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Motiva Enterprises (2719), Convent
Causal Factor: Equipment Failure
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 84764 2005-12-24 | Steam Boilers 31F-801, 31F-802, 31F-803, 31F-805, and 31F-810 | Cause: Steam Boiler 31F-810 tripped (shutdown) at approx 03:56 In order to stabilize and maintain the refinery steam system, the firing rates and subsequent steam production from 801, 802, 803, and 805 boilers were increased and adjusted over the next 35 hours. Maintaining the refinery steam system is critical in continuing the operation of process units and potentially preventing environmental incidents from any abrupt unit shutdown or malfunction. The 810 boiler shutdown when erratic air flow readings into the boiler were detected because ambient conditions caused false pressure readings on the air flow monitors, which, in turn, caused the forced draft fans to shutdown. The shutdown of the forced draft fans initiated an instrment protective func Followup: Yes Notes: [Final report] Immediate action was taken to ensure the safe operability of the 810 boiler, and the process for restarting the boiler began as soon as all safety and operability concerns were addressed. The 810 Boiler was refired and began producing plant steam on the afternoon of 12/25/05, and the normal operation of steam boilers resumed and excess Nitrogen Oxide emissions ceased. For the 810 Boiler, a project s being implemented to install a more reliable air measurement device, which will be finalized once proven over the operating range of the boiler. The operating constraints for 801, 802, 803, and 805 Boilers are being updated to reflect the environmental requirements for those boilers" | Nitrogen Oxide: 92.0 pounds |
| 81365 2005-08-16 | Mississippi River Docks 1&2 Fire Water Pump 33G-5 and 33G-4 | Cause: Experiencing problems with electric and diesel raw water pumps and need to use fire water diesel pumps to supply raw water to raw water treatment plant. Followup: No Notes: Are developing a tracking system to monitor more closely the operation of all diesel fired equipment. Dock 1 electric pumps are scheduled to be replaced with new pumps by the end of 2005. The site has received from the LADEQ an air permit variance to cover the emissions from these pumps for the remainder of 2005. | Nitrogen Oxide: 18,141.0 pounds |
| No LDEQ Reported 2005-01-27 | TGTU No. 5 Incinerator Stack | Cause: Loss of a boiler and corresponding loss of steam availability Followup: No Notes: Has not completed an investigation of this incident and final determination still pending. | |
| 91442 2006-10-17 | TGTU no. 1 incinerator stack and TGTU no. 4 incinerator stack | Cause: Sulfur Recovery Unit (SRU) No. 5 tripped due to low airflow, which was caused by the trip of the turbine air blower (81C-101) on SRU-5. This subsequently causde TGTU-5 to trip, as these two units operate in series. With the trip of SRU-5/TGTU-5, acid gas processing ability decreased causing a subsequent increase in pressure on the acid gas header. This increase in pressure led to the trip of SRU-2/TGTU-1. The turbine air blower was determined to have tripped as designed due to excessive vibration from a mechanical failure in the turbine's speed governor. Followup: Yes Notes: Minimized acid gas production by reducing charge rates, worked to restart units. Motiva plans to evaluate the process rate reductions needed from the acid gas generating units when upset conditions occur in the SRU/TGTU units in an attempt to reduce the potential for SO2 emissions from overloading the operating SRU/TGTU units. Motiva also plans to install a "Stackmatch" system in TGTU-1 during a 2008 Maintenance turnaround to reduce the delays associated with the lighting of the heater inline pilot. No LDEQ report in this file. Exceeded RQs and permit limits. | Sulfur Dioxide: 795.0 pounds |
| 88309 2006-06-04 | MTBE tank #1 | Cause: Had trouble with pumps while trying to empty & clean MTBE (methyl tert-butyl ether) Tank No. 1. Roof was off float, creating emissions from "breathing losses."
Exceeded hourly emission limits but not RQ for 24hr period. Ongoing for a few days but not clear exactly how long. Had to get temporary variance permit to deal with it--granted on 6/9/06.
No LDEQ report in this file--hazmat and two letters. Followup: Yes Notes: "Mechanical problems are currently preventing Motiva from bringing the tank back on float. Motiva will bring the tank back on float after necessary maintenance work is completed." | |
| 87052 2006-04-06 | hydrotreating unit no. 2 | Cause: Fire due to hydrogen leaking from a heat exchanger at hydrotreating unit no. 2.
No LDEQ report in this file. Followup: No Notes: "personnel immediately extinguished the fire" | Hydrogen: 3.0 pounds |
| No LDEQ Reported 2007-06-13 | Tail Gas Treating Unit-1 | Cause: malfunction of SRU-2 Diverter valves Followup: No Notes: Under investigation - no remedial actions specified | |
| 95180 2007-04-09 | Fluid Catalytic Cracking Unit | Cause: malfunction of a relief valve Followup: No Notes: Letter states that follow-up investigation indicated no RQ's were exceeded for Flares 1 and 2 | |
| No LDEQ Reported 2008-10-28 | VPS-2 Atmospheric Heater (83H-101) | Cause: a bearing failure on the induced draft fan caused the heater to make a swtich that resulted in a suddens shift in heater firing and oxygen levels in the heater Followup: No Notes: Affirmative defense letter. | |
| 107837 2008-08-06 | Hose at the Water Treatment Plant | Cause: a pump suction hose ruptured. Followup: No Notes: Although acid entered a stormwater drainpipe and flowed into an open ditch and culvert to the south, Motiva states that there was no offsite impact. Motiva's Process Engineering Dept conducted an evaluation of the hose and recommended a more compatible hose type (Stallion Acid-Chemical resistant Teflon-lined hose). New hose installed 8/7/08. In addition, Motiva's Pressure Integrity Inspection group will conduct a weekly visual inspection of the hose. Release exceeded the 1,000 pound reportable quantity for sulfuric acid | Sulfuric Acid: 188.0 gallons |
| 106378 2008-06-11 | Tail Gas Treating Unit No 4 (78H-101) | Cause: Faulty solenoid valve of the O2 valve which tripped and unreacted H2S entered the TGTU Followup: No Notes: Motiva claims affimative defense. Data here provided in DEQ report and Motiva letter of 6/18/08. Operations contacted the electrical and instrumentation (E&I) department to investigate the cause of the closure of the oxygen trip valve. After finding the faulty solenoid on the oxygen trip valve, E&I installed a new solenoid. | Sulfur Dioxide: 968.0 pounds |
| No LDEQ Reported 2008-04-23 | None Reported | Cause: malfunctioning flow meter causes release Followup: No Notes: Affirmative defense letter. | |
| 104915 2008-04-09 | Tail Gas Treating Unit No 4 (78H-101) | Cause: process ratio analyzer malfunction causes operational instability that resulted in excess SO2 emissions. Followup: No Notes: Affirmative defense letter. | |
| 103830 2008-03-07 | None Reported | Cause: malfunctioning airflow control valve Followup: No Notes: Affirmative defense letter. | |
| No LDEQ Reported 2008-03-06 | None Reported | Cause: control valve malfunction allows excess H2s to enter Concentration Column Followup: No Notes: Affirmative defense letter. | |
| 102537 2008-01-23 | TORVEX Incinerator EPN 79J-904 | Cause: failure of an antifriction ball bearing in the blower results in shutdown of the incinerator. Followup: No Notes: Rotating equipmt and other supporting engineering personnel will complete the investigation of the failure and implement necessary changes to monitoring inspection and maintenance procedures | Hydrogen Sulfide: 42.0 pounds Methanol: 1,203.0 pounds Carbon Monoxide: 9,204.0 pounds Volatile Organic Compounds: 1,166.0 pounds |
| 102246 2008-01-12 | HGU WWTU Flare (EPN 85D-105) | Cause: malfunctioning level controller let to Pilot outage on flare due to liquid extinguishing the flare. Followup: No Notes: Cold weather led to salt disposition on a level gauge that suppressed the high level alarm on the flare knock out drum. Letter states that remedial action will be taken, but does not specify whic | |
| 102008 2008-01-02 | Tail Gas Treating Unit 1 (17AH-103) | Cause: a pressure transmitter malfunctions causing a shutdown of TGTU-1 inline heater. This sparks a chain of events that result in release of SO2 Followup: No Notes: Motiva will review potential threats for the transmitter to determine appropriate modifications or adjustments if any | Sulfur Dioxide: 1,301.0 pounds >100 |
| 119481 2009-11-12 | BACT box and FCCU | Cause: Exceeded minimum hourly average in BACT box for O2--excess CO emissions during shutdown of Fluid Catalytic Cracking Unit due to mechanical problems with recycle feed pump. (CO not mentioned in follow-up letter but is noted in DEQ report).
SEE ALSO incident 119480 from the previous day--looks like it was an ongoing problem.
No RQs exceeded. Followup: Yes Notes: no information given | |
| No LDEQ Reported 2009-11-11 | FCCU wet gas scrubber | Cause: Mechanical problems with recycle feed pump, had to shut the Fluid Catalytic Cracking Unit down to make repairs, resulting in increased CO emissions.
File contains no DEQ report--hazmat and follow-up only; wrong DEQ and state police #s seem to have been written on top of the follow-up. Followup: Yes Notes: Tried to minimize CO emissions during event, will modify startup and shutdown procedures, will update current standard alarm and add an additional critical alarm to monitor the amount of CO exiting the stack. Operations will be trained on both the procedure modifications & the alarm updates. | Carbon Monoxide: 1,701.0 pounds |
| 119480 2009-11-11 | FCCU wet gas scrubber | Cause: Exceedance of CO maximum of emission rate limit due to shutdown of Fluid Catalytic Cracking Unit Wet Gas Scrubber Stack because of mechanical problems with the recycle feed pump.
Exceeded RQ for CO but no amount given.
SEE ALSO incident 119481 from the next day--looks like it was an ongoing problem. Followup: Yes Notes: no information given | |
| 119017 2009-10-23 | Tank 20T-210 and Tank 20D-47 | Cause: Routing slop oil to tank 20T-210 while tank operators were simultaneously transferring slop from tank 20T-210 to tank 20D-47. Tank level in 20T-210 got too low and tank floating roof came to rest on its legs. Level gauge on tank 20T-210 malfunctioned & not reading accurately.
Incident does not seem to have caused any emissions or releases. Followup: Yes Notes: No Information Given. | |
| 117144 2009-08-07 | flare no. 2 and wet gas scrubber | Cause: Regenerated Catalyst Slide Valve (RCSV) of the Fluid Catalytic Cracking Unit (FCCU) changed position without a corresponding command from the control system causing trip of the gas turbine driving the Wet Gas Compressor because of high exhaust temperature--overpressure control valve opened to flare.
Exceeded RQ's. Followup: Yes Notes: "Took immediate action to begin the process of stabilizing, slowing down, and diverting feed from the FCCU riser." Circuit board replaced, cleaned the servo and will replace it when spare arrives. | Sulfur Dioxide: 76,337.0 pounds Nitrogen Oxide: 333.0 pounds Hydrogen Sulfide: 191.0 pounds Carbon Monoxide: 11,369.0 pounds Volatile Organic Compounds (VOCs): 688.0 pounds Particulate Matter 10: 37.0 pounds |
| 113955 2009-04-04 | SRU-4 thermal reactor; TGTU-3 | Cause: Level 2 fire at Sulfur Recovery Unit (SRU)no. 4's thermal reactor due to failure of the SRU-4 thermal reactor vessel. Tail Gas Treating Unit (TGTU) No. 3 upset during firefighting efforts causing additional emissions.
Fenceline monitoring indicated no offsite impacts.
Exceeded RQs. Followup: Yes Notes: In-house fire dept and ERT worked to extinguish fire, reduced operating rates on units producing acid gas or rich amine and to distribute the acid gas flow to other operation SRU/TGTUs during firefight to safely shut down SRU/TGTU-4. | Sulfur Dioxide: 7,000.0 pounds Hydrogen Sulfide: 147.0 pounds Ammonia: 2.0 pounds |
| 112974 2009-02-24 | Tail Gas Treating Unit Number 1 (17AH-103) | Cause: The Booster Compressors (17BC-101 & 17BC-102) unexpectedly shutdown due to high differential pressures, while operations was swapping booster compressor operations. A malfunction of the stackmatch pilot delayed the restart of the inline heater, which ultimately caused emissions to exceed the RQ. Followup: No Notes: Ceased emitting once Convent Refinery restarted the TGTU-1 inline heater and resumed normal acid gas processing. | |
| 128271 2010-12-18 | Flange: H-Oil Unit | Cause: LDEQ states that a leak at a flange occurred, causing a hydrogen and light cycle oil cloud to develop while bringing the unit up. Followup: No Notes: BRQ. Refinery letter states that "detailed calculations performed...and that no RQ exceedence" occurred." Temperature and pressure were reduced so that the flange could be bolted, and the leak could be stopped. | |
| 133665 2011-09-08 | Refinery Flare No.1, No.2 and No.3 | Cause: Motiva states that initially the upset began after routine maintenance on a Wet Gas Compressor flow transmitter. The Suspected Controller sent a signal to open the anti-surge spill-back creating a recycle from the compressor discharge to suction. A compressor malfunctioned causing flaring in Refinery Flare No.1, Flare No.2 and Flare No.3 cumulatively beyond permit limit and the release of 2,097 pounds of SO2. Followup: No Notes: LDEQ and Follow-Up provided, but there was no Refinery Letter included. Motiva states that there was a non-preventable release of approximately 1,952 pounds of SO2 and 3.68 pounds of H2S. The Catalytic cracking controllers (CCC) were replaced and the data recording software was upgraded and is being analyzed. | Sulfur Dioxide: 1,952.0 pounds Hydrogen Sulfide: 3.7 pounds |
| 139974 2012-05-24 | Flare #3 | Cause: During normal operation, two redundant level control valves on the bottom of 70F-107 failed, and liquid filled the vessel. This caused the pressure of the vessel to increase, resulting in the vessel's pressure relief device to open to the flare. Sent to Flare #3 Followup: Yes Notes: Gases were contained in the Flare Gas Recovery system until maximum operating pressures of the system required the refinery to flare. The operating unit immediately reduced charge to minimize the generation of gas routed to the flare. Reactor temperatures and charge rates were reduced while maintenance repaired the two valves. Stable operations were established and the flaring ended. Manager bypassed the unit to stabilize the vessel. Fugitive emissions sent to Flare #3. Another follow-up report will be submitted at the conclusion of the investigation of the root cause and any appropriate modifications or adjustments. | Sulfur Dioxide: 14,841.0 pounds |
| 152354 2013-11-13 | discharge hose | Cause: On November 13, 2013, a release of brine (produced) water occurred at Motiva's Salt Dome Storage Facility in Sorrento, Louisiana. At the time of the release, brine water was being pumped from the South Pit to the North Pit when the discharge hose began spraying produced water onto the ground surface just outside of the brine pits.
Initial verbal notification indicates that release was the result of a hose malfunction.
The incident was initially reported as a potential exceedance of the 1 barrel reportable quantity for produced water. However, after further calculation, the total amount released during this incident was determined to be below the 1 barrel reportable quantity. Followup: No Notes: Upon discovery, operations personnel immediately shut down the pump which stopped the leak. | |
| 152121 2013-11-01 | HTU-1 | Cause: On November 1, 2013, there was a release of hydrogen sulfide due to an equipment failure on HTU-1. Followup: No Notes: The incident was initially reported as a potential exceedance of the 100-lb Reportable Quantity for hydrogen sulfide. However, after further calculation, the total hydrogen sulfide emissions from this incident were not above the reportable quantity. | |
| 155952 2014-05-12 | LUI West Tank Farm, Tank 20D-2 | Cause: Waste water containing ammonia salts and phosphoric acid leaked through a roll-off box and a secondary-containment unit that had a small hole. The box and the collapsible secondary-containment unit were themselves inside an earthen containment.
Both the primary and secondary containment systems failed in this case. The incident occurred at the LUI West Tank Farm, Tank 20D-2. Followup: No Notes: Letter did not indicate that any remediation activities had occurred, nor that the containment units had been replaced or repaired. | |
| 153346 2014-01-08 | H-Oil Unit | Cause: On January 8, 2014, Motiva Enterprises, LLC Convent Refinery (Motiva) reported an upset of the H-Oil Unit which caused emissions of sulfur dioxide (SO2) from the combustion and flaring of hydrocarbons containing sulfur compounds. At approximately 2:45 AM, the H-Oil Unit Fractionator Tower began to build a liquid level, due to the bottoms pump losing suction. The loss of forward flow from the fractionator tower bottoms up resulted in increased liquid level in the fractionator tower. While trying to re-establish suction to the pump, the pressure increased on the overhead of the Fractionation Tower. Followup: No Notes: While trying to re-establish suction to the pump, the pressure increased on the overhead of the Fractionation Tower. The pressure was relieved through automated controls and PSV's To Flare Relief and Fuel Gas Recovery (FGR) system. In order to prevent an unsafe condition from the elevated hydrogen sulfide (H2S) and pressures in equipment, at 6:30 AM the stream was taken out of FGR and routed to Flare No. 3. The fuel gas H2S concentration remained elevated until approximately 6:40 AM. The system was stabilized by 2:10 PM when the stream was returend to FGR and Flaring at Flare No. 3 ceased. The incident was initially reported as a potential Reportable Quantity (RQ) exceedance. However, during the event, no release exceeding an RQ occurred. Therefore, Motiva is submitting this letter to clarify that the referenced incident did not result in an RQ exceedance and the verbal report made on January 8, 2014 should be considered a courtesy notification. |
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