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Phillips 66 (2418), Belle Chasse

Causal Factor: Equipment Failure

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
80826

2005-07-29
308F-D-1 Low pressure flare
Cause: The liquid/gas pressure relay on transformer XFR 5CE at electrical substation 5C unexpectedly tripped breaker VCB 3CG.

Followup: Yes

Notes: Claimed preventative maintenance could have been used, but the failure was unforeseeable. The level of SO2 exceeded that of a reportable level.
Hydrocarbon: 215.3 pounds
Hydrogen Sulfide: 6.6 pounds
Nitrogen Oxide: 22.5 pounds
Sulfur Dioxide: 653.4 pounds
77459

2005-03-08
Saturated Gas processor 7991 -K-1
Cause: Saturated Gas processor 7991 -K-1 tripped off line due to a mechanical trip failure of compressor metal end blades.

Followup: No information given

Notes: None
Sulfur Dioxide: 407.8 pounds
76389

2005-01-23
301-D-3 FCC Generator Flue Gas Bypass Stack;308F-D-2 High pressure flare
Cause: FCC regenerator flu gas expander, 1291-k-1 tripped offline due to a mechanical failure causing an emergency shutdown of the FCC Unit

Followup: Yes

Notes: They claimed preventative maintenance is possible, but just the regenerator failing was unforeseeable.
Carbon Monoxide: 20,645.0 pounds
Hydrocarbon: 846.0 pounds
Sulfur Dioxide: 5,016.0 pounds
75953

2005-01-03
592-X-1 Heat exchanger
Cause: There was a small leak in the 592-X-1 heat exchanger which caused the temperature to drop which in turn made there no proper control for the sulfur conversion at the 592 unit.

Followup: No information given

Notes: It was below the RQ standard of SO.
Sulfur Dioxide: 389.5 pounds
90091

2006-08-18
1291-D-1 (FCC Regenerator Flue Gas Vent)
Cause: Unexpected trip of the forced draft fan of the CO-B Boiler.

Followup: No

Notes: The forced draft fan was checked for any damage and then put back on line and the CO-B Boiler was broght back on line with minimal impact to refinery operations.
Carbon Monoxide: 22,355.0 pounds
89872

2006-08-09
308F-D-1 Low Pressure Flare
Cause: During Coke Drum switch the actuator on isolation valve XV627 malfunctioned which in turn caused the compressor kickback valve to open.

Followup: No

Notes: Coker unit operations and pressures were stabilized and the valve to the flare was closed.
Hydrocarbon: 241.9 pounds
Hydrogen Sulfide: 34.0 pounds
Sulfur Dioxide: 3,364.1 pounds
89168

2006-07-11
412-A-FF
Cause: The propane refrigeration compressor 100K2 was unable to lower the pressure. The venting to the flare was not sufficient to lower the pressure, so the vent to atmosphere was opened.

Followup: No

Notes: Preliminary investigation results indicate the insulating coating applied as a replacement of asbestos containing insutation removed duringt he Hurricane Katrina recovery period is not performing as advertised. This results in higher tank temperaure.
Propane: 64,202.0 pounds
88378

2006-06-06
308F-D-1 Low Pressure Flare
Cause: The level float column in the 1291 V 15 Sour Water Drum malfunctioned causing its level controller OLC 180 to open and caused a higher than normal rte of sour water and hydrocarban to inter the Sour Water Stripper Flash Drum v12.

Followup: No

Notes: The OLC 180 controller valve was manually closed and then re opened to establish a proper water level in the Sour Water Drum.
Hydrocarbon: 81.0 pounds
Hydrogen Sulfide: 2.0 pounds
Nitrogen Oxide: 8.1 pounds
Sulfur Dioxide: 128.0 pounds
86412

2006-03-13
308F-D-1 Low Pressure Flare
Cause: Failure of the motor for the 592K1A blower

Followup: No

Notes: The release was due to 2 problems: first the motor powering the blower failed. Second when an alternate blower was placed in service the discharge valve at the blower failed to open due to a hidden mechanical failure. The valve was repaired.
Sulfur Dioxide: 1,839.0 pounds
99785

2007-09-27
308F-D1 Low Pressure Flare
Cause: The Delayed Coking Unit was in hot circulation and preparing for startup after unexpectedly losing its coke cutting water pumps and its compressor (891 K-1) tripped off line due to high liquid level in the compressor suction drum 891-V-12, unexpectedly carried over to V-15. The compressor's suction stream is automatically diverted to the Low Pressure Flare during an emergency shutdown.

Followup: Yes

Notes: Investigation to determine the cause of liquid carryover from the Delayed Coking Unit combination tower overhead drum. The refinery claims that there was no offsite impact.
Sulfur Dioxide: 683.8 pounds
Hydrocarbon: 42.9 pounds
Hydrogen Sulfide: 6.9 pounds
Nitrogen Oxide: 4.5 pounds
98459

2007-08-07
Product Dock 1
Cause: During loading of gasoline onto the ship moored at the product dock. An odor prompted an investigation that found a leaking vacuum breaker valve on the marine vapor recover system leaking. LDEQ report states that the vacuum breaker malfunctioned and started leaking vapors.

Followup: Yes

Notes: Operator immediately shutdown the vessel loading and maintenance replaced the valve. Below reportable quantities.
Flammable Gas: 346.0 pounds
Benzene: 1.8 pounds
97401

2007-06-26
308F-D-1 Low Pressure Flare
Cause: The Delyaed Coking Unit compressor 891 K-1 tripped offline due to high level in the suction drum, 891-V-15. Liquid from the DCU combination tower overhead drum, 891-V-12, carried over to V-15 due to plugged strainers on the V-12 on the water boot pumps and hydrocarbon pumps or some other flow restriction. The compressors suction stream is automatically diverted to the Low Pressure Flare during and emergency shutdown of the compressor.

Followup: Yes

Notes: Operators tried to mitigate the accident by cleaning the strainers and tried to draw liquid from V-15 to the flare drums. Attempts were unsuccessful and the K-1 compressor still tripped. Compressor was purged of liquid and restarted. ConocoPhillips claims "no offsite impact" from fenceline monitoring.
Sulfur Dioxide: 1,136.0 pounds
Hydrogen Sulfide: 11.0 pounds
96562

2007-05-26
301 D 3 CO Bypass Stack
Cause: The actuator on the 301 HV 2 malfunctioned and would not respond to commands from the distributed control system board to open to allow CO gases to be routed to the boilers.

Followup:

Notes:
Carbon Monoxide: 850,074.0 pounds
94176

2007-02-23
Incinerator Stack
Cause: The condensate boot on the Tail Gas Treater Unit reboiler malfunctioned resulting in a loss of temperature on the 591-V-33 Stripper. This caused excess emissions of SO2.

Followup: No

Notes:
Sulfur Dioxide: 492.9 pounds
94074

2007-02-19
Unit 294
Cause: The pump shaft bering in the LOw Sulfur Gasoline Unit failed causing significant pump vibrations. The vibrations caused the nuts on the bolts of the suction and discharge of hte pump to back out. A small portion of release vaporized to atmosphere a portion was collected in the wastewater system and a portion condensed into the the ground adjacent to the unit.

Followup: No

Notes: Water deluge system was activated and motor operated valves were activated to secure the pump. The LSG unit was shut down.
Naphtha: 24,192.0 gallons
Benzene: 126.0 gallons
94025

2007-02-07
FLARE - 308F-D-1 Low Pressure Flare
Cause: A 34.5KV lightning arrestor failed near breaker W5305 (Carlisle #1 Line Bus, and an insulator failed on the disconnect switch on the other side of breaker W5305 (ConocoPhillips # 2 Line Bus). ConocoPhillips Alliance breakers W5305, W5301, W5304 tripped along with Carlisle W6922 breaker. All of these de-energized ConocoPhillips #2 Line to the plant leading to the Coker Compressor to trip off the line. The compressors suction stream was automatically diverted to the Low Pressure Flare (308F-D-1) during the emergency shutdown of the compressor.

Followup: No

Notes: Three arrestors on breaker W3505 were replaced, as well as a failed insulator. Preventive measures are in place, but incidents of this type could not be anticipated by the prevention measures. A further investigation to discover the root cause of the malfunctions is ongoing.
Sulfur Dioxide: 646.9 pounds
Hydrogen Sulfide: 6.5 pounds
Nitrogen Dioxide: 8.3 pounds
Hydrocarbon: 79.9 pounds
110898

2008-11-19
308F-D-1 (Low Pressure Flare); 308F-D-2 (High Pressure Flare); 191-FF (191-PSV-009A); 191-FF (191-PSV-011)
Cause: On 11/19/09, the refinery "experienced an unexpected internal electrical power phase to ground fault." This fault caused a power interruption from internal Substation 5D to the Crude Unit 191 and resulted in the loss of most of the Crude Unit's pumps and several fin fans causing a major unit upset and emergency shutdown. These upset operations subsequently caused the Atmospheric Tower's pressure relief valve (191-PSV-009A) to open to protect the upper section of the Atmospheric Tower. An attempt to circulate the liquid inventory in the Vacuum Tower (VT) back to the Crude Tanks caused as unexpected high liquid level and the VT pressure relief valve (191-PSV-011) opened up to protect the upper section of the VT. This relief valve relieved vapors, liquid hydrocarbons, and crude oil from a vent at the top of the VT. The loss of the Crude Unit forced most of the refinery's process units to shutdown resulting in intermittent flaring. Following the shutdown and the re-establishment of power to substation 5D, the process of restarting several refinery units was initiated. The Coker Unit's Compressor (891-K-1) motor amp limit controller (PJC-404) unexpectedly opened the flare valve (PPC-998) due to a very high motor amperage surge at its initial start. Flares smoked intermittently throughout shutdown and startup events. Fenceline monitoring indicated "no offsite impact." Fenceline monitoring

Followup: No

Notes: Immediate: Units were shut down until electrical supply was repaired. After a formal investigation, the cause of the incident was determined to be a loose connection between the bus and runback rod that put enough electrical load on the connecting bolt to melt it thus creating the ground fault. Connecting bolts are now inspected and replaced as necessary, COP electricians are being further trained, and a QC checklist and testing procedures to verify proper electrical connections have been implemented. Discharge classified as "Extremely Hazardous Substance" Regulated by OSHA HazCom
Sulfur Dioxide: 1,951.0 pounds
Crude Oil: 4,805.0 pounds
Hydrogen Sulfide: 5.0 pounds
Hydrocarbon: 150,428.0 pounds
Nitrogen Oxide: 5.0 pounds
114566

2009-04-30
308F-D-1 (Low Pressure Flare)
Cause: On April 30, 2009 at approximately 2:40 AM, the Coker compressor unexpectedly tripped off-line. At approximately 2:41 AM the suction drum flare valve opened, which it is designed to do when the compressor experiences an unexpected complete shutdown. The suction stream is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown.

Followup: No

Notes: The compressor was started and brought online following review of alarm and trip logs.
Sulfur Dioxide: 1,871.0 pounds
Hydrogen Sulfide: 18.9 pounds
Nitrogen Oxide: 5.1 pounds
Hydrocarbon: 52.1 
114066

2009-04-08
308F-D-1 (Low Pressure Flare)
308F-D-1 (Low Pressure Flare); 191-PSV-009
Cause: The 891-K-1 Compressor tripped off-line due to a high liquid level inside the first stage suction drum (891-V-15). This was caused by high liquid levels in the fractionator tower's reflux drum (891-V-12) due to coke fines plugging the filters of the L-11 reflux pumps and L-13 Sour Water pumps at an unexpectedly rapid rate. The compressor's suction steam is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown of the compressor. Monitoring at the refinery permitter was performed and "there was no offsite impact."

Followup: No

Notes: The compressor was started and brought online as soon as proper levels could be established in the first stage suction drum. An investigation is in process to determine the cause of the high levels in the first stage suction drum (which caused the compressor to trip).
Sulfur Dioxide: 1,254.0 pounds
Nitrogen Oxide: 5.0 pounds
Hydrogen Sulfide: 13.0 pounds
Hydrocarbon: 49.0 pounds
113242

2009-03-08
308F-D-1 (Low Pressure Flare)
Cause: Problems with the Coker drum steam condensate operations caused inadequate heating of the"inactive Coke drum. To avoid shutting down the Coker Unit, Operations personnel switched Coker feed from teh "active" drum into the "inactive" drum that was much cooler than normal operating systems. The switch into a cooler coke drum reduced the flow to the 891-K-1 compressor and caused the "compressor kickback" control scheme to activate. This scheme caused the compressor kickback valve to open, sending additional flow to the compressor's suction drum (891-V-15). The pressure in the compressor suction drum increased to the point that the pressure control system opened the valve to the Low PRessure Flare (308F-D-1).

Followup: No

Notes: Coker unit operations and pressure were stabilized and the valve to the flare was closed.
Sulfur Dioxide: 627.0 pounds
Nitrogen Oxide: 5.0 pounds
Hydrogen Sulfide: 6.0 pounds
Hydrocarbon: 46.5 pounds
113178

2009-03-05
308F-D-1 (Low Pressure Flare)
Cause: The refinery experienced an unexpected trip in the Coker Compressor which resulted in an unexpected release of SO2. Approximately 1,480.5 lbs of S02 was released. The 891-K-1 Compressor tripped off-line due to a low seal oil liquid level inside Tank (891-V-23). This was due to a lack of pressure controller (PCV-152) causing sea oil to spill back into the main Seal Oil Tank (T-2B-X) and not holding enough pressure to keep the overhead seal oil tank properly filled. The compressor's suction sctream is automatically diverted to the Low Pressure Flair (308F-D-1) in an emergency shutdown.

Followup: No

Notes: The compressor was started and brought online as soon as proper Seal Oil level could be established in the Overhead Seal Oil Tank. "No offsite impact detected."
Sulfur Dioxide: 1,480.5 pounds
123980

2010-06-05
low pressure flare
Cause: "the Crude Unit's Vacuum Tower experienced a flooded liquid condition which caused its overhead pressure control valve to open to the Low Pressure Flare. The cause of this condistion seems to be the Vacuum Tower's Bottoms section was experiencing unexpected problems achieving adequate flow of its product stream to the Coker Unit."

Followup: No

Notes: "the Tower bottoms product stream was eventually routed back to Crude Tankage until the conditions in the lower half of the Vacuum Tower stabilized and the flaring stopped."
Sulfur Dioxide: 445.0 pounds
123185

2010-05-02
Cooling water exchanger & Coker compressor (891-K-1), Low-pressure flare (308F-D-1)
Cause: Report states that the release occurred as a result of a breaker trip in the Coker Compressor. Which seems to have originated within the compressor's motor.

Followup: Yes

Notes: RQ. Reportable quantity for sulfur dioxide was exceeded. LDEQ report states that "The facility will be referred to the Circuit Rider Review process for failure to submit an updated notification within 60 days of the initial 7 day letter as required by LAC 33:I.3925.A.3." An investigation is in process to determine the cause of the electrical breaker trip after which, corrective actions will be implemented.
Sulfur Dioxide: 8,174.9 pounds
Hydrocarbon: 533.2 pounds
Hydrogen Sulfide: 82.6 pounds
Nitrogen Oxide: 52.7 pounds
133170

2011-08-17
FLARE: Low Pressure Flare (308F-D-1)
Tail Gas Treater/Sulfur Incinerator Stack (591-D-21X)
Cause: During operational adjustments to the air flow to SRU-592 Claus unit, the air blower discharge pressure decreased below the set point and diverted gas from the tail gas treater (TRT) to the SRU incinerator (591-D-21X) to the Low Pressure Flare (308F-D-1).

Followup: No

Notes: SRU operations were stabilized allowing the flare valve to be closed and the tail gas to be routed back into the Tail Gas Treater.
Sulfur Dioxide: 355.0 pounds
Sulfur Dioxide: 375.0 pounds
132895

2011-08-02
FLARE: Low Pressure Flare (308F-D-1)
Cause: The bottoms control valve malfunctioned and could not be closed allowing the loss of all amine liquid in the contractor vessel (410-V-3). The hydrocarbon carryover prompted the amine flash drum's (591-V-38) flare valve to open to the Low Pressure Flare (308F-D-1).

Followup: No

Notes: The amine contractor's bottoms control valve was manually closed to re-establish liquid levels.
Sulfur Dioxide: 1,664.0 pounds
132791

2011-07-30
FLARE: Low Pressure and High Pressure Flares (308F-D-1 and 308F-D-2)
Cause: The Unit 1291 Fluid Catalytic Cracking (FCC) Unit's slurry pumparound pump (1291 L-6C) deteriorated and was shutdown. This disrupted cooling of the FCC Unit's fractionator tower and this was also shutdown. Overhead gases were routed to the Low Pressure and High Pressure Flares (308F-D-1 and 308F-D-2).

Followup: No

Notes: BRQ. No Information given regarding remedial actions because gases were routed through permitted emission points. No SPOC report available. The incident date on the LDEQ report (7/30) and the Incident report (7/31) are different.
Sulfur Dioxide: 448.0 pounds
Carbon Monoxide: 219.0 pounds
146671

2013-02-14
Low Pressure Flare
Cause: Power was inadvertently interrupted to the electronic speed governor for the Fluidized Catalytic Cracking (FCC) Unit's Wet Gas Compressor. The governor performed as designed, reducing the compressor's rotating speed to minimum but not shutting down the machine. The excess gasses the compressor no longer could process were routed to the Low Pressure Flare in order to protect the compressor. The Flare Gas Recovery's Water Seal Drum for the Low Pressure was compromised at the initial onset of this event resulting in flaring.

Followup:

Notes: Operations began the process of increasing the compressor's speed back to normal. Once returned to normal speed and the water seal at the seal drum was re-established, the flaring of all excess gases stopped.
Sulfur Dioxide: 481.0 pounds
153687

2014-02-04
Amine Feed/Effluent Exchangers bank
Cause: On 2/4/14, the amine stripper vessel experienced an upset involving its Amine Feed/Effluent Exchangers bank; this resulted in an unexpected high level in the stripper's reflux drum causing Rich Amine to contaminate the Lean Amine that circulates to various amine contactors throughout the refinery. Unable to established proper levels at the amine stripper, vessel stripper efficiencies were minimal which resulted in increased levels of hydrogen sulfide in the Refienry's fuel gas system. The increased levels of hydrogen sulfide subsequently caused all on-line heaters and one supplemental boiler to exceed for a period of time their permitted sulfur dioxide emissions limits. A Root Cause Analysis (RCA) investigation was completed and revealed that bolt failures due to amine and sulfide stress cracking in the 591-X-4B exchanger bundle floating head caused rich amine to immediately saturate teh lean amine with hydrogen sulfide inside of the heat exchanger shell. With the amine saturated and unable to absorb hydrogen sulfide at the fuel gas conractors, hydrogen sulfide in fuel gas spiked above exceedance limits.

Followup: Yes

Notes: Reduced acid gas feed make by immediately implementing the sulfur shedding plan documented in the Refinery's PMO plan (consent decree required) for the remaining Refinery operating units. The following corrective actions were identified: 1) Replace the existing 591-X-4A/B/C floating head bolting with stainless steel bolting material to eliminate sulfide stress cracking 2) Evaluate bolts used in other exchangers to make sure the metallurgy is compatible with the service of the exchanger 3) Identify additional equipment that is susceptible to sulfide stress cracking adn evaluate their bolting material metallurgy
Sulfur Dioxide: 19,306.0 pounds