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Marathon Ashland Petroleum (3165), Garyville

Causal Factor: Instrument Failure

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release

Tank 120-6 (EIQ No. 16-74 and EQT 76)
Tank 120-6 (EIQ No. 16-74 and EQT 76) Tank 120-6 (EIQ No. 16-74 and EQT 76)
Cause: It is suspected that there was a failed level indicator on 6/26/05 which led to the product being on the roof of the tank. The cause of the failure in unknown.

Followup: Yes

Notes: The product was transferred to a finished gasoline storage tank. The cause of the failure and subsequent leak are still unknown and are awaiting the results of the investigation.
Benzene: 102.0 pounds
Ethylbenzene: 11.0 pounds
n-Hexane: 348.0 pounds
2,2,4-Trimethylpentane: 175.0 pounds
Cumene: 0.4 pounds
Naphthalene: 0.5 pounds
Toluene: 115.0 pounds
Xylene: 45.0 pounds
Organic Compounds: 24,916.0 pounds

Conservation vents Tank 55-5(EQI No. 44-74/EQT No. 104)
Cause: Tank 55-5 high pressure equal to 2 inches of water column caused the tank conservation vents to open to the atmosphere. The pressure transmitter failed giving a false low pressure in tank 55-5.

Followup: No

Notes: Currently under investigation. BELOW REPORTABLE QUANTITY.
Butane: 134.9 pounds

FLARE - Unit 59 North Flare [EQT0162, EIQ83-74]; Unit 05
Cause: "Due to instrumentation malfunction, the inlet valve on the Unit 05 Coker Wet Gas Compressor Suction Drum closed. The compressor shut down and the material was routed to the North Flare. FLARE.

Followup: No

Notes: RQ. The reportable quantity for sulfur dioxide was exceeded during this incident. Detailed emissions report included. Inlet valve on Unit 50 was opened, the compressor was restarted, and material was routed to the compressor. No additional information given.
Sulfur Dioxide: 3,500.0 pounds

FLARE - North Ground Flare
Cause: Instrument malfunction in the Hydrocracking Unit caused liquid material to be routed to the GME Crude Unit overhead gas system, compressor shut down, routed to flare until liquid was drained. FLARE.

Followup: No

Notes: RQ. Exceeded reportable quantities during this incident; detailed emissions report included. Technicians troubleshooting malfunction.
Sulfur Dioxide: 1,101.0 pounds

FLARE - South Ground Flare
Cause: Shutdown of Hydrocracker, Unit 215. New unit with unknown problems causing it to smoke. "Shut down as a result of a high temperature alarm" but "it is believed that the alarm gave inaccurate readings." "Pollutants emitted during the event are accounted for in the facility Air Quality permit." No info given regarding what exactly was released.

Followup: No

Notes: BRQ. Refinery letter states that no reportable quantities were exceeded.Air monitoring team dispatched to ensure no offsite impacts.


Unit 259 North Ground Flare
Cause: On 9/16/11, level transmitted 205-LC-2050 failed which resulted in the filling of the Unit 205 C3/C4 Overhead Drum. This caused a pressure increase in the C3/C4 Splitter that led to the opening of the relief valve, 205-PSV-7077. This valve is routed to the flare header and the North Ground Flare.

Followup: No

Notes: The unit vessel levels were manually adjusted to stop the over-pressure condition. The level transmitter, 205-LC-2050, was repaired. An incident investigation is ongoing. C3/C4 Splitter Overhead leaked for 20 min. Report says the leak lasted 10 min but the release lasted 20 min.
Propane: 684.9 pounds
Propylene: 1,008.0 pounds
Isobutane: 0.4 pounds
Nitric Oxide: 176.7 pounds
Carbon Monoxide: 148.6 pounds
Particulate Matter 10: 13.5 pounds
Ethane: 0.1 pounds

RBS Flare
Cause: False reading on the 66LT0511 level controller caused the two NC4 compressors to trip. The high pressure on the receiver, due to high liquid level, caused the 66PC0507 valve on the receiver to open the RBS flare. Approximately 6.67 lbs of VOCs were released as a result.

Followup: No

Notes: The operator blew down transmitter 66LT0511 and opened the bypass valve on the receiver to send the liquid back to the RBS tank. The faulty level transmitter was taken out of service and repaired.
Propane: 0.1 pounds
n-Butane: 0.6 pounds
Isobutane: 2.2 pounds
1-Butene: 0.9 pounds
Isobutylene: 1.1 pounds
T-butene2: 1.1 pounds
cis-2-Butene: 0.8 pounds
Nitrogen Oxide: 0.5 pounds
Carbon Monoxide: 2.5 pounds
Particulate Matter 10: 0.1 pounds
Particulate Matter 2.5: 0.1 pounds

Volatile Organic Compounds (VOCs): 6.7 pounds
No LDEQ Reported

dock platform sump
Cause: During a heavy rainfall event on May 2, the electric sump pump on Dock 3A did not function properly. A dock operator found the oil and water mixture from the sump going onto the dock platform and into the Mississippi River. After an incident investigation, the root cause was identified as Equipment Difficulty/Design/Design Specs Need Improvement. The equipment that was improperly designed was the level indicator on the oily water sump - therefore the root cause per LABB's protocol is Instrument Failure.

Followup: Yes

Notes: Once the spill was detected, all transfers on Docks 2, 3A, and 3B were terminated. Approximately 1300 feet of absorbent boom was deployed in the Mississippi River. A spare air pump was brought to the dock to pump the sump and oily water on the dock out. Absorbent pads were utilized to clean up oil that sprayed on, or was leaked on, the dock. The Refinery's Shift Emergency Response Team and Air Monitoring Teams along with ES&H were dispatched to assist with the containment, monitoring the cleanup activities. The next day, two US Coast Guard representatives witnessed the cleanup efforts. The area was monitored for emissions and odors, and the Air Monitoring Data can be found in attachment 1 of the attached PDF. The actions taken to prevent recurrence are to install secondary level indications on the oily water sumps on all docks. This recommendation is to be completed by January 15, 2014. No applicable air quality regulations were exceeded; however, the reportable quantity for oil spilled into a water-body was exceeded.
Oil: 15.0 gallons

Unit 259 North Ground Flare
Cause: Unit 222 Sats Gas Plant experienced an upset due to an over-pressure condition on the debutanizer column. As a result, pressure relief valves lifted, sending debutanizer overhead material to the refinery's North Ground Flare. Root cause was a faulty pressure transmitter.

Followup: No

Notes: The Board Operator decreased pressure on the debutanizer column. The faulty transmitter was replaced. Initial reports from January, 2013 stated no permit limits were exceeded concerning released pollutants. Final calculations from April 4, 2013 determined otherwise.
Nitrogen Oxide: 89.6 pounds
Carbon Monoxide: 487.3 pounds
Volatile Organic Compounds (VOCs): 1,138.0 pounds
Particulate Matter 10: 9.8 pounds
Particulate Matter 2.5: 9.8 pounds
Highly Reactive Volatile Organic Compounds: 1.3 pounds
Methane: 96.1 pounds
Ethane: 11.9 pounds
Ethylene: 0.7 pounds
Propane: 75.7 pounds
Propylene: 0.6 pounds
n-Butane: 565.1 pounds
Isobutane: 442.3 pounds
1-Butene: 3.4 pounds
Pentene Plus: 46.0 pounds
Carbon Dioxide: 3.4 pounds
Hydrogen: 3.2 pounds
Nitrogen: 7.4 pounds

Tank 5000-6
U215 hydrocracker
Cause: An emergency shutdown device was triggered due to an incorrect reading on the Treating Reactor Bed 3 temperature indicator in the U215 hydrocracker which depressurized the unit to the South Ground Flare. In response to the shutdown, operations utilized the refinery slop line to deinventory the unit, routing material to Tank 500-6. Natural gas was inadvertently routed through the refinery slop line where Tank 500-6 received the vapor, causing a release through the tank seals. Human factors also played a role in the incident.

Followup: Yes

Notes: Root causes identified as Equipment Difficulty-Design Specs and Procedures Followed Incorrectly. At the time of the release, the emergency shutdown system was activated as designed shutdown the hydrocracker. Multiple recommendations have been identified to prevent a recurrence. The Tech Services Department at MPC has been tasked with mitigating the hazards of a single point of failure due to false temperature indication (anticipated completion 1/31/15). The operations department will develop and implement a system to verify all steps are completed and signed off when following procedures. A team will be developed to conduct a hazard analysis on the entire refinery slop system to implement necessary safeguards to prevent unwanted material from entering the slop system.
Sulfur Dioxide: 5,278.0 pounds
Compressed Flammable Gas: 13,735.0 pounds
NOx: 108.3 pounds
Carbon Monoxide: 589.2 pounds
Volatile Organic Compounds (VOCs): 230.6 
Particulate Matter 10: 11.9 pounds
Particulate Matter 2.5: 11.9 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs): 0.2 pounds
Hydrogen Sulfide: 21.3 pounds