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Phillips 66 (2538), Lake Charles

Causal Factor: Process Upset

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
No LDEQ Reported

Cause: Leaking valve

Followup: No

Notes: operator cleaned header and used absorbent pads to pick up oil from dock to water.
<1/2 pint

C-Szorb Unit
Cause: Fire due to a flange leak on the feed exchanger to the S-Znob Unit.

Followup: No

Notes: Fire was extinguished, the course was isolated and the unit was shut down. Incident was preventable; flake leak caused by unequal heat expansion due to incorrect application of insulation.
Volatile Organic Compounds: 8.0 pounds

Nitrogen Oxide: 17.0 pounds

Area B- South Flare (EP31)
Cause: Release caused by poor NaHS operation and south flare caustic scrubber startup not completed.

Followup: No Information Provided

Notes: South Flare Caustic Scrubber is in full operation. HAZMAT # 06-01158
Sulfur Dioxide: 5,600.0 pounds
Hydrogen Sulfide: 61.0 pounds
Nitrogen Oxide: 1.0 pounds

Level control valve(#4 Crude Unit tower)
Cause: level control valve

Followup: No

Notes: Spill did not reach ground, slight residue on tower equipment. Some naptha evaporat
Naphthenic Crude: 5.0 gallons

West Flare
Cause: Sat Gas plant experiences upset that results in flaring

Followup: No

Notes: No information given
Sulfur Dioxide: 456.0 pounds

South Flare - EQT 080
Cause: upset in the ARU

Followup: No

Notes: Level indicator on #2 regenerator tower malfunctioned and there isn't a redundant level indicator. Root Cause analysis estimates release at 19,800 lbs - approx 3,000 lbs more than original repor
Sulfur Dioxide: 19,800.0 pounds
Hydrogen Sulfide: 178.0 pounds

Area A, B, and C heater stacks
Cause: The skimming of hydrocarbons at the #3 Flash Drum led to a foaming upset of the regenerator and inefficient H2S removal from the amine utilized in the high pressure fuel gas (HPFG). This caused a #3 Amine Regeneration Unit (ARU) system upset that resulted in combustion of refinery fuel gas with high H2S in the HPFG system. Ultimately, this caused SO2 to be released from fired heater stacks in Areas A, B, and C.

Followup: Yes

Notes: NOTE: Follow-up occurred on 3/31/09. Exceeds RQ. Immediate action taken was to add anti-foam to get the system back to normal and cleaning up the amine. Firing rates of heaters reduced to decrease SO2 released. Planned remedial action include increase frequency of skimming the #3 Amine Flash Drum to prevent sending large amounts of hydrocarbon to the regenerator all at once.
Sulfur Dioxide: 716.0 pounds

Sulfur Recovery Unit (SRU)
Cause: Upset in the sulfur recover unit; the "tail gas unit experienced a foaming incident," which allowed SO2 and SO3 to escape into the atmosphere.

Followup: No

Notes: No information given


West flare EQT330
Cause: "During start-up of the HDC [hydrocracker] unit, the amine contactor foamed leading to amine carryover and a high liquid level in the knockout drum which shutdown the recycle hydrogen compressor and triggered depressurizing of the unit to the flare." SO2 release above permitted amounts of 500lbs/hr but below RQs Flame carryover from flaring resulted in a "small" grass fire along the right-of-way of PPG Drive which was extinguished by the Westlake Fire Dept.

Followup: No

Notes: "Amine flow to the contactor has been reduced from typical to prevent recurrence."
Sulfur Dioxide: 949.0 pounds

FLARE: West flare
Cause: Foaming event in hydrocracker amine contactor (W-11001) resulted in liquid carryover into the knock-out drum of a compressor, which caused the compressor to shut down, opening the dump valve to flare. FLARE.

Followup: No

Notes: BRQ. Liquids drained from knock-out drum and compressor was restarted.
Sulfur Dioxide: 152.0 pounds
No LDEQ Reported

FLARE: South Flare System
Cause: A third party vendor was preparing a line for maintenance by isolating and purging it. During the maintenance activity a high concentration H2S containing gas was sent to the South Flare System.

Followup: No

Notes: Fresh caustic solution and water were added to the South Flare Scrubber during the event to keep the scrubber as effective as possible. There is no SPOC report and no LDEQ report attached to this file.
Sulfur Dioxide: 600.0 pounds

#7 HDS
Cause: On 5/7/14 there was a release from the Area A North Flare (EQT 0539) caused by a process upset in the #7 HDS, likely due to feed contamination.

Followup: No

Notes: Reduced charge rate / changed barge off load tank.
Sulfur Dioxide: 1,358.0 pounds

North Flare
Cause: A sudden loss of the Hydrogen supplied from another facility caused a process upset in the PSA unit.

Followup: No

Notes: Telephone notification was made on 1/7/2014 regarding a release of SO2 from the North Flare. A sudden loss of the Hydrogen supplied from another facility caused a process upset in the PSA unit. Based upon engineering calculations, it was determined that the amount of SO2 released during the upset was less than the RQ. There was no information given on the duration.