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Chalmette Refining (1376), Chalmette

Causal Factor: Piping or Tubing

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
84418

2005-12-09
Slop Oil Line
Cause: A leak had occurred from a slop oil line between a benzene storage take and a larger, aromatics feed storage tank.

Followup: No

Notes: At approximately 0345 hours on December 9, 2005 refinery personnel identified a hydrocarbon odor on the refinery property. The area was located within the refinery, along the south side of the Hydrodesulfurization Unit. After investigating the odor it was determined that a leak had occurred from a slop oil line between a benzene storage tank and a larger, aromatics feed storage tank. Liquid recovered was returned to refinery slop oil for processing. Excavated soils were containerized on staged on site pending proper disposal at an off site disposal facility. When the situation was discovered, the transfer was stopped immediately, ending the incident. The line has been removed from service and inspected in order to implement an appropriate repair plan. The section of the line which resulted in this release is being replaced with new piping. The refinery claims that the liquid released was contained on refinery property and recovered via vacuum truck. No migration off of refinery property or to groundwater has been observed. Excavated soils were containerized and staged on site pending proper disposal at an off site disposal facility. *The quantity of benzene and slop oil, although listed as separate pollutants below have one quantity totally 288 pounds (39.3 gallons).

Benzene: 288.0 pounds
No LDEQ Reported

2005-07-24
Above ground transfer piping
Cause: Drip from a transfer line on Crude Terminal Dock.

Followup: No

Notes: Line determined to be leaking was isolated; Boom was deployed to contain and absorb the sheen on the wirer surface. The section of pipe that leaked was repaired and placed back in service. BELOW REPORTABLE QUANTITIES
Sweet Crude Oil: 1.8 pounds
80566

2005-07-16
Hydrodesulphurization (HDS) Unit problem went to No. 2 Flare
Cause: Leak in the HDS due to failure in the piping. Sulfur dioxide released into atmosphere through the refinery Number 2 Flare.

Followup: No

Notes: The unit was shut down so that the leak could be isolated and repaired. Although Chalmette Refinery listed the release of hydrogen sulfide as below reportable quantities, LDEQ's final report states that the minimum reportable quantity was released.
Hydrogen Sulfide: 100.0 pounds
Volatile Organic Compounds (VOCs): 72.0 pounds
Sulfur Dioxide: 1,126.0 pounds
80533

2005-07-15
Cat feed hyrdrotreater unit problem caused release to the No. 2 Flare
Cause: Cat feed hydrotreater (CFHT) developed a leak due to a failure in the piping. The unit was shut down in order to eliminate the lead and safely conduct repairs. Vented through flare 2

Followup: No

Notes: Cat Feed hydrotreater (CFHT) was shut down and hydrogen and process gas vented to the refinery flare system. Operations were conducted in order to minimize emissions while maintaining a safe and orderly shutdown and restart of the CFHT. Chalmette Refinery rescinded its notifications of both gas oil and sulfur dioxide, stating that there was not a reportable amount of gas oil spilled on the concrete slab, and also that 0 lbs of sulfur dioxide was released.
Nitric Oxide: 127.0 pounds
Nitrogen Dioxide: 14.0 pounds
80303

2005-07-04

Cause: Leak in crude oil feed line leading to one of their units.

Followup: No

Notes: BELOW REPORTABLE QUANTITIES.

78348

2005-04-18
No information given
Cause: A broken pipe led to the release

Followup: No

Notes: Below reportable quantities
Hydrogen Sulfide: 1.0 pounds
78166

2005-04-11
Refinery dock #4 transfer line
Cause: Drip from the transfer line on Refinery Dock #4 caused a release of diesel fuel to the surface of the Mississippi River.

Followup: No

Notes: Absorbent materials placed under the drip to contain the material; a boom was used to contain and absorb the sheen on the water surface; vacuum trucks were also used. Note: a subsequent letter from the same day rescinds the report. See below.
Diesel Fuel: 8.0 gallons
77290

2005-03-02
Waste Gas Compressor Number 4 (K-406); Copper tubing connecting C-435 (first stage suction drum) to high-level instrumentation
Cause: Waste gas compressor number 4 (K-406) shut down due to failure of piece of copper tubing connecting C-435 to high-level shutdown instrumentation. When it failed, a false high level reading was recorded, causing automatic safety shutdown system to become engaged.

Followup: No

Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize amount sent to the flare. C-435 was retubed, K-406 was checked and restarted.
Carbon Monoxide: 182.0 pounds
Hydrocarbon: 118.0 pounds
Hydrogen Sulfide: 17.0 pounds
Nitric Oxide: 30.0 pounds
Nitrogen Dioxide: 3.0 pounds
Particulate Matter 10: 8.0 pounds
Sulfur Dioxide: 6,322.0 pounds
92464

2006-12-07
Lube Oil Cooler on Waste Gas Compressor K-406
Cause: leak in lube oil cooler tubing on WGC

Followup: No

Notes: Lube oil cooler on compressor was shut down. Leaking cooler tubing was repaired and all of the tubing was hydro-tested.
Lubricating Oil: 5.0 gallons


92469

2006-12-07
Lube Oil Cooler on Waste Gas Compressor K-406
Cause: leaking lube oil cooler on WGC

Followup: No

Notes: Letter written to rescind notification of 12/7/6


Lubricating Oil: 5.0 gallons
92327

2006-11-29
Rich Solvent Line in Sulfolane Unit
Cause: small leak detected on a rich solvent lin in the Solfolane Unit (06-07211). Small pinhole leak with slow drip. Clamped leak until pipe can be replaced

Followup: No

Notes: 27 lbs is a large amount for a slow leak lasting 25 min.
Benzene: 27.0 pounds
92297

2006-11-27
No information given
Cause: release escapes from leaking pipe

Followup: No

Notes: Letter sent to rescind notification of 11/27/6
Benzene: 1.0 pounds
91826

2006-11-02
Number 2 Prefrac Bottoms Stream Line to TK61
Cause: number 2 prefrac bottoms stream line to TK61 was leaking due to a hole in the pipe. Maphtha migrated across sOil and accumulated in an onsite concrete drain pipe.

Followup: No

Notes: Line was isolated and released material was contained within refinery property and recovered for proper handling. Excavated sOils were containerized and stored on site. Put in place a piping inspecion program to routinely assess and inspect pipes in order to reduce the likelihood of an incident occurring due to the same root cause.
Naphtha: 719.0 pounds
89255

2006-07-13
AE-AOA-05-0109 EPN 46
Cause: section circulation impeded when an exchanger is plugged resulting in diversion from train 2 to train 1

Followup: No

Notes: Repairs to Train 2 MDEA Lean/Rich Exchanger (E8062) are being scheduled in order to return Train 2 tail gas section to service.
Sulfur Dioxide: 1,136.0 pounds
88213

2006-05-31
Number 2 Flare
Cause: cracked tubing caused an instrument to malfunction and caused WGC to trip

Followup: No

Notes: The cracked copper tubing was replaced with stainless steel tubing in order to improve durability. The refinery will evaluate installations on the Low Pressure Waste Gas system where copper tubing is utilized for instrument connections and make upgradesto that tubing, if deemed appropriate, during the next unit turnaround.
Sulfur Dioxide: 782.0 pounds
87979

2006-05-19
Process unit
Cause: leak in a fan in a process unit

Followup: No

Notes: No information given
Sulfur Dioxide: 301.0 pounds
Nitric Oxide: 1.0 pounds
Compressed Flammable Gas: 486.0 pounds
86075

2006-02-27

Bleeder valve plug in truck loading rack area
Cause: a bleeder valve failed on a line leading to the truck loading facility

Followup: No

Notes: DEQ report with no corresponding letter from CRLLC. Valve was quickly isolated and replaced. Liquid was recovered via vacuum.
Diesel Fuel: 70.0 gallons

85198

2006-01-15
Flare
Cause: leak in the LPG line

Followup:

Notes: DEQ report with no corresponding letter from CRLLC

101270

2007-11-27
#2 Flare
Cause: frozen material in a pipe prevented material from the HCU and Pretreater to leave towers. Pressure was relieved to flare.

Followup: No

Notes: CRLLC repaired the level gauge and the level transmitter on the De-ethanizer
Sulfur Dioxide: 763.0 pounds
101172

2007-11-20
Refinery Pipeline
Cause: pinhole leak in a pipe

Followup: No

Notes: No information given


100395

2007-10-22
Cooling Water Exchanger
Cause: cooling water exchanger leak

Followup: No

Notes: No information given

99712

2007-09-24
None Reported
Cause: clamp on a finfan E7776B line leaked

Followup: No

Notes: Letter states that no RQ's were exceeded
99492

2007-09-16
#1 Flare
Cause: hole in the pipeline

Followup: No

Notes: Letter states that no RQ's were exceeded

99133

2007-09-04
#1 Reformer
Cause: #1 Reformer had piping failure on debutanizer reflux line…compressed gas

Followup: No

Notes: Letter states that no RQ's were exceeded

98779

2007-08-20
Flare
Cause: compression fitting on tubing failed on salt water stripper

Followup: No

Notes: No information given

No LDEQ Reported

2007-07-04
Outfall 210
Cause: pipe connection malfunctioned allowing a small leak to occur

Followup: No

Notes: CRLLC has excavated the area around the leak and isolated the leak in order to make appropriate repairs before placing the line back in service.
Hydrocarbon: 1.0 pounds
93200

2007-01-10
1st Stage Fin Fan E2415 tube
Cause: leak in tube on 1st stage fin fan

Followup: No

Notes: Root cause analysis initiated. Tube has been sent offsite for analysis. Measures will be taken based on result of analysis.
Nitrogen Oxide: 1.0 pounds
Volatile Organic Compounds: 469.0 pounds

Hydrogen Sulfide: 194.0 pounds
Sulfur Dioxide: 25.0 pounds
111122

2008-11-28
Desalter relief valve header piping
Cause: desalter relief valve header piping developed aleak

Followup: No

Notes: Release was isolated, line depressurized and scanned, and a clamp was installed. As of 12/1/08 the line was back in service
Crude Oil: 1,100.0 pounds
Volatile Organic Compounds: 9.0 pounds
109831

2008-10-06
LGO line
Cause: diesel leak from piping on the Coker Light Gas Oil line. Overpressuring in piping caused components to loosen

Followup: No

Notes: Line was isolated to stop leak. Vacuum truck recovered released liquids. Training on the interaction of two hot streams with an ambient temperature stream in a common pipe was discussed with the operators
Diesel Fuel: 64.0 gallons
109521

2008-09-23
Outfall 003
Cause: tube leak on overhead exchanger

Followup: No

Notes: Shut down the cooling unit and isolated the exchangers. Letter states that emissions were BRQ. Verbal report indicates emission of 1000 lbs of compressed gas.

108060

2008-08-15
number one pump around
Cause: -- piping leak on number one pump around

Followup: No

Notes: Claims emission was below RQ.



107890

2008-08-08
Sour Water line depropanizer feed surge drumlevel controller at the LEP
Cause: leak on the sour water line

Followup: No

Notes: Claims emission was below RQ.

106853

2008-06-30
No information given
Cause: -leak on underground piping

Followup: No

Notes: Claims emission was below RQ 5000 lbs.
Butane: 4,124.0 pounds
105733

2008-05-19
Transfer run down line
Cause: Transfer run down line from xylene unit to tank leaked

Followup: No

Notes: Letter states that emissions were BRQ.
Xylene: 58.0 pounds
No LDEQ Reported

2008-02-01
16 inch upriver loading arm
Cause: a vacuum breaker line failed causing release of crude from barge into Mississippi

Followup: No

Notes: Wharf personnel immediately ceased unloading of the cargo and closed all valves on the transfer line. Absorbent booms deployed.
Crude Oil: 6.0 pounds
120390

2009-12-28
#3 Pretreater overhead accumulator
Cause: #3 Pretreater overhead accumulator had leak on site glass.

Followup: No

Notes: RQ not exceeded.


120342

2009-12-22
flange
Cause: Leaking flange caused release.

Followup: No

Notes: RQ not exceeded. Clamp was placed over the leak.

118252

2009-09-28
tank M3
Cause: Tank M3 leaking at base.

Followup: No

Notes: RQ not exceeded. Vacuum truck to clean up leak. Pan placed under leak.


118170

2009-09-24
Tank 65
Cause: Leak in gas oil line at Tank 65. Line is underground and gas oil with very low pressure.

Followup: No

Notes: RQ not exceeded. Area around the leak excavated. Leak repaired through a clamp that reinforced the line at the site of the leak.
Non-Flammable Organic Liquid: 42.0 gallons
117789

2009-09-01
10" pipe
Cause: pinhole leak in 10" pipe.

Followup: No

Notes: RQ not exceeded.

116591

2009-07-20
Desulphurization unit clamp
Cause: Desulphurization unit clamp leaked.

Followup: No

Notes: RQ not exceeded.




116493

2009-07-14
outfall 013
Cause: While an operator was back flushing the HF Alky Unit's heat exchanger, a leak was discovered on the heat exchanger. The heat exchanger released chemicals into the cooling water system (outfall 013) which was subsequently released to the Mississippi River.

Followup: No

Notes: The Alkylation Unit was shut down. 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 monitored. Root cause of the leak is being investigation, and the follow up should have been filed.
Hydrofluoric Acid: 3,257.0 pounds
126946

2010-10-08
flare
Cause: Flaring due to isolation of a line involved in a prior incident on 10/4/10 -- see incident #126868. Reportable quantity for Sulfur dioxide was exceeded three times during incident, beginning on 10/10/10.

Followup: No

Notes: RQ. "Valve was fully seated to achieve complete isolation." "No chronic or acute health risks are anticipated as a result of this release..."
Sulfur Dioxide: 78,395.0 pounds
126868

2010-10-04
saturated gas line to saturated amine contactor
Cause: WORKER DIED 10/6--"cause of death under investigation" "saturated gas line to the saturated amine contractor started leaking sour gas to the atmosphere through a previously installed clamp" which had been installed 9/22/10.

Followup: Yes

Notes: area barricaded off, work stopped & personnel moved to safe area, respiratory protection for workers in immediate vicinity, internal & external monitoring, clamp on leak repaired/isolated, will have to flare intermittently until line can be completely replaced. "No chronic or acute health risks are anticipated to have occurred off-site or beyond immediate proximity of release point."
Hydrogen Sulfide: 732.0 pounds
Compressed Flammable Gas: 4,263.0 pounds
126465

2010-09-17
hydraulic winch at dock
Cause: "While loading a coke barge and adjusting the barge position utilizing the down river winch, the winch's hydraulic hose failed and released oil on the dock...it was later discovered that hydraulic oil had landed on the roof of the shelter and dripped down the wall to the river."

Followup: No

Notes: Absorbent material placed on dock, boom in river to contain/recover material. Notified St. Bernard Parish Water Board.
Hydraulic Oil: 0.9 pounds
121804

2010-02-27
tubing at tank #33
Cause: tubing leaking at tank #33

Followup: No

Notes: no information given

131594

2011-06-05
Outfall 003; Outfall 210
Cause: Outfall 003 cooling water system line developed a leak and discharging commenced to Contaminated Stormwater Outfall 210 to prevent equipment and property damage.

Followup: No

Notes: BRQ. Refinery letter states that effluent permit limits were not exceeded for Outfall 003 or Outfall 210. A clamp was installed on the leaking pipe to mitigate the volume of water being discharged via Storm water 210 outfall. The affected piping will be isolated and repaired/replaced.
Cooling Water (non-contact): 1,268,400.0 gallons
No LDEQ Reported

2011-04-26
Cooling exchanger
Cause: There was a pinhole leak in a naphtha tube of the cooling exchanger.

Followup: No

Notes: At the time of the State Police Hazmat Line report, the refinery was preparing to shut the unit down and make repairs within 24 hours. There were no injuries, fires, fatalities, or road closures.

128760

2011-01-21
#2 Bundle Heat Exchanger Lube Oil Cooler
Cause: LDEQ states that an oil sheen observed near Dock #4 by the US Coast Guard was caused by a leak in the lube oil cooler for a compressor on the Fluid Catalytic Cracker. The cooling water leaving Outfall 013 is non-contact and thus should not have oil in it.

Followup: No

Notes: The water will be blinded off. Boom was deployed in the area. Referred to Enforcement on 4/11/11. LDEQ report only. No refinery letter.

148946

2013-05-31

Cause: ON Friday, May 31 2013, at approximately 1118 hours, Chalmette Refinery L.L.C (CRLLC) personnel observed a small visible sheen at the Number Four Dock due to a leak in the fuel supply line to the Once Through Cooling Water (OTCW) pump. Immediate notifications were made to the appropriate agencies and US Environmental deployed containment and absorbent boom to contain and collect sheen. An investigation determined that the source of the leak was from a hole in the suppy hose. The leak was immediately isolated at 1125 hours. No emergency conditions resulted from this release.

Followup: No

Notes: Immediate notifications were made to the appropriate agencies and US Environmental deployed containment and absorbent boom to contain and collect the sheen. Additional shields will be installed around the supply hose area for the supply pumps to provide an additional barrier preventing diesel from escaping the containment area.
Diesel Fuel: 1.0 gallons
148919

2013-05-27
Leaking pipe
Cause: On May 27, oil from a leaking pipe was found on the ground near the land between the river and the levee.

Followup: No

Notes: The area was cleaned with the collected material held for proper disposal. The piping identified as the root cause has been clamped to prevent recurrence. No oil reached the water.
Oil: 10.0 gallons
148825

2013-05-20
Fuel gas line
Cause: On May 20, at approximately 3:15 PM, a leak was detected from a fuel gas line near the Hydrocracking Unit. A failure analysis conducted on the failed section of the pipe indicated that increased water saturation and chloride content in the stagnant zone of the pipe was the cause of the degradation.

Followup: Yes

Notes: Immediate remedial action was to barricade the area and water was used to dissipate vapors from the release. The line was isolated and a clamp was installed to mitigate the leak. Onsite monitoring was conducted during the events and all results were zero. No emergency conditions or adverse offsite impacts resulted from this release.
Compressed Flammable Gas: 3,445.0 pounds
147393

2013-03-17
piping
Cause: Due to a crack on a pipeline compressed gas and hydrogen sulfide were released to the air. According to a letter submitted by Chalmette Refining, this was a courtesy notification.

Followup:

Notes:


147210

2013-03-07
Hydrogen Feed Pipe at the Hydrodesulfurization Unit
Cause: On Thursday, March 7, 2013, at approximately 20:30 hours, a leak was detected from a hydrogen feed pipe at the hydrodesulfurization unit. CRLLC is conducting a failure analysis of the pipe to determine the cause of the failure and prevent recurrence. Onsite monitoring was conducted during the events and all results were zero. Compressed flammable gas were released to the air. A failure analysis was conducted and indicated stress relieving due to high cycle fatigue was the root cause of the event.

Followup: Yes

Notes: The unit was depressurized and taken out of service in order to isolate and replace the pipe. CRLLC conducted a failure analysis of the pipe to determine the cause of the failure and prevent recurrence. The failure analysis indicated stress relieving due to high cycle fatigue was the root cause of the event. To prevent future recurrence, all existing supports surrounding the piping were inspected and repaired as needed. An additional support was also added near the failure location.
Compressed Flammable Gas: 1,864.0 pounds
146189

2013-01-20
Crude 2 unit
Cause: On Sunday, January 20, 2013, at approximately 06:05 hours unit personnel identified a leak at the Crude 2 unit from a failed bleeder valve. A root cause failure analysis and investigation is ongoing and results will be provided in a 60-day follow-up report. Off-site monitoring by a third party contractor was initiated following identification of the leak and all results were non-detect for benzene and hydrogen sulfide. Low levels of VOC's were detected. The root cause of bleeder valve failure occurred from a failure mechanism of piping assembly due to high-cycle fatigue caused by line vibration during the PSV relief.

Followup: No

Notes: Upon discovery, the bleeder valve was isolated to stop the leak and cleanup of the area was immediately isolated. Notifications were made to shift supervision and the area was barricaded off to restrict access to the unit. All work was stopped and personnel were directed to a safe area. The appropriate agencies were notified. Internal and external monitoring was initiated. CRLLC has installed gussets on the bleeder valves of both desalter PSV's with similar design configurations. CrLLC will also ensure that all future Project Hazard Analysis (PHA) identify whether lines in vibrating service are adequately supported to avoid/mitigate any future re-occurrence of this root cause.
Crude Oil: 100.2 gallons
Benzene: 20.7 pounds
156774

2014-06-13
Pipe running to tank D-9008
Cause: Personnel identified a pinhole leak on a pressurized light strait run gasoline pipeline that runs to tank D-9008. CRLLC is conducting an investigation to determine the cause of the leak and measures to prevent recurrence.

Followup: Yes

Notes: Upon discovery, site personnel immediately began working to depressure the line and isolate the leak. At approximately 1201 the leak on the line was noted to have ceased and a plug was safely inserted at approximately 1210 to isolate the line. CRLLC is conducting an investigation to determine the cause of the leak and measures to prevent recurrence.
Compressed Flammable Gas: 1,807.0 pounds
153490

2014-01-30
None Reported
Cause: Community complaint of "visible release of gas plume from stack, burning smell, extremely loud noise related to the discharge keeping residents awake even after 10:00pm". LDEQ contacted Jeff Bergeron, Environmental Adviser for Chalmette Refining, who stated that the noise was due to an underground steam line (600 psi) which developed a leak at this time, leading to the loud noise. The line was isolated and repairs will be made, according to Mr. Bergeron. He stated that the line contained only steam, and no odors were associated with the steam leaks.

Followup: No

Notes: None given