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Phillips 66 (2418), Belle Chasse

Causal Factor: Instrument Failure

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

FCC Unit #1291
Cause: The FCC Unit #1291 system tripped off-line due to a false airflow alarm.

Followup: No information given

Notes: They claimed they restarted it and it is now safe and secure.
Carbon Monoxide: 952.0 pounds
Hydrogen Sulfide: 2.0 pounds
Nitrogen Dioxide: 3.2 pounds
Sulfur Dioxide: 314.0 pounds

Saturate Gas Unit (7991-PSV-18)
Cause: Pressure control valve BPC-244 malfunctioned gave a false signal of being open when actually in the closed position. This caused the pressure relief valve 7991-PSV-18 to lift for 5 minutes.

Followup: Yes

Notes: Assured they would operate this at a Òlow pressureÓ pending findings of the investigation.
Butane: 91.0 pounds
Hydrogen Sulfide: 90.0 pounds
Propane: 8,881.0 pounds

X-4 and X-5 exchangers in the coke fractioner
Cause: The compressor second state knockout drum received a high level alarm. Inadequate cooling of verhead vapors at the X-4 and X-5 exchangers in the coke fractioner caused the 891-K-1 compressor to trip offline

Followup: No information given

Notes: They claimed they changed operational procedures and the compressor was restarted.
Nitrogen Oxide: 8.7 pounds
Sulfur Dioxide: 317.0 pounds

Low Pressure Flare
Cause: The inlet temperature signal increased unexpectedly at the suction drum and the recycle flow rate increased causing the compressor to trip off line due to a high amperage reading fromt eh compressor's motor.

Followup: No

Notes: Operational changes were made immediately to correct the temperature signal at the suction drum and the compressor was restarted.
Nitrogen Dioxide: 8.6 pounds
Sulfur Dioxide: 188.5 pounds

100-PSV-5B on 100-T-205
Cause: The pressure transmitter malfunctioned and showed no further increase as the level of the sphere increased.

Followup: No information given

Notes: None
Hydrocarbon: 320.0 pounds
Nitrogen: 517.0 pounds

Saturated Gas plant 7991 -V-1
Cause: The signal to the 7991-V-1 straight run Debutinizer Bottoms level controller stopped transmitting it's signal from the field of the distributed control system

Followup: No information given

Notes: After inspection a set of wires appeared to be frayed. They sent a group of employees to fix the frayed wires.
Benzene: 344.8 pounds
Hydrogen Sulfide: 565.8 pounds
Volatile Organic Compounds: 16,789.1 pounds

308F-D-1 Low Pressure Flare
Cause: The 891-K-1 compressor tripped off line due to a faultry level indicator on the high level alaerm in the compressor interstage drum. There was foreign material collecting and plugging the level bridle on V-16.

Followup: No

Notes: The liquid levels in the interstage drum were drained manually and the circuit breaker for the compressor was reset and the compressor put back on line. A periodic flush of the V16 level bridle with fresh water is the corrective action.
Hydrocarbon: 152.7 pounds
Hydrogen Sulfide: 10.9 pounds
Nitrogen Oxide: 15.9 pounds
Sulfur Dioxide: 1,081.6 pounds

Cause: The 293-KN-1 compressor tripped due to a false high level alarm from the suction drum 293-V-5. The suction drum had had been drained by the unit operator but the local level alarm continued to show a high level signal to the compressor. Thie high level alarm indicator caused the compressor to trip unexpectedly. The compressor's turbine could not be reset immediately resulting in 293-PSV-4A lifting to the atmosphere for a short duration.

Followup: yes

Notes: None
Butane: 340.0 pounds
Hydrocarbon: 9,123.3 pounds
Hydrogen Sulfide: 449.0 pounds
Propane: 904.0 pounds

Spent Catalyst Slide Valve 1291-LV92
Cause: The local valve position indicator showed the valve to be closed.

Followup: No

Notes: 1291LV92 was manually hand jacked to preperly seat the valve and lock it in place.
Methane/Ethane Mixture: 952.0 pounds

4000 hp compressor --FLARE
Cause: Trip of 4000 hp compressor caused by a low oil alarm trip caused by an air bubble in the lube oil system.

Followup: Yes

Notes: New operrating procedure developed and implemented to prevent the problem from reoccuring. Verbal report


308F-D-1 (Low Pressure Flare); 308F-D-2 (High Pressure Flare)
Cause: Approximately three hours following the installation of the level transmitter, operating conditions within the saturated gas unit began to show periodic spikes of liquid carryover into the inlet of the compressor (7991-K-1) by having periodic compressor speed slowdowns. The liquid carryover seems to have been attributed to the level transmitter malfunctioning both in response time and level indication. The next day, the Saturated Gas Unit Compressor unexpectedly shut down due to a high level alarm in the compressor's suction drums (7991-V-7 and V-8) which get their feed from the Absorber/Stripper column (V-2). Several process unites then flared due to inlet gases being routed to the FCC Compressor and subsequent upset conditions from suddenly swinging into a different compressor system. This eventually caused the FCC compressor to shut down. When the FCC Compressor shuts down in an emergency, it causes the entire Low Sulfur Gasoline Units (among other operations) to shutdown as well. *Could also be classified as start up/shut down.

Followup: No

Notes: Immediately tried to restart the Saturated Gas Unit's compressor as well as route the inlet gases to the FCC Compressor which began to also have de-stabilizing operating conditions. "No offsite impact noted throughout the event."
Sulfur Dioxide: 1,446.0 pounds

FLARE-Low Pressure Flare (308-D-1); Crude Unit Towers (191-V-6; 191-V-3)
Cause: The Crude Unit's Vacuum Tower (191-V-6) malfunctioned and the Saturated Gas Unit compressor's first stage suction drum's (7991-V-7) level instrument also malfunctioned. Gas was routed to the Low Pressure Flare (308-D-1).

Followup: No

Notes: BRQ. Liquid levels at both the Crude Vacuum Tower and Saturated Gas Compressor suction drum were stabilized and flaring was secured. The incident date from the incident report does not match the SPOC and LDEQ reports. There is an e-mail string between ConocoPhillips and LA gov. regarding this discrepancy. There is a note that material did go offsite in the report.
Sulfur Dioxide: 466.0 pounds