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Marathon Ashland Petroleum (3165), Garyville

Causal Factor: Seal or Gasket

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
87670

2006-05-08

Leaking flange gasket in distilate hydrotreater
Cause: During startup of the distillate hydrotreatmer, a flange gasket on a manway of the recycle gas amine scrubber was found leaking.

Followup:

Notes: BELOW REPORTABLE QUANTITY.
Hydrogen: 19.7 pounds
Nitrogen: 9.4 pounds
Hydrogen Sulfide: 0.0 pounds
98486

2007-08-08
Heavy Vacuum Gas Oil Pumparound Pump
Cause: HVGO Pumparound Pump had a seal failure and leaked oil to the pump pad which goes to the oily water sewer.

Followup: No

Notes: Claims emission was below RQ. Pump will be taken out of service to replace the pump seal.

105094

2008-04-23
Rubber gasket on the inlet line to the Clow Unit on Dock 3
Cause: Failure of rubber gasket on the inlet line to the Clow Unit on Dock 3.

Followup: No

Notes: "Do not use/operate" sign put on toilet at Dock 3. An emergency work order was written to replace the rubber gasket. A scaffold is being built to reach the pipe for the gasket replacement.
Wastewater: 2.0 gallons
120284

2009-12-19
unit 63
Cause: The tend pump in unit 63 Tank FArm blew a seal releasing propylene to the atmosphere

Followup: Yes

Notes: the pump was vented to flare.

116896

2009-07-29
unit 27
Cause: Hydrogen Fluoride mixed with iso-butane, butane, and a seal barrier fluid sprayed from a quick connect on the seal pot of the main fractionator reflux pump onto an operator's left arm and shoulder. The injured operator was kept in a hospital overnight.

Followup: No

Notes: the pump was isolated and the line plugged.
Hydrogen Flouride: 0.2 pounds
112890

2009-01-23
flare
south flare
Cause: A valve misalignment on the iso-butane pump allowed iso-butane to be routed to the flare for approximately six hours before being discovered. While troubleshooting the flaring incident, operations found the relief valve on th DHT unit's recycle gas scrubber "chatter" to the flare. during the investigation it was discovered that the newly installed valve had malfunctioned

Followup: Yes

Notes: none, the releases went unnoticed until later.
Volatile Organic Compounds: 386.0 pounds
Nitrogen Oxide: 111.5 pounds
Carbon Monoxide: 606.5 pounds
Volatile Organic Compounds: 748.0 pounds
Hydrogen Sulfide: 89.1 pounds
Nitrogen Oxide: 1,031.8 pounds
Sulfur Dioxide: 33,375.0 pounds
Carbon Monoxide: 5,614.4 pounds
111745

2009-01-04
Unit 11
Cause: A flash fire occurred when a valve above a bank of heat exchangers developed a leak in unit 11.

Followup: Yes

Notes: fire extinguished and heat exchanger blocked in. Also it was reported in the hazmat report that butane was a chemical identified during this accident occurrence. Unknown amount of butane release was not identified
Naphtha: 15.0 pounds
125243

2010-07-29
Unit 212 - Reactor #2
Cause: Flange leak located on Unit 212 released hydrogen. The hydrogen self-ignited, since the Unit runs at a temperature above the auto-ignition temperature of hydrogen. Scaffolding caught on fire. Louisiana State Police Hazmat and LDEQ responded to the incident. FIRE.

Followup: No

Notes: LDEQ report states that "the unit was swept with nitrogen to purge unit of hydrocarbons and air monitoring was performed." No injuries, fatalities, or road closures resulted from this incident. LDEQ and State Police reports only. No refinery letter.

125145

2010-07-25
Unit 212 - Reactor #2
Cause: Flange leak on Unit 212, Reactor #2. Leaking hydrogen ignited and start a small fire that lasted for approximately 5 minutes. FIRE.

Followup: No

Notes: BRQ. No reportable quantities were exceeded during this incident. "Steam was increased around the leaking flange. This snuffed out the flame and cooled the flange sufficiently to stop the leak."

135746

2011-12-06
HF Alkylation Unit
Cause: According to Mr. Chris Delaney, Marathon Petroleum, an estimated 4oz of Hydrofloric Acid (HF) was released into the oily water sewer system during the planned demolition of a blind flange in a pipe leading from the HF Alkylation Unit. Pipe was isolated from all other sources, source of the acid secured, and disconnected prior to installation. The acid traveled through the oily water treatment unit where it was then diluted and treated. Mr. Delaney stated the release was reported to the Louisiana State Police as a courtesy notification because an employee was exposed to the acid and treated for skin irritations.

Followup: No

Notes: Employees were wearing Level B protective clothing. Employees removed protective clothing upon completion of installation. Calcium gluconate was administered at Marathon's medical facility onsite. Employee was escorted to River Parish Medical Facility for further observation. Suspected exposure occurred during removal of clothing.
Hydrofluoric Acid: 0.3 pounds

132513

2011-07-16
Unit 212 Platformer Unit
Cause: A fire occurred on the outlet flange of the Reduction Gas Heater #2 in Unit 212. The fire was the result of hydrogen leaking from a flange which ignited due to high temperatures. The fire was extinguished at 1:15 and a small amount of hydrogen continue to leak until 3 am when the process was isolated.

Followup: No

Notes: The flange was isolated, the fire was extinguished, and the leak was stopped. An incident investigation will result in recommendation items designed to prevent the recurrence of this event.
Hydrogen: 231.1 pounds
Methane: 0.2 pounds
No LDEQ Reported

2012-02-22
Unit 46, Propylene Splitter
Cause: A fire occurred when residual material in a line was ignited during the removal of a valve. Vented into atmosphere and fire associated. NO LDEQ Incident #, no LDEQ report. Agent reached was Rachel Mroch and no # assigned. Propane not included in the output values and the date on the second attachment precedes the event.

Followup: No

Notes: Personnel in the area used fire extinguishers to put out the fire. Blinds were installed on the line to contain the material leaking by the block valve. There is no SPOC report and no LDEQ report attached to this file.
Propylene: 65.0 pounds
Propane: 3.1 pounds
151160

2013-09-20
flange bolts on HGO flush line
Cause: Flange bolts on the HGO flush line to the 01 charge pump were loosened upstream of the isolation causing HGO to be released.

Followup: No

Notes: The sift emergency response team (SERT) was activated as a precaution to the HGO flashing. The flange bolts to the pump were tightened and the leak isolated.
Heavy Gas Oil: 42.0 gallons
150563

2013-08-23
Seal on Crude Tank 500-1
Cause: The leak occurred on Storage Tank 500-1, however the leaking component was an agitator which is permitted with Tank Farm- Unit 63 Fugitives. The Unit 63 Fugitives EIQ number is Unit 63 Fug (EQT No. FUG 084). Approximately 9.05 barrels (2568 pounds) of crude oil was released onto the ground within the tank dike. Also Human Performance Difficulty (procedures not used and training needs improvement), Product Control did not turn off mixer when spotted the leak.

Followup: Yes

Notes: The shift supervisor dispatched a vacuum truck to the site to recover the oil that had leaked onto the ground. In addition, a large catch basin was placed under the leaking mixer seal so the crude oil could be collected as it was leaking while the tank was being emptied. Recommendations: - Provide training on the message responses and operating procedures. - Develop a Lessons Learned to address Process Safety recognition failure. Evaluate changing the 12 feet message to and actual alarm on 63-LI-5001.
Crude Oil: 2,568.0 pounds
149428

2013-06-29
flange on process line in U212 Platformer Unit
Cause: On June 29, a small leak and hydrogen fire was observed on the 48" flange on the process piping going from Cell 2 of the Unit 212 Charge Heater to Reactor #2. The leak was hair line sized in width and no larger than 1" around the circumference of the flange.

Followup: No

Notes: Steam was applied to the flange to extinguish the flame and the flange was hot bolted to secure the leak. Once investigation is complete, recommendations will be implemented. There were no known offsite impacts.
Compressed Flammable Gas: 5.9 pounds
Volatile Organic Compounds (VOCs): 8.6 pounds
Benzene: 0.5 pounds
Xylene: 0.3 pounds
Compressed Flammable Liquid: 3.5 pounds
148876

2013-05-22
U212 Platformer unit
Cause: On May 22, a small leak and hydrogen fire was observed on the 48" flange on the process piping going from cell 1 of the Unit 212 Charge Heater to Reactor #1. The leak was pinhole sized in width and no larger than 1" around the circumference of the flange. The emission point involved was a flange on a process line in the U212 Platformer unit.

Followup: Yes

Notes: Steam was applied to the flange to extinguish the flame and the flange was hot bolted to secure the leak. Once the investigation is complete, recommendations will be implemented. An additional followup on 10/23/13 corrected the initial followup report's emissions data regarding greenhouse gas releases.
Methane: 0.0 pounds
Ethane: 0.0 pounds
Propane: 0.0 pounds
n-Butane: 0.0 pounds
Isobutane: 0.0 pounds
Pentane: 0.1 pounds
n-Pentane: 0.0 pounds
Pentene Plus: 0.3 pounds
Cyclohexane: 0.1 pounds
n-Hexane: 0.1 pounds
Benzene: 0.0 pounds
Toluene: 0.0 pounds
Xylene: 0.0 pounds
Hydrogen: 0.0 pounds
NOx: 0.1 pounds
Carbon Monoxide: 0.3 pounds
Volatile Organic Compounds (VOCs): 0.7 pounds
Particulate Matter 10: 0.0 pounds
Particulate Matter 2.5: 0.0 pounds
Carbon Dioxide: 0.8 pounds
146481

2013-02-07
Sulfur Recovery Unit flange
Cause: On February 7, 2013, at 10:17 hours, the LDEQ Official was contacted via the Louisiana State Police. The incident was a flange fire that began at 9:51 hours on February 7, 2013, and was secured by 10:00 hours (9 minutes). The intial reports approximates that 6 pounds of total volatile organic compounds (VOCs) were released during the flange fire. A followup on October 23, 2013, revised the VOC estimate to 0.58 pounds. The Unit was placed on internal circulation due to the Sulfur units shutting down. The outlet flange on 56-2501 Reactor outlet developed a small leak and caught on fire and burned for approximately 9 minutes.

Followup: No

Notes: The flange fire was extinguished with a water hose reel station and a steam hose was placed under the insulation blanket. An incident investigation was conducted to determine the causes or causes of the incident. Per the investigation, the root cause was identified as Management System - Communication of SPAC needs improvement. 1. Evaluate the U 56 Internal Circulation Procedure to determine if any modifications can be made to mitigate or minimize the unit temperature/ pressure swings experienced. This recommendation is to be completed by May 16, 2013. 2. Investigate modifying the insulation core spec (SP-80-01) to state that all flanges are to be uninsulated. This recommendation is to be completed by July 17, 2013. 3. Coordinate the effort to verify the flanges identified which operate at temperatures above 400 degrees Fahrenheit have had their insulation removed. This recommendation is to be completed by May 31, 2013. Material did go offsite as a result of this fire. A final follow up submitted on October 23, 2013 describes greenhouse gas emissions in the original follow-up as erroneous and updates the emission estimates.
Volatile Organic Compounds (VOCs): 0.6 pounds
Sulfur Dioxide: 0.3 pounds
Carbon Monoxide: 0.1 pounds
NOx: 0.0 pounds
159275

2014-10-09
Unit 205, Delayed Coking Unit
Cause: The 1201 drum in the Delayed Coking Unit was on line. There was a small anti-foam and Heavy Gas Oil (HGO) carrier leaking from a flange. The leak saturated the insulation on the side of the 1201 drum. As plant insulators were working to remove the insulation, air hit the saturated insulation. When combined with the heat from the drum, a small fire was ignited. Facility report to the State Police Hazmat Hotline states that the material involved was Anti-foam (a kerosene mixture including 60-100% kerosene).

Followup: No

Notes: At the time of the accident, the fire was extinguished and the leaking line was blocked in to stop the leak. Report states that a new designed spring support cans will be properly installed by the end of 2014.
Heavy Gas Oil: 1.0 gallons
157392

2014-07-13
Unit 215, Hydrocracking Unit
Cause: While checking the 215-PSV-7006 cold HP separator for a leak, the downstream 12-inch block valve was closed and a leak developed around the valve bonnet gasket. The leak size was assumed to be 1/64-inch in thickness and 2 inches in width based on operator reports. Emission occurred in Unit 215, Hydrocracking Unit.

Followup: No

Notes: The line containing the valve was blocked in and the pressure reduced. An incident investigation will result in recommendation items designed to prevent the recurrence of this event.
Methane: 12.0 pounds
Ethane: 2.8 pounds
Propane: 3.2 pounds
n-Butane: 1.4 pounds
Hydrogen: 435.1 pounds
Hydrogen Sulfide: 4.6 pounds
153395

2014-01-16
Unit 212 platformer, reactor 2 outlet flange
Cause: On January 16, 2014, at 02:58 hours during the Unit 212 Platformer shutdown procedure, an H2 leak developed from the Reactor 2 Outlet flange during the H2 sweep cooldown step, which resulted in a flange fire.

Followup: No

Notes: Steam was applied to the flange to extinguish the flame and the flange was hot bolted to secure the leak. The reactor circuit was depressured to the south ground flare, which took approximately 30 minutes.
Nitrous Oxide: 0.7 pounds
Carbon Monoxide: 3.7 pounds
Volatile Organic Compounds (VOCs): 0.0 pounds
Particulate Matter 10: 0.1 pounds
Particulate Matter 2.5: 0.1 pounds