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ExxonMobil Refinery (2638), Baton Rouge

Causal Factor: Seal or Gasket

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

2005-11-14
SRLA battery limit block valve
Cause: a flange leak on the SRLA battery limit block valve containing ammonia acid gas leaked along with a minor pinhole leak.

Followup: No

Notes: The inspection history will be reviewed and more frequent inspections will be performed if appropriate; it was not preventable because the gasket failed, and the gasket was appropriate for the servi
Hydrogen Sulfide: 117.0 pounds
Ammonia: 59.0 pounds
No LDEQ Reported

2005-07-08
alkylation unit
Cause:

Followup: No

Notes: water was sprayed on the vapor cloud to mitigate hazards from the release. Upstream and downstream block valves had to be closed to stop the leak; this was not preventable because the gasket failed- it was an appropriate gasket for the service
n-Pentane: 112.0 pounds
Sulfuric Acid: 10,269.0 pounds
Propane: 87.0 pounds
Isobutane: 2,650.0 pounds
n-Butane: 1,418.0 pounds
2,3-Dimethylbutane: 96.0 pounds
2-Methylpentane: 54.0 pounds
3-Methylpentane: 26.0 pounds
2-Methylhexane: 23.0 pounds
2,3-Dimethylpentane: 49.0 pounds
3-Methylhexane: 22.0 pounds
Isooctane: 676.0 pounds
2,3,3-Trimethylpentane: 75.0 pounds
2,4-Dimethylhexane: 52.0 pounds
2,3,4-Trimethylpentane: 344.0 pounds
2,3,3-Trimethylpentane: 402.0 pounds
2-Methylheptane: 5.0 pounds
4-Methylheptane: 28.0 pounds
3,4-Dimethylhexane: 13.0 pounds
3-Methylheptane: 13.0 pounds
2,2,5-Trimethylhexane: 161.0 pounds
n-Nonane: 1,271.0 pounds
2,3-Dimethylhexane: 71.0 pounds
2,5-Dimethylhexane: 98.0 pounds
2,4-Dimethylpentane: 73.0 pounds
2,2,3-Trimethylbutane: 6.0 pounds
2,2-Dimethylbutane: 2.0 pounds
Isopentane: 407.0 pounds
No LDEQ Reported

2005-06-03
P-271A
Cause: distillate pump blew a seal

Followup: No

Notes: shut down the pump and started up a spare
Highly Reactive Volatile Organic Compounds (HRVOCs): 118.0 pounds
91339

2006-10-13
5 light ends unit T-2 Depropanizer
Cause: the 5 Light Ends Unit T-2 Depropanizer tower reboiler had a leaking channel box. This leak is thought to have been caused by the failure of the channel box seal.

Followup: No

Notes: This incident was not preventable because this reboiler channel box seal failure was unexpected. Remedial Measures - The seal will be replaced. The reportable quantity for butenes has been exceeded.
Butene: 265.0 pounds
Propylene: 5.0 pounds
Volatile Organic Compounds (VOCs): 200.0 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 46.0 pounds
100273

2007-10-17
Exchanger leak-at Heavy Cat Naptha Unit
Cause: Leaking tubes and gasket

Followup: Yes

Notes: Unit was shut down to stop release. Exchanger will be inspected and repaired as appropriate. If warranted, follow will be reporte
Benzene: 145.0 pounds
95549

2007-04-22
Flare/Safety valve release
Cause: leaking seal/safety valve release

Followup: Yes

Notes: Several actions were taken to avoid or reduce the environmental impacts from this incident. The different gas streams were redirected in a manner appropriate to minimize emissions.
Volatile Organic Compounds: 6,828.0 pounds
Butene: 3,041.0 pounds
Propylene: 4,814.0 pounds
Nitrogen Dioxide: 20.0 pounds
1,3-Butadiene: 18.0 pounds
Ethylene: 169.0 pounds
Hydrogen Sulfide: 154.0 pounds
Sulfur Dioxide: 1,505.0 pounds
Nitrogen Oxide: 123.0 pounds
Flammable Vapor: 1,000.0 pounds
Hydrocarbon: 579.0 pounds
94148

2007-02-23
Leak
Cause: failed seal

Followup: No

Notes: Line was removed from service and drained to minimize leak. Faulty seal was replaced.
Oil: 92.0 gallons
111124

2008-11-28
NIG
Cause: According to the LDEQ incident report, a mixer seal on a gasoline tank leaked to the soil.

Followup: No

Notes: According to the LDEQ incident report, the release possibly exceeded the benzene RQ, but refinery letter states that release is BRQ.

110960

2008-11-20
NIG
Cause: According to the LDEQ incident report, an opening line and bleeder valve were left open. Flammable gas escaped from the bleeder valve.

Followup: No

Notes: The release of flammable gas was BRQ.

110113

2008-10-14
NIG
Cause: According to the LDEQ incident report, a safety valve lifted and caused a crude oil spill.

Followup: No

Notes: Hot crude oil spilled and placed in sewer system and some of the material may have evaporated. This release is BRQ.

107539

2008-07-26
Hydrocracker unit reactor #101 safety valve flange
Cause: Hydrocracker unit Reactor #101 safety valve flange is leaking.

Followup: No

Notes: source is subject to facility's Leak Detection and Repair program and is permittable activity under Hydroprocessing Complex Title V permit.



105934

2008-05-26
Unit SRLA Tyler 310
Cause: Flange leak occurred on unit SRLA Tyler 310.

Followup: No

Notes: A crew tightened the flange and repaired as needed.

105717

2008-05-17

Cause: Release was a spontaneous occurrence from a flange.

Followup: No

Notes: Release occurred at the hydrocracker unit.

105559

2008-05-12

Cause: DO16 waste released to the ground from piping from a remediation well due to a leak in a flange.

Followup: No

Notes: Process water was released.

105322

2008-05-03

Cause: Experienced a slight leak on a flange.

Followup: No

Notes: Product released is reformer feed. Attempts to stop the leak are ongoing at time of SPOC report.


119856

2009-12-04
T2-61A
Cause: Pump seal leak on T2-61A.

Followup: No

Notes: LDEQ report states "propylene, ethylene, H2S and benzene expected to exceed reportable quantities. ExxonMobil in its report states that reportable quantities were not exceeded. Isolated the leak.



117816

2009-09-09
No Information Given
Cause: Small fire occurred due to flange leak on control valve. of heavy oil

Followup: No

Notes: Release is BRQ. Fire was extinguished and leak was controlled.


115976

2009-06-25
seal on Tank 797
Cause: Seal failure from the Tk-797 mixer occurred.

Followup: No

Notes: RQ not exceeded. Container put in place to collect leaking material. Vacuum truck put in place to recover material from container and ensure container did not overflow to soil. Will remove mixer seal and replace.
Oil: 92.4 pounds
114093

2009-04-13
Tk-192 mixer
Cause: Leak from seal failure of Tk-192 mixer.

Followup: No

Notes: RQ exceeded. Contaminated soil removed. Shut-off shaft to stop leak. Mechanism of failure is under investigation.
Oil: 88.2 pounds
113528

2009-03-20
701 tank manifold
Cause: Flange leaking at 701 tanks manifold located at R and 20th. Flange not tightened properly. Reason for unaligned flange is under investigation.

Followup: No

Notes: RQ exceeded. Line evacuated and flange was realigned and tightened. Contaminated ground has been removed. New quality control application expected to come out of the investigation.
Xylene: 158.0 pounds
Oil: 281.4 pounds
112696

2009-02-11
alky unit
Cause: According to the SPOC verbal report, gas leaked in the Alky unit from a valve packing.

Followup: No

Notes: SPOC report indicates that as a result of this ongoing incident, an estimated 1,000 pounds/day of isobutane is being released. However the refinery letter reports that no RQs were exceeded. No information provided regarding when the incident was secured.

112551

2009-02-05
No Information Given
Cause: According to the SPOC verbal report, a pipe flange leaked.

Followup: No

Notes: The release of an unspecified material was BRQ.

127131

2010-10-16
E-304 exchanger
Cause: A possible leak in the flange of the exchanger caused the incident.

Followup: No

Notes: State Police report states that they blocked exchanger and began the process of depressurizing it. The area was ropped off until leak stopped. No information given on repairs. Initial State Police report estimates release as greater than 1000 lbs of hydrogen. Refinery Letter states that no reportable quantities were exceeded. [BRQ].

125972

2010-08-27
no information given
Cause: A leak on a gasket caused a release of Hydrogen.

Followup: No

Notes: Compressor valve isolated and depressurized. This release was BRQ.

125332

2010-08-02
Depropanizer column
Cause: Alarm was triggered on the depropanizer column. There was a leaking flange.

Followup: No

Notes: This release is BRQ. The leaking flange was secured. Refinery Letter states that "after further evaluation, we have determined that this release is regulated by the Leak Detection and Repair regulations and is not considered an unauthorized discharge."

124680

2010-07-08
Valve
Cause: A valve leak with packaging was discovered. There was no active leaking when discovered.

Followup: No

Notes: BRQ. The location was excavated and remediated. One-fourth of a pint of jet was discovered. The area will remain open for monitoring. Less than one gallon of oil was released which is BRQ.
Oil: 1.0 gallons
123603

2010-05-19
no information given
Cause: Flange leak on pipe with terrible odor.

Followup: No

Notes: Isolated and drained pipe to do needed repairs. No additional information given. LABB only has access to the LDEQ incident report. No RQs exceeded.

122467

2010-03-30
No Information Given
Cause: Worker discovered ice ball around flange which indicates a leak of gas had occurred.

Followup: No

Notes: Equipment shut down, leak isolated and repaired. This release was BRQ.


129282

2010-01-14
Air Supply Control Valve
Cause: A leak developed in the air supply control valves that regulate natural gas flow to the Mixed Gas Oil tanks. For safety reasons, the valves are designed to fail open, so loss of instrument air resulted in excess natural gas entering the tanks. The vapor recovery system could not recover all of the gas, and some natural gas was vented to the air.

Followup: No

Notes: Release exceeds RQ. The instrument air was repaired, and the natural gas control valves were returned to service. LDEQ initially noted 13 months after incident, and there is no explanation provided for the delay. LDEQ report from 3/30/11 only states that incident will be deferred until next inspection.
Flammable Vapor: 3,953.0 pounds
120709

2010-01-11
safety valve on gas compressor
Cause: Safety valve lifted on gas compressor releasing hydrogen.

Followup: No

Notes: No reportable quantities were exceeded.

136029

2011-12-20
PSLA #10 quench line flange
Cause: The release resulted from a leak caused by a loose flange.

Followup: Yes

Notes: A pan was placed under the leaking flange to collect oil for reprocessing, and to mitigate further release of the material to soil. The bolts were replaced and tightened which stopped the leak. The contaminated soil was remediated immediately after the leak was isolated. 1.5 barrels of Coker feed (or 63 gallons) was also spilt to soil but is not reported as a specific pollutant emitted. However, coker feed has the same RQ as crude oil (1 barrel or 42 gallons) and is thus exceeded. The RQ for PAHs was also exceeded.
Anthracene: 0.2 pounds
Polynuclear Aromatic Hydrocarbons: 1.9 pounds
Volatile Organic Compounds (VOCs): 544.8 pounds
Phenanthrene: 0.8 pounds
Naphthalene: 0.8 pounds
135837

2011-12-09
check valve on pump to cooling tower 12
Cause: There was a leak from a check valve (over pressure on a check valve on a pump going to cooling tower 12).

Followup: No

Notes: No information given on remedial actions. Initial notification was for a release of 1000 lbs of pentane. Later, ExxonMobil determined that no reportable quantities were exceeded.

134100

2011-09-20
#8 depropanizer
Cause: Alarm went off on console because it lost pressure. They discovered a pump lost a seal on the number 8 depropanizer overhead.

Followup: No

Notes: Approximately 35 pounds of material was release, the majority of which was propane. Less than one pound of hydrogen sulfide was released. To end the release, the pump was shut down, isolated, and depressurized. An initial report indicated a release of greater than 1000 pounds of flammable gas and more than 100 pounds of hydrogen sulfide. However, upon further review from ExxonMobil, Exxon confirmed that no RQs were exceeded.
Propane: 34.0 pounds
Hydrogen Sulfide: 1.0 pounds
133873

2011-09-11
Safety Valve Discharge Header Piping weld
Cause: LDEQ received written notification from ExxonMobil Baton Rouge Refinery that there was a release of 200 pounds of flammable vapor due to a pin hole in a weld on a safety valve discharge header piping.

Followup: No

Notes: This release is BRQ.
Vapor: 200.0 pounds
132824

2011-08-02
F-105 orafice flange off of D-40 propane drum
Cause: There is an ongoing leak on the F-105 orafice flange off of D-40 propane drum.

Followup: No

Notes: 39 pounds of propane was released from valve's leak before an attempt to repair was made. The leak has now been reduced in size to less than one pound of propane per 24 hour period and permanent repair is underway.
Propane: 39.0 pounds
132065

2011-06-23
pin hole leak in valve going to P-646 meter
Cause: Pin hole leak found on a coupling between 3/4 inch block valves going to P-646 meter.

Followup: No

Notes: The leak was blocked out and depressurized. The release was similar in size to a valve packing leak detected through the refinery's Leak Detection and Repair Program. After calculations, total emissions were calculated to be less than the 100 pound reportable quantity set for propylene.

131897

2011-06-18
flange
Cause: ExxonMobil Baton Rouge Refinery wrote a letter to the LDEQ on June 18, 2011 for notification of the events and circumstances surrounding the flange release that occurred at the facility. Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded.

Followup: No

Notes: No information given.
Hydrogen: 28.0 pounds
131254

2011-05-19
R-3 outlet
Cause: The release was a flange leak on the R-3 unit.

Followup: No

Notes: BRQ: the fugitive component is covered by the site's Leak Detection and Repair program and there were people on site to tighten up bolts on the outlet. Phla Reactor Purge No further information was given.

130354

2011-04-04
Flange leak on core outlet of furnace
Cause: A flange leak on the core outlet of the furnace caused a release of hydrogen. When this release was reported, the incident was not secured and hydrogen was still being released.

Followup: No

Notes: ExxonRefinery has determined that no reportable quantities are being exceeded while shutdown procedures are being executed for Furnace F-901. This incident is related to Incident # 130442.

129868

2011-03-13
Flange
Cause: A flange leak released approximately 184 pounds of flammable vapor.

Followup: No

Notes: This release is BRQ.
Vapor: 184.0 pounds
129079

2011-02-06
Valve Bonnet Gasket
Valve Bonnet Gasket & Exchanger E-527
Cause: TWO INCIDENTS OCCURRED ON SAME DAY & INCLUDED IN SAME REPORT. Emissions from second incident breached the reportable threshold for a 24-hour period. First incident - LDEQ states that there was a leak in a valve bonnet gasket. Lube oil was spilled. 2nd incident involved a release from Light Ends Unit #3. Exchanger E-527 leaked into a condensate system that is open to the atmosphere. A follow up report will be submitted with the root cause in 30 days.

Followup: No

Notes: RQ. The valve was isolated to prevent further release. Vacuum trucks were used to remove oil, and soil remediation is complete.
Oil: 499.8 gallons
Volatile Organic Compounds (VOCs): 5,036.0 pounds
128851

2011-01-26
Flange
Cause: A leak was discovered on the flange of a coker unit. Oil gas was released to the soil and waste water treatment system.

Followup: No

Notes: BRQ. The leak was cleaned up and isolated. Refinery letter states that "complete containment of the spill and very low vapor pressure properties of the material prevented any impact to the environment."

128526

2011-01-07
Flange
Cause: A flange leak occurred in the sulfur unit. Sulfur dioxide and hydrogen sulfide were released.

Followup: No

Notes: BRQ. After further evaluation, ExxonMobil determined that no reportable quantities were exceeded. Mechanical unit cranked down on the bolts to secure the leak.
Hydrogen Sulfide: 2.3 pounds
Sulfur Dioxide: 1.0 pounds
145306

2012-12-13
NIG
Cause: A small pump leaked and released propylene into the air.

Followup: No

Notes: No reportable quantities were exceeded: approximately 1 pound of propylene was released. Exxon isolated the equipment to shut it down.
Propylene: 1.0 pounds
145216

2012-12-07
Flare Gas Recovery System
Cause: A safety valve at the LELA-S unit lifted, but was later determined that all emissions were captured by the refinery flare gas recovery system. ExxonMobil states that were no emissions to the environment as a result of this event.

Followup: No

Notes: ExxonMobil's notification states that there were no emissions to the environment as a result of this event. Correspondence reports from LDEQ and ExxonMobil display that hydrogen sulfide and flammable vapor were released from a unit, but later ExxonMobil stated that all gases were contained by the flare gas recovery system and that nothing was released into the environment.


144281

2012-10-29
MOV XD 21 valve
Cause: The Coker D-1D drum overhead valve, MOV XD 21, leaked.

Followup: No

Notes:
Flammable Vapor: 157.0 pounds
Hydrogen Sulfide: 1.5 pounds
135182

2012-10-24
HCLA unity C-102B compressor
valve at the HCLA unity C-102B compressor
Cause: HCLA unit C-102B compressor developed a leak near the threads of the valve. Approximately 52 pounds of volatile organic compounds (VOCs), 221 pounds of flammable vapor, and less than 1 pound of hydrogen sulfide (H2S) were released.

Followup: No

Notes: After further evaluation, ExxonMobil determined that no reportable quantities were exceeded.
Volatile Organic Compounds (VOCs): 52.0 pounds
Flammable Vapor: 221.0 pounds

143294

2012-09-17
control valve R002
Cause: A flame was discovered at the top of HCLA D-115 condensable blowdown drum stack. 803 pounds of flammable vapor and 60 pounds of Hydrogen Sulfide were released.

Followup: No

Notes: Steam was injected into the stack to extinguish the flame. Control valve R002 was discovered leaking. No reportable quantities were exceeded.
Hydrogen Sulfide: 60.0 pounds
Flammable Vapor: 803.0 pounds
139413

2012-05-04
Tank 778
Cause: On May 4, 2012, at approximately 1:00 pm, there was an oil spill to soil at the ExxonMobil Baton Rouge Refinery. Operations personnel in the area detected a hydrocarbon odor resulting from a leaking mixer seal on tank 778.

Followup: Yes

Notes: The spill was discovered on May 4, 2012 at 2:50 pm, and the line was isolated by 3:00 pm. Spill containment measures were implemented immediately to minimize the environmental impact. The tank mixer seal was locked in order to isolate the leak, and soil remediation was completed on May 7, 2012. The mixer seal will remain locked until permanent repairs can be completed during the next planned internal section and cleaning interval for Tank 778. Routine rounds to monitor the tank mixer will be completed. A 60-day follow up letter was sent about 11 months after the incident.
Oil: 63.0 gallons
136303

2012-01-05
flange on ICN unit
Cause: A contractor detected a hydrogen smell on compressor C-830. A flange on the ICN unit leaked Hydrogen. The leak rate was 100lbs/hr.

Followup: No

Notes: Unit personnel tightened the flange and the leak was isolated. No RQs were exceeded. 60.7 pounds of hydrogen, 7.9 pounds of methane, 1.4 pounds of ethane, and less than a pound of propane was released.
Hydrogen: 60.7 pounds
Methane: 7.9 pounds
Ethane: 1.4 pounds
Propane: 1.0 pounds
149602

2013-07-11
Black Valve Flange
Cause: On July 11, 2013, the Baton Rouge Refinery experienced an oil spill to soil at the West Complex of approximately 2.7 barrels. During a raffinate transfer, a leak developed on a block valve flange due to unbalanced gasket stress. Upon discovery, the transfer was immediately stopped and the line was steamed out. This event resulted in an exceedance of the LDEQ reportable quantity for oil to soil.

Followup: No

Notes: Immediately upon discovery, mitigation measures were initiated, the spill source was isolated, and soil remediation began. Soil remediation was completed on July 13, 2013 at 4 pm. Gasket was replaced and thermal cycles will be reduced procedurally. The contaminated soil had been removed, and no groundwater impacts are expected.
Oil: 113.4 gallons
159786

2014-11-05
OSD area
Cause: On November 5, 2014 the Baton Rouge Refinery experienced an oil spill to soil in the OSD area of approximately 53 barrels. During rounds, Dock personnel discovered oil leaking from a flange on the #2 fuel line.

Followup: No

Notes: Upon discovery, the line was depressured and the flange gasket was replaced. Vacuum trucks were used to remove the oil. Soil remediation was completed on November 8 2014.
Oil: 2,226.0 gallons
Volatile Organic Compounds (VOCs): 16,286.0 pounds
158694

2014-09-11
No Information Given
Cause: On Sept. 11, 2014, ExxonMobil Refinery had a release of hydrogen sulfide when a pump seal blew out on a unit. Release of 0.23 lbs of hydrogen sulfide. Initial report to state police hazmat hotline states that refinery is "unsure of what cause[d] seal to blow".

Followup: No

Notes: No Information Given, prompt incident response mitigated the event duration.
Hydrogen Sulfide: 0.2 pounds
155201

2014-04-10
flange on pump suction line, South Field area
Cause: On April 10, 2014 the Baton Rouge Refinery experienced an oil spill to soil in the South Field area. After being notified of an odor, a unit operator discovered jet fuel leaking from a flange on a pump suction line.

Followup: No

Notes: Immediately upon discovery of leak the flange was tightened. A vacuum truck was used to remove oil and soil remediation was completed by April 11, 2014. The incident is under investigation to provide mitigating steps to prevent recurrence.
Oil: 79.8 gallons