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Phillips 66 (2538), Lake Charles

Causal Factor: Piping or Tubing

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

FLARE (Area B-South Flare EP-31)
Cause: Leaking in the 24 inch flare line leaving the AlkyCasinghead Area.

Followup: No

Notes: Repairs were made to the pipe to stop the leak and restore the integrity of the pipe. Although report indicates the incident was preventable the reportable quantity for Volatile Organic Compounds of 5000 lbs was not exceeded during this event. Notice as
Volatile Organic Compounds: 800.0 pounds

2624-V5 Emission Point FUG009
Cause: Leak in underground piping venting to atmosphere

Followup: No Information Provided

Notes: Pipe was isolated from the process and depressured in order to make necessary repairs. HAZMAT#
Volatile Organic Compounds: 200.0 pounds

High Pressure Fuel Gas Heater Stacks
Cause: Exchanger leak caused the H2S in the High Pressure Fuel Gas (HPFG) System to increase. This resulted in SO2 being released from all heater stacks on that system.

Followup: Yes

Notes: Investigating the root cause of the leak. Adjusted the pressure balance of the process as to not leak H2S into the Lean Amine System. Repair the heat exchangers at the next until shutdown.
Sulfur Dioxide: 340.0 pounds

#2 Fuel oil dock line
Cause: Leak developed in pipe rack

Followup: No

Notes: Leak isolated and began vacuuming spill to clean up, line will be taken out of service and replace
Light Cycle Oil: 84.0 gallons

Pipe rack in Area C
Cause: Leak developed in pipe rack

Followup: No

Notes: Vacuum truck cleaned up spill, line was blinded to ensure no future recurrenc
Heavy Vacuum Gas Oil: 210.0 gallons

T-371 Discharge Line
Cause: pollutant leaks through a hole in the discharge line

Followup: No

Notes: Water spilled through hole in T-371 discharge line

X-861 Exchanger in Area A #2HDS Unit
Cause: Exchanger leak in tube bundle

Followup: No

Notes: Exchanger was isolated from cooling tower and unit was shut down to repair exchanger
Volatile Organic Compounds: 5,902.0 pounds

Agitator on T-2002
Cause: flange leak

Followup: No

Notes: The mixer was shut down and the flange repaired. Once the resid hardened it was picked up by Conoco contract personnel


Service line
Cause: unused service line leaked

Followup: No

Notes: A pipeline developed a hole causing the spill. This spill was cleaned with absorbent pads and vacuum trucks. Line was purged with nitrogen.


Area C No. 4 Crude Unit
Cause: valve packing leak on a warmup line

Followup: No

Notes: Letter states that emissions were BRQ. No reason for leak is given.
Heavy Vacuum Gas Oil: 30.0 gallons

Alkylation Unit pipeline
Cause: leak in overhead pipeling in alkylation unit. No cause of leak stated.

Followup: No

Notes: Letter states that emissions were BRQ. Rates were reduced and the unit was shutdown for repairs.
Sulfuric Acid: 30.0 gallons

FCC Unit at Tower W-73
Cause: drip on a valve bonnet

Followup: No

Notes: INCIDENT EXCEEDS RQ. DEQ report indicates that letter from C-P will be forthcoming with quantity of pollutant released. Valve bonnet repaired and control valve repaired
Slurry Oil: 84.0 gallons

Area A Exchanger
Cause: excessive temperature swings in a reboiler caused a flange to open and release stabilized gasoline

Followup: No

Notes: Report states that emission were BRQ. Gas Recovery Plant reboiler leak

Benzene: 1.0 pounds
Volatile Organic Compounds: 62.0 pounds

Ballast water line in T36
Cause: leak in a 4-inch metal line that passes through an earthen containment levee

Followup: No

Notes: EXCEEDS RQ. Oily water contained in a diked area. Vacuum truck used to collect oily water. Section of line where loss occurred was clamped. Pipeline has history of issues and has been targeted for replacement. Prior replacement would have prevented incident.
Slop Oil: 63.0 gallons

South Flare - EQT 080
Cause: malfunction of south flare gas caustic scrubber level due to a plugged drain line

Followup: No

Notes: Caustic line unplugged and spent caustic replaced with fresh caustic
Sulfur Dioxide: 1,317.0 pounds
Hydrogen Sulfide: 32.0 pounds

T-84 tank dike wall
Cause: pinhole leak in a transfer line

Followup: No

Notes: No information given about remedial actions
Crude Oil: 2.0 gallons
No LDEQ Reported

#2 Crude unit
Cause: A piece of tubing ruptured in the #2 crude unit.

Followup: No

Notes: oil was cleaned up.


GRP unit
Cause: Exchanger leak in the GRP unit. The channel head was leaking due to a reduction in charge rates.

Followup: No

Notes: No information given.
Benzene: 1.1 pounds
Hydrogen Sulfide: 10.9 pounds

sump for tanks T-120 and T-104
Cause: Outlet drain at the sump for tanks T-120 and T-104 was plugged with solids and overflowed.

Followup: No

Notes: Outlet line is being line moled and the sump is being cleaned.
Slop Oil: 63.0 gallons

exchanger X-16107
Cause: #10 Reformer exchanger X-16107 leaked to cooling water system.

Followup: Yes

Notes: Unit was shutdown to pull bundle for repair.
Volatile Organic Compounds: 1,264.0 pounds

Exchanger X-428
Cause: Exchanger X-428 was leaking into the cooling water system.

Followup: No

Notes: The exchanger was removed from service.
Volatile Organic Compounds: 467.0 pounds

Cause: A line inside the T-37 dike wall failed and released approximately 10 gallons of reduced crude.

Followup: No

Notes: No information Given
Crude Oil: 10.0 gallons

T-36 tank spillback line
Cause: The T-36 tank's spillback line was leaking in the dike wall.

Followup: No

Notes: Secured pipeline and ES&H performed cleanup operation with pads and vacuum truck. Line was taken out of service for repair/replacement and spillback rerouted.
Diesel Fuel: 84.0 gallons

3700 undergroudn piperack
Cause: Leak from 3700 piperack underground. The insulation from #1 Fuel oil Dock Line underground had oil seeping out. An oil sheen was detected at outfall 006.

Followup: No

Notes: ES&H performed cleanup with vacuum trick. Pads were deployed under the pipe rack to contain spill, and everything was packed with clay earth in the dike. Area is monitored everyday and no more instances of oil on the ground. #1 Fuel Oil Dock line is out of service, and the underground piperack will be excavated for further investigation.


Targa underground pipeline
Cause: Third party operated (Targa), underground pipeline was found ruptured.

Followup: Yes

Notes: ES&H performed cleanup of the oil leak site, and Targa was notified immediately to begin repairing the ruptured pipeline. Targa later called in the incident and is linked to #112264.
Kerosene: 420.0 gallons

exchanger X-430
Cause: FCCU Vapor Recovery Unit exchanger X-430 developed a leak into the cooling water tower Y1/Y2 (EP-152).

Followup: Yes

Notes: Greater than RQ. X-430 was taken out of service. The exchanger bundle will be repaired, including replacement if needed.
Volatile Organic Compounds: 1,780.0 pounds

amine gas feed line to #1 ECC
Cause: Leak on the amine gas feed line pipe at the #1 ECC #1 sulfur recovery unit. LDEQ report states that "leak was originally discovered when an internal H2S monitor picked-up an unknown quantity from inside the refinery."

Followup: No

Notes: Feed taken out of the line and nitrogen introduced to purge amine gas; #1 SRU unit shut down; line replaced.
Hydrogen Sulfide: 1,050.0 pounds
Sulfur Dioxide: 1,050.0 pounds

no information given
Cause: Sheen on river -- loading paraffin at dock and had used nitrogen to clear a line, some material leaked through a valve and escaped to the water.

Followup: No

Notes: No information given. LDEQ report only. No refinery letter.


piping on Pump P-20038
Cause: Failure of piping network around the HGVO Product Pumb (P-20038) due to high vibration. Refinery states that offsite impact investigation concluded that .6 to 1/2 barrels of HVGO aerosolized and dispersed into the air.

Followup: Yes

Notes: RQ: The amount of HGVO released exceeded reportable quantities. The diameter of the discharge piping will be increased to recommended engineering standards and a program will be developed to identify and maintain settings on the spring cans. Second follow-up letter was dated 12/22/10.
Heavy Vacuum Gas Oil: 2,562.0 gallons


unspecified pipeline
Cause: Pipeline developed leak inside the refinery, some of diesel released got into Bayou Verdine and created a sheen adjacent to Outfall 004.

Followup: No

Notes: Absorbent materials and booms used to clean up. LDEQ report only. No refinery letter.
Diesel Fuel: 168.0 gallons

no information given
Cause: "Kerosene released in a containment area when loading a railcar at the refinery--control valve was shut and the pump did not shut off when loading was in progress and caused a relief valved to release the kerosene."

Followup: No

Notes: "Area was flushed with fresh water and padded up with absorbent materials." LDEQ report only. No refinery letter.
Kerosene: 75.6 gallons

diesel line near tank 378
Cause: Leak in diesel line near Tank 378 resulted diesel fuel being released.

Followup: No

Notes: Release was inside diked wall area--picked up with vacuum truck & absorbent materials. LDEQ Verbal report only. No refinery letter.
Diesel Fuel: 42.0 gallons

inside dike wall T-398
Cause: "Pinhole leak" in diesel pipeline inside dike wall.

Followup: No

Notes: RQ. Line depressurized & permanently clamped off, area cleaned up.
Diesel Fuel: 63.0 gallons

electric heated exchanger
Cause: Fuel gas (ethane), after leaking from electric heat exchanger, was ignited by electric heat system. "Combustion resulted in less than reportable quantity [RQ]." FIRE.

Followup: No

Notes: BRQ. Line was depressurized,fire extinguished, and unit was shut down.


piping near Tk-342
Cause: According to the refinery letter, the release occurred when a pipe near T-342 began leaking due to corrosion issues.

Followup: No

Notes: RQ: The oil was cleaned using vacuum trucks and the diesel was returned to the system to be processed. A clamp was installed on the pipe to protect from further leakage.
Diesel Fuel: 64.0 gallons

East Tank Farm
Cause: Heavy Naphtha #11 runline expansion joint developed a leak. Refinery letter states that engineering calculations were used to determine quantities of pollutants released.

Followup: No

Notes: The line was blocked in and isolated. ES&H aided in the clean up of the leak and is standing by for support. Expansion joint was removed from the line. They will inspect other expansion joints and replace/remove as necessary. Naphtha is referred to as "oil" in first part of refinery letter, but listed as naphtha in pollutants released section.
Naphtha: 63.0 gallons
Volatile Organic Compounds (VOCs): 286.0 pounds
Benzene: 0.0 pounds

Cause: A pressure change caused oil to leak from a line in Tank-347. 35 gallons of crude oil was released.

Followup: No

Notes: Spill response personnel conducted clean-up. The tank is out of service while the floor of the tank is repaired.
Crude Oil: 35.0 gallons

Transfer line at the Area D #2 Dock
Cause: An insulated pipeline at the marine dock area started leaking and released gas oil to the land and water during a transfer from a barge. Area D #2 Dock. 35 Gallons were releasedfrom the gas oil transfer line. at the Clooney Loop connecting to the Calcasieu ship canal.

Followup: No

Notes: The transfer was stopped and the line was isolated when the leak was discovered. The area was boomed off by ES&H personnel and the gas oil was cleaned up. Insulation will be removed to determine the location of the leak so repairs can be made.
Gas Oil: 35.0 gallons