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ExxonMobil Refinery (2638), Baton Rouge
Causal Factor: Human Factors
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| No LDEQ Reported 2005-06-20 | FLARE | Cause: flaring occurred when the wrong fan was shutdown on No35 cooling tower; the breakers were labeled 'A' and 'B' instead of 'East' and 'West' so one was mistakingly shut down Followup: No Notes: pressure was reduce in No12 depropanizer by temporarily returning the West Cell to service. The flare was relit, which reduced the emissions of propylene and propane to the atmospher | Flammable Vapor: 551.0 pounds Propylene: 367.0 pounds Ethylene: 35.0 pounds Butene: 2.0 pounds Nitrogen Oxide: 1.0 pounds |
| No LDEQ Reported 2005-06-09 | No9 Pipestills | Cause: occurred when the pipestills controller reduced the opening on the induced draft guide vanes to optimize furnace efficiency. Followup: No Notes: the furnace guide vanes were reopened and the furnace returned to its normal carbon monoxide levels. (no typical report #); this was not preventable because this is a new parameter for the Pipestill controllers; they are learning to control to the new limits and how changes in the furnace affect the carbon monoxide emissions | Carbon Monoxide: 126.0 pounds |
| No LDEQ Reported 2005-06-08 | C-102 compressor | Cause: flare was caused by a leaking block valve that had been opened when work was being done on the compressor Followup: No Notes: the leaking block valve that was allowing additional hydrocarbon to be fed to the Refinery Gas Compression Unit was tightened down to stop the flaring | Sulfur Dioxide: 651.0 pounds Nitrogen Oxide: 16.0 pounds |
| No LDEQ Reported 2005-04-22 | F-3 furnace | Cause: furnace smoked for 3 minutes because the fuel gas rate to the furnace increased. This was due to the controller typing 3200 instead of 2300 kscf. Followup: No Notes: Other controllers were informed of the consequences and were asked to double check manual inputs prior to execution; fuel gas rates were immediately cut back and the air damper was opened. | Volatile Organic Compounds (VOCs): 41.0 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 9.0 pounds 1,3-Butadiene: 1.0 pounds |
| 77590 2005-03-14 | 2 bleeder valves | Cause: there was a white water diesel release on a new line running from Tank 798 to the East Train Hydrofiner in the Baton Rouge Refinery; the 2 bleeder lines were left open while charging the line Followup: No Notes: report stated there are no ground water wells in the vicinity of the release. The contaminated soil has been removed from the area and the soil will be remediated on site at the SABRE Unit. | White Water Diesel: 546.0 gallons |
| 86579 2006-03-18 | East Train Hydrofiner (HHLA-E) | Cause: -Exchanger on the East Train Hydrofiner (HHLA-E) was leaking into a cooling tower. The seating surface and gasket on the floating head were upgraded during the turnaround. Operations personnel installed the exchanger correctly . However, when the exchanger was worked offsite, the contracting company installed the wrong bolts in the floating head of the exchanger. The bolts broke due to wet hydrogen sulfide cracking which caused the exchanger to leak. Note: the accident started at 10:00am on 03/17/06 but was not discovered until 1:50pm on 03/18/2006 Followup: No Notes: The cause of the accident is listed as preventable in the company's report, but there is no explanation whatsoever as to why it was preventable - that section is blank. In the report it does state that further investigation of the incident is currently being conducted. Remedial measure are listed as - the exchanger bolts replaced with appropriate material for the predetermined run length. Reportable quantities were exceeded for hydrogen sulfide and volatile organic compounds | Water: 3,493.0 pounds Hydrogen Sulfide: 399.0 pounds Ethane: 412.0 pounds Methane: 407.0 pounds Hydrogen: 127.0 pounds Volatile Organic Compounds: 18,121.0 pounds |
| 86548 2006-03-16 | FLARE - Alkylation Feed Preparation Unit | Cause: The Methyl Tertiary-Butyl Ether Unit was converted to an Alkylation Feed Preparation Unit (AFP). The AFP was beginning its initial start up. As the level in one of the towers increased, steam was added to the reboiler to begin producing overhead product. During this time, the safety valves on the tower began relieving to the flare system, which resulted in the reported flare. During the conversion of the unit the overhead pressure meter was reranged in the field, but was no reranged in the control room. Due to this oversight the operator believed he was at a significantly lower pressure and did not immediately discover that the safety valves on the tower had lifted to the flare system. The calculations automtically completed by the flare system Followup: No Notes: The cause of the accident is listed as preventable in the company's report, but there is no explanation whatsoever as to why it was preventable - that section is blank. The only remedial measure listed is that the pressure meter range was corrected in the control room. The letter to LDEQ states that reportable quantities of nitrogen oxide and butenes were exceeded. | Nitrogen Dioxide: 9.0 pounds Nitrogen Oxide: 50.0 pounds Sulfur Dioxide: 180.0 pounds Butene: 121.0 pounds Hydrocarbon: 281.0 pounds Butadiene: 1.0 pounds Hydrogen Sulfide: 1.0 pounds Methane: 14.0 pounds Ethylene: 2.0 pounds Ethane: 7.0 pounds Propylene: 81.0 pounds Propane: 316.0 pounds Butane: 9,978.0 pounds Isobutylene: 5,742.0 pounds 1-Butene: 5,058.0 pounds 1,3-Butadiene: 288.0 pounds n-Butane: 5,276.0 pounds trans-2-Butene: 6,380.0 pounds 2,2-Dimethylpropane: 4.0 pounds cis-2-Butene: 4,671.0 pounds 3-Methyl-1-Butene: 423.0 pounds Isopentane: 4,005.0 pounds 1-Pentene: 543.0 pounds 2-Methyl-1-Butene: 917.0 pounds n-Pentane: 496.0 pounds Isoprene: 42.0 pounds trans-2-Pentene: 653.0 pounds cis-2-Pentene: 318.0 pounds 2-Methyl-2-Butene: 691.0 pounds 1-t-3-Pentadiene: 15.0 pounds 1,3-Cyclopentadiene: 14.0 pounds 2,2-Dimethylbutane: 8.0 pounds Cyclopentene: 64.0 pounds Cyclopentane: 22.0 pounds 2,3-Dimethylbutane: 3.0 pounds 2-Methylpentane: 24.0 pounds 3-Methylpentane: 11.0 pounds Cyclohexane: 509.0 pounds |
| 101166 2007-11-19 | spill | Cause: blind isolating line from tank was removed and not reinstalled causing fuel to spill Followup: Yes Notes: Blind was reinstalled and vacuum truck was used to remove pooled oil and contaminated soil was removed. | Aviation Fuel: 1,520.0 pounds |
| 100949 2007-11-10 | atmospheric safety valve release | Cause: Barge worker did not reopen vapor outlet and overpressure began Followup: Yes Notes: Exxon Mobile reported that since this incident was the cause of a barge worker that it is the responsibility of Kirby barge to submit a follow up report with details and release quantities. | unknown |
| 99493 2007-09-16 | Spill | Cause: Incomplete weld on #1 PHLA Line Followup: No Notes: Once identified line was removed from service andleak was clamped to stop release. Line will be re routed in overhead pipeband. | Oil: 1,260.0 gallons Toluene: 1,668.0 pounds Xylene: 1,626.0 pounds o-Xylene: 675.0 pounds Pseudocumene: 655.0 pounds Ethylbenzene: 441.0 pounds Hydrocarbon: 3,849.0 pounds o-Xylene: 675.0 pounds Flammable Vapor: 1,458.0 pounds |
| 97986 2007-07-20 | None Reported | Cause: operator drew water from tank containing gasoline and did not close control valve to tank Followup: No Notes: When discovered water draw valve was closed. Tank considered for auto shut off system. | |
| 96760 2007-06-04 | Release-Tank vapor release | Cause: employee inadvertently deactivated vapor recovery system Followup: No Notes: the vapor recovery unit was restarted upon the discovery that it was deactivated. | Benzene: 64.0 pounds Toluene: 140.0 pounds Flammable Vapor: 3,940.0 pounds |
| 107363 2008-07-18 | Spill/suction line | Cause: Leaking oil was caused by an improperly installed blind on a common suction line used for mixing gasoline components. Followup: No Notes: A vacuum truck immediately began to pick up the pooled oil. The blind was reinstalled and other installations for the same mechanical work were checked. Contaminated soil removed. The LDEQ reportable quantity for oil to soil (1 barrel) was exceeded and the RQ for Benzene (10 lbs) was also exceeded. Amount of Light Cat Naptha released was 11.3 barrels and amount of benzene released was 31.7 pounds. | Volatile Organic Compounds (VOCs): 2,904.0 pounds Toluene: 115.0 pounds Xylene: 84.0 pounds Benzene: 32.0 pounds Light Catalytic Reformed Naphtha (LCR): 470.4 gallons Ethylbenzene: 21.6 pounds o-Xylene: 29.3 pounds Pseudocumene: 51.4 pounds n-Hexane: 37.2 pounds |
| 104779 2008-04-16 | oil spill to soil | Cause: An apprentice operator at West Complex was transferring lube oil from #9 agitator to a product tank. The pump lost suction, the operator assumed the level of oil in the drum was minimal, and the transfer operation was stopped. Per normal procedure, the drain valve was opened to send the remaining residual material to the slop tank via an enclosed sump system. The unattended open valve was found after the shift change. Meanwhile, the sump pumping system was overwhelmed, the lube oil backed up into the agitator basin and spilled over the concrete and entered the sewer. Followup: No Notes: The amount of material remaining in the agitator was grossly underestimated and the operator left the valve open while attending to another task. The open valve was immediately blocked to stop the release. A vacuum truck began to pick up the pooled oil from the sewer, concrete, and soil. A project to install a high level alarm on the sump is being considered. This alarm would notify the operator of a high level in the sump such that appropriate actions can be taken to prevent an overfill incident. The employee was counseled to follow appropriate procedures and no leave open valves unattended. The contaminated soil was removed. | Lubricating Oil: 25,246.0 gallons Volatile Organic Compounds (VOCs): 358.0 pounds |
| 114924 2009-05-12 | flare system | Cause: Personnel was making valve alignment changes when a block valve on the suction of the coker compressor was inadvertently closed. This caused the pressure to build in the overhead system until the pressure exceeded that of pressure vent set point. The pressure vents opened, resulting in overhead vapor to be released to the flare system, which resulted in the flaring of the hydrocarbon. Followup: No Notes: The RQ for SO2 was exceeded. The valve was reopened. Additional training and discussion was held for the personnel about the importance of valve misalignment. Company letter and State Police HAZMAT report differs on pollutant released. | Sulfur Dioxide: 836.0 pounds Volatile Organic Compounds (VOCs): 500.0 pounds Hydrogen Sulfide: 100.0 pounds |
| 112910 2009-02-20 | Bateman Lake Natural Gas header | Cause: Technician working on pressure instrument did not notify unit operating controller. Malfunction caused pressure control valve to open, which caused the pressure in the Bateman Lake Natural Gas header to exceed that of safety vavle set point. Followup: No Notes: A total of 2030 pounds of flammable vapor was release which exceeds RQ. Pressure control valve was taken out of automatic control and placed into manual control. | Carbon Dioxide: 53.1 pounds Nitrogen: 33.3 pounds Methane: 1,966.3 pounds Ethane: 63.8 pounds |
| 128021 2010-12-07 | No Information Given | Cause: SPOC states while moving a NalcoCorexit tote with a fork lift, it was damaged. NalcoCorexit is basically an alcohol with a major component of Sodium Nitrite. Followup: No Notes: Clean up is under way. This release is below reportable quantity. | NalcoCorexit: 50.0 gallons |
| 127934 2010-11-30 | FLARE: Refinery MEA Scrubbing Tower (T-585) | Cause: FOLLOW-UP REPORT: Root cause determined to be incorrectly calibrated level instrument.
INITIAL REPORT: Refinery letter incidents that a process upset was the cause. MEA is used in several towers in the refinery to remove hydrogen sulfide from the hydrocarbon streams. A refinery MEA scrubbing tower, T-585, lost its MEA liquid level, allowing hydrocarbon vapor to enter the MEA system. This malfunction caused flaring. Combined incident involving both the ExxonMobil refinery and ExxonMobil Chemical Plant in Baton Rouge. Followup: Yes Notes: INITIAL RESPONSE: Tower T-585 was isolated from the MEA system to eliminate the root cause of incident release potential. Unit operations were adjusted to minimize emissions potential and incident duration. The tower was isolated, and liquid level was restored to stop the incident. FOLLOW-UP RESPONSE: LDEQ states it will investigate further during next facility inspection. | Sulfur Dioxide: 4,392.0 pounds |
| 130466 2011-04-06 | 20" sewer line | Cause: According to the refinery letter, a 20" sewer line was damaged by a back hoe that resulted in a release of sewer water. 30 gallons and 250 pounds of refinery sewer water. Followup: Yes Notes: RQ.The amount of primary sludge released exceeded the reportable quantities of 1 lb. A pump was installed upstream of the release point to divert material to another sewer trunk line. The line will be repaired before returning to service and soil remediation is underway. | F037 Hazardous Waste: 250.0 pounds |
| 129440 2011-02-24 | Sulfur Recovery Unit incinerators | Cause: On February 24th, 2011, at approximately 8:23 am, there was a Tail Gas Incineration event at the ExxonMobil Baton Rouge Refinery.
The Sulfur Recovery Unit (SRLA) was undergoing monthly equipment evaluation when material that is normally routed from SRLA to the Tail Gas Clean Up Unit (TGCU) instead bypassed TGCU and was directed to the SRLA incinerators. This resulted in approximately 476 pounds of sulfur dioxide emissions above the incinerator permit limit. The cause of this release was inadvertent human error.
Within the same twenty four hour period, the Powdered Catalyst Unit(PCLA) experienced seal leaks on furnace F-301. The furnace produces steam, and the steam production tubes exit the furnace convection section. Seals where the steam tubes exit the furnace were leaking, allowing flue gas containing sulfur dioxide to exit the furnace. The leaks released 30 pounds of sulfur dioxide to the atmosphere.
Together, these two releases emitted approximately 506 pounds of SO2.
There were no offsite impacts, injuries, or complaints as a result of this incident. Followup: Yes Notes: To end the release, SRLA tail gas was routed through the Tail Gas Clean Up Unit (TGCU). After further review, ExxonMobil determined that the leaks from the Powdered Catalyst Unit were successfully repaired prior to February 24, 2011. Approximately 476 pounds of sulfur dioxide were released on February 24 due to Tail Gas Incineration. No reportable quantities were exceeded. Total sum of two incidents in 24 hours was 506 lbs which is reportable quantity. | Sulfur Dioxide: 506.0 pounds |
| 145500 2012-12-21 | NIG | Cause: On December 21, 2012 at 11:38 am, the Coker C-551 compressor tripped due to a low oil pressure indication. While filling the exchanger with lube oil, the pressure dipped and caused the C-551 compressor to trip. The resulting compressor trip routed gas to the Refinery flare system where it was combusted. The compressor was restarted and flaring ceased at 12:31 PM. After further investigation, it was determined that a procedure existed, but was not followed by unit personnel while completed by this task. Followup: Yes Notes: The resulting compressor trip routed gas to the Refinery flare system where it combusted. The compressor was restarted and flaring ceased at 12:31PM. LDEQ conducted fence line monitoring with the result of no detection. ExxonMobil also conducted monitoring with the result of no detection. The reportable quantity of SO2 was exceeded as a result. Oil pressure was restored to operating range and the compressor was restarted. Refresher training has been conducted with unit personnel on the procedures for placing the lube oil exchanger back in service. | Sulfur Dioxide: 3,694.0 pounds |
| No LDEQ Reported 2012-10-07 | #3 starboard compartment | Cause: Tankerman overfilled the #3 starboard compartment on the barge. Approximately 1 gallon of heavy aromatic fuel oil (HAFO) was released to the Mississippi River. Followup: No Notes: No Information Given | Heavy Aromatic Fuel Oil (HAFO): 1.0 gallons |
| 143246 2012-09-05 | Loading arm drain valve | Cause: On September 5, 2012 at approximately 3:10 AM, there was an oil spill to the Mississippi River from the ExxonMobil Baton Rouge Refinery Dock. The discharge controller noticed oil on the deck of the dock while discharging cargo. Discharge operations were immediately discontinued to prevent further release of crude oil. The controller failed to follow procedures to properly align the transfer system by leaving a loading arm drain valve open to the sump during discharge operations. The sump system became overwhelmed, causing crude oil to back out through the drains onto the deck.
The amount released was less than 5 barrels of oil, and the reportable quantity is 1 barrel.
After additional analysis and review with the US Coast Guard, a theoretical maximum potential oil spill volume of approximately 1800 gallons/43 barrels was calculated using theoretical oil spill recovery calculations. Followup: Yes Notes: Discharge operations were immediately discontinued to prevent any further release. The ExxonMobil Emergency Response Team was activated immediately to minimize environmental impact. Deployment of 35,000 feet of boom, 16,000 pads, and 9 boats with drum skimmers. Approximately 2,000 gallons of oil water was collected from skimming operations. Refresher training was conducted with Dock personnel on operating procedures to prevent recurrence. Further, additional level instrumentation is being evaluated to provide potential early incident detection. Spilled quantity was based on the sheen size calculation of 2.4 bbl, and the amount of oily water collected from skimming operations. Also states later that 5 bbls released into the Mississippi River and 5 bbls released onto the loading docks, and 50 bbls were contained onsite in the refinery's stormwater retention basin. All contaminated soil has been remediated. | Crude Oil: 1,800.0 gallons |
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