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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 | valve at the HCLA unity C-102B compressor 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 |
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