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ExxonMobil Refinery (2638), Baton Rouge

Causal Factor: Process Upset

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

2005-07-25
FLARE- No17 & 19
Cause: the sulfur plant shut down causing refinery upset and causing flaring from No17 and No18.

Followup: No

Notes: significant rate reductions were made to refinery units that send hydrogen sulfide to SRLA to reduce flaring.
Sulfur Dioxide: 35,257.0 pounds
Hydrogen Sulfide: 1,405.0 pounds
Nitrogen Oxide: 53.0 pounds
Nitrogen Dioxide: 9.0 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 4.0 pounds
No LDEQ Reported

2005-04-30
FLARE- GLA-3x compressor
Cause: the MEA scrubber on No. 2 Light Ends Unit experienced an operational upset due to a high level in the MEA scrubber to overhead drum; GLA-3x compressor shut down causing the RGCU to become overloaded and a gas leakage which flared

Followup: No

Notes: operations attempted to restart GLA-3x and then reduced rates to the FCCU to eliminate flaring; a new alarm was added that is more visible and will alert the controller of increased level in the interstage drum; other items identified by the ongoing investigation will be evaluated and implemented; flaring occurred from 3:20 PM to 4:40 PM on April 30th; the Wet Gas Scrubber exceeded its regulatory limit of 500 PPM of carbon monoxide from 4-6PM; the carbon monoxide concentration increased to 639 PPM fhe hour from 1-2 on May 1st
Sulfur Dioxide: 5,903.0 pounds
Carbon Monoxide: 4,308.0 pounds
Propylene: 195.0 pounds
Nitrogen Oxide: 167.0 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 136.0 pounds
Nitrogen Dioxide: 29.0 pounds
Hydrogen Sulfide: 16.0 pounds
No LDEQ Reported

2005-03-26
None Reported
Cause: leaking saftey valve

Followup: No

Notes: Leaking safety valve-below Reportable Quantities; the report stated that the event was monitored by the LDAR program and is not reportable.
No LDEQ Reported

2005-01-24
No.3 Fluid Catalytic Cracking Unit
Cause: fresh caustic being blocked away from the WGS when the No.3 fluid catalytic cracking unit, PCLA-3, was shutdown for squa

Followup: No

Notes: Fresh caustic was lined up to the system to bring sulfur dioxide emissions down.
Sulfur Dioxide: 3,476.0 pounds
100569

2007-10-27
FLARE-Flare #5,20
FLARE-Flare #5,20,23,24
Cause: Safety valve lifted and did not reseat after depressure

Followup: No

Notes: Measures were taken to reduce the operating pressure on unit. Safety valve was taken out of service and will be evaluated for proper set pressure.
Nitrogen Oxide: 56.0 pounds
Methane: 20.0 pounds
100015

2007-10-06
FLARE-Flare #17
Cause: Safety valve released to flare due to overpressure

Followup: No

Notes: Valve outlet line removed from service and D-105 was opened to relieve pressure
Sulfur Dioxide: 6,963.0 pounds
Nitrogen Oxide: 52.0 pounds
99362

2007-09-12
safety valve release
Cause: overpressure pressure in safety valve caused it to lift

Followup: No

Notes: The pressure control valve outlet on the outlet of the reactor was opened to lower the reactor pressure. Safety valve was taken out of service after second incident. Unit alarms will be reset and procedures evaluated to prevent further releases.
Flammable Vapor: 11,001.0 pounds
99170

2007-09-05
None Reported
Cause: safety valve released to flare

Followup: No

Notes: no information given
98081

2007-07-24
None Reported
Cause: Hydrocracker safety valve leak

Followup: No

Notes: Release permitted under ExxonMobil's Leak Detection and Repair program(LDAR)
97184

2007-06-18
None Reported
Cause: safety valve release

Followup: No

Notes: no information given
94023

2007-02-17
safety valve release
Cause: safety valve release

Followup: No

Notes: unit feedrate was reduced until the faulty indicator could be repaired.
Hydrogen: 1,679.0 pounds
Hydrogen Sulfide: 1,640.0 pounds
Ammonia: 81.0 pounds
Benzene: 40.0 pounds
Volatile Organic Compounds: 10,527.0 pounds
Flammable Vapor: 10,527.0 pounds
Methane: 1,589.0 pounds
111541

2008-12-19
NIG
Cause: 2 units tripped off and caused an emergency vent to air.

Followup: No

Notes: The LDEQ notes that the odors of H2S may have been perceived off site as this is an abnormal situation. This release of unspecified material is BRQ.

111420

2008-12-15
Opelousas Natural Gas header
Cause: An atmospheric safety valve was lifted on the Opelousas Natural Gas header at the Baton Rouge Refinery. The pressure of this header is maintained via a control valve which lets down high pressure natural gas to a low pressure natural gas header. The control valve that connected the high and low pressure headers failed and remained in an open position, resulting in increased pressures in the low pressure header. As the pressure increased, the controller called for the start of a booster compressor. Neither of the two booster compressors started immediately, resulting in the lifting of the low pressure header safety valve, resulting in the release.

Followup: No

Notes: The energy booster compressor was started and pressure control was swapped to a separate control valve. This release exceeded the flammable vapor RQ.
Flammable Vapor: 2,951.5 pounds
111454

2008-12-14
flare #17
Cause: Flaring at #17 flare.

Followup: No

Notes: Official letter from Exxon missing.

110037

2008-10-13
Flare
Cause: An Emergency Isolation Valve (EIV) on the suction to GLA-2X compressor at the Catalytic Cracking unit unexpectedly closed. As a result, gases that normally feed the compressor were sent to the Refinery Gas Compression Unit as capacity allowed, and the remainder was flared. The flares burned for 14 minutes while unit personnel investigated the source of the flare. When the EV was found in the closed position, the controller immediately opened it to resume flow to the compressor and stop the flaring.

Followup: No

Notes: The flares burned for 14 minutes while unit personnel investigated the source of the flare. When the EV was found in the closed position, the controller immediately opened it to resume flow to the compressor and stop the flaring. Feed rates to the Cat unit were reduced from 117 to 104 KBD. The EIV was reopened to resume flow to the compressor. This release exceeded the RQ for SO2.
Sulfur Dioxide: 627.0 pounds
109228

2008-09-16
PSV
Cause: Pipestill #7 seed valve was closed and caused a process upset. 1600 pounds of flammable gases through the PSV

Followup: No

Notes: Release is BRQ.

108842

2008-09-09
NIG
Cause: According to the verbal report, Exxon lost their primary control device on the Sulfur Recovery Unit so they diverted to the secondary control device. They reduced rates to minimize flaring amounts.

Followup: Yes

Notes: LABB only has access to the SPOC verbal reports. These initial reports estimate that both sulfur dioxide and hydrogen sulfide were released above reportable quantity. Material went offsite. LABB only has access to the SPOC verbal report.
Sulfur Dioxide: 500.0 pounds
Hydrogen Sulfide: 100.0 pounds
109154

2008-09-04
None Reported
Cause: Process Upset- valve overpressured and release chemicals

Followup: No

Notes: release valve was blocked to stop release and maintenance was performed on valve before returning it to operation.
108376

2008-08-26
Leak-valve was leaking tail gas
Cause: Process upset-air operated valve leaking tail gas back into valve

Followup: No

Notes: The air operated valve was hand tightened to ensure closure, the valve lineup was restored to norma
Hydrogen Sulfide: 101.0 pounds
107711

2008-08-02
flare gas compressor
Cause: Flare gas compressor tripped off. Back up compressor started back up which stopped the other from flaring. This in turn secured the incident

Followup:

Notes: No additional information given.
Sulfur Dioxide: 500.0 pounds
107172

2008-07-12
Hydrocracker unit safety valve
Cause: Safety valve lifted on the hydrocracker unit and went to flare.

Followup: No

Notes: The compressor was unloaded and pressure was brought down.

No LDEQ Reported

2008-05-23
D-24B, the 24 Flare Knocokut Drum
Cause: Personnel discovered processed waste water leaking into a storm water sewer. The unauthorized discharge was a result of water within a Phenex drum at PCLA overfilling into the flare system causing D-24B, the Flare Knockout drum, to carry over into D-24A Seal drum which then carried over into the storm water sewer. Processed waste water is not permitted to enter a storm water sewer.

Followup: No

Notes: PCLA controller made adjustments to operations in order to reduce the level in the Phenex drum. Also, the Gas Collector started P-24 pump which lowered the level in D-24B, and the WCLA controller diverted the 3/4 separators to tanks 21 and 22. Exxon is currently evaluating how best to detect and prevent this incident in the future. The duration of this incident is an estimated 5 hours and 30 minutes, but since the actual start time is unknown, the time could be slightly longer The pounds released is unknown, and no information provided if this release is RQ.

105542-105544

2008-05-11
safety valve release/ FLARE-Flare 17,23
Cause: process upset/under investigation

Followup: Yes

Notes: In response to the suspected exchanger tube leak, the unit was shut down per appropriate procedures. Safety valve inlet line was cleaned and replaced.
Hydrocarbon: 2,814.0 pounds
Hydrogen Sulfide: 2,000.0 pounds
Sulfur Dioxide: 241.0 pounds
Nitric Oxide: 11.0 pounds
Nitrogen Dioxide: 2.0 pounds

Butene: 2.0 pounds
Propylene: 1.0 pounds
Hydrogen: 3,408.0 pounds
Ammonia: 134.0 pounds
Methane: 3,871.0 pounds
Ethane: 1,261.0 pounds
103871

2008-03-12
FCCU Stack
Cause: The FCCU stack was experiencing a spike in Nitrogen oxide emissions and to keep it in compliance they had to increase the ammonia injection for nitrogen oxide control. This had been going on for the past 2 days and possible excess ammonia i forming ammoniaum sulfate which might have caused the opacity problem.

Followup: No

Notes: A complaint was made about the excess particulate emissions from the calcraker scrubber stack as evidenced by opacity for the past couple of days. ExxonMobil Refinery state that they were not aware of any operational problems. On 3/12 they informed the LDEQ about the FCCU stack and that this had been going on for the past 2 days. The scrubber stack will undergo internal repairs and will be retested son. The stack test was to be conducted with the normal ammonia injection for nitrogen oxide control.

102960/102918

2008-02-08
FLARE-Flare 5,17,19
Cause: Process Upset-recycle gas compressor shut down due to process upset./Other-high pressure in the refinery gas collection system due too a high volume of vent gas from other refinery units.

Followup: No

Notes: Process upset conditions at the catalytic cracking unit were resolved and recycle gas compressor was restarted to stop flaring. When the high pressure burner line overpressured, efforts were made to reduce the amount of gas sent to HPBL and increase gas amount taken by Enterg
Hydrocarbon: 159.0 pounds
Hydrogen Sulfide: 1.0 pounds
Sulfur Dioxide: 445.0 pounds
Nitric Oxide: 48.0 pounds
Nitrogen Dioxide: 8.0 pounds
Butene: 6.0 pounds
Ethylene: 6.0 pounds
Propylene: 15.0 pounds
102815

2008-02-03
None Reported
Cause: Process Upset

Followup: No

Notes: written notification from Exxon Mobile surrounding the safety valve release incident stating that after further evaluation no reportable quantities were exceeded.
102441

2008-01-18
None Reported
Cause: Process Upset

Followup: No

Notes: written notification from Exxon Mobile surrounding the safety valve release incident stating that after further evaluation no reportable quantities were exceeded.
111757

2008-01-04
No Information Given
Cause: Flaring incident. No further information given.

Followup: No

Notes: RQ not exceeded. Flaring incident. No further information given.

120247

2009-12-17
flare
Cause: Flaring occurred.

Followup: No

Notes: RQ not exceeded.

119723

2009-11-27
No information given.
Cause: Unit instability caused a unit upset which resulted in the release.

Followup: No

Notes: Release is BRQ. Unit will be shut down.

No LDEQ Reported

2009-11-27
No Information Given
Cause: Unit instability.

Followup: No

Notes: Company letter missing. RQ not exceeded. Unit will be shut down.

117870

2009-09-11
FLARE
Cause: Safety release flaring. No further information provided.

Followup: No

Notes: Release is BRQ. No further information provided.

117813

2009-09-07
No Information Given
Cause: PCLA unit in the F201 furnace was upset.

Followup: No

Notes: Release is BRQ. LABB only has access to LDEQ and SPOC reports.
Carbon Monoxide: 489.0 pounds
116294

2009-07-07
flare system
Cause: Safety valve lifted in the plant which caused 6 different flares to ignite.

Followup: No

Notes: This release estimate exceeds RQs. The incident was secured. LABB only has access to the SPOC verbal report, and all of these quantities are the initial estimates.
Volatile Organic Compounds (VOCs): 5,000.0 pounds
Ethylene: 100.0 pounds
Propylene: 100.0 pounds
Sulfur Dioxide: 500.0 pounds
Hydrogen Sulfide: 100.0 pounds
Nitrogen Oxide: 1,000.0 pounds
115216

2009-05-22
No Information Given
Cause: The PV vent is venting due to high pressure and a safety valve release.

Followup: No

Notes: The SPOc verbal report indicates that this release occurred on 05/24/09, but the refinery report states that the report occurred on 05/22/09. This release is BRQ.

114479

2009-04-27
FLARE
Cause: Flaring occurred when compressor tripped off line.

Followup: No

Notes: RQ not exceeded. Restarted compressor. No LDEQ report or follow up.






114483

2009-04-26
safety valve on coker drum
safety vavle on coker drum
Cause: Safety valve release on coker drum.

Followup: No

Notes: RQ not exceeded. Material rerouted to another drum.



113795

2009-03-30
No Information Given
Cause: Safety valve lifted on tank. Pressure dropped.

Followup: No

Notes: RQ not exceeded.



113150

2009-03-05
#20 flare
Cause: Flaring occurred at #20 flare.

Followup: No

Notes: RQ not exceeded.

113020

2009-02-26
#100 tank
Cause: Pressure venting on tank #100 on vapor recovery system.

Followup: No

Notes: RQ not exceeded.

112835

2009-02-17
Safety Valve
Cause: Safety valve release due to over-pressure.

Followup: No

Notes: Rates cut to relieve pressure. Release is BRQ.

128351

2010-12-27
Flares #17 and #19
Cause: The alkylation unit was being shutdown and a compressor at the hydrocracker unit was starting up, this helped the flare gas recover unit to receive higher than normal hydrocarbon vapor rates. This exceeded the vapor recovery system capacity leading to temporary flaring of flare #17 and #19, and the leaking of sulfur dioxide.

Followup: No

Notes: "Unit operations were adjusted to end the flaring." "Increased monitoring will be conducted on gas vent rates to prevent recurrence"
Sulfur Dioxide: 1,127.0 pounds
128094

2010-12-10
FLARE
Cause: Upset in light ends unit caused high pressure, had to flare. FLARE.

Followup: No

Notes: BRQ. LDEQ report states that this incident was below reportable quantities. No information given. LDEQ report only. No refinery letter included.
Sulfur Dioxide: 500.0 pounds
126604

2010-09-23
FLARE; D-10 Safety
Cause: LDEQ states a safety mechanism that keeps a D-10 from over pressurizing a jet drum malfunctioned and prematurely lifted. It released an unknown amount of flare gas containing like hydrocarbons.

Followup: No

Notes: Facility staff isolated the gas as soon as it was noticed, and blocked it in. This release was Below Reportable Quantities [BRQ]. This incident was the second time in two days a safety valve prematurely lifted releasing hydrocarbons.

126578

2010-09-22
FLARE
Cause: The LDEQ report states that a safety valve prematurely lifted due to a malfunction, but also states that an investigation by facility staff is ongoing at this time.

Followup: No

Notes: Escaped hydrocarbon vapors were sent to the flare. Refinery letter provides no additional details, except that release was determined to be Below Reportable Quantities [BRQ].

125914

2010-08-24
flares # 17 and 19
Cause: An upset on the process unit caused flaring.

Followup: No

Notes: No further information provided,


124487

2010-06-26
Tank #100 pressure vacuum vent
Cause: Tank #100 pressure vacuum vent blew releasing benzene.

Followup: No

Notes: ExxonMobil lowered the pressure to close the vent. LABB only has access to the LDEQ incident report. This release was BRQ.

124285

2010-06-18
FLARE: vapor recovery system
Cause: All cooling towers are over temperature limit and will be flaring at the coker unit.

Followup: No

Notes: Feed rates reduced to stop temporary flaring. 1,039 pounds of SO2 were released through the flare which is RQ. LABB only has access to the LDEQ incident report.
Sulfur Dioxide: 1,039.0 pounds
123218

2010-05-03
Powerformer tower
Cause: Atmospheric safety valve lifted on the Powerformer tower due to operational issues with gas compressor that supply material to different refining units.

Followup: No

Notes: Relieving the pressure on the tower did not reseat the valve. Operators suited up and isolated the valve when it reseated stopping the release. Procedures for removing the compressors from service will be altered to prevent a similar occurrence. This release exceeded the RQ for flammable vapors.
Benzene: 8.0 pounds
Flammable Vapor: 4,350.0 pounds
120862

2010-01-19
sulfur recovery unit
Cause: Sulfur Recovery Unit process upset. No further details provided.

Followup: No

Notes: Release is BRQ.


120697

2010-01-10
Coker unit
Cause: Coker unit had pressure release valve blow briefly into blowout drum.

Followup: No

Notes: Release was secured and BRQ.

135756

2011-12-06
Flare: #19 due to safety valve release on storage tank D-50
Cause: Flare #19 flared as a result of a safety valve lifting on the propane storage tank D-50.

Followup: No

Notes: No information given.

133778

2011-09-03
Safety Valve
Cause: A level controller went bad on a hot separator, causing a safety valve to release. The root cause of this event was a plugged level instrument that resulted in high unit pressures.

Followup:

Notes: Upon discovery of the venting, the level instrument controls were bypassed. This allowed unit pressures to return to normal which ended the release.
Hydrogen: 18.0 pounds
Gas Mixture: 2.0 pounds
130442

2011-04-05
Unspecified furnace
Cause: Hydrogen released when a furnace had a pipe go through a temperature swing. Tied to T130054 incident. Furnace shutdown was on f-901 furnace.

Followup: No

Notes: No Information Given regarding remedial actions.

130070

2011-03-20
FLARE: ICN unit/R-800 reactor
Cause: During unit start-up there was a system pressure relief via flare causing a release of sulfur dioxide.

Followup: No

Notes: This release was BRQ. No additional information given.
Sulfur Dioxide: 2.0 pounds
129962

2011-03-17
FLARE: Power former unit
Cause: During start-up of power former unit, sulfur dioxide went to the flare to relieve pressure in the system.

Followup: No

Notes: This release was BRQ. Due to the low hydrogen sulfide content of the material flared, less than one pound of sulfur dioxide was emitted. Initial report included 500 pounds of sulfur dioxide.
Sulfur Dioxide: 1.0 pounds
129066

2011-02-05
FLARE: Unspecified flare
Cause: 2 units were shutdown and caused flaring. Two light end PCLAs. Sulfur Dioxide was released.

Followup: No

Notes: There is no information given regarding remedial actions.
Sulfur Dioxide: 286.0 pounds
128902

2011-01-28
FLARE: #4 Unit
Cause: As the #4 unit was starting up, it had a unit swing. To relieve the pressure, flaring took place. During the same 24 hours, the Powdered Catalyst Unit (PCLA) also underwent startup operations. Difficulties with compressor GLA-2X during startup resulted in additional flaring. As a result of this flaring, 1616 pounds of sulfur dioxide was released. Combined, these two sources release 1,716 pounds of sulfur dioxide. However, in a follow-up letter dated March 21, 2011, ExxonMobil stated that 2,063 lbs of sulfur dioxide were released.

Followup: Yes

Notes: This release is RQ. To end the Light Ends Flaring, pressures on the 4 West Rerun and 4 West Splitter towers were reduced. To end the PCLA flaring, compressor GLA-2X was started. To prevent recurrence, procedures will be reviewed for the Light Ends area startups following unplanned downtimes. Additionally, startup procedures for the GLA-2X compressor will be reviewed.
Sulfur Dioxide: 2,063.0 pounds
Nitrous Oxide: 3.9 pounds
Nitrogen Dioxide: 0.7 pounds
Hydrocarbon: 51.8 pounds
Hydrogen Sulfide: 0.3 pounds
Propylene: 5.0 pounds
Methane/Ethane Mixture: 1.0 pounds
Carbon Dioxide: 15.5 pounds
Methane: 0.0 pounds
138086

2012-03-19
LELA-S compressor C-351 Safety Valve
Cause: The LELA-S compressor C-351 tripped, venting flammable vapor to the atmosphere through a safety valve.

Followup: No

Notes: The situation was secured, and the gas vented. ExxonMobil initially reported releasing over a 1000 lbs of flammable vapor, but they report a release of 157 lbs of flammable vapor in the written report.
Flammable Vapor: 157.0 pounds
136880

2012-02-01
Flare #17
Cause: The Alkylation Unit lost a cooling tower pump (P-451B), which resulted in the D-301 safety valve lifting and venting to flare #17 for 8 minutes.

Followup: No

Notes: ExxonMobil later determined that no reportable quantities were exceeded.
Hydrogen Sulfide: 0.1 pounds
Sulfur Dioxide: 23.0 pounds
Nitrogen Oxide: 1.0 pounds
Nitrogen Dioxide: 0.2 pounds
136547

2012-01-16
FLARE: Flare #17 and #23
Cause: The Feed Prep unit experienced an upset which resulted in flaring of SO2 from flares #17 and #23.

Followup: No

Notes: No information given regarding remedial actions taken. Initial notification of a release of an estimated 500 lbs of sulfur dioxide.
Sulfur Dioxide: 94.0 pounds
Nitrogen Oxide: 6.5 pounds
Nitrogen Dioxide: 1.1 pounds
152611

2013-11-27
Sulfur Complex
Cause: On November 27, the ExxonMobil Baton Rouge Refinery Sulfur Complex experienced an operational upset as a result of hydrocarbon carry over from the Sour Water Stripper #1 (SWS #1) in the feed to the SRLA unit. Since emissions in the tail gas routed to the vent increased, the tail gas was diverted from the vent to the incinerators to minimize overall environmental impact. Immediately upon the upset, feed to the Sulfur Complex was reduced by cutting unit production rates from other operating units within the Refinery. Air monitoring was conducted every four hours for the duration of the incident. The SWS #1 is preceded by a coalescer that separates water from hydrocarbon. The hydrocarbon is drawn off the top of the drum and the water from the bottom of the drum is routed to the SWS #1 for further separation. The level instrument can be verified in the field by a site glass; however, the site glass was fouled, preventing the water/oil interface from being visible in the site glass. The Reportable Quantity for Sulfur Dioxide was exceeded.

Followup: Yes

Notes: Tail gas was diverted to the incinerators to minimize environmental impact. Feed to the Sulfur Complex was reduced by cutting unit production other operating units within the Refinery. Confirmed level instrument operations on SWS #1 coalescer. ExxonMobil will replace SWS #1 coalescer site glasses with fouling resistant gauges.
Sulfur Dioxide: 1,057.0 pounds
150804

2013-09-03
No Information Given
Cause: On September 3, ExxonMobil Refinery was in the process of prepping equipment. Flared some C4 and C5 for a few minutes. Some seal oil got into the flare system causing a lazy flame. LDEQ report mentions a release of seal oil to the flare stack causing a lazy flame.

Followup: No

Notes: Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded.

156455

2014-06-01
Frac Tank
Cause: On 6/1/2014 ExxonMobil Baton Rouge Refinery was draining a frac tank and some hydrocarbon was spilled onto the soil. Draining was stopped upon discovery.

Followup: No

Notes: Draining was stopped upon discovery of spill.
Hydrocarbon: 5.1 gallons