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Phillips 66 (2538), Lake Charles

Causal Factor: Equipment Failure

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
80241

2006-06-30
FLARE-South Flare (EP-31)
Cause: Incident due to combustion of sour gases at the flare which were diverted from the South Flare Gas Recovery system. The SFGR compressors were operating at reduced gas compression volumes as a result of the presence of excess steam in th

Followup: No Information Provided

Notes: As soon as the problem was resolved the compressors resumed operating at full capacity and the release ended. Emissions didn't exceed permit limits and no reportable quantities were exceeded, therefore the notification was made as courtesy only.
Sulfur Dioxide: 639.0 pounds
No LDEQ Reported

2005-12-09
Spill
Cause: Loading arm failed while loading diesel onto dock

Followup: No

Notes: Loading was shut down and loading arm secured. Procedure to test loading arm pressure has been reinstated.

84329

2005-12-05
FLARE (Area A North Flare)
Cause: The Gas Recovery Plant COmpressor malfunctioned, resulting in a release of Sour Gas to the North Flare.

Followup: No

Notes: Shutdown of SFGR. The high temps experienced were a result of a surge of has flow from another process unit. This has stream flow rate was corrected and the GRP compressor returned to its normal status.
Sulfur Dioxide: 3,080.0 pounds
84330

2005-12-05
FLARE (South Flare Are B EP-31)
Cause: The South Flare Gas Recovery Compressor was shutdown in an attempt to get the GRP compressor to run.

Followup: No

Notes: Compressor started back as soon as possible.
Sulfur Dioxide: 1,780.0 pounds
83599

2005-11-02
FLARE-(Area A South Flare Gas Reciovert C-1430)
Cause: South Flare Gas Recovery Compressor was Shut down due to nipple failure.

Followup: No

Notes: Emissions didn't exceed permit limits, and no reportable quantities were exceeded, therefore this notification was made as a courtesy only. Compressor was shut down.
Sulfur Dioxide: 1.0 pounds
83574

2005-11-01
FLARE (Area A South Flare EP-31)
Cause: Export Compressor shutdown.

Followup: No

Notes: Release over reportable quantities. Operators shut down export compressor. Incident unpreventable due to compressor spillback problems.
Sulfur Dioxide: 702.0 pounds
83518

2005-10-29
FLARE (Area B-South Flare EP-31)
Cause: Incident due to shutdown of the SOuth Flare GAs Recovery System. the SFGR System compressors were shutdown as a result of a compressor upset condition in the Has Recovery Plant.

Followup: No

Notes: Once normal operation of the Gas Recovery Plant was restored, the SFGR compressors were restarted and the release ended. Permit limits not exceeded for the period of the release. The incident was determine dto be unpreventable as the compressor upset
Sulfur Dioxide: 2,200.0 pounds
83522

2005-10-29
FLARE (North Flare Area A EP-64)
Cause: Incident due to an upset at the No. 2 Coker Unit. A suction strainer on compressor C-3301 had plugged an caused the compressor to shutdown. The gazes normally handled by the compressor were rerouted and the release ended.

Followup: No

Notes: Incident determined to be unpreventable as the plugging of the compressor strainer could not be foreseen.
Sulfur Dioxide: 30,400.0 pounds
82372

2005-09-21
FLARE (Area A South Flare EP-31)
Cause: release due to a loss of 2 compressors located at the South Flare location that became inoperative due to high oxygen levels in the compressor's suction.

Followup: No

Notes: Incident Secured by purging the lines on the date of notification. emissions didn't exceed reportable quantities, therefore the notification shall serve as a courtesy call. No further action required
Sulfur Dioxide: 300.0 pounds
81725

2005-08-28
FLARE (South Flare EP-31)
Cause: The incident occurred due to the impaired capability of the South Flare Gas Recovery System. The impairment in the gas recovery system was caused by high inlet temperature resulting from high blowdown system temperature.

Followup: No

Notes: Facility took immediate corrective action to make the necessary adjustments and return the SFGR system to normal operation. The letter states that no reportable quantities were exceeded and the notification was made as a courtesy only.
Sulfur Dioxide: 341.0 pounds
80427

2005-07-10
FLARE (North Flare EP-64)
Cause: Release due to shutdown of the #4HDS, #5HDS, and C-3301 Wet Gas Compressor.

Followup:

Notes: Operations took immediate corrective action to minimize emissions by curing unit charge rates, The unit rates were reduced until equipment could be repaired and brought back online. Incident determined to be unpreventable. Refinery indicated that the
Sulfur Dioxide: 13,200.0 pounds
80086

2005-06-24
Y-5 Cooling Tower
Cause: Incident due to leaking exchanger. The root of the cause of the exchanger leak is currently being investigated.

Followup: No

Notes: Facility initially identified a sheen on Y-5 Cooling Tower and the company's environmental monitoring contractors detected 10, 000 ppm or greater VOC vapor concentration on water to Y-5 Cooling Tower. A comprehensive research was immediately initiated
Volatile Organic Compounds: 43,313.0 pounds
Benzene: 57.0 pounds
79470

2005-05-31
FLARE (South Flare EP-31)
Cause: South Flare Gas Recovery Compressors shutdown.

Followup: No

Notes: Release ended as soon as the compressor was restarted. Emissions were not in excess of permit limits and no reportable quantities were exceeded, therefore the notice was made as a courtesy only.
Sulfur Dioxide: 8.0 pounds
79328

2005-05-24
FLARE (South Flare EP-31)
Cause: This incident resulted due to combustion of excess vent gases from he South Flare Gas recovery System.

Followup: No

Notes: Emissions not in excess of permit limits and no reportable quantities were exceeded. The notice was sent as courtesy.
Sulfur Dioxide: 360.0 pounds
78633

2005-04-29
FLARE (South Flare EP-31)
Cause: Momentary loss of pilot gas to the South Flare, causing the pilots to go out. Instrumentation didn't show any flow to the flare at the time. Therefore there may not have been a release

Followup: No

Notes: No process gasses going to the flare at the time of this event. Only a small amount of sweep gas was present into he system and any VOC emissions would have been well below reportable quantity. Notification made as courtesy only.

78175

2005-04-12
Y-2 Cooling Tower (Ep-152)
Cause: The release occurred over a 3 day period due to leaking exchangers. The exchangers are in CatPoly depropanizer overhead service.

Followup: No

Notes: Once the leaking exchangers were pinpointed through sampling efforts, the Depropanizer Tower was shutdown and blocked in to stop the leak and make repairs to the exchangers. The incident was found to be unpreventable as the leas was not foreseen (a rou
Hydrocarbon: 2,930.0 pounds
77849

2005-03-28
FLARE (North EP-64)
Cause: Compressor C-1202 shut down due to mechanical problems. As a result they had to shur down No. 4 and 5 and 5 HDS Units. Had to depressor the unit to flare to sweep the reactors. The shutdown was caused by burned-out motor leads at the

Followup: No

Notes: Corrective action was taken immediately to replace the damaged electrical components and return the compressor to service. This incumbent was found to be unpreventable as the equipment failure could not be anticipated. No reportable quantities were exce
Sulfur Dioxide: 445.0 pounds
77765

2005-03-22
FLARE (North Flare)
Cause: No. 4/5 HDS Recycle Compressor, C-1202, motor tripped off-line. Could not reset the motor to restart the compressor and proceeded to shutdown both units. Per the emergency shutdown , they removed the charge from each unit and purges

Followup: No

Notes: Shutdown both HDS units immediately. Removing the charge from the reactor sections stops H2S production.
Sulfur Dioxide: 542.0 pounds
76759

2005-02-04
Excel- Sulfur Plant (EP-11)
Cause: while calibrating the Amine Acid Gas Flow Meter the main air flow decreased when the Amine Acid Gas Meter indicated zero flow. Analyzer stabilization was put on manual and air demand analyzer wasn't, which caused the thermal Oxidizer

Followup: No

Notes: Added air. No excess emissions above permit limits, therefore the notification as made as a courtesy. Incident investigation is underway which will generate the necessary actions to prevent reoccurrence.
Hydrogen Sulfide: 86.0 pounds
75949

2005-01-02
Y-1 Cooling Tower (EP-152)
Cause: The incident involved a release of hydrocarbons from the Y-1Cooling Tower due to leaking exchangers.

Followup: No

Notes: Upon discovery of release, the facility procedures to identify the leak source based on hydrocarbon sampling of cooling water retune lines and further sampling of specific exchangers. Operations personnel took immediate steps to isolate the leaking e

91101

2006-10-04
Area A- North Flare EP64
Cause: RV leakage

Followup: No Information Provided

Notes: Relief Valve is being changed to prevent further leakage to the flare. HAZMAT#0606201
Sulfur Dioxide: 3,026.0 pounds
85529

2006-02-01

Excel Paralubes SRU (EP-111)
Failed check valve
South Flare (EP-31)
West Flare (EP-110)
Cause: Loss of containment occurred due to the structural failure of check valve on the discharge of Heater H-11001, which allowed a hydrocarbon release to the atmosphere. The hydrocarbons ignited causing significant damage to the process piping and insturmentation associated with the heater

Followup: Yes

Notes: root cause failure analysis is being conducted. Its results will be used to develop actions that will preclude a recurrence of this event.
Sulfur Dioxide: 140.0 pounds
Hydrogen Sulfide: 1,200.0 pounds
Sulfur Dioxide: 4,260.0 pounds
Hydrogen Sulfide: 900.0 pounds
Nitrogen Oxide: 154.0 pounds
Sulfur Dioxide: 27,600.0 pounds
Hydrogen Sulfide: 3,000.0 pounds
Nitrogen Oxide: 7.0 pounds
Sulfur Dioxide: 3,000.0 pounds
Hydrogen Sulfide: 2.0 pounds
Nitrogen Oxide: 68.0 pounds
84930

2006-01-04
South Flare, Compressor C-1430
Cause: C-1430 had a release valve which was leaking in the reverse direction. This caused an increase in the flare gas to the South Flare header.

Followup: No

Notes: A DCS alarm to indicate run status of C-1430 is proposed.
Sulfur Dioxide: 5,880.0 pounds
100875

2007-11-08
North Flare
Cause: relief valve lifted

Followup: No

Notes: No information given
Sulfur Dioxide: 6,517.0 pounds
100243

2007-10-17
Sulfuric Acid Plant duct
Cause: hole developed in duct work

Followup: No

Notes: No information given
Sulfur Dioxide: 34.0 pounds

100164

2007-10-13
Tank 73
Cause: internal floating roof on Tank 73

Followup: No

Notes: No information given
Hydrogen Sulfide: 1.0 pounds
99137

2007-09-03
Pig trap
Cause: see notes

Followup: No

Notes: Report states that closure hatch on pig trap failed
Crude Oil: 6.0 gallons
98135

2007-07-26
Sulfur Recovery Unit
Cause: Hydrocarbons were entrained into feed and a loss of containment occurred.

Followup: No

Notes: Incident is related to 07-4185, occurred within 24h of each other, and have the same root cause. Units producing sour water/acid gas rates were reduced and feed was shifted to #4/5 SRU and NaSH plant. #2 SRU was shut do
Sulfur Dioxide: 930.0 pounds
98116

2007-07-25
Sulfur Recovery Unit
Cause: Hydrocarbons were entrained into feed and a loss of containment occurred.

Followup: No

Notes: #1 SRU feed was redirected to #2 SRU, #1 SRU was shut down for repai
Sulfur Dioxide: 2,269.0 pounds
Sulfur Dioxide: 142.0 pounds
97863

2007-07-14
Flange at East Manifold in Area A
Cause: Overpressure of dock line caused leak

Followup: No

Notes: No information given
Gas Oil: 5.0 gallons
97829

2007-07-13
North Flare
Cause: see notes

Followup: No

Notes: a root cause failure analysis will be completed to determine the cause of the equipment failure. Once emissions were noticed, unit was shut dow
Sulfur Dioxide: 21,950.0 pounds
Carbon Monoxide: 2,191.0 pounds
Nitric Oxide: 403.0 pounds
Volatile Organic Compounds: 829.0 pounds
97272

2007-06-20
Sulfur Recovery Unit
Cause: Gas header tripped due to loss of fuel gas

Followup: No

Notes: No information given
Sulfur Dioxide: 386.0 pounds
92923

2006-12-29
North Flare
Cause: wet gas compressor tripped and shut down

Followup: No

Notes: Facility is conducting root cause failure analysis to prevent future recurrence and ensure extra insulation on the bus is adequate during shutdowns
Carbon Monoxide: 1,302.0 pounds
Sulfur Dioxide: 27,964.0 pounds
Volatile Organic Compounds: 492.0 pounds
Nitrogen Oxide: 239.0 pounds
110208

2008-10-19
Slurry Pump Bypass Valve
Cause: slurry oil leaked around bypass on control valve

Followup: No

Notes: HYDRCHEM responded and performed cleanup
Slurry Oil: 25.0 gallons
107264

2008-07-16
Area D Tank Farm
Cause: Seal failure on P-486 resulted in loss of containment of sour naptha

Followup: No

Notes: INCIDENT EXCEEDS RQ. Pump suction and discharge were blocked in when operators were alerted to event from an adjacent operating area
Sour Naphtha: 210.0 gallons
Benzene: 8.0 pounds

Volatile Organic Compounds: 93.0 pounds
106325

2008-06-10
No. 7 HDS Unit
Cause: leaking plug on HDS cited as cause of release

Followup: No

Notes: Letter states that emissions were BRQ.


No LDEQ Reported

2008-04-11
Dock 1 - light oil manifold
Cause: see notes

Followup: No

Notes: Booms and pads deployed to capture the Oil. Drops released during annual pressure test designed to expose flaws and weaknesses in lines and joints.

110380

2007-07-05
Y-1 Cooling Tower in Area C
Cause: leak in exchangers X-447/18 in the FCCU Vapor Recovery Unit

Followup: No

Notes: DEQ report states that emission was BRQ
Volatile Organic Compounds: 1,475.0 pounds
116265

2009-07-05
West Flare
Cause: A 2A fuse blew which caused the five control valves in the Hydro-cracker unit to fail closed. The safety system worked as designed, and dumped the reactor pressure to the flare.

Followup: No

Notes: No information given

115990

2009-06-25
West Flare
Cause: Wet gas compressor tripped on low lube oil pressure. Report makes note that lube oil pressure should be verified by operators prior to switching pumps to prevent unit shutdown.

Followup: No

Notes: Modify anti-surge controller pressure transmitter set-points to allow restart or alert operation that pressure is reading top of scale.
Sulfur Dioxide: 1,707.0 pounds
113432

2009-03-16
Outfall 006
Cause: Control valve malfunctioned which caused an overflow of the EQ sump in Area A and B.

Followup: No

Notes: Overflow led to a ditch which releases to Bayou Verdine via Outfall 006. Water had no visible oil present and had a pH of 7. Samples were taken according to NPDES parameters and will be reported accordingly.

111853

2009-01-07
North Flare
Cause: A net gas compressor shut down due to high vibrations, this resulted in a high volume of material being sent to the north flare.

Followup: Yes

Notes: No information given



125333

2010-08-01
D-2302 sight glass
Cause: Sight glass covering a drain ruptured while operator was draining water off of vessel [D-2302] in Tank Farm [Area D], glass rupture caused release of propane-propylene (VOCs).

Followup: No

Notes: "Replacing sight glass with spool piece on D-2302. All propane-propylene bullet sight glasses will be replaced with spool pieces"
Propane/Propylene Mix: 4,365.0 pounds
124631

2010-07-02
Tote tank
Cause: Leaking valve on tote tank containing sodium hypochlorite (bleach)--spilled into stormwater pond.

Followup: No

Notes: Spilled material treated in the wastewater treatment system prior to discharge, vacuum truck used to remove remaining material from tank to prevent further leakage. LDEQ verbal and field report only. No refinery letter.
Sodium Hydrochlorite: 60.0 gallons
122272

2010-03-21
A4X45003--sump relief valve
Cause: API sump relief valve (A4X45003) leaked, allowing gases high in H2S to bypass the scrubber on the Area B - API flare, allowing for elevated H2S levels released from the flare.

Followup: No

Notes: Verified elevated emissions
Sulfur Dioxide: 1,300.0 pounds
131210

2011-05-11
flare
Cause: Flare went out. No further information given.

Followup: No

Notes: No information given regarding amount released. LDEQ and SPOC reports only; no refinery letter.

138385

2012-03-28
#4 SRU
Cause: Due to a shutdown of the #1 SRU, additional amine gas was sent to the #4 SRU, resulting in elevated sulfur dioxide emissions. This caused a flare.

Followup: No

Notes: The flare was less than the RQ in SO2 and the notice was a courtesy notification

137276

2012-02-17
FLARE: SRU Stack No.1 and No.2
Cause: Excess hydrocarbons in the feed composition to the No.1/No.2 SRU caused the reducing gas generators (RGGs) to shutdown. SO2 was released.

Followup: No

Notes: Air monitoring was conducted.
Sulfur Dioxide: 2,623.0 pounds
153015

2013-12-25
caustic scrubber pump
Cause: Sulfur Dioxide was released from the facility's API/CPI flare due to the unexpected failure of a pump on the caustic scrubber system due to low temperatures.

Followup: No

Notes: Refinery personnel reestablished circulation through the scrubber using steam to heat the pump and associated piping. Causal factor could also be Equipment design if the currently used equipment is not able to support the low temperatures that are occurring.

152968

2013-12-20
4/5 SRU
Cause: The thermal oxidizer on the unit lost the flame when the when the combustion air blower shut down.

Followup: No

Notes:

148023

2013-04-08
Tank-77
Cause: A plug from a previous repair on the roof of Tank-77 failed. The tank was full; the gasoline pool on the roof grew until the roof was landed on 4/9/13, and estimated to be 14 ft. in diameter at that time.

Followup: No

Notes: Notified SPOC on 4/10/13. The gasoline was drained off and 500 lbs were recovered; an estimated 5800 lbs evaporated between 4/8/13-4/9/13. Based on the composition, an estimated 44 lbs of benzene and 285 lbs of xylene evaporated. Tank-77 taken out of service to repair roof. Engineering calculations estimate 5,800 lbs of VOCs, 44 lbs of Benzene, and 285 lbs of Xylene gases were released, which exceeds the reportable quantity for these compounds.
Gasoline: 5,800.0 pounds
Benzene: 44.0 pounds
Xylene: 285.0 pounds
146063

2013-01-16
external floating roof of Tank-7
tank-7 roof drain
Cause: External floating roof check valve failed, slowing tank contents on top of the roof. The incident resulted from a mechanical failure of a check valve. Tank material (gasoline/oil/water mix) got on top of floating roof allowing mixture to spill to ground via roof drain. Estimated 2bbls of oil to ground into secondary containment.

Followup:

Notes: s13-22018 due to a damaged floating roof, gasoline released to containment. A notification was made regarding a release from the external floating roof of Tank-7 located in Area D Tank Farm. An estimated 2 barrels of a gasoline, oil, and water mixture was spilled to the ground through the roof drain within secondary containment. Evaporative losses from spill contained benzene and potentially H2S. Immediate area monitoring non-detect for H2S but detected for benzene. ESH personnel remediated the spill. Blocked roof drain to limit mixture spilling to ground. Drained material from roof but due to slow drain and rain, pump to be put roof top and pump material off floating roof. An estimated 7752 lbs of volatile organic carbons were released to the air exceeding the reportable quantity for VOCs. Fenceline monitoring was conducted for VOCs and Benzene and no offsite impact occurred. Material was cleaned up without any offsite impacts. Investigation will provide more specific cause(s) and any appropriate actions to prevent reoccurrence.
Volatile Organic Compounds (VOCs): 7,752.0 pounds
Benzene: 1.0 pounds
Gas Mixture: 63.0 gallons
157528

2014-07-18
C-3301 Wet Gas Compressor
Cause: The wet gas compressor shut down due to high amps, emitting Sulfur dioxide from the flare.

Followup: No

Notes: Unit rates were cut to minimize flaring, and work on the compressor started immediately to get it running and back in service. Began cutting rates and working the electrical issue. Restarted C-3301 Wet Gas Compressor.
Sulfur Dioxide: 2,995.0 pounds
156201

2014-05-25
Sour Crude Recycle Hydrogen Compressor (C-3702)
Cause: The Sour Crude Recycle Hydrogen Compressor (C-3702) has a failure of the rheostat, which is a component that controls the DC current to the compressor motor. This component failure caused the compressor to shut down. This was not operator error, according to facility reports. Shut down of the compressor resulted in flaring at the Area A North Flare.

Followup: No

Notes: Rates were immediately reduced to stabilize the units and reduce flare. Permit levels were exceeded for the North Flare EQT0539.
Sulfur Dioxide: 1,246.0 pounds
153631

2014-02-03
T-38 Flare (EQT 240) of Area D
Cause: An unknown quantity of H2S was released from a flare to the atmosphere due to a pilot flame outage. The source was identified as the T-38 Flare (EQT 240) of Area D, Permit 2626-V9. The flare is equipped with an automatic shut-off valve on the flare piping at the time of the flame outage the valve closed as the intended design, and thus only the material in the flare piping was released.

Followup: No

Notes: The flare pilots were out for approximately 20 minutes. Engineering calculations determined that the amounts of H2S and VOC release during the outage was less than the reportable quantity. There is no mention of what caused the pilot outage.