SRU 1 | Cause: There was sudden unexpected loss of O2 supply from Air Products causing SRU1 to immediately shut down. Acid gas (SO2 and H2S) was released intermittently through Number 1 Flare. SRU 1 was sole operating SRU at the time of incident, as SRU 2 was shutdown for maintenance. Followup: No Notes: Steam controllers have been repaired and rebuilt. There was also an evaluation of alarm changes to provide more response time. EPA Acid Gas Flaring report included. LDEQ conducted an investigation in response to this incident on 12/8/11. | Sulfur Dioxide: 164,891.0 pounds Hydrogen Sulfide: 595.0 pounds |
| 134390 2011-10-07 | Tank 71 Floating roof Tank 403 Cam Lock fiting | Cause: Oil was initially discovered on the roof of Tank 71 on August 9, 2011. The emissions were determined to be less than reportable quantities, so no notifications were required. To mitigate leak potential and offsite impacts, the oil was removed daily to prevent accumulation and emissions potential until repair investigation efforts could be completed.
On October 7, 2011, at approximately 1040 hours, while cleaning the tank roof to allow for additional inspection, roof scale was dislodged, and a roof leak developed, eventually covering the entire surface area of the tank roof with oil. Foam was applied to the tank roof at 1540 hours, mitigating odors and emissions. Oil was removed from the tank roof October 9, 2011. Though ongoing emissions following removal of the oil are estimated to be below reportable quantities, the tank roof is not floating on the product, thus incident response efforts are still considered in progress, as repairs are completed.
At approximately 0915 hours on October 11, 2011 a separate incident at a different tank resulted in hydrocarbon and benzene emissions for approximately 1 hour. Followup: Yes Notes: Mitigation efforts to reduce emissions potential commenced promptly, as tank level was reduced, however, the product could not be removed from the tank roof. Foam was applied to the tank roof at 1540 hours,greatly reducing emissions from the event. The tank roof was landed Sunday, October 9, and the oil was able to be removed from the floating roof. Additionally, the tank contents were drained and water was introduced into the tank, however, a thin oil layer remained present as repairs were progressed. Repairs were completed October 14, 2011. Repairs were completed on areas where thickness readings determined necessary on October 14, 2011. | Hydrocarbon: 21,085.0 pounds Benzene: 191.0 pounds Xylene: 361.0 pounds Gasoline: 20.0 gallons |
| 133679 2011-09-06 | Tank Roof Leak | Cause: Emission values included in the later report of 134390. All values in notes for this report. On August 9, 2011, at approximately 0930 hours, oil was discovered on the roof of Tank 71. The roof was cleaned and visually inspected, and though no leaks were discovered, it was determined that additional inspection was required, including mechanical thickness readings. Additional cleaning was necessary for this to occur. Concurrently, it was determined that the source of the oil was likely a failed check valve on the tank roof drain. This drain was plugged to ensure no oil could back up onto tank roof.
On Friday, October 7, 2011 at approximately 1040 hours, while cleaning the roof of Tank 71 to allow the inspection group to access the roof for mechanical thickness reading, scale was removed and a hole developed in the roof. Cleaning was stopped at that point and personnel exited the roof and notified Refinery personnel. The initial leak estimate determined it to be potentially in excess of 1000 lbs of hydrocarbon and 10 lbs of benzene. Prompt notifications to the agencies were made upon discovery.
In a separate event at 0915 hours on October 11, 2011, approximately 20 gallons of gasoline were released to the soil when a cam lock fitting did not seal properly at Tank 403. The emissions associated with this event were approximately 116 lbs hydrocarbon and 1 lb of benzene. In combination with the above incident, the RQ for benzene was exceeded. Followup: No Notes: Mitigation efforts to reduce emissions potential commenced promptly, as tank level was reduced, however, the product could not be removed from the tank roof. Foam was applied to the tank roof at 1540 hours, greatly reducing the emissions from the event. The tank roof was landed Sunday, October 9, and the oil was able to be removed from the floating roof. Additionally, the tank contents were drained and water was introduced into the tank, however a thin oil layer is still present as repairs progressed. There were multiple complaints associated with this incident; a. Terrible odor coming from the direction of the river where there is a barge parked, and several facilities in that direction as well. t134349 b. Terrible odor coming from the direction of the river making several people in area sick. Vomiting, headache, and child exposure. t133866 c. Barge that has been tied up at the docks for 2 days is producing terrible odors. No tempo # d. Incredibly strong and foul odor coming from the direction of the river. No Tempo # | |
| 133061 2011-08-11 | FLARE: Unspecified location | Cause: A high pressure waste gas flaring system shut down. The flare gas recovery compressor could not handle the load and sulfur dioxide was released into the atmosphere. Followup: No Notes: The unit rates were reduced to lower the amounts going to the flare. | |
| 132057 2011-06-26 | Slop Oil Tank #72 | Cause: A leak from the umbilical cord of Slop Oil Tank #72 released oil on the ground in containment area. Followup: No Notes: The valves were isolated and the leak secured. The slop oil was contained in the dike area and USES went out for clean-up. | |
| 131213 2011-05-13 | FLARE-No. 1 Flare; Sulfur Recovery Unit (SRU) Train II | Cause: Air Products, third party oxygen supplier, experienced a malfunction of an emergency safety device. Oxygen supply was lost to Train II of SRU. The Flare Gas Management System shutdown because of acid gas from the DGA strippers. Two follow-up letters dated 10/25/11 and 11/15/11. Followup: Yes Notes: Report states that Air Products re-secured a loose control relay and has ordered a new relay that will fit more securely. EPA Acid-Gas Flaring incident report included. Follow-up letters: A new control relay has been obtained and will be installed in Q4 2012 during a planned outage. | Sulfur Dioxide: 117,344.0 pounds |
| 131070 2011-05-09 | PGC 2nd Stage Aftercooler | Cause: The PGC 2nd Stage Aftercooler leaked hydrocarbon vapors and compressed flammable gas was released to water. OFFSITE IMPACT: Mississippi River. Followup: No Notes: BRQ. Refinery letter states that release was below reportable quantities. The exchanger was isolated and the path to water was closed. A boom was deployed at the source and downriver. | Compressed Flammable Gas: 1,952.0 pounds |
| 131074 2011-04-30 | Cooling Water Platform | Cause: An operator making a normal round at the Cooling Water Platform noticed oily water sump, D8410, overflowing to the river bature. It was later determined that the check valve on the discharge of the pump had failed in the open position, allowing untreated wastewater to backflow in to the sump. Less than one gallon of oil was released. Followup: Yes Notes: Upon discovery, the operator secured the valve and started the pump to evacuate the sump. United States Environmental Services (USES) was dispatched to deploy containment boom around the immediate area and use absorbent boom to recover any potential hydrocarbon present. The clean up was completed on Monday, May 2, 2011. CRLLC replaced the sump check valve on May 4, 2011. Additionally, in an effort to minimize the likelihood of a reoccurence, CRLLC installed an independent high level alarm system on the sump. | Wastewater: 10.0 gallons Oil: 1.0 gallons |
| 129573 2011-03-01 | Flare | Cause: Malfunction of the compressor spillback valve. The Fluidized Catalytic Cracker (FCC) main fractionator overhead accumulator pressure control valve (79PC502F) began to open to flare due to a sudden increase in pressure in the accumulator, which led to flaring at the #1 Flare. The sudden pressure increase was the result of a stuck compressor spillback valve. Followup: No Notes: Feed rate to the unit was reduced, pressure was reduced and the pressure control valve setpoint was raised. CRLLC has determined the cause of this release to be a malfunction of the compressor spillback valve. The valve has been evaluated by a technician and the pressure control valve setpoints are being reviewed. | Sulfur Dioxide: 1,014.0 pounds |
| 129367 2011-02-17 | Alky Unit, leak in release valve | Cause: A pin hole leak in a release valve released Isobutane and Hydrofluoric Acid. Followup: No Notes: BRQ. The unit was deactivated and air monitoring commenced. | Isobutane: 1,000.0 pounds Hydrofluoric Acid: 2.0 pounds |
| 141431 2012-07-21 | external floating roof on Tank 1 Tank 1 (ground level) | Cause: The external floating roof on the Tank 1 crude tank sunk and exposed contents of the tank to the environment.
A leak developed from Tank 1 floor area and released oil to the ground inside of the containment area. Foam was applied to the top of the tank to mitigate potential vaporization of hydrocarbons. Mitigation efforts are ongoing to empty the tank and the majority of oil has been emptied from the tank. Water has been successfully introduced to vessel to float the oil later off the tank floor. Currently, oil is no longer leaking to the ground. Followup: Yes Notes: Foam was applied to the top of the tank. Trace amount of benzene were indicated by monitoring data. Foam was applied to the top of the tank to mitigate potential vaporization of hydrocarbons. Mitigation efforts are ongoing to empty the tank and the majority of oil has been emptied from the tank. Water has been successfully introduced to vessel to float the oil later off the tank floor. Oil is no longer leaking to the ground. Air monitoring was conducted at the tank perimeter, fence line and offsite. No fence line or offsite impacts were identified. Low levels of benzene and volatile organic compounds were detected periodically at the perimeter of the tank, but no adverse impacts occurred. | Oil: 42.0 gallons |
| 140083 2012-05-26 | Cause: The facility experienced malfunctions when the high pressure waste gas system was shut down in the Coker unit, releasing sulfur dioxide to the flare. High Pressure Waste Gas System (HPWGS) compressors K402 and K406 were unavailable due to mechanical issues and the Flare Gas Management System was used instead. This usually works but the depropanizer surge drum water boot sprung a leak and heavy material entered the shut down HPWGS. Followup: No Notes: The high pressure waste gas system had been restored by the time of the LDEQ Incident Report. | Sulfur Dioxide: 5,769.0 pounds Compressed Flammable Gas: 1,000.0 pounds Hydrogen Sulfide: 100.0 pounds | |
| 152005 2013-10-31 | D acid cooler Flare #1 | Cause: On October 30, personnel identified increased fluoride levels of routine samples at the battery limits of the Alkylation unit in the cooling water return system from 0.39 parts per million (ppm) to 0.5 ppm. Based on preliminary findings, the "D" acid cooler at the alkylation unit appears to have developed a leak. Sampling conducted at Outfall 013, which measures fluoride concentration, suggests a neutral pH, dilute solution of HF was leaking from a heat exchanger in the cooling water system and discharged through the outfall. CRLLC personnel began to shutdown the unit in order to isolate the cooler on October 31. As a result of the leak and subsequent shutdown of the unit, intermittent flaring occurred at the #1 Flare beginning on October 31 and ending on November 2. Followup: No Notes: The Alkylation Unit was shut down in a safe and controlled manner in order to isolate the acid cooler. The acid cooler is being inspected and repaired to minimize the risk of recurrence. The rates were reduced and the acid was evacuated from the unit. Fluoride samples were measured from the cooling water effluent throughout the shutdown of the unit. The pH of Outfall 013 was continuously monitored. | Hydrogen Flouride: 218.0 pounds Sulfur Dioxide: 10,360.0 pounds |
| 150109 2013-08-05 | Pump G-1083 | Cause: On August 5, 2013, personnel identified a leak at a clay tower charge pump (G-1083) which was determined to be from a broken nipple on the pump. Once the area was isolated, the pump was turned off and removed from service. Community monitoring was conducted during the event and all results were non-detect. Onsite fenceline monitoring indicated no offsite impacts to the community. Followup: No Notes: The pump was turned off and removed from service to isolate the leak. Improvements are being conducted which will replace the current schedule 80 nipple with a schedule 160 nipple to reduce the risk of future failures. A gusset will also be installed on the nipple for support. | Benzene: 80.6 pounds |
| 149989 2013-07-28 | Flare #1 | Cause: On Sunday, July 28, 2013, at approximately 0349 hours, the flare gas management (FGM) compressors began to lose suction and stopped pumping resulting in the staging of the #1 Flare for approximately 7 minutes. With the inability of the compressors to pump reliably, a water change out was required to get the system back in normal and stable operation. This process intermittent flaring between 10:44 and 18:11. Followup: Notes: Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. An ongoing evaluation of the equipment during the event revealed the flare gas recovery water purge capability was restricted. This resulted in increased unreliability of the compressors due to the reduced discharge rate of the high molecular weight water recirculating in the system. The water purge capability was restored on 7/29 and should result in faster recovery times from unplanned high molecular weight gas events. LDEQ conducted "onsite discussions" with Chalmette Environmental and business supervisor related to three accidents related to the FGC and WGC units between 7/25-7/28 (149927, 149989, 150004) on 8/28/2013. | Sulfur Dioxide: 1,548.0 pounds |
| 149525 2013-07-07 | FGM compressor | Cause: On July 7, 2013, the flare gas management (FGM) compressors began to lose suction intermittently due to mechanical issues caused by high molecular weight material being routed to the compressors. A comprehensive investigation determined that controlled venting from Tk-9005 and a PSV leaking from the FCC Unit and relieving to the FGM system were the cause of the FGM compressor mechanical issues. The two identified sources were blocked in and the compressors were brought back online. Community monitoring was conducted during the event and all results were zero. Followup: Yes Notes: Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. TK-9005 vent and the FCC PSV were blocked in to isolate the materials from being routed to the flare gas compressors. | Sulfur Dioxide: 1,854.0 pounds |
| 149521 2013-07-06 | No information given | Cause: On July 6, 2013, mechanical problems with the FGR compressors caused a release of sulfur dioxide. No reportable quantities were exceeded as a result of this release. Followup: Notes: No information was provided in addition to the release being below reportable quantity. | Sulfur Dioxide: 50.0 pounds |
| 149333 2013-06-22 | No Information Given | Cause: On June 22, 2013, sulfur dioxide released to air due to compressor trip. Followup: No Notes: The refinery letter only included that the incident was below reportable quantity. No information regarding duration or point source were included. | |
| No LDEQ Reported 2013-01-20 | Cause: Broken valve caused spill. Followup: Notes: Material cleaned up and no offsite impacts noted, leak secured at time of first follow up call. A second follow call in the evening notified me that the facility was receiving notifications from citizens about oil on Co Rd S. Dense fog is suspected to be cause for material leaving site. Facility has set up a number for citizens to report any impacts. Clean up is a priority. A follow-up visit will be conducted once material has been cleaned. 36 barrels of crude oil were released. | Crude Oil: 1,512.0 gallons | |
| 159191 2014-10-02 | K406 waste gas compressor | Cause: On Thursday, October 2 2014, at approximately 01:47 hours, Waste Gas Compressor K-406 tripped an overspeed and routed all gas to the flare gas recovery (FGR) system. The FGR system was unable to handle the excess gas and flaring occurred intermittently for 25 minutes until K-406 could be restarted. While investigating the cause of the K-406 compressor trip, another overspeed trip occurred at approximately 23:42 hours on October 2, 2014. All waste gas was routed again to the FGR system which was unable to recover the excess gas and intermittent flaring occurred for approximately 22.06 hours after several attempts to restart the compressor failed.
During this time Waste Gas Compressor K-402 was also down for repairs after a mechanical failure had previously occurred. With both waste gas compressors down there was no ability to recover any of the waste gas to relieve some of the flow to the FGR system.
Investigation of the accident determined that the cause of the K-406 trip was a sticking butterfly valve which regulates the fuel gas flow to the compressor. Personnel conducted extensive analysis and troubleshooting on K-406 to determine potential causes for the compressor trip.
The initial compressor trip was reported under LDEQ # 159284, however the emissions for both events were reported under 159191. Followup: No Notes: Flow rates to the flare system were minimized as much as possible throughout the refinery until Waste Gas Compressor K-406 could be returned to service. After K-406 was returned to service the FGR system also returned to normal operation and flaring ceased. Once it was determined that the butterfly valve was the leading root cause the valve was lubricated and returned to service. Chalmette Refining is developing an equipment procedure to add the butterfly valve as a potential failure scenario and conduct annual preventative maintenance on the valve to prevent any future recurrences. | Sulfur Dioxide: 30,620.0 pounds Volatile Organic Compounds (VOCs): 1,380.0 pounds |
| 156690 2014-06-10 | Compressor K81-01 | Cause: K 81-01 shut down - the compressor that usually pumps this gas, located in the #2 Coker Unit. Followup: No Notes: Shut down unit. | |
| 154346 2014-03-09 | Heat exchanger | Cause: A heat exchanger leaked and leaked back to process Followup: No Notes: Leak fixed; booms deployed as precautionary measure; they are in the process of raising the pressure to prevent any sheen to river' visual monitoring; no outfall analyzer readings | |
| 153798 2014-02-22 | Sulfur Recovery Unit, reactor bed | Cause: During start up, personnel was putting air through the sulfur recovery unit when the sulfur on the reactor bed lit off causing emissions. The small fire inside the unit was caused due to induction of air through the train. Followup: No Notes: Nitrogen was utilized to remove fire from the reaction bed. Notification letter on 2/17/14 with same state police number references an accident on 2/10/2014. No information about that accident. | |
| 153612 2014-01-30 | Crude #1 PSV | Cause: On January 30, 2014, at approximately 06:30, Chalmette Refining personnel identified an atmospheric Process Safety Valve (PSV) leaking on the Crude #1 stabilizer tower, resulting in a release of a liquid petroleum gas (LPG) material comprised primarily of propane and butane. Followup: No Notes: The issue was safely resolved at 07:15 am by blocking the inlet to the relief valve. The PSV on the Crude #1 stabilizer tower was sent our for evaluation and it was determined that the internal spring had fractured causing the malfunction. A failure analysis of the PSV is being conducted to determine the cause of the failure and prevent recurrence. 60 day follow up is promised but has not been available to LABB. | Compressed Flammable Gas: 24,340.0 pounds |
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