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Marathon Ashland Petroleum (3165), Garyville
Causal Factor: Process Upset
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 79431 2005-05-28 | North Flare (EIQ No. 83-74) | Cause: The regenerate stream from the Unit 28 Butane Isomerization Liquid Feed Drier was inadvertently blocked in. The Liquid Feed Drier then over-pressured and released to the flare. Followup: Yes Notes: The rundown line was opened up and the regenerate was routed to the Tank Farm to lower the pressure of the Liquid Feed Drier. This incident is currently under investigation. | Butane: 914.0 Hydrogen Sulfide: 26.0 Sulfur Dioxide: 49.0 |
| 79261 2005-05-22 | Thermal Oxidizer Cap (no EPN) | Cause: A local pressure controller in Unit 19 (Amine/Sour Water Stripper) closed due to high pressure and stopped amine flow to the Regenerator. Amine pump to Unit 15 (Heavy Gas Oil Hydrotreater) was tripped and the Unit 45 Sulfur Plant shut down due to the low amine acid flow. The sulfur plants all went off-ratio and began smoking 2 of the 3 Thermal Oxidizers , exceeding the opacity limit. The Unit 45 Sulfur Plant's Thermal Oxidizer then went below 900 F for app. 9 m which led to excess emissions of Hydrogen Sulfide. Followup: Yes Notes: An Air Monitoring Team was dispatched and no off-site impacts were found. Operations worked to get the Sulfur Plants back on ratio and minimized emissions. The incident is under investigation. | Hydrogen Sulfide: 0.2 pounds |
| No LDEQ Reported 2005-01-11 | Thermal Oxidizer Cap (no EPN) | Cause: Liquid hydrocarbon carry-over entered the Unit 45 Thermal Oxidizer.
Followup: Yes Notes: Operational adjustments made; currently under investigation | Sulfur Dioxide: 1,110.0 pounds |
| 88512 2006-06-10 | Flaring from Unit 21 Absorber and North Flare (EQI No. 83-74/EQT 162) flaring from fuel gas mix drum | Cause: Shell, Norco, had an unexpected shutdown of one of their units which processes Marathon Petroleum Company off gas, MPC had to flare excess off-gas/ fuel gas during this time. Followup: Notes: BELOW REPORTABLE QUANTITY. | Volatile Organic Compounds (VOCs): 2,352.5 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 9.6 pounds Sulfur Dioxide: 0.2 pounds Volatile Organic Compounds (VOCs): 14.5 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 6.9 pounds |
| 85928 2006-02-19 | The North Flare (EIQ No. 83-74/EQT 162) | Cause: During maintenance a valve was opened to the flare to reduce the amount of ethanes contaminating the purity of the propylene. Followup: Notes: BELOW REPORTABLE QUANTITY. | Propylene: 2.0 pounds |
| 100086 2007-10-10 | Cause: The packing in a lean amine bypass control valve blew out releasing amine and sour hydrogen gas to the atmosphere. To repair the valve the unit required depressurizing to the south flare Followup: No Notes: A high level incident investigation is underway | ||
| 99754 2007-09-26 | South Flare | Cause: Shell off gas compressors had to shutdown and gas was put into the fuel gas system. Fuel gas system overpressured and relieved to flare. Followup: No Notes: Claims emission was below RQ. | Sulfur Dioxide: 1.0 pounds Olefins: 2.0 pounds |
| 98775 2007-08-18 | North Flare | Cause: The Crude Overhead Compressor overpressured and was relieved to the North Flare Followup: No Notes: Claims emission was below RQ. Installing pressure indicators on the first stages of both overhead compressors which will be routed to the control room for iproved monitoring. | Sulfur Dioxide: 199.0 pounds Nitrogen Oxide: 10.0 |
| 96496 2007-05-23 | North Flare | Cause: HS Alkylation Unit Depropanizer bottoms relief valve opened. Failure of 3 way valve. Followup: No Notes: Claims emission was below RQ. Emission contained iso butane and propane. A design and engineering package has been approved for a pressure indication device upstream of the three way control valve to be installed in 2008. 80 | Volatile Organic Compounds: 82.0 pounds |
| 95653 2007-04-25 | North Flare | Cause: Scheduled drum swap caused Drum 1 to pressure up. The relief valve on the Fractionator Overhead line relieved to the flare. Followup: Notes: Claims emission was below RQ. | Sulfur Dioxide: 76.0 pounds |
| 127916 2010-11-29 | FLARE: Unit 59 South Flare | Cause: Refinery letter states that an unexpected change in the feed composition caused an over-pressurization of the high pressure stripper column. This resulted in the opening of the process safety valve to relieve pressure within the column. FLARE. Followup: No Notes: RQ. Reportable quantities for sulfur dioxide were exceeded. Changes were made in Unit 15 to compensate for the increase in pressure in the high pressure column. | Volatile Organic Compounds (VOCs): 85.7 pounds Hydrogen Sulfide: 8.2 pounds Sulfur Dioxide: 752.8 pounds |
| 121187 2010-02-01 | FLARE - North & South Ground Flares; Thermal Oxidizers #1, #2, #3; GME Thermal Oxidizer #1, #2 FLARE - North & South Ground Flares; Thermal Oxidizers #1, #2, #3; GME Thermal Oxidizer #1, #217m | Cause: A transformer breaker tripped causing multiple operating units to shut down, including sulfur plants. FLARE. Followup: No Notes: RQ. Reportable Quantities were exceeded for sulfur dioxide during this incident. Detailed emissions report included. Refinery's Air Monitoring Team dispatched. "The breaker was reset and the units were quickly brought back on line." LDEQ report date is 2/18/2011. | Sulfur Dioxide: 5,201.0 pounds Volatile Organic Compounds (VOCs): 290.8 pounds Nitric Oxide: 154.2 pounds |
| 121169 2010-01-30 | Unit 34 Sulfur Recovery Unit (EQT FUG037) | Cause: "While switching unit 34 tailgas from the Unity 34 Thermal Oxidizer to the Unit 20 Thermal Oxidizer, Unit 34 pressured up causing acid gas to back out of the low range air blower vent valve in Unity 34."
Reportable quantity for Hydrogen Sulfide exceeded. Followup: No Notes: RQ. Reportable quantities were exceeded during this incident; detailed emissions report included. Refinery report states that "tailgas [was] switched back to the Unit 34 Thermal Oxidizer which corrected the problem immediately." | Hydrogen: 0.0 pounds Carbon Dioxide: 301.1 pounds Nitrogen: 69.1 pounds Oxygen: 10.3 pounds Methane: 0.5 pounds Ethylene: 0.5 pounds Ethane: 1.6 pounds Propane: 10.6 pounds Propylene: 1.0 pounds Isobutane: 7.0 pounds n-Butane: 27.2 pounds 1-Butene: 0.4 pounds Isobutane: 0.4 pounds Butene: 0.4 pounds Butene: 0.4 pounds Pentane: 12.0 pounds n-Pentane: 15.4 pounds Pentene: 9.2 pounds Hydrogen Sulfide: 829.1 pounds |
| 121073 2010-01-26 | FLARE - North Ground Flare [EQT 0282] | Cause: Unit 210 Crude Offgas Compressor Suction Drum over pressured due to excessive crude offgas from the Sats Gas Plant. Followup: No Notes: BRQ. No reportable quantities exceeded, but detailed emissions report included. Offgas flow from the Sats Gas Plant reduced, spillback to the Crude Suction Drum closed. | Sulfur Dioxide: 232.0 pounds |
| 121042 2010-01-25 | FLARE - South Flare | Cause: Crude Unit had liquid carryover into compressor suction drum, causing compressors to trip and increase the drum's pressure, opening the relief valve to the South Flare. Followup: No Notes: BRQ. No reportable quantities were exceeded, but detailed emissions report included. Flow to compressors stopped, level in the drum pumped down; restarted and flow resumed asap. | Sulfur Dioxide: 242.0 pounds |
| 136157 2011-12-27 | 205 Coker Unit to Unit 259 North Ground Flare | Cause: The incident occurred when the facility was switching from the online drum to the blowdown drum. During the switch, the Wet Gas Compressor surge controller attempted to open the second stage spillback valve. The valve hesitated to open, causing a spillback to trip open. This caused the frac and blowdown to pressure up and the compressor to send the product to the flare until the operations pressure returned to normal.
At the time of the written notification, the incident was still being investigated to determine the cause of the overpressure condition. Followup: No Notes: The unit pressure levels were automatically corrected by the wet gas compressor surge control system. | Nitrogen Oxide: 6.4 pounds Particulate Matter 10: 0.6 pounds Carbon Monoxide: 6.8 pounds Sulfur Dioxide: 591.0 pounds Hydrocarbon: 55.7 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 1.3 pounds Volatile Organic Compounds (VOCs): 8.5 pounds |
| 134819 2011-10-22 | Includes U21, U43, U55, U212, and U243 | Cause: On 10/21/11 the Propane Shipping Pump, 63-1537-01, was shutdown due to vibration problems which limited propane throughout the refinery. Operations made moves to cut charge rates and lined up the propane to the fuel gas system. Intermittently flared from Units 21, 43, 55, 212, and 243. No known off site impacts. Incident investigation is being conducted to determined the why the incident occurred. Followup: No Notes: Opened 21P6431C, sweet fuel gas valve to flare to reduce pressure on fuel gas header and lower the level in 43-1202 (3:22am -4:09 am) bullet. Unit 63 shutdown propane shoppin pump, 63-1537-01, and U22 & U222 propane was routed to the bullet, 21HC6431 sweet fuel gas valve opened to the south flare from (8:21 am - 3:30pm). Fuel Gas Mix Drum 243-PC-0180B opened to flare due to Unit 205 sending excess propane to fuel gas header. Valve opened intermittently during this time from (11:15 am- 4:28pm) not opened above 10%. C3 propane from Domains 1 and 9 in refinery fuel gas causing high fuel gas pressure and 43PC5355 opened to flare three times (11:20am-11:30am), (11:53am-12:20pm), (12:45pm-1:05pm). Unit 55 Flare sweet refinery fuel gas from C3 propane in RFG Domain 1 and 9, 10/22/11 (11:28 am -3:55pm), 10/22/11 (7:42pm)- 10/23/11 (4:07am). An incident investigation will result in recommendation items designed to prevent the recurrence of this event. Values for carbon monoxide and nitrogen oxides do not match the sum of the daily reports. They are higher than the sum of the reportable values. | Methane: 2,282.0 pounds Pentene: 282.6 pounds Hydrogen: 590.6 pounds Hydrogen Sulfide: 0.1 pounds Nitrogen: 88.8 pounds Sulfur Dioxide: 441.7 pounds Carbon Monoxide: 4,634.5 pounds Pentane: 176.0 pounds Isopentane: 331.9 pounds n-Butane: 1,365.6 pounds Isobutane: 425.1 pounds Propane: 2,018.0 pounds Ethane: 2,272.1 pounds cis-2-Butene: 60.9 pounds trans-2-Butene: 16.3 pounds 1-Butene: 105.7 pounds Propylene: 137.1 pounds Ethylene: 172.9 pounds Carbon Dioxide: 35.0 pounds Oxygen: 7.7 pounds Nitrogen Oxide: 850.1 pounds |
| 132261 2011-07-07 | Unit 259 South Ground Flare (EQT 286) | Cause: A heat exchanger in the Hydrocracker Unit (Unit 215) began to leak as the unit was starting up and achieving normal operating conditions. Some material was depressured to the flare so that maintenance on the exchanger could be performed.
An incident investigation is being conducted to determine why the incident occurred. Followup: No Notes: The equipment was allowed to depressure to the flare until repairs could be made. At the time of the police report, all had been secured. An incident investigation will result in recommendation items designed to prevent the recurrence of this event. | Volatile Organic Compounds (VOCs): 188.0 pounds Hydrogen Sulfide: 10.6 pounds NOx: 8.0 pounds Sulfur Dioxide: 99.9 pounds Carbon Monoxide: 43.4 pounds |
| 132152 2011-06-30 | Unit 59 North Flare | Cause: The pressure relief valve on the unit 232 rich amine flash drum failed. Material in the flash drum was depressured by flaring until the relief valve would have closed. Leaking release valve and sour water stripper. Material was sent to Unit 59 North Flare (EQT# 0162 and EIQ# 83-74) Followup: No Notes: The flash drum was allowed to depressure to the flare until the relief valve would have close and the valve could be repaired. an incident investigation will result in recommendation items designed to prevent the recurrence of this event. | Sulfur Dioxide: 1.3 pounds Propane: 17.9 pounds Ethane: 0.2 pounds Methane: 0.2 pounds Hydrogen: 0.2 pounds Nitrogen Oxide: 1.2 pounds Carbon Monoxide: 1.0 pounds Particulate Matter 10: 0.1 pounds Hydrogen Sulfide: 0.0 pounds |
| 144469 2012-11-06 | Unit 59 North Flare | Cause: A unit upset occurred in the Fluidized Catalytic Cracking Unit (FCCU) due to a sudden shift in feed composition. Subsequently, pressure increased in the fractionator overhead accumulator causing the pressure control valve to open to the refinery's North Flare for 11 minutes. Followup: No Notes: | Sulfur Dioxide: 45.0 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 6.0 pounds |
| 138329 2012-03-25 | RBS Flare | Cause: The pressure safety valve for Tank 250-2 had opened, so the operator blocked in the PSV. Followup: No Notes: No offsite impact was associated with the event. | Highly Reactive Volatile Organic Compounds (HRVOCs): 0.9 pounds Nitrogen Oxide: 9.7 pounds Carbon Monoxide: 52.8 pounds Volatile Organic Compounds (VOCs): 139.3 pounds Particulate Matter 2.5: 1.1 pounds Particulate Matter 10: 1.1 pounds |
| 138219 2012-03-22 | Unit 20 Thermal Oxidizer, Unit 34 Thermal Oxidizer, Unit 45 Thermal Oxidizer, Unit 220 Thermal Oxidizer, Unit 234 Thermal Oxidizer, and all process heaters that combust refinery fuel gas. | Cause: Chain of Events: While placing amine filters in service, an upset occurred in the Unit 247 Amine Regeneration Unit Overhead Receiver. A high liquid level in the Receiver caused liquid to be sent to the Sulfur Plants. The Unit 220 and 234 Sulfur Plants shut down due to high knockout drum levels. This caused an elevated flow to the remaining operational sulfur plants. The Unit 34 Sulfur Plant then shutdown due to low boiler feed water level in the Reaction Furnace. Unit 247's lean amine became saturated as a result of the high acid gas header pressure, resulting in less than adequate hydrogen sulfide absorption in RFG producing units, causing both Refinery Fuel Gas Mix Drums to experience high levels of hydrogen sulfide. This fuel gas was then combusted in all the refinery's heaters that were operating on refinery fuel gas.
Summary: An upset in the Unit 247 Amine Regeneration Unit caused an opacity exceedance and sulfur dioxide reportable quantity exceedance in the Sulfur Plants and at all the process heaters, which combust refinery fuel gas.
MPC originally reported that the upset began in the Coker Unit, but, after further investigation, stated that the Coker Unit was not involved in the incident. Followup: Yes Notes: Process unit charge rates were reduced in accordance with the refinery's sulfur shedding plan. Sulfur plants were re-started as soon as possible in order to convert more hydrogen sulfide to sulfur. The refinery dispatched 3 Air Monitoring Teams, and no pollutants were detected at the fenceline. The Air Monitoring Team data is attached to the report. Mobile SO2 meter was post calibration expiration. (AreaRAE #240) Corrective actions given in follow-up report: Review and reinforce procedure use with 552 Board Operator, Issues Lessons Learned to emphasize the requirement and importance of using procedures, Review and reinforce procedure use with 532 Operator, Investigate a means to maintain LP BFW header supply while spare LP BFW is out-of-service, Investigate upgrading U220/U234 Amine Acid Gas KO Drum Pumps from 25 gpm max to 50 gpm max, Train 001 shift supervisors on the updated refinery sulfur shedding procedure and importance of following the procedure to emliminate a large sulfur dioxide emissions incident, Update Unite 232/247 Carbon After Filter Change-out Procedure to utilize FC0051 to help ensure that a surge of flow cannot be routed to Regenerator during the filter start-up, Update DCS graphics to clean-up the FC0051 split-range control and PC0021 selector control schematic to help improve operator understanding, Provide face-to-face training on the updated procedure and schematics for each Board Operator, and Update refinery sulfur shedding procedure such that unit charge rates are reduced quickly enough to minimize sulfur dioxide emissions during sulfur unit shutdowns. | Sulfur Dioxide: 73,200.0 pounds |
| No LDEQ Reported 2013-07-24 | Unit 250 North Ground Flare | Cause: On July 24, 2013, the Unit 210 Crude Overhead Compressor shut down at 16:11 hours and was restarted at 16:26 hours. A second shutdown occurred at 16:48 hours and was restarted at 17:02 hours. A third shutdown occurred at 17:25 hours and was re-started at 17:56 hours. The duration of Unit 210 venting to the North Ground Flare was 60 minutes.
Approximately 613 pounds of sulfur dioxide were released (over the reportable quantity of 500 pounds). Followup: No Notes: Liquid was drained from the Unit 210 Compressor Suction Drum. The Unit 210 Crude Overhead Compressor was re-started. A very similar event occurred on March 25, 2013 with emissions from the same point source. This report retrieved from EDMS was labeled with the LDEQ number corresponding to the March 25, 2013 incident (LDEQ # 147603). The March 25th event also involved multiple shutdowns of the Unit 210 Crude Overhead Compressor, and the report labeled that event as preventable. It is interesting to note that a similar event labeled preventable occurred less than four months later. | Sulfur Dioxide: 613.0 pounds Ethane: 6.2 pounds Ethylene: 0.1 pounds Propane: 58.3 pounds n-Butane: 123.1 pounds Isobutane: 65.7 pounds 1-Butene: 0.4 pounds Pentene Plus: 101.2 pounds Hydrogen Sulfide: 6.7 pounds NOx: 25.2 pounds Carbon Monoxide: 137.3 pounds Volatile Organic Compounds (VOCs): 350.2 pounds Particulate Matter 10: 2.8 pounds Particulate Matter 2.5: 2.8 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 0.3 pounds Carbon Dioxide: 370.7 pounds Methane: 2.5 pounds Nitrous Oxide: 0.5 pounds Propylene: 0.2 pounds |
| 149911 2013-07-24 | Unit 259 North Ground Flare | Cause: On July 24, the Unit 222 Debutanizer Accumulator level reached 100%. This condition caused the pressure controller to open sending liquid overhead to the Unit 210 Compressor Suction Drum. The high level in the Compressor Suction Drum caused a shutdown of the Crude Overhead Compressors and a release to the North Ground Flare. Followup: Yes Notes: Liquid was drained from the Unit 210 Compressor Suction Drum. The unit 210 Crude Overhead Compressor was restarted. To prevent recurrence of a liquid overfill from putting liquid into the Low Pressure Recovery Header (LPRH) and tripping the U210 compressors, it is recommended to: institute a high level override on 222PC0316-02 that will close 222PC0316-02 in the event of a high level in the Debutanizer Accumulator; institute a high level trip on U214 Feed Surge Drum pressure controller, U214 LP Stripper Overhead Receiver, U215 Coker Feed Surge Drum, U215 Feed Surge Drum, U215 Fractionator Overhead Receiver, and U215 Naphtha Splitter Overhead Receiver that will close the vent to the LPRH in the event of a high level in the respective vessel. To prevent recurrence of tripping the compressors due to overwhelming the Suction Drum pumps, it is recommended to: evaluate all sources to the LPRH that do not currently have a control valve, and evaluate all sources to the Eocene header to determine if additional safeguard are required to prevent liquid carryover. Also, it is recommended to determine what the normal operating pressure and low alarm set point should be to insure the Interstage KO Drum Pumps can successfully pump any material that condenses in the KO drum, update the alarm database with information regarding the importance of KO drum pressure on operation of the KO Drum pumps, and evaluate the performance of the U210 Interstage KO Drum Pressure during INC49711 to determine if tuning parameters can be changed or controls modified to allow the pressure set point on the drum to be reached quickly after startup of the U210 compressors. An additional followup on 10/23/13 corrected the initial followup report's emissions data regarding greenhouse gas releases. | Sulfur Dioxide: 613.0 pounds |
| No LDEQ Reported 2013-07-21 | Crude Unit Overhead Accumulator | Cause: On July 21, 2013, an overpressure condition in the Crude Unit Overhead Accumulator due to the shutdown of the Sats Gas Unit. Followup: Yes Notes: An initial report for this incident, which included details on what happened and what pollutants were emitted in what quantities, was submitted to LDEQ on July 26, 2013. This follow-up report corrects emissions data submitted by Marathon which originally included greenhouse gas emissions in the incident calculations. | Sulfur Dioxide: 33.5 pounds Carbon Monoxide: 97.0 pounds NOx: 17.8 pounds Ethane: 0.8 pounds Particulate Matter 2.5: 2.0 pounds Particulate Matter 10: 2.0 pounds Volatile Organic Compounds (VOCs): 247.1 pounds |
| 149651 2013-07-15 | Unit 259 North Ground Flare | Cause: On July 15, 2013, due to a crude oil switch, a high level occurred in the Unit 222 Sats Gas Plant (SGP) Compressor Suction Drum which caused the Sats Gas PLant Compressor to temporarily shutdown. This resulted in some flaring of the overhead gas to the North Ground Flare for about 55 minutes.
The first incident began at 09:05 hours on July 15, 2013, and was secured by 10:00 hours. The second incident began at 19:32 hours on July 15, 2013, and was secured by 19:33 hours. Followup: No Notes: For Incident 1, the level in the Sats Gas Plant Compressor Suction Drum was lowered and the Sats Gas Plant Compressor was re-started. For Incident 2, operating personnel made operating changes to the unit to bring it out of upset conditions. These incidents will be investigated and an action plan to prevent recurrence will be generated. Follow up report submitted 10/23/13 states that original report included Greenhouse Gas emissions, however these emissions are not required to be evaluated for reportable quantity because they are not permitted pollutants. The report updates the calculations without greenhouse gases included. | Hydrogen Sulfide: 3.6 pounds Nitrogen Oxide: 10.4 pounds Sulfur Dioxide: 333.7 pounds Volatile Organic Compounds (VOCs): 99.7 pounds Particulate Matter 10: 1.1 pounds Particulate Matter 2.5: 1.1 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 0.0 pounds |
| 149346 2013-06-24 | all heaters and boilers that are supplied fuel gas from the Unit 43 Fuel Gas Mix Drum | Cause: The Unit 47 Amine Unit tripped twice on June 24. The trips caused an increase in hydrogen sulfide going to the Unit 43 Fuel Gas Mix Drum which would have normally been removed by the Amine Unit. The Fuel Gas Mix Drum supplies fuel gas to 28 different process heaters within the refinery. As a result, each heater experienced an increase in sulfur dioxide emissions above the maximum allowable permitted lbs/hr rate.
The two ambient air monitoring stations located downwind of the incident did not detect a significant increase in sulfur dioxide emissions. Followup: Yes Notes: Operations re-established amine system levels, restarted the Unit 47 lean amine pump and re-established amine circulation to the Amine Treaters. The U-5 LPG Treater amine circulation rate was restricted at a lower flow rate due to foaming/emulsion as evidenced prior to shutdown. The Unit 47 Amine Unit was brought back on-line removing hydrogen sulfide from the fuel gas. Recommendations: - Tech Service to be present while inspecting the Sponge Oil Absorber during the October 2013 Shutdown. - Develop temporary operating guidelines to address tower operation at reduced gas rates. - Issue a lesson learned on this incident to D5, D7, & D8 operators & supervisors. - Add a low level override controller on the U-19/47/221/232/247 amine strippers to reduce the amine flow to their respective treaters. - Add a low level override controller on the U-32 mine stripper flow to the respective treaters (4). - Modify the low level override controller on the U-21 amine stripper flow to the respective treaters (3) to include #3 TGTU. | Sulfur Dioxide: 37,913.0 pounds |
| 148240 2013-04-20 | Unit 259 North Ground Flare | Cause: On April 20, 2013 the Unit 210 Crude Unit experienced an upset due to a change in the incoming crude state. The flaring in U210 and U222 associated with the upset started at 7:12 AM on April 20, 2013 and was complete at 8:35 AM on April 20, 2013. The duration of Unit 210 and 222 venting to the North Ground Flare was 83 minutes. Approximately 75 pounds of sulfur dioxide were released.
The Unit 210 Crude Unit experienced an upset due to a change in the incoming crude state. The incoming crude had a greater quantity of light components as well as some water. The upset resulted in high liquid levels in vessels upstream of the crude off-gas compressors and the sals gas compressor. In order to minimize the amount of liquid sent to the compressors, which could cause a shutdown of the compressor, a portion of the liquid generated in the upset was routed to the North Ground Flare knock out drum. This action reduced the severity of the incident. Followup: Yes Notes: The crude tank line up was modified to remove the tank thought to be the cause of the water and light ends going to the Crude Unit. In addition, the crude charge rate was reduced to help manage the unit upset. The routing of liquids to the flare knock out drum was an attempt to minimize the results of the upset and prevent equipment shutdowns which would ahve resulted in a much more significant release. An additional followup on 10/23/13 corrected the initial followup report's emissions data regarding greenhouse gas releases. | Sulfur Dioxide: 75.9 pounds Methane: 17.5 pounds Ethane: 1.7 pounds Ethylene: 0.1 pounds Propane: 3.9 pounds n-Butane: 2.3 pounds Isobutane: 2.1 pounds 1-Butene: 0.0 pounds cis-2-Butene: 0.0 pounds Carbon Dioxide: 43.7 pounds Hydrogen: 4.1 pounds Nitrogen: 0.9 pounds Hydrogen Sulfide: 0.8 pounds NOx: 3.0 pounds Carbon Monoxide: 16.1 pounds Volatile Organic Compounds (VOCs): 8.5 pounds Particulate Matter 10: 0.3 pounds Particulate Matter 2.5: 0.3 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 0.1 pounds |
| 146471 2013-02-07 | Unit 59 North Flare Heaters on the Unit 243 Fuel Gas Mix Drum, Unit 234 Thermal Oxidizer #5, Unit 59 North Flare | Cause: On February 7, 2013, around 2:15am heavy rains caused 215-1202 Hot HP Separator to swing 8 degrees high and 215-1204 Hot LP Flash Drum causing liquid carry over to the Sour Fuel Gas header. Hydrocarbons hit Unit 243 Fuel Gas Treaters and carried through to Unit 247 Amine Regenerator. This caused high SO2 on sulfur units (U34, U220, U234) thermal oxidizer stacks and high H2S in the 243 Fuel Gas Mix Drum. In order to minimize any further upsets in the refinery, the hydrocarbons were routed to the North Stick Flare. As a result, Opacity from the Units 205, 210, 212, 214, and 215 heater stacks and the North Stick Flare were observed.
Emission points involved were Unit 59 North Flare, Coker Charge Heater, Crude Heater, Naptha Hydrotreater Stripper Reboiler Heater, Platformer Heater, KHT Reactor Charge Heater, KHT STripper Reboiler Heater, HCU Train 1 Reactor Heater, HCI Train 2 Reactor Heater, HCU Fractionator Heater, Boiler #1, Thermal Oxidizer #5.
A Root Cause Investigation determined the causes of the accident to be 1) Human Performance and 2) Equipment difficulty. Details about causal factor investigation are found in attached PDF. Followup: Yes Notes: Refinery wide, unit charge rates were reduced and hydrotreaters were placed on internal circulation where possible to reduce production of sour gas and sulfur plant feed. The amine that was contaminated with hydrocarbon was stripped to ensure hydrocarbon did not reach the sulfur plants and caused further emissions and/or unit trips. The Unit 215 Hydrocracker level instrumentations heat tracing and insulation was inspected to ensure proper operation. The Unit 247 Amine System Carbon Filter was also placed on-line after the carbon was replaced to remove any remaining trace hydrocarbon from the system. An additional followup on 10/23/13 corrected the initial followup report's emissions data regarding greenhouse gas releases. | Hydrogen Sulfide: 611.0 pounds Sulfur Dioxide: 57,313.0 pounds Nitric Oxide: 14.5 pounds Carbon Monoxide: 78.8 pounds Volatile Organic Compounds (VOCs): 0.8 pounds Particulate Matter 10: 1.6 pounds Particulate Matter 2.5: 1.6 pounds Carbon Dioxide: 16.8 pounds |
| No LDEQ Reported 2013-02-07 | North Flare | Cause: The Unit 215 Hydrocracker Hot High Pressure Separator level control failed causing a liquid carryover to the Unit 243 Sour Fuel Gas System. The liquid hydrocarbon entered the Unit 247 amine system through the sour fuel gas treaters. Once the hydrocarbon was in the amine system, the capability to regenerate the amine was compromised, resulting in high H2S in the sweet fuel system. While working to recover regeneration, hydrocarbon was carried into the Unit 220 and Unit 234 Sulfur Recovery Units (SRU) resulting in activation of their associated ESD system. After several unsuccessful attempts to restart the SRUs, the unit 247 Amine Regenerator Tower overhead product was routed to flare to remove the hydrocarbon from the amine. Once the hydrocarbon was removed, the system returned to normal operation. The resulting emissions from this event were 57,312.75 lbs/SO2 and 611 lbs/H2S. Followup: No Notes: 1. Process unit charge rates were reduced in accordance with the refinery's sulfur shedding plan. 2. The amine that was contaminated was stripped to ensure hydrocarbon did not reach the sulfur plants and cause further emissions and/or unnecessary unit trips. 3. Maintenance was contacted to address the failed level instrumentation in Unit 215. | Sulfur Dioxide: 57,312.8 pounds Hydrogen Sulfide: 611.0 pounds |
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