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Marathon Ashland Petroleum (3165), Garyville

Causal Factor: Equipment Failure

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

2005-08-28
North Flare
Cause: In preparation for Hurricane Katrina, the last stage of emergency shutdown, the steam boilers were shutdown. There was leakage of hydrocarbons into the flare line. Causing the North Flare to smoke for 2 days during which the refinery was shutdown. Categorized as an "upset".

Followup: No

Notes: Plant was shutdown as per preparation for Hurricane Katrina

80326

2005-07-06
UTLX Railcar No. 910150
Cause: There was a leak in the sample valve of UTLX Railcar No. 910150.

Followup: Yes

Notes: The MAP technician who discovered the leak attempted to tighten the valve but this just led to valve remaining open and inoperable. This event is currently under investigation. Water was sprayed on the railcar.
Ethane: 0.2 pounds
Propane: 111.3 pounds
Propylene: 523.9 pounds
Butane: 0.9 pounds
n-Butane: 52.4 pounds
Isobutane: 0.3 pounds
Pentane: 0.6 pounds
79520

2005-05-31
No Information Given
Cause: A faulty level transmitter on the sump pump at the on-site Fire Training grounds and excessive rain water caused the sump to over-flow into an internal ditch."

Followup: Yes

Notes: BELOW REPORTABLE QUANTITIES. A boom was deployed to prevent the mixture (of Tek-Flame and rainwater) from spreading to the Refinery's external outfall. A vacuum truck removed the fuel/water mixture from the ditch. Incident is currently under investigation.
Tek-Flame: 15.0 gallons
77730

2005-03-19
Distillate Hydroteating Unit
Cause: Leaking thermowell

Followup: No

Notes: Called inspector who found the leak; built encapsulation clamp; Report makes estimated leaks in pounds even though discharge was in drops
Hydrogen Sulfide: 1.0 pounds

Hydrogen: 1.0 pounds

Methane: 1.0 pounds
Ethane: 1.0 pounds



nC5 - 350 F: 5.0 pounds
nC5 + 350 F: 23.0 pounds
89533

2006-07-26

South Flare (EQI No. 69-74/EQT 160)
Cause: The Absorber Reboiler was leaking hot gas into the Hot Oil Surge Drum causing it to overpressure.

Followup: No

Notes: BELOW REPORTABLE QUANTITY.
Sulfur Dioxide: 26.3 pounds
Hydrogen Sulfide: 0.1 pounds
88771

2006-06-21

Propylene Cooling Tower (EQI No. 123-91/EQT 49)
Cause: The C3/C4 condenser was leaking product into the cooling water.

Followup: No

Notes: The cooling system associated with propane tower is being evaluated.
Propylene: 639.0 pounds
Propane: 213.0 pounds
88629

2006-06-14

Propylene Cooling Tower (EQI No. 123-91/EQT 49)
Cause: The C3 Product cooler was leaking on the cooling water side.

Followup:

Notes: None.
Propylene: 493.0 pounds
Propane: 164.0 pounds
85091

2006-01-11

The North Flare (EIQ No. 83-74/EQT 162)
Cause: The uninterpretable power supply failed, causing a shutdown of the FCC unit.

Followup: No

Notes:
Olefins: 78.7 pounds
Volatile Organic Compounds: 251.5 pounds
Sulfur Dioxide: 210.8 pounds
84997

2006-01-06
Flange near the Crude Bottoms Pump in the Crude Unit
Flange near the Crude Bottoms Pump in the Crude Unity
Cause: While preparing the Crude Unit for Turnaround activities a fire occurred. It is assumed that the bolts on the flange of a crude pump opened and products was released. The exact cause is still under investigation, but it is assumed that one of the isolation valves were leaking.

Followup: No

Notes: MPC assumed the entire amount of the sulfur present was combusted even though there was substantial product left on the cement of the unit.
Sulfur Dioxide: 2,039.0 pounds
Volatile Organic Compounds: 121.0 pounds
98913

2007-08-24
North Flare; weep holes on the HF Acid Shelter relief valve and the Main Fractionator Bottom relief valve
Cause: Unit 27 substation failed and shut down HF Alkylation, Butamer and Amine Treating. Failure of the bellows in Unit 27 Main Fractionator Bottoms relief valve

Followup: No

Notes: Claims emission was below RQ.
Hydrocarbon: 794.1 pounds
Olefins: 19.1 pounds
Hydrogen Flouride: 0.1 pounds
Nitrogen Oxide: 277.2 pounds
98913A

2007-08-24
North Flare; weep holes on the HF Acid Shelter relief valve and the Main Fractionator Bottom relief valve
Cause: Unit 27 substation failed and shut down HF Alkylation, Butamer and Amine Treating. Failure of the bellows in Unit 27 Main Fractionator Bottoms relief valve

Followup: No

Notes: Claims emission was below RQ.
Hydrocarbon: 794.1 pounds
Olefins: 19.1 pounds
Hydrogen Flouride: 0.1 pounds
Nitrogen Oxide: 277.2 pounds
98487

2007-08-07
FCCO Cooling Tower and the North Flare
Cause: The PGC Aftercooler trim cooler was found leaking hydrocarbons into the FCCO cooling tower.

Followup: No

Notes: Claims emission was below RQ.
Highly Reactive Volatile Organic Compounds (HRVOCs): 81.4 pounds
Volatile Organic Compounds (VOCs): 309.5 pounds
Hydrogen Sulfide: 3.9 pounds
Carbon Monoxide: 0.1 pounds
Sulfur Dioxide: 7.4 pounds
93979

2007-02-14
North Flare and Heater/Boiler CAP
Cause: Recycle compressors shutdown in the Gasoline Desulfurization Unit

Followup: Yes

Notes: Stopped hydrocarbon carryover to Amine Scrubber which reduced pressure in the Amine Flash Drum.
Sulfur Dioxide: 716.0 pounds
Volatile Organic Compounds (VOCs): 35.0 pounds
93924

2007-02-12
South Flare
Cause: Two steam boilers shutdown unexpectedly causing steam pressure facility wide to drop. The Crude Unit experienced an upset due to the loss of steam pressure and flared off of the Splitter Overhead receiver.

Followup: No

Notes: No Information Given. DEQ claims emission was below RQ.
Sulfur Dioxide: 11.0 pounds
90321

2007-01-03
North Flare
Cause:

Followup: No

Notes: Claims emission was below RQ. No Information Given


110200

2008-10-18
Unit 22, Saturates Gas Plant
Cause: Electrical fuse blew causing Unit 22 to trip offline.

Followup: No

Notes: According to report, no unauthorized discharge occurred. No data for amt of pollutants released. No remedial action planned at time of report.

107688

2008-08-01
)
North Flare (EQT162 / EIQ 83-70)
Cause: FCCU shutdown due to an unknown failure in the unit's Wet Gas Compressor.

Followup: No

Notes: Motor associated with the WGC was replaced.
Highly Reactive Volatile Organic Compounds (HRVOCs): 33.0 pounds
Volatile Organic Compounds (VOCs): 80.0 pounds
Sulfur Dioxide: 0.0 pounds
Nitrogen: 746.0 pounds

107159

2008-07-13
North Flare (EQT162 / EIQ 83-70)
Cause: Wiring issue in Wet Gas Compressor causes FCCU shutdown.

Followup: No

Notes: Report states that shutdown is permitted twice annually, so all emission are permitted. No info on which pollutants were released or the amounts.


102284

2008-01-15
7 h 22 m
Unit 46 - Deethanizer Reboiler
Unit 59 - North Flare
Unit 66 - RBS Flare
Cause: Shell's off gas compressor tripped causing the fuel gas pressure to increase and relieve to flare

Followup: No

Notes: FCCU Reactor Temperature was cut back to reduce off-gas production
Highly Reactive Volatile Organic Compounds (HRVOCs): 28.5 pounds
Volatile Organic Compounds (VOCs): 52.1 pounds
Carbon Monoxide: 5.8 pounds
Nitrogen Oxide: 15.7 pounds
120288

2009-12-20
Unit 63 Tends Pump
Cause: Hydrogen leak in the #4 reactor lead to a fire within unit 212 platformer.

Followup: Yes

Notes: SERT was notified and responded.

116971

2009-08-03
coke drum
Cause: During coke cutting operation, a sudden fall-out of the coke drum contents took place.

Followup: No

Notes: personnel sheltered until the nature of the accident was understood.

116933

2009-07-31
None Reported
Cause: A small fire occurred as a result of a malfunction of the coker conveyor belt. No RQs were exceeded.

Followup: No

Notes: The fire was extinguished. Exact pollutants are not know and were not disclosed. "Products of combustion" were reported released by Marathon. The fire lasted about 40 minutes.
116261

2009-07-07
Railcar loading rack, Unit 64 (EQI 14-97, EQT 0055)
Cause: Leaks on a relief valve flange and a dome flange were discovered on a rail-car when it arrived at the plant.

Followup: Yes

Notes: The car was relieved to flare instead of pressuring the car to off-load the contents, which is the normal procedure. Pressuring the car would have made the leaks worse.
Propylene: 728.0 pounds
Nitrogen Oxide: 176.0 pounds
Carbon Monoxide: 955.0 pounds
115720

2009-06-16
exchanger 05-1313
Cause: Pinhole leak from exchanger, 05-1313, caused a release of naphtha to the coker unit pad.

Followup: Yes

Notes: the exchanger was isolated, and contents were directed to the oily water sewer.
Ethylene: 0.1 pounds
Propane: 5.3 pounds
Propylene: 2.8 pounds
Isobutane: 0.7 pounds
n-Butane: 4.2 pounds
1-Butene: 3.6 pounds
1-Pentene: 2.5 pounds
n-Pentane: 9.1 pounds
Pentene: 65.3 pounds
Hexane: 68.4 pounds
Hydrogen Sulfide: 0.1 pounds
115394

2009-06-01
Unit 15 HGO hydrotreater
Cause: Pin-hole leak in unit 15's hot separator overhead fin fan.

Followup: Yes

Notes: Fin fan was blocked in and tube isolated.
Hydrogen Sulfide: 20.0 pounds
Volatile Organic Compounds (VOCs): 24.0 pounds
Ethane: 55.2 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 0.9 pounds
80067

2005-06-25
no information given
Cause: Leaking clamp. No emission point source associated with it.

Followup: No

Notes: "The unit was shutdown to minimize the leak. Once shut sown the section of piping where the clamp was located was replaced prior to starting up the unit."
Slurry Oil: 5.0 pounds
125901

2010-08-22
North Ground Flare
Cause: Incident was the result of an electrical problem for the new production unit. A triplicated Triconex level indicator on the 1st stage suction drum malfunctioned, filled with liquid and tripped the wet gas compressor. Drum over-pressured which caused 205-PC-1511-V1 and V2 to open to the North Ground Flare. Released to air.

Followup: No

Notes: Reportable quantities for sulfur dioxide, hydrogen sulfide, and HRVOCs were exceeded. Remedial actions: The unit 205-delated coker reduced charge rate to minimize the release.
Highly Reactive Volatile Organic Compounds (HRVOCs): 531.9 pounds
Volatile Organic Compounds (VOCs): 3,855.1 pounds
Methane/Ethane Mixture: 1,880.4 pounds
Sulfur Oxides: 46,227.2 pounds
Hydrogen Sulfide: 501.2 pounds
124866

2010-07-15
No Information Given
Cause: State Police report states that there was a leak on a pressure gauge; fire occurred and was put out by the time of call to Hazmat hotline. No additional information given. FIRE.

Followup: No

Notes: BRQ. Refinery letter states that no reportable quantities were exceeded. Line was blocked in and gauge was tightened, stopping the leak.

123579

2010-05-18
FLARE: Unit 59 North (EQT #0162 EIQ #83-74) & South Flares (EQT #0160 EIQ #69-74)
Cause: Refinery letter states that liquid material from the refinery's FCCU carried over into the fuel gas system, causing incomplete combustion in the refinery's process heater and flares.

Followup: No

Notes: The source of the liquid stream was identified and isolated from the fuel gas system. The remaining liquid was drained from the process units' knockout drums. The process heaters were then restarted. Steps to prevent a recurrence of the incident will be taken once the root cause analysis is completed. NOTES: Nitrogen Oxides were released.
Nitrogen Oxide: 135.0 pounds
Sulfur Dioxide: 0.3 pounds
Volatile Organic Compounds (VOCs): 413.0 pounds
123361

2010-05-11
No Information Given
Cause: Boiler blew out, released large quantity of steam. No further details given.

Followup: No

Notes: BRQ. LDEQ reports states that no reportable quantities were exceeded during this event. No additional information given. LDEQ report only. No refinery letter.

123330

2010-05-07
Truck loading rack [EIQ #1497]
Cause: Relief valve on transport truck opened at a pressure below what was supposed to open it during offloading.

Followup: No

Notes: BRQ. Refinery letter states that reportable quantities were not exceeded, but detailed emissions report included. "The truck was offloaded to process to relieve [sic] the pressure and stop the event."
Volatile Organic Compounds (VOCs): 13.6 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 9.4 pounds
121955

2010-03-08
FLARE - South Ground Flare [EIQ 20B-08]
South Ground Flare
Cause: FLARE. Heat exchanger leak & fire required shutdown of Hydrocracking Unit, had to flare.

Followup: No

Notes: BRQ. Refinery letter states that no reportable quantities were exceeded and that "no specific remedial action is required in this case." Detailed emissions report included.
Hydrogen: 165.4 pounds
Methane/Ethane Mixture: 35.8 pounds
Nitrogen Oxide: 148.7 pounds
Carbon Monoxide: 808.8 pounds
121170

2010-01-30
Tank - gas oil pump
Cause: Suction bellows of a Gas Oil Pump leaked out of pipe coming from pump leading to storage tank, valve on pump failed, heavy gas oil spilled in nearby ditch.

Followup: No

Notes: RQ. Exceeded reportable quantities for oil on the ground. Heavy gas oil line depressurized to stop leak, area boomed off, vacuum trucks brought in to remove product from the ground, outside spill response company brought in to complete clean-up. Release lasted 15m after discovery.
Heavy Gas Oil: 2,100.0 gallons
120841

2010-01-16
hydrocracker unit 215
hydrocracker unti 215
Cause: Leaking flange on new hydrocracker unit discovered at initial startup. "Authorized discharge" under existing permits.

Followup: No

Notes: BRQ. Refinery letter states that no reportable quantities were exceeded. Repair work begun immediately, air monitoring team dispatched to monitor area and fenceline, but found no detectable emissions.


120620

2010-01-15
South Ground Flare (EQT 0284)
Cause: New Naphtha Hydrotreating Unit relief valve failed--opened intermittently at lower pressures than it was supposed to and sent stream to flare. Discovered problem thanks to citizen complaint re: the smell. Reportable quantity for SO2 exceeded. Duration given below is an estimate; emissions were intermittent from 1758 hrs to 2215 hrs.

Followup: No

Notes: RQ. Faulty valve taken out of service & sent for repairs. RQ. Detailed release calculations attached to refinery letter.
Sulfur Dioxide: 2,413.0 pounds
Hydrogen: 1.2 pounds
Methane: 2.6 pounds
Ethane: 5.7 pounds
Propane: 12.5 pounds
Isobutane: 6.1 pounds
n-Butane: 11.5 pounds
Pentane: 0.2 pounds
n-Pentane: 0.1 pounds
Pentene: 7.8 pounds
Hydrogen Sulfide: 6.4 pounds
Water: 0.6 pounds
134363

2011-10-05
Unit 15 Heavy Gas Oil Hydrotreater
Cause: A 3/4 inch bleeder valve failed on the Reactor Charge Startup Bypass Line while process equipment was being cleaned with LCO. There was no known off-site impact. An incident investigation is being conducted to determine why the incident occurred. LCO was released to and contained to the concrete slab of the Unit.

Followup: No

Notes: The line was allowed to depressure to the flare until the pressure on the line was atmospheric. LCO was processed in the onsite Waste Water Treatment Plant. An incident investigation will result in recommendation items designed to prevent the recurrence of this event.
Light Cycle Oil: 3,112.2 gallons
133637

2011-09-06
North Flare Stack
Cause: On 9/2/11 the valve wheel broke on the propylene mix pump relief valve. The valve stem then failed on 9/6/11 allowing propylene from the loading rack to be sent to the north flare stack.

Followup: Yes

Notes: Valve was blocked in to stop propylene flow to the flare. An incident investigation will result in recommendation items designed to prevent the recurrence of this event. The 1 1/2" Bypass valve leaked for 6 days. NO LDEQ Report, no First follow-up report, and no SPOC Report.
Propylene: 608.2 pounds
Propane: 298.1 pounds
131865

2011-06-16
RGP truck
Cause: While unloading a truck full of Refinery Grade Propylene (RGP), the relief valve on the truck began leaking to the atmosphere. Water was sprayed on the truck to cool it and the relief valve reseated in 20 minutes. An incident investigation is being conducted to determine why the incident occurred.

Followup: No

Notes: The lines coming from the truck were immediately closed. The deluge (water) system was opened and water was sprayed on the truck to cool the truck until the relief valve closed. An incident investigation will result in recommendation items designed to prevent the recurrence of this event. Initial report mentions that problem could be weather related. Propylene is the HRVOC included in the numbers. Propane is the VOC in the report. Together, they constitute 3lbs of VOC or 2.1lbs of HRVOC separately.
Propane: 0.9 pounds
Propylene: 2.1 pounds
143319

2012-09-23
Emissions from Flare
emissions from flare and Unit 45 Thermal Oxidizer
Cause: Marathon experienced a partial power outage caused by a malfunctioning substation in the refinery resulted in multiple pieces of equipment in the refinery losing power. Low pressure stripper Offgas flared in the South Flare due to partial power outage. Enterprise incident due to a plant farther downstream that had uncharacteristically ceased operation due to an upset condition. The pressure safety valve, as designed, released discharging natural gas to atmosphere due to high pressure on the pipeline caused by the upset condition farther down the line. Emission points involved were the Unit 59 North Flare and the Unit 45 Thermal Oxidizer.

Followup: No

Notes: Marathon power was restored and the equipment that was shutdown was restarted to minimize further releases. An incident investigation will result in recommendation items designed to prevent the recurrence of this event. High sulfur dioxide from one of the thermal oxidizer stacks in Unit 45 and in addition to a small amount of Unit 15 low pressure stripper offgas was flared which contains a small amount of hydrogen sulfide which is converted to sulfur dioxide in the North Flare. Emission points involved were the Unit 59 North Flare and the Unit 45 Thermal Oxidizer. Enterprise personnel immediately began the process of taking the plant down in order to end the release event. Amount of natural gas released is above reportable quantity.
Nitric Oxide: 0.2 pounds
Carbon Monoxide: 0.8 pounds
Sulfur Dioxide: 90.7 pounds
Volatile Organic Compounds (VOCs): 1.4 pounds
Hydrogen Sulfide: 0.1 pounds
Methane: 0.2 pounds
Ethane: 0.2 pounds
n-Butane: 0.2 pounds
n-Pentane: 0.2 pounds
1-Pentene: 0.2 pounds
Pentene Plus: 0.2 pounds
Natural Gas: 28,000.0 pounds




Propane: 0.5 pounds
Isobutane: 0.1 pounds
No LDEQ Reported

2012-09-11
N/A
Cause: The pumps on the in-ground sump failed to operate

Followup: No

Notes: An oily water sewer in-ground sump located in the MPC tank farm near the gasoline blending building was observed to be overflowing oily water onto the ground. The breaker of pump 67-1567-01 was reset and the breaker of pump 67-1567-02 was repaired. The contaminated soil was removed from around the sump.
Gasoline: 5.0 gallons
140561

2012-06-16
Flange on the Pitch Exchanger 210-1317-08
North Ground Flare
Cause: The 210-1513-01 Vacuum Bottoms Pump inboard and outboard motor bearing housings were smoking during routine observations. The 210-1513-02 Vacuum Bottoms Pump (back-up) was already out of service for repairs. The board operator was notified and started reducing Crude charge rate. The 210-1513-01 Vacuum Bottoms pump was shut down due to the outboard motor bearing igniting. The 210 Crude Unit shutdown procedure was initiated. The 210-1801-01 Offgas Compressor tripped due to a high level in the 210-1202 Compressor Suction Drum. Both pumps were already on in automatic. The outsider operator opened the bypass around the flow controller to the Product Receiver. Crude overhead gas was flared in the North Ground Flare. About 5 gallons of crude oil from a flange on the Refinery's Oily Water Sewer and processed in the WWTP.

Followup: No

Notes: The boardman cut charge rates to Crude Unit 10 and shut down Crude Unit 210. Both Compressor Suction Drum pumps were turned on, and the bypass around the flow controller was opened. The operator increased the suction drum pressure to assist the pumps in pressuring out the level to the startup compressor. The incident investigation will result in recommendation items designed to prevent the recurrence of this event. Initial report states material did go offsite. Verbal report and Hazardous Materials Incident Reporting Form state that H2S was released (and incorrectly reporting that the reportable quantity for it is 500 lbs), while the refinery statement letter reports only SO2.
Sulfur Dioxide: 309.2 pounds
Crude Oil: 5.0 gallons
Hydrogen Sulfide: 1.0 pounds
Nitric Oxide: 0.8 pounds
Carbon Monoxide: 4.5 pounds
Volatile Organic Compounds (VOCs): 10.3 pounds
Particulate Matter 10: 0.1 pounds
Particulate Matter 2.5: 0.1 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 0.1 pounds
Compressed Flammable Gas: 10.3 pounds
Flammable Liquid: 0.2 pounds
137652

2012-03-05
Unit 59 North Flare
Cause: The incident that occurred was a unit shutdown and associated flaring event. The wet gas compressor in the Fluidized Catalytic Cracking Unit tripped offline followed by an entire unit shutdown. The shutdown caused hydrocarbons to be routed to the north flare.

Followup: Yes

Notes: RQs exceeded for SO2 and HRVOCs. Also, the opacity standard was exceeded for 8 minutes. Incident only lasted 26 minutes, but the depressuring of the unit continued and flaring lasted approximately 425 minutes. Remediations included cleaning the wet gas compressor motor aux contact and retest to verify appropriate resistance, and also revised compressor control system programming to include motor current to improve reliability of failed-to-start interlock logic.
Sulfur Dioxide: 1,257.0 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 355.0 pounds
137244

2012-02-16
Unit 59 South Flare (EQT0160, EIQ69-74)
Cause: During an upset of the U15 High Pressure Stripper, liquid and vapor were sent to the 19-1211 Fuel Gas Absorber KO Drum. A control valve and a bypass were opened on the bottom of the drum, sending liquid to the flare in order to maintain level in the drum.

Followup: Yes

Notes: In U15, HP Stripping Steam was cut and charge was reduced to bring the upset under control.
Sulfur Dioxide: 1,359.0 pounds
136541

2012-01-14
Unit 59 South Flare, Unit 45 Thermal Oxidizer, Unit 220 Thermal Oxidizer, Unit 234 Thermal Oxidizer, and Unit 33 Sour Water Tank
Cause: Chain of Events: 1/14/12: Hydrocarbon carryover from the Unit 19 Sour Water Stripper caused Unit 220 (sulfur unit) and Unit 45 Thermal Oxidizer to trip. As a result, a sulfur dioxide plume was released from the Unit 45 Thermal Oxidizer. During the release, hydrocarbons from the ammonia acid gas header were steamed out to the flare. Units were then shut down to limit environmental impact. 1/15/12: A similar incident took place approximately four hours after Unit 220 startup. During this incident, the flare valve on the fuel gas absorber knockout drum opened to flare to relieve pressure on the drum. Hydrocarbon from the carryover was also sent to the sour water storage tank, which resulted in the tank venting to the atmosphere. 1/16/12: The flare valve from the fuel gas absorber knockout drum was closed at approximately 9:30, and the incident was then determined to be secure. The entire incident is under investigation. Follow up report issued 2/26/2013 summarizes results of internal Marathon investigation.

Followup: Yes

Notes: During the initial upset (1/14/12), Cargill was notified of the plume. All work with the Marathon refinery was put on hold, and the plant's Air Monitoring Team (AMT) was dispatched. The data that they collected is attached to the report. The contents of the Unit 19 Sour Water Storage Tank and ammonia acid gas header were then purged to eliminate existing hydrocarbons. Similar actions were taken to mitigate emissions from the second incident (1/15/12). Units were shut down, the AMT was activated, and fire water was introduced to limit emissions from the sour water tank. This incident was determined to be secured (1/16/12) when the flare valve from the fuel gas absorber knockout drum was closed to the South Flare. An incident investigation was conducted to determine the cause or causes of the incident. Per this investigation, the root cause was identified as Equipment Difficulty-Problem Not Anticipated. The recommendation from this investigation was to review disposition of Fuel Gas Absorber knock-out drum liquid. Report states this action was completed 6/27/12. Only states that SO2 emissions were above reportable quantities.
Hydrogen Sulfide: 7.6 pounds
Sulfur Dioxide: 829.2 pounds
Nitrogen Dioxide: 87.8 pounds
Carbon Monoxide: 477.6 pounds
Volatile Organic Compounds (VOCs): 1,428.4 pounds
Particulate Matter 10: 9.6 pounds
Particulate Matter: 9.6 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 0.5 pounds
Ammonia: 1.6 pounds
152421

2013-11-18
Unit 10 Naphtha Splitter
Cause: On November 18 during startup of the Naptha Splitter, a leak was found in the vessel shell. As soon as the leak was discovered, the vessel was deinventoried and all liquid feeds were blocked in. The source of the leak was from a hole the side of a pencil, the cause of which is under investigation.

Followup: Yes

Notes: As soon as the leak was discovered, the vessel was deinventoried and all liquid feeds were blocked in. An incident investigation will determine the cause and recommendations to prevent future occurrences will be made.
Volatile Organic Compounds (VOCs): 127.0 pounds
Benzene: 2.3 pounds
Compressed Flammable Gas: 39.5 pounds
Compressed Flammable Liquid: 87.5 pounds
No LDEQ Reported

2013-09-13

Cause: Crude oil seeped through the deck plugs of the pump containment of Bouchard Transportation barge B235 which filled the pump containment area spilling approximately 1/2 gallon of product into the Mississippi River.

Followup: No

Notes: Product was contained on the barge and boom was deployed in the Mississippi River.
Crude Oil: 0.5 gallons
149704

2013-07-15
Unit 259 North Ground Flare
Cause: ON July 15, 2013, an upset in Crude Unit 210 caused the Crude Compressor Suction Drum to vent to the North Ground Flare for approximately one minute. The first incident was due to a crude oil switch causing the Unit 22 Sats Gas Plant Compressor to shutdown on high level. The second incident was due to an upset in the Unit 210 Crude Unit that cause the Unit 210 Crude Compressor Suction Drum to vent to the North Ground Flare.

Followup: Yes

Notes: Operating personnel made operating changes to the unit to bring it out of upset conditions. October 23, 2013 additional follow-up report corrects emissions data submitted by MPC. MPC erroneously included greenhouse gas (GHG) emissions in the incident calculation. GHGs are not permitted pollutant and are not required to be evaluated for reportable quantities.
Nitrogen Oxide: 10.1 pounds
Sulfur Dioxide: 333.7 pounds
Volatile Organic Compounds (VOCs): 99.7 pounds
Carbon Monoxide: 56.4 pounds
Particulate Matter 10: 1.1 pounds
Particulate Matter 2.5: 1.1 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 0.0 pounds
149069

2013-06-11
Heat Exchanger 215-1304-02
Cause: On June 11, 2013, a small vapor leak developed on Heat Exchanger 215-1304-02. There were no offsite impacts.

Followup:

Notes: The area was cordoned-off. The exchanger head was hot bolted to secure the leak. No specific action is recommended for this incident.
Compressed Flammable Gas: 74.0 pounds
Compressed Flammable Liquid: 48.3 pounds
Hydrogen Sulfide: 7.1 pounds
Volatile Organic Compounds (VOCs): 71.3 pounds
148974

2013-05-31
North Stick Flare (EQT 162/EIQ 83-74)
Cause: On May 31, 2013, while discharging a propylene tank truck, the operator noticed that the propylene unloading drum was leaking to the North Stick Flare. There were no known offsite impacts.

Followup: Yes

Notes: Shutdown the unloading of the tank truck and blocked in the propylene drum to prevent any additional product into the drum. To reduce pressure, the liquid in the drum was pumped down from 50% to 20% and routed to the spheres. Both the truck and rail racks were shutdown. The bypass valve will be replaced An additional followup on 10/23/13 corrected the initial followup report's emissions data regarding greenhouse gas releases.
Propylene: 0.8 pounds
Propane: 0.4 pounds
NOx: 0.1 pounds
Carbon Monoxide: 0.4 pounds
Volatile Organic Compounds (VOCs): 1.1 pounds
Particulate Matter 10: 0.0 pounds
Particulate Matter 2.5: 0.0 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 0.8 pounds
157829

2014-08-01

Wet Gas Compressor
Cause: The wet gas compressor tripped due to a motor issue, which caused the overhead of the Fractionator to pressure up. The high pressure reached a safety limit and the unit shutdown. During the time that motor was undergoing repairs, fuel gas was routed into the unit to prevent excess oxygen from getting into the unit regenerator, fractionator and overhead accumulator which resulted in flaring. The unit was then started up in accordance with a written procedures. An incident investigation was conducted and identified Equipment Difficulty-Equipment/Parts Defective-Manufacturing as the Root Cause. Investigation states that the trip was initiated by the motor differential circuit detecting a differential of currency within the motor. The motor relay was initially expected to be the issue.

Followup: Yes

Notes: The SIS system reacted as designed to shutdown the Fluid Catalytic Cracking Unit (FCCU) due to the high pressure in the fractionator. An incident investigation was conducted and included the following recommendations: 1) Send relay to manufacturer for analysis (Complete), 2) Review findings from the manufacturer (Complete), 3) Test the differential circuit at the next available opportunity (Deadline-10/31/16)
Sulfur Dioxide: 3,297.0 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 363.0 pounds
NOx: 580.9 pounds
Carbon Monoxide: 2,989.9 pounds
Volatile Organic Compounds (VOCs): 2,134.3 pounds
Particulate Matter 10: 230.7 pounds
Particulate Matter 2.5: 230.7 pounds
Hydrogen Sulfide: 12.1 pounds
Methane: 414.3 pounds
Ethane: 107.4 pounds
Ethylene: 18.2 pounds
Acetylene: 0.4 pounds
Propane: 253.6 pounds
Propylene: 345.0 pounds
n-Butane: 414.1 pounds
Isobutane: 2.0 
No LDEQ Reported

2014-07-05
valve on diesel line on Dock 1
Cause: A valve on a diesel line on Dock 1 began leaking, and product was spraying out of the valve. The operator noticed the leak immediately and blocked in the line. The operator released the pressure from the line and isolated the leak by closing a valve upstream to the leaking valve. The operator walked downstairs and noticed that diesel product was leaking through the dock penetration cover. Material was released into the Mississippi River, but no sheen occurred.

Followup: No

Notes: Once product was seen spraying from the valve, the line was immediately isolated. No boom was deployed into the Mississippi River, as the product dissipated immediately. An incident investigation will be conducted to determine corrective actions.

No LDEQ Reported

2014-07-05
valve on diesel line on Dock 1
Cause: A valve on a diesel line on Dock 1 began leaking, and product was spraying out of the valve. The operator noticed the leak immediately and blocked in the line. The operator released the pressure from the line and isolated the leak by closing a valve upstream to the leaking valve. The operator walked downstairs and noticed that diesel product was leaking through the dock penetration cover. Material was released into the Mississippi River, but no sheen occurred.

Followup: No

Notes: Once product was seen spraying from the valve, the line was immediately isolated. No boom was deployed into the Mississippi River, as the product dissipated immediately.

157090

2014-06-27
Unit 25 FCCU wet gas compressor shutdown
Cause: The wet gas compressor (WGC) suction flow and discharge pressure dropped suddenly, causing the WGC spillback valve to open 100%. The fractionator overhead pressure increased when the WGC spillback opened up. The high fractionator pressure SIS trip point was reached (36 psi), which tripped the unit. Fuel gas was routed to the fractionator overhead accumulator, which was being vented to the flare to keep pressure on the reactor to prevent O2 from the regen from backing into the reactor. No offsite impacts were observed by the air monitoring team. The reportable quantities for Sulfur Dioxide, HRVOCs and VOCs were exceeded. Update: cooling coil in Alkyl Unit Vent Gas Absorber (27-1107) failed.

Followup: Yes

Notes: The SIS system reacted as designed to shutdown the FCCU due to the opening of the compressor spillback valve. An incident investigation will result in recommendation items designed to prevent recurrence of this event. Update: The root causes were identified as 1) cooling coil in Alkyl Unit Vent Gas Absorber (27-1107) failed. Cause of failure is unknown. Root Cause #1: Cannot be determined until the Alkyl Unit Shutdown. Recommendation: Inspect the cooling coil in the Alkyl Unit Vent Gas Absorber (27-1107) and determine cause of failure. Based on the cause of failure, recommendations will be generated to prevent recurrence. [Complete by December 15, 2016] 2) Quaterly PMs on cooling coil in Alkyl Vent Gas Absorber failed to identify the coil was leaking. Root Cause #1: No Procedure. Recommendations: Create Operations procedure for performing the quarterly leak testing on the cooling coil in the alkyl Vent Gas Absorber. Include a step that requires operators to verify proper documentation of test result in PM work order closure. [Complete by November 18, 2014]. Root Cause #2 Preventive/Predictive Maintenance Needs Improvement. Indetify flouride sample locations for discovering a leak in Alkyl Vent Gas Absorber cooling coil [Complete by November 18, 2014].
Sulfur Dioxide: 8,994.0 pounds
Highly Reactive Volatile Organic Compounds: 246.0 pounds
Methane: 415.8 pounds
Ethane: 112.1 pounds
Ethylene: 5.3 pounds
Acetylene: 0.3 pounds
Propane: 397.7 pounds
Propylene: 84.7 pounds
n-Butane: 807.2 pounds
Isobutane: 324.0 pounds
Butene: 193.6 pounds
Pentene Plus: 719.8 pounds
Carbon Dioxide: 2,158.5 pounds
Carbon Monoxide: 171.5 pounds
Hydrogen: 50.2 pounds
Nitrogen: 105,957.5 pounds
Hydrogen Sulfide: 10.6 pounds
NOx: 669.9 pounds
Particulate Matter 10: 266.0 pounds
Particulate Matter 2.5: 266.0 pounds
Methane: 415.8 pounds
Ethane: 112.1 pounds
Ethylene: 5.3 pounds
Acetylene: 0.3 pounds
Propane: 397.7 pounds
Propylene: 84.7 pounds
n-Butane: 807.2 pounds
Isobutane: 324.0 pounds
Butene: 193.6 pounds
Pentene Plus: 719.8 pounds
Carbon Dioxide: 2,158.5 pounds
Carbon Monoxide: 171.5 pounds
Hydrogen: 50.2 pounds
Nitrogen: 105,957.5 pounds
Hydrogen Sulfide: 10.6 pounds
NOx: 669.9 pounds
Particulate Matter 10: 266.0 pounds
Particulate Matter 2.5: 266.0 pounds
15660

2014-06-07
FCCU wet gas compressor first stage
Cause: A loose wire in a satellite building caused the Fluid Catalytic Cracking Unit (FCCU) wet gas compressor first stage spillback to open, which led to high fractionator pressure. The safety instrumented system (SIS) tripped the FCC unit on high fractionator pressure. During the FCC unit startup, the debutanizer pressured up and had to be vented to flare due to lack of heat in the upstream stripper reboiler (heating medium is BPA from the fractionator) which sent ethane to the debutanizer. The flaring event due to the FCCU Shutdown began on June 7, 2014 at 14:37 hours and stopped on June 7, 2014 at 15.48 hours for a duration of 70 minutes. The flare event due to the FCCU startup began on June 7, 2014 at 18:21 hours and stopped on June 7, 2014 at 20:18 hours for a duration of 117 minutes. The total duration of the flaring was 187 minutes.

Followup: No

Notes: The SIS system reacted as designed to shutdown the FCCU due to the opening of the compressor spillback valve. During FCCU startup the operating procedure was followed to minimize emissions to the extent possible. An incident investigation will result in recommendation items designed to prevent the recurrence of this event.
Sulfur Dioxide: 3,873.0 pounds
NOx: 22.1 pounds
Carbon Monoxide: 113.9 pounds
Volatile Organic Compounds (VOCs): 40.1 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 5.5 pounds
Hydrogen Sulfide: 0.4 pounds
Methane: 8.2 pounds
Ethane: 23.8 pounds
Ethylene: 9.5 pounds
Propane: 36.9 pounds
Propylene: 141.2 pounds
n-Butane: 10.2 pounds
Isobutane: 27.7 pounds
1-Butene: 22.3 pounds
T-butene2: 9.1 pounds
Pentene Plus: 22.1 pounds
Hexane: 2.7 pounds
Pentane: 3.7 pounds
155856

2014-05-09

Railcar Inlet Valve
Cause: After loading a propylene railcar, the operator noticed that the inlet valve was leaking and could not be closed. The railcar was depressured to the flare so it could be disconnected and the valve repaired.

Followup: No

Notes: None. The contents of the railcar were vented to the North Flare Stack. The railcar was sent for repairs.
Highly Reactive Volatile Organic Compounds: 70.0 pounds
NOx: 11.4 pounds
Carbon Monoxide: 61.9 pounds
Particulate Matter 10: 1.3 pounds
Particulate Matter 2.5: 1.3 pounds
Volatile Organic Compounds (VOCs): 93.1 pounds
Ethane: 0.3 pounds
155846

2014-05-08
Relief valve
Cause: Beginning at 1030 on 5/8/14, operations noticed the North Flare Stack SO2 analyzer was reading 20-30 lbs/hr. The source of emission was unknown at the time and the environmental department was notified. A courtesy notification was made at approx. 1930. The cause of the emission has since been determined to be a leaking relief valve (RV). This was an allowable emission under facility permit 2580-00013-V12. There were no known offsite impacts.

Followup: No

Notes: Operations took multiple samples of the flare system to determine source of the material.

155782

2014-05-04
Conveyor (EQT 028)
Cause: Malfunction at Marathon's coke belt. The conveyor belt split and the belt was patched with clips. Because of the clips, the scrapers which remove coke from the belt could not be reinstalled. After the repair, the belt was restarted, which caused the fines to enter the Mississippi River. There were no known offsite impacts.

Followup: No

Notes: No remedial actions taken. The petroleum coke fines dispersed immediately upon entering the water. Refinery letter indicates that an investigation was in progress as of 5/4/2014.