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Phillips 66 (2418), Belle Chasse

Causal Factor: Start Up, Shut Down

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

Condensate capture tank
Cause: Pipeline restarted after it had been shut down for an extended period. When started up contaminates overwhelmed the econdensate capture tank.

Followup: Yes

Notes: 31.5 gallons of contaminates were spilled outside of containment into a ditch on refinery property. Ditch was blocked and pollutant was picked up with absorbants.
Water/Natural Gas/Oil: 630.0 gallons

Fluid Catalytic Cracker (FCC) Unit
Cause: The Fluid Catalytic Cracking Unit was shut down to repair an eroded slide valve stem at the regenerator.

Followup: No

Notes: Alkylation Unit placed on standby and low sulfur gasoline unit lost feed. All three units restarted. Emissions Below reportable quanitities.


Distillate Hydrotreater (DHT)

Followup: YES

Notes: Distillate Hydrotreater shut down and restarted to make repairs on a leak in a pump seal. Courtesy notification. Verbal report made but no but no written report followed.
Sulfur Dioxide: 1.0 pounds

Fluid Catalytic Cracker (FCC) Unit

Followup: Yes

Notes: Restart of FCC unit after shutdown in incident # 106591 on 6/19/2008 due to a problem with a slide valve. Facility experimenting with "Full burn mode" during start up to try to reduce emissions. Investigation into root cause to take place.
Carbon Monoxide: 3,909.0 pounds
Sulfur Dioxide: 181.0 pounds

Fluid Catalytic Cracker (FCC) Unit

Followup: no

Notes: Courtesy call and notice of potential falring during a shutdown because of a slide valve problem with the FCC. Emmissions Below Reportable Quantities.
Carbon Monoxide: 85.0 pounds
Sulfur Dioxide: 156.0 pounds

(308F-D-1) Low Pressure Flare, (308F-D-2) High Pressure Flare, (301-D-3) CO Bypass Stack

Followup: Yes

Notes: FCC slide valve mechanical failure discovered while the FCC was down for maintenance. FCC restarted in full combustion mode and vented through the Carbon Monoxide boiler which was then later restarted. Investigation into how to prevent further emmissions during start up to follow.


Fluid Catalytic Cracker (FCC) Unit

Followup: No

Notes: (See Incident Report 106039) Incident caused by a starting up the Fluid Catalytic Cracker (FCC) after it underwent repairs for a faulty valve. Investigated on 6/28/2008


Fluid Catalytic Cracker (FCC) Unit, 308-D-1 Low Pressure FLARE, 308F-D-2 High Pressure FLARE, 301-D-3 CO Bypass Stack

Followup: Yes

Notes: FCC shut down to repair a crack. During repairs, a broken valve was discovered and also repaired (#106247). Emissions released during startup of FCC and below reportable quantities. Investigation into procedures to prevent flarting during shutdown/startup
Carbon Monoxide: 23.9 pounds
Hydrogen Sulfide: 8.6 pounds
Nitrogen Oxide: 107.5 pounds
Sulfur Dioxide: 848.2 pounds

Unit 294 FLARE

Followup: Yes

Notes: Courtesy Call. Below Reportable Quanitities.
Sulfur Dioxide: 449.0 pounds

Diesel Hydrotreater Unit 293
Cause: Start Up, Shut Down --Unit 239 restarted after repairs completed on failed tubes

Followup: No

Notes: Community monitoring during a planned emission. Incident considered a courtesy notification for potential flaring.

No LDEQ Reported

308F-D-1 (Low Pressure Flare)
Cause: "During the planned and controlled shut down of the Saturated Gas Unit's Compressor for an emergency maintenance repair, the Diesel Hydrotreater Overhead gases were re-routed to the FCC Unit's compressor. While routing the gases to the FCC compressor, increased pressure drop caused the Diesel Hyrdrotreater overhead pressure controller to open the Low Pressure Flair (308F-D-1). The overhead pressure was adjusted which subsequently stabilized operations resulting in the closing of the flare valve..."


Notes: After a root cause investigation, it was determined that the a corrective action should be implemented. The Diesel Hydrotreater's Overhead pressure "shall be increased prior to routing that streat to the FCC compressor. This step should minimize the chance of opening the flare valve in the overhead system and also overcome the pressure drop phenonenon experienced while routing the gases to the FCC compressor. Fence-line monitoring reported "no offsite impact."
Sulfur Dioxide: 407.3 pounds

no information given
Cause: Following maintenance of the air blower train, a planned and controlled start up of the Fluidized Catalytic Cracking (FCC) Unit was begun on August 7th followed by the planned and controlled start up of the Alkylation Unit and Low Sulfur Gasoline Unit. All units started up as planned. However, following the start up of the FCC Unit in full-combustion mode, some feed quality issues caused a small amount (826lbs) of carbon monoxide to be emitted.

Followup: No

Notes: No offsite impact reported.
Carbon Monoxide: 826.0 pounds

308F-D-1 (Low Pressure Flare)
Cause: The FCC Regenerator Flue Gas Expander, 1291-K-1, tripped offline due to a mechanical failure causing an emergency shutdown of the FCC Unit. Flaring occurred from the Low Sulfur Gasoline (LSG) Unit 294 and the Diesel Hyrdrotreater Unit 292 due to the emergency shutdown of the FCC Unit. There was also a small fire on the Expander's lube oil and seal oil piping that occurred incidentally with the Expander mechanical failure, but was quickly extinguished with a fire extinguisher.

Followup: No

Notes: FCC Unit initiated emergency shutdown procedures.
Sulfur Dioxide: 2,522.4 pounds

308F-D-1 (Low Pressure Flare)
Cause: Following various maintenance repairs at the Alkylation Unit, start-up procedures for the FCC Unit were initiated. The FCC Unit started up and some flaring at the Low Pressure flare (308F-D-1) occurred. There were some emissions of sulfur dioxide that occurred during the flaring event, but below RQ.

Followup: No

Notes: The Alkylation and Low Sulfur Gasoline Units were subsequently started up following the FCC Unit with no further flaring or venting noted. Community monitoring was performed throughout the start-up of all three refinery process unites with no offsite impact noted.
Sulfur Dioxide: 298.0 pounds

308F-D-1 (Low Pressure Flare); 1391-FF (1391-PSV-009); 301-D-3 (CO Bypass Vent)
Cause: During the startup of the FCC Unit following a 36 day refinery maintenance turnaround outage, the unit unexpectedly transitioned to partial-burn combustion in the catalyst regenerator for less than an hour before the bypass vent was closed. Shortly after starting up the Reformer Unit during a test of newly installed burners in heater 1391-H-4, a high concentration of very light material (hydrogen and propane) caused the Depentanizer tower's overhead pressure to rise, resulting in the PSV-009 to relive for approximately 3 minutes. This reduced the pressure and the PSV re-sealed properly. While starting up the Coker Unit, light material in its feed stream from the Crude Unit also caused an unexpected increase in pressure in the suction drum of the compressor which caused the flare valve at the suction drum to open into the low pressure flare. Compressor suction drum pressure was stabilized as feed quality to the Coker Unit improved and the flare valve was closed.

Followup: No

Notes: Operations has developed for its operators responsive drills for rapidly occurring unstable conditions which will eventually help minimize impact of emissions to the environment.
Carbon Monoxide: 15,764.0 pounds
Hydrocarbon: 16,742.0 pounds
Sulfur Dioxide: 161.0 pounds

308F-D-1 Low Pressure
308F-D-1 Low Pressure Flare
Cause: A notification for the controlled shutdown of the entire plant was made on January 7, 2009. On January 8, the Sulfur Recovery Unit/Tail Gas Treater (SRU/TGT) was determined to have pluggage issue that precipitated the premature shutdown of the SRU/TGT. This led to flaring and SO2 emissions. The loss of the SRU/TGT required the initiation of a controlled shutdown of the remaining process units which contributed additional Sulfur Dioxide emissions.

Followup: No

Notes: An immediate shutdown was conducted of refinery process units. An investigation of the SRU upset is in progress and "will be reported in a subsequent letter."
Sulfur Dioxide: 9,757.0 pounds
Hydrogen Sulfide: 7.9 pounds
Hydrocarbon: 48.0 pounds