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Chalmette Refining (1376), Chalmette

Causal Factor: Weather

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
81776

2005-08-27

FCC debutanizer overhead condenser
no.1 and no.2 flares
Cause: HURRICANE KATRINA (storm) Release of sulfur dioxide, nitric oxide, nitrogen dioxide, and hydrogen sulfide was due to overpressurization of the FCC debutanizer overhead condenser, resulting in flaring and a small ground fire.

Followup: Yes

Notes: This follow-up letter has been delayed due to Hurricane Katrina. This is a notification that the total refinery shutdown resulted in an evacuation of the refinery and the potential emergency release of wastewater from the wastewater treatment plant outfall. Chalmette Refining conducted a detailed analysis of emissions resulting from the refinery shutdown for Hurricane Ivan in September 204. Since the refinery shutdown for Hurricane Katrina was similar, they have assumed that the quantities released during Katrina shutdown are the same as the Ivan shutdown. Chalmette Refinery is rescinding the 8/27/05 notifications for S02, H2S, NO2, and hydrocarbons (non-speciated VOCs). Upon further review, the facility claims that the total amounts were estimated to be less that the reportable quantities (RQ= 100 lbs). The original estimated quantity of NO was 467 lbs, and was later changed to be estimated at 74 lbs. Shutdown was undertaken in preparation for the forecasted potential for Hurricane conditions. Operations were conducted in order to minimize emissions while maintaining a safe and orderly shutdown. Emissions resulted from gas flaring, fuel gas quality changes, and standby operation modes necessitated by the shutdown. Sometime after Hurricane Katrina, the pilots on the flares were extinguished. By that time, predominantly natural gas was being flared and no reportable quantities were exceeded.The pilots were re-lit on all flares by September 8, 2005 At approximately 12:00 hours on 8/27/05, the FCC debutanizer overhead condenser overpressured due to a failure with a pressure controller, resulting in flaring and a small ground fire. 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.
Nitric Oxide: 74.0 pounds
Sulfur Dioxide: 34,400.0 pounds
Nitrogen Dioxide: 52.0 pounds
Hydrogen Sulfide: 64.0 pounds
80548

2005-07-12
Coker 2, gas then vented to Tank 304
Cause: During tropical storm Cindy there was a power failure. This release happened upon re start.

Followup: No

Notes: The line which allowed the gas to go to the tank was isolated and the incident was ended. The flow indication was calibrated and process logic updated to minimize recurrence. No time given for which the release was stopped, but the event occurred on 07/12/05 at 16:33 hours, was identified at 21:06 hours, and subsequently emission estimates were completed on 07/14/05 at 17:25 hours. No information was given on the amount released of refinery fuel gas in this report.
Hydrogen Sulfide: 683.0 pounds
No information given
Volatile Organic Compounds (VOCs): 12,779.0 pounds
80322

2005-07-06
No information given
Cause: Power failure due to Tropical Storm Cindy, resulting in an unplanned shutdown.

Followup: No

Notes: Due to the multi-day nature of the event CRLLC was unable to give a comprehensive report at this time. As of this report, equipment repairs were still ongoing and addition emissions may occur. Operations were conducted to minimize emissions while maintaining a safe and orderly shutdown.
Hydrogen Sulfide: 229.0 pounds
Nitric Oxide: 167.0 pounds
Nitrogen Dioxide: 19.0 pounds
Sulfur Dioxide: 50,599.0 pounds
Volatile Organic Compounds (VOCs): 1,736.0 pounds
77135

2005-02-23
D-401 refinery tank
Cause: Notified by the Saint Bernard Fire Department that a neighbor witnessed a lightning strike in the refinery's East Tank farm, and could see smoke. Refinery personnel identified it as tank D-401, a finished unleaded gasoline tank. Investigations revealed that a portion of the secondary roof had been burned/melted in the fire, while the primary seal remained intact.

Followup: No

Notes: Fire was extinguished using emergency sprinklers and foam.

88541

2006-06-12
Feed/Effluent Exchanger (E7502 A-f)
Cause: automatic shutdown due to interruption in electrical current, water leak following thunderstorms.

Followup: No

Notes: Feed to the #1 Pretreater was shut off, steam was applied to the channel head, and water was used to flush naphtha to the refinery oily water system
Benzene: 27.0 pounds
Xylene: 122.0 pounds
Volatile Organic Compounds: 3,399.0 pounds
100878

2007-10-31
Oil/water sewer system
Cause: sewer backed up during heavy rains causing oil inside a pipe to flow to the soil

Followup: No

Notes: DEQ letter states that emission was BRQ of 1000 lbs
Hydrocarbon: 914.0 pounds
100419

2007-10-23
Tank 1024
Cause: due to heavy rain, personnel were filling Tank 1024 to manage excessive storm water for processing. The tank overflowed.

Followup: No

Notes: Isolated the tank. 3rd party environmental clean up firm called in to do clean up. Vacuum trucks deployed; foam applied to minimize volatilization of spilled material and absorbent materials used to contain the discharge to the vicinity of the tank.




Slop Oil: 68,102.0 pounds
Benzene: 115.0 pounds
100401

2007-10-22
Oil/water sewer system
Cause: several heavy rainstorms deposited over nine inches of rain in less than 18 hrs and backed the lube oil out of the oil/water system.

Followup: No

Notes: Vacuum trucks deployed and absorbent materials used to contain oil to immediate vicinity.
Mobile DTE Oil: 1,497.0 pounds
100421

2007-10-22
Tank 1017
Cause: ; the motorized operated valve between the Alkylation Sump and tank 1017 failed to close properly allowing liquid to continue filling the tank until it overflowed. The level gauge also failed.

Followup: No

Notes: CRLLC issued work orders to replace the Tank 1017 gauge and valve. Also initiated an investigation to determine why the gauge failed. In the process of excavating contaminated soils around Tank 1017.
Light Cycle Oil: 51,050.0 pounds
99113

2007-09-01
Tank D-0036
Cause: cause of leak in Tank is corrosion between new floor and existing walls of the tank.

Followup: No

Notes: Spill became visible after heavy rain. CRLLC is in the process of emptying, cleaning, and preparing the tank for inspection. CRLLC added an additional corrosion prevention lining to the floor of the Tank prior to putting it back in service. CRLLC has also verified that all other tanks in the same service have lined floors.
Benzene: 28.0 pounds
Xylene: 124.0 pounds
95913

2007-05-04
No information given
Cause: oil washed up from the sewers due to heavy rainfall

Followup: No

Notes: Letter written to rescind notification of 5/4 concerning release of hydrocarbons. Oil released was recovered and treated within the API separator. Contaminated soil treated for hydrocarbon removal and remaining residue manifested and properly disposed of.
Hydrocarbon: 5.0 pounds
110661

2008-11-07
No information given
Cause: a 5 gallon bucket used to catch leaks of released liquids from threads in piping blew over.

Followup: No

Notes: Letter states that emissions were BRQ.

Xylene: 2.0 pounds
108944

2008-09-12
Flare #2
Cause: Hurricane Ike causes a scaffold to fall and damage a power line. Power outage causes shut down of Crude 1 and Crude 2 Units

Followup: Yes

Notes:


Sulfur Dioxide: 6,180.0 pounds


108502

2008-09-03
None Reported
Cause: shut down damage and stary up of refinery due to Gustav

Followup: No

Notes: Planned and controlled release due to leak in Alky Isostripper, need to depressure the vessel to flare
108648

2008-09-02
Facility Sewers
Cause: due to Hurricane Gustav, facility sewers backed up

Followup: No

Notes: Liquids were vacuum truck recovered

108492

2008-08-31
outfall 004 and 110 at wastewater treatment plant
Cause: bypass of WWTP due to hurricane discharged into Lake Borgne Basin

Followup: No

Notes: Untreated wastewter discharge
Non compliant pH: 11,655,000.0 gallons
No LDEQ Reported

2008-08-30
Flare
Cause: shutting down units due to hurricane

Followup: No

Notes: All incidents grouped in one report concerning activities surrounding start up and shut down near the arrival of Hurricane Gustav. CRLLC reports requesting a variance for all emissions resulting from these events.
Sulfur Dioxide: 671,171.0 pounds
Hydrogen Sulfide: 1,506.0 pounds
Nitrogen Oxide: 1,024.0 pounds
Liquid Hydrocarbons: 72.0 gallons
108453

2008-08-29
No information given
Cause: shutting down units due to hurricane

Followup: No

Notes: Letter states that emissions were BRQ.

108528

2008-08-20
Flare
Cause: shutting down units due to hurricane

Followup: No

Notes: No Information Given




103974

2008-03-15
No information given
Cause: high winds blew a tarp into a power line; cooling water pumps were lost

Followup: No

Notes: Letter states that emissions were BRQ.

No LDEQ Reported

2008-02-12
1st Stage High Pressure Separator on the Hydrocracker Unit
Cause: ; thermal stress from start up and shut down, along with cold rain that occurred on the day the leak was detected caused a flange to leak

Followup: No

Notes: CRLLC sends letter to rescind prior notification of H2S release.

Compressed Flammable Gas: 1,388.0 pounds
111744

2009-01-03
No Information Given
Cause: Lube detected floating on water collected near the Hydrocracker Unit. Heavy rainstorms caused lube oil to get backed out of the oil/water sewer system.

Followup: No

Notes: Vacuum trucks were immediately deployed and absorbent materials used to contain the lube oil. Contaminated soil and absorbent materials were removed and containerized for disposal.
Mobile DTE Oil: 54.6 gallons
121281

2010-02-04
storage tank
Cause: floating storage tank roof tilted during heavy rains, released gasoline to roof and roof drain, traveled down drain to soil. Release picked up by air monitor at Chalmette HS. DEQ report only in this file--references a "seven-day notification" but it's not included.

Followup: No

Notes: RQ. gasoline foamed to reduce volatilization, recovered from soil with vacuum truck, contaminated soil excavated, bioremediation agent applied to soil.
Gasoline: 798.0 gallons
Volatile Organic Compounds (VOCs): 633.0 pounds
133625

2011-09-01
No information given
Cause: A heavy rain occurred then the sulfur plant started having problems around 1130 hrs. They started seeing emissions. They believe it is due to an instrument malfunction.

Followup: No

Notes: Chalmette Refining LLC provided a courtesy notification to the LDEQ regarding a release of sulfur dioxide to the atmosphere on September 1, 2011. After further review, there were no RQ exceedances or permit violations as a result of this event.

132500

2011-07-18
refinery sewer
Cause: Large amounts of rain caused flooding at the refinery and Oil backed up into their sewers. There was potential for the Oil to enter the parish's sewer system, but it did not.

Followup: No

Notes: No remedial actions needed because the Oil did not enter the parish's sewer system. No refinery letter included in the file.

142422-142489-143217

2012-08-27
Coke Conveyor Facilities
flare
isolated areas of standing stormwater
Wastewater treatment Unit
Cause: Chalmette Refining LLC shut down operations because of the approach of Hurricane Isaac. Following established shutdown procedures and protocols, CRLLC was safely and systematically shutdown due to the approach of Hurricane Isaac. Likewise, CRLLC followed standard startup procedures and protocols and minimized excess emissions during recovery and startup efforts.

Followup: Yes

Notes: There are three LDEQ incident numbers assigned for the events at Chalmette Refining LLC surrounding Hurricane Isaac: 142422, 142489, 143217. On August 27, 2012 the CRLLC began to safely shut down unit operations due to Hurricane Isaac. The emergency shut down resulted in potential permit deviations and reportable quantity exceedances. However CRLLC believes that this event qualifies as an upset as defined in LAC 33:III.507.J. Below are the detailed quantities released from each unit during the startup/shutdown activities: Acid Gas and Hydrocarbon Flaring: During the shutdown and equipment preparation, excess process gases were vented to the flare system in order to reduce emissions to the atmosphere. The duration of flaring was approximately 21.1 hours. Below are the emissions which occurred during shutdown activities: 23.6 Tons S02 126 lbs H2S 133 lbs NO 133 lbs N02 714 lbs CO 558 lbs VOC 72 lbs PM10 On August 31, 2012, CRLLC began start-up operations and equipment preparation which required periodic hydrocarbon flaring. There were temporary visible emissions of smoke from flaring activities. Further, during startup of the SRU, there was a transient period which resulted in flaring amine acid gas prior to directing to the SRU. Below are the estimated emissions during startup of refinery operations. The duration of the amine acid gas flaring was 89 minutes and the duration of the intermittent hydrocarbon flaring during startup was 84 hours. Actual emissions were: 10.03 Tons S02 (> 500 lbs RQ) 0.03 Tons H2S (> 100 lbs RQ) 0.28 Tons NO/N02 (> 1000 lbs RQ) 1.52 Tons CO 0.69 Tons VOC (>5000 lbs RQ) 0.08 Tons PM10 <1 00 lbs Benzene (> 10 lbs RQ) There were approximately 9 hours where the H2S 162 ppm 3-hour rolling flare limitation was exceeded during shutdown and startup activities. These excess emissions are covered under startup/shutdown provisions provided in NSR CD Paragraph 58. As such, no additional action is required by agency. Flare Gas Recovery equipment was being repaired and so no FGR was used during this process. Tail Gas Incident: On August 27, 2012 the CRLLC Sulfur Recovery Unit was safely shut down and equipment was prepared. During this process Tail Gas Incident resulted from Source ID EIQ193. Predicted emission estimates were approximately 25 tons S02 for the shutdown. On September 5-6, 2012 the Sulfur Recovery Unit was started-up. There were no tail gas incidents during this process. As such, no additional action is required by agency. Sulfur Pit Venting: Emission estimates were expected to be less than 200 pounds H2S during shutdown and start-up operations. It is important to note that these exceedances occurred during the period when CRLLC was shutting down equipment and subsequently starting up and lining out operations. Actual emissions were -72 lbs. H2S and -50 lbs. S02. These excess emissions are covered under startup/shutdown provisions provided in NSR CD Paragraph 58. As such, no additional action is required by agency. H2S Concentration of 162 ppm in Fuel Gas: During shutdown on August 27, 2012 the refinery had the potential to exceed the H2S concentration of 162 ppm in the fuel gas system. FCCU NOx, S02, CO, PM, and Opacity Permitted Emission Limits: During shutdown and subsequent start-up operations, the refinery exceeded the emission concentration limit for CO for 14 hours and the differential pressure parameter for 32 hours at the FCCU. There were no Title V permit limit lb/hr exceedences during these times. SRU Permitted Emission Limits (lbs/hr & concentration): During the shutdown and subsequent start-up operations, the refinery exceeded the permitted emission limit of 95 lbs/hr for S02 for three (3) hours at the Sulfur Recovery Unit. The 250 ppm concentration limit was exceeded for approximately 48 hours. It is important to note that these exceedances occurred during the period when CRLLC was starting up and lining out operations. These excess emissions are covered under the start-up/shutdown provisions provided in NSR CD Paragraph 23 and 29. Flare Pilot Outages: During the shutdown due to the higher than normal rain and wind volumes, flare pilots experienced temporary outages. Data Availability from Continuous Emission Monitoring Systems (CEMS): The CEMS analyzers at the CRLLC may be adversely affected by nitrogen constraints. Some selected CEMS may have reduced data availability during the time period of storm landfall, recovery, and start-up activities. The specific duration of reduced data availability will be provided in the 30- day follow-up report. Missing LDAR Monitoring: CRLLC is subject to several Louisiana & Federal Regulations requiring Leak Detection and Repair (LDAR) as noted below. Hurricane Isaac and its aftermath have not allowed completion of some of the timing obligations, and will prevent us from meeting all the timing obligations of the required August monitoring. Approximately 250 components will receive delayed monitoring, but will be monitored in September. Details of the number of components subject to delay will be provided in the 30-day follow-up report. Consistent with USEPA's decision for Hurricane Gustav, CRLLC requests that the delayed monitoring and repair be exempted from enforcement under the applicable Force Majeure provisions. Approximately 255 monthly LDAR components received delayed monitoring, but were monitored in September. In addition, 7 leaks that missed the 5 day attempt and 6 leaks that missed the 15 day attempt due to Hurricane Isaac. Isolated Areas of Standing Stormwater: There were isolated pockets of stormwater in the refinery which contained some sheen material and potential hydrocarbon. All of these areas were contained within the refinery boundaries and no material migrated offsite. Areas include tank firewall areas, overflow of sumps, and low-lying areas. There is the potential to exceed more than one (1) barrel of total oil accumulative across the complex from all the isolated areas. All hydrocarbon and sheen material was removed and properly disposed/treated. Any contaminated soil has been remediated. This information is reported in accordance with the site waste management plan. Coke Conveyor Facilities: The coke conveyor facilities sustained some minor damage which resulted in loss of covers over portions of the conveyor belt system. There are also minor amounts of coke material on the ground which is being collected. Some small particulate emissions may result from recovery and re-start Operations. Covers will be repaired/replaced as soon as possible. The 30-day follow-up report will describe the specific repairs and dates of completion. The conveyor covers that were damaged during the hurricane have been repaired/replaced. This accident is linked to Bypass of Wastewater Treatment Unit (LSP incident # 12-05781; NRC Incident # 102-2486). Actual storm rainfall was 30". In consideration of personnel safety and increasing weather severity, the refinery initiated the emergency discharge bypass for Outfall 004 from wastewater treatment facilities to MS River on August 28, 2012. It is important to note that the refinery process operations were shutdown previously which mitigated wastewater hydrocarbon content. Water discharge was essentially storm water. Samples were collected to document wastewater quality. On August 29, 2012 all parameters were within current permit limits with the exception of Total Suspended Solids. Preliminary analysis indicates a potential exceedance of 4,444 lbs/day versus permitted limit of 3,180 lbs.


Crude Oil: 42.0 gallons
Benzene: 100.0 pounds
Particulate Matter 10: 232.0 pounds
Volatile Organic Compounds (VOCs): 1,938.0 pounds
Carbon Monoxide: 3,754.0 pounds
Nitrogen Dioxide: 133.0 pounds
Nitrogen Oxide: 693.0 pounds
Hydrogen Sulfide: 258.0 pounds
Sulfur Dioxide: 117,310.0 pounds