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Phillips 66 (2538), Lake Charles

Causal Factor: Human Factors

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

Hose From Vacuum Truck
Cause: -workers disconnected a hose from a vacuum truck and did not put the plug in the hose. Hose discharged 84 lbs of light oil onto a grave/dirt road.

Followup: No Information Provided

Notes: Refinery immediately took care of the spill by placing it in a dumpster (roll off box).
Oil: 84.0 gallons
No LDEQ Reported

No.1 Dock
Cause: -In the process of loading diesel at Dock No.1, a flange on the barge began to leak.

Followup: No

Notes: Absorbent pads. Clean Harbor called to complete clean up. In future, wrap flange with absorbent material to allow detection of a leak before a spill occurs. 1 pint release
No Information Provi

Tank Truck
Transfer Truck
Cause: Someone left a valve oin a tank truck open, spilling sulfuric acid.


Notes: Refinery representative Kevin McGee reported that less than reportable quantity was released. Small amount spilled on highway. Clean Harbors Environmental Services was contracted to perform the cleanup. A written letter of notification is not required.
No Information Provi
Spent Acid: 2.0 gallons
No LDEQ Reported

Load Arm at No 3 Dock
Cause: -Operators were unhooking loading arm off of a barge when a small spray of diesel came out of the flange. A few drops of this diesel went into the water and cause a small sheen.

Followup: No

Notes: Operators thru absorbent pads in the water and had Coastal Gulf come to help with the clean up.


#2 Cooker
Cause: -Release due to accidental opening of an atmospheric valve on a coke drum which occurred during a drum switch.

Followup: No

Notes: Immediately upon discovery the valve was closed and the release ended. The incident was preventable, however the reportable quantities were not exceeded, therefore notification made as courtesy only. Release associated with citizen complaint above, in
Hydrogen Sulfide: 7.0 pounds
Hydrocarbon: 543.0 pounds

Area A - No. 1 Coker
Cause: A six inch drain valve on a live coke drum was inadvertantly opened by operator.

Followup: Yes

Notes: Interlocks that failed to prevent this event is being looked at. Live drum indications and permissive controls from the board are planned. HAZMAT #
Hydrogen Sulfide: 53.0 pounds
Volatile Organic Compounds: 336.0 pounds

North Flare (EP-64)
Cause: Crude Tower pressure control valve, instrument air line was blocked in by a contractor. The control valve opened and the crude tower started depressing to the flare. The air line block valve was opened and the control valve closed of

Followup: Yes

Notes: Instrument air lined back up to valve to close off from flare.
Sulfur Dioxide: 1,820.0 pounds

LPG Skid Flange
Cause: weld on flange developed leak

Followup: No

Notes: Depressured the receiver to flare so the leaks could be repaired
Benzene: 6.0 pounds
Volatile Organic Compounds: 21.0 pounds
Reformate: 67.0 gallons

#1 RGG furnace
Sulfur Recovery Unit
Cause: operator pressed button that shut down #1 RGG furnace causing release

Followup: No

Notes: No information given
Sulfur Dioxide: 29.0 pounds
Sulfur Dioxide: 29.0 pounds

No. 8 HDS Separator Piping
Cause: -weld on line failed, developed le

Followup: No

Notes: Unit depressurized while weld repaired. Spool piece installed and unit returned to normal operation the next day
Gas Oil: 630.0 gallons
Volatile Organic Compounds: 21.0 pounds
Hydrogen Sulfide: 11.0 pounds

Talens Marine Barge TM-5
Cause: -while being loaded barge was overfilled

Followup: No

Notes: in the process of removing a line from barge the tank was overfilled. Spill was cleaned up with abosorbent pads and booms
Diesel Fuel: 4,200.0 gallons

Cause: -while being loaded barge was overfilled

Followup: No

Notes: Diesel was cleaned up by Conoco personnel
Diesel Fuel: 20.0 gallons

Area D Dock 2B East
Cause: spill was caused by Hard's Marine Service tankerman on barge

Followup: No

Notes: Letter states that header pipe on Barge MMI-304 ruptured when loading was commenced. Not clear what connection exists b/w tankerman and ruptured pipe. Operators shut down the loading pump and emergency shutdown valve was closed.


Area D Tank Farm
Cause: leak from a pump bleeder block valve that was left open

Followup: No

Notes: Pump bleeder block valve was blocked in and the area was flagged off
Slop Oil: 5.0 gallons

API/CPI system sludge sump
Cause: gasoline entered the oily water system and caused an upset after operator fails to use appropriate control device

Followup: No

Notes: LEL alarms lowered to alert Operations sooner of hydrocarbons in the atmosphere. Process and procedures surrounding mgmt of tank water draws and process indicators will be reviewed. Follow-up letter from DEQ states that C-P failed to notify DEQ within 24 hrs of incident and that the tank operator failed to use a control device to block gasoline from entering wastewater system
Volatile Organic Compounds: 1,333.0 pounds
Benzene: 12.0 pounds
Hydrogen Sulfide: 1.0 pounds
Slop Oil: 420.0 gallons

frac tanks
Cause: While operator was transferring oily material from T-120 to frac Tanks, it appears that the tanks were inadvertently overfilled which resulted in both frac tanks to spill approximately 1 bbl into the secondary containment area around and under the frac tanks.

Followup: No

Notes: material was cleaned up.
Oil: 42.0 gallons

No Information Given
Cause: Faulty pipe line-up using demo line while preparing to transfer product into a process unit, resulting in a spill out of a valve. State Police report states that an estimated 1 gallon of gas oil went into water. Visible sheen on Bayou Verdine, approximately 10 x 10 feet. Refinery letter states that sheen might have been from a faulty line or related to an earlier sheen on 7/28/10; source not confirmed and sheen was gone when environmental personnel & Coast Guard inspected the site.

Followup: No

Notes: State Police [SPOC] report states that boom was placed in water on 7/30/10. No report available for incident referenced on 7/28/10.
Gas Oil: 1.0 gallons

pipe in heater process area
Cause: Gas oil released when mechanics removed a pipe elbow on a pipe that had been capped.

Followup: No

Notes: RQ. Spill was in the refinery on a concrete floor, cleaned up with vacuum truck and floor dry granules. LDEQ report only, which states "...informed [refinery] that notification of unauthorized discharge was required." No refinery notification letter.
Gas Oil: 63.0 gallons

#3 Cargo Sump
Cause: Unauthorized discharge report states that kerosene flowed out of the concrete basin surrounding #3 Cargo Pump House Sump PPS-29, onto the ground underneath the piperack west of PPS-29 and into the concrete rainwater catch basin southwest of PPS-29. The operator left D-1216 draining unattended. The radar span on PPS-29 was not set properly.

Followup: No

Notes: Sump level was pumped down. The radar span on PPS-29 has been adjusted. The company will consider installing redundant radar level indication on PPS-29. They will consider scheduling annual preventive maintenance and testing on PPS-29 level control system as well as a low level alarm to PPS-29.
Kerosene: 63.0 gallons
Volatile Organic Compounds (VOCs): 635.0 pounds
Benzene: 0.1 pounds

Area B process unit (north land farm); temporary roll-off box
Cause: A roll-off box containing oily wastewater sludge classified as hazardous waste (F037) shifted causing some of the material to spill to the ground.

Followup: No

Notes: Oily wastewater sludge released from a temporary roll off box during offload process. ES&H personnel were dispatched to cleanup and remove contamination. A further review will be conducted during the next compliance evaluation inspection. They claim that no offsite impact resulted from this spill. The material was immediately cleaned up. Longer term actions include: providing a tool which requires a specific individual to be responsible for verifying that the cited criteria is met, and the box is suitable for safe transportation. This practice is to be implemented within a half hour of the box transportation to ensure the conditions tested are consistent during transport.
Oily wastewater and Bio Sludge: 100.0 gallons

Area C Demo Line
Cause: The root cause was found to be operator error. The operator failed to secure the line during a unit shutdown to clean equipment. Thus, some temporary piping that had been put in and left open-ended upon disconnection.

Followup: No

Notes: Corrective action was taken to isolate the open-ended pipe identified during the incident investigation.
Flammable Gas: 5,441.0 pounds

Fuel tank in Area D T-100
Cause: A diesel fuel tank shifted while being moved with a containment berm with a fork lift. Both the fuel tank and containment berm slid off the fork lift tipping the tank to the side in the berm and 75 gallons of diesel fuel was spilled from the fill nozzle on the fuel tank.

Followup: No

Notes: Oil soak pads were used. ES&H cleaned the diesel and contaminated soil. To prevent future occurrences, a mobile tank will be used. Bioremediation specialist and Environmental Sciences were called within company.
Diesel Fuel: 75.0 gallons

Barge CBC-196 at the loading docks on Calcasieu River
Cause: Barge operators loaded barge CBC-196 unevenly causing the barge to shift and a small amount of lube oil was spilled into the Calcasieu River.

Followup: No

Notes: Loading was stopped and absorbent pads were placed on the sheen. There is no LDEQ report and no SPOC report in the file.
Lubricating Oil: 0.0 gallons

lube oil containment
Cause: This was an overfill of lube oil caused by operator error on barge. 10 gallons of lube oil was spilled by barge personnel during the loading process. They claim that the barge was not being operated by Phillips 66 personnel.

Followup: Yes

Notes: In the initial report, they state that Conoco Phillips is not the responsible party and that this is 3rd party information. Lube oil spilled into Clooney Loop just off Calcasieu River/Ship Channel and it appeared that it had slight overfill of lube oil barge. The area was boomed off and ES&H began clean-up of area. Oil was released to the water due to overfill of lube oil containment. On January 5, 2013, the Phillips 66 Refinery near Lake Charles experienced a release of approximately 10 gallons of lube oil from a dock area near the Calcasieu River Ship Channel. ES&H was the cleanup contractor and the sheen was boomed off and evacuated from the water. A courtesy notification was sent to the SWRO on 01/09/13. The spill was satisfactorily cleaned up by the contractor. No further action is required. Phillips 66 made this regulatory notification as a 3rd party courtesy only notification.
Lubricating Oil: 10.0 gallons