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Phillips 66 (2538), Lake Charles

Causal Factor: Instrument Failure

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

FLARE (Area B South Flare EP-31)
Cause: Incident due to excessive flaring associated with FCC unit Start-up.

Followup: No

Notes: Facility personnel were having difficulty in starting a compressor during the FCC start up due to faulty instrumentation on the compressor suction drum. Once the instrumentation was repaired, operations completed start yp of the unit and the release en
Sulfur Dioxide: 9,514.0 pounds

FLARE (South Flare EP-31)
Cause: The Incident involved a release of Sulfur Dioxide from the South Flare due to a shutdown of the South Flare Gas Recovery System (SFGR) resulting from a faulty O2 analyzer on the compressor inlet gas.

Followup: No

Notes: The O2 analyzer was repaired thus the SFGR system was returned to operation and the release ended.
Sulfur Dioxide: 472.0 pounds

FLARE (South Flare EP-31)
Cause: The oxygen analyzer sample plugged up causing a false reading in the analyzer which triggered a shut down of the flare recovery system.


Notes: Instrument craftsmen cleaned out the sample system and the compressors were restarted.
Sulfur Dioxide: 3,200.0 pounds

FLARE (South Flare EP-31)
Cause: Failure of O2 Analyzer; failed and tripped out the South flare gas recovery system.

Followup: No

Notes: Instrument craftsmen is repairing the analyzer. Previously identified capital project w/in days of completion installs 2 redundant, non-intrusive 02 analyzers with 2 of 2 voting required for shutdown.
Sulfur Dioxide: 8,400.0 pounds

FLARE (South Flare and Refinery Process Heater/s Boilers)
Cause: Release of sulfur dioxide from the Refinery Process Heaters/Boilers and the south Flare due to an upset of the No.3 Amine Unit.

Followup: No

Notes: Corrective action to end the release entailed repairing a defective level indicator and stabilizing the amine system to return to normal operation. No permit limits were exceeded and the notification was made as a courtesy only.
Sulfur Dioxide: 298.0 pounds

Sulfuric Acid Plant
Cause: Acid strength analyzer failed

Followup: No

Notes: Letter states that emission was BRQ. No information given
Sulfur Dioxide: 76.0 pounds


#1/2 Sulfur Recovery Unit (SRU)
Cause: An instrumentation malfunction occurred which resulted in a unit upset.

Followup: No Information Provided

Notes: No information given
Sulfur Dioxide: 40.0 pounds

Excel Paralubes' Boiler 76001 (EP109)
Cause: HDC loss of containment occurred. Nox instrument indicated a release of Nox but futher investigation determined this did not occur. Instrument air was lost during HDC incident and fuel gas BTU analyzer used in Nox calcs failed. Also, Nox CEMS sample system plugged from plume blowing from the HDC to this boile

Followup: No

Notes: Instrument malfunction gave false reading indicating excess emissions. No remedial action taken.


North Flare
Cause: loss of flare analyzer

Followup: No

Notes: Report states no excess emissions from North Flare during loss of flare analyzer


Tank T-1105
Cause: the level indicator malfunctioned

Followup: No

Notes: Vacuum truck sent to clean up area
Gas Oil: 1,386.0 gallons

None Reported
Cause: the level indicator malfunctioned

Followup: No

Notes: Level lowered in W-80 and indicator was repaired/replaced.

South Flare
Cause: instrument malfunction on a drum on the scrubber on the flare header

Followup: Yes

Notes: Cause analysis being performed to determine cause and prevent recurrence.
Sulfur Dioxide: 1,329.0 pounds
Hydrogen Sulfide: 12.0 pounds

Excel Paralubes West Flare (EP110)
Cause: see notes

Followup: No

Notes: The shut down of the Sat-Gas compressor caused the release of sulfur dioxide. Shut down resulted from pressure transmitter producing a false reading of a compressor seal leak.
Sulfur Dioxide: 3,967.0 pounds

North Flare
Cause: instrument fails due to high temperatures from steaming out process

Followup: No

Notes: Technicians worked on 02 analyzer and the compressors were brought back to service


Cause: Pump Failed to start and sump overfilled. Pump failure was caused by failure of level switch on T-74 sump pumps.

Followup: No

Notes: Pumps were started manually, and the spill was cleaned up
Gas Oil: 100.0 gallons

air-demand analyzer
Cause: According to the refinery letter, during the start-up of the sulfur reaction furnace, an air-demand analyzer malfunctioned causing excess air to the hydrogenation bed resulting in elevated SO2 emissions.

Followup: No

Notes: BRQ: No further information on remedial actions was given. Refinery letter and SPOC report only; no LDEQ report.


T-74 Oily Sewer Sump
Cause: Refinery unauthorized discharge notification report states that the T-74 oily sewer pump level indicator appears to have failed to start the pumps operating. Overflow of crude oil into a railroad ditch occurred.

Followup: No

Notes: The oil was cleaned up using vacuum trucks, absorbent booms, and pads. The frequency of operator rounds has been increased. Refinery letter states that no off-site impact occurred and that impact to the sides of railroad ditch were "almost nonexistent."
Crude Oil: 17,220.0 gallons
Volatile Organic Compounds (VOCs): 18.0 pounds
Benzene: 0.0 pounds
Hydrogen Sulfide: 0.0 pounds

1/2 SRU
Cause: Instrumentation failure caused the No. 1 SRU unit to shutdown.

Followup: No

Notes: An instrument tech repaired the instrument. Operations started the unit back up. Determined that the amount of sulfur dioxide released during the upset was less than the reportable quantity. The incident began at 0339 hours and was secured at 0742 hours on October 27, 2012.