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Motiva Enterprises (1406), Norco
Causal Factor: Piping or Tubing
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 84612 2005-12-15 | Hydrogen and hydrocracker units | Cause: An unexpected piping failure on an exchanger led to a release of Hydrogen and a subsequent shutdown of the hydrogen and hydrocracker units. Followup: No Notes: Operations personnel immediately took corrective actions to safely shut down the units and to minimize emissions. Data gathering and investigations to perform calculations and determine root cause is ongoing. | |
| 84579 2005-12-14 | Sanitary sewer line | Cause: Junction box in the main sewer line broke and the overflow material was discharged into Wastewater treatment system; overflow was traced to a blockage in the sewer line. Followup: No Notes: While a portion of the process was bypassed, Motiva noted that the material did receive treatment prior to discharge. | |
| 82888 2005-10-07 | No information given | Cause: Piping flange began leaking due to overpressure releasing coke feed oil to soil. Followup: Yes Notes: Spill was cleaned using a vacuum truck and by removing contaminated soil and filling the area with fresh soil. | Oil: 84.0 gallons |
| 79889 2005-06-16 | Sanitary sewer line serving the Central Refining Control Room | Cause: Sanitary sewer line serving the Central Refining Control Room became plugged, resulting in overflow of sewer clean-out hub. This sewage flowed into nearby stormwater drain. The sanitary sewage was routed to the refinery effluent treatment system and subsequently discharged through LPDES Outfall per permit. Followup: No Notes: Maintenance personnel were immediately notified. The line was unplugged and flow returned to normal. Motiva notes that although a portion of the treatment system was bypassed, the material did receive treatment prior to discharge. | |
| 77243 2005-02-27 | Alkylation Unit Control Room Sanitary Sewer Discharge Line | Cause: Sanitary Sewage discharge line serving the Alkylation Unit Control Room became plugged, causing water to overflow to effluent system. Followup: Yes Notes: Sewage was diverted from normal treatment to the refinery wastewater treatment system due to a clogged pipe. The clogged pipe was repaired within 24 hours and flow was returned to normal. Motiva noted that even though a portion of the treatment system was bypassed, the material did receive some treatment prior to discharge. | |
| 92393 2006-12-02 | RGHT Unit | Cause: Release was due to leaking flange on exchanger E-8110B during normal operating conditions. Followup: No Notes: No information given. | Benzene: 0.0 pounds Toluene: 0.0 pounds Volatile Organic Compounds (VOCs): 0.5 pounds |
| 91657 2006-10-26 | Cause: Operators discovered a pin hole leak in a finishing butadiene line while conducting air monitoring. Followup: Yes Notes: Upon discovery, a temporary clamp was installed and an order was placed for a permanent clamp. Once permanent clamp was fabricated and delivered, it was installed over the leak. | 1,3-Butadiene: 4.9 | |
| 91490 2006-10-18 | West Ops Ground Flare (EPN# 9-84) | Cause: Shell Chemical's Boiler #7 shutdown unexpectedly due to a tube failure. As a result, several production units has to shutdown to safely stabilize the steam system. The Shell Chemical GO-1 Process Unit had to shutdown the process gas compressor as a result of the boiler shutdown. The shutdown of the process gas compressor resulted in flaring at the Motiva West Operations Ground Flare. Followup: No Notes: Process gases were flared a the West Operation Ground Glare at Motiva until the GO-1 compressor at Shell Chemical was restarted and the processes under control. | Nitrogen Oxide: 33.0 pounds Volatile Organic Compounds (VOCs): 82.0 pounds Sulfur Dioxide: 3.0 pounds Benzene: 2.3 pounds 1,3-Butadiene: 6.0 pounds |
| 91050 2006-10-02 | No iCoker Flare FE-401 (EPN 2-84)nformation given Coker Flare FE-401 (EPN 2-84) | Cause: Flaring resulted from the 3/4" drain line on the case of pump P-1983 breaking off while decon piping was being installed, causing the Coker Unit to be shutdown. Flushing oil was released from the pump casing to secondary containment but there was no release outside of the containment or to soil or water. Followup: Yes Notes: The Coker Unit was shut down and PV-901 depressured to reduce leaking while pump was isolated. Further corrective actions are being reviewed by Motiva Enterprises' legal department. | Carbon Monoxide: 19.5 pounds Nitrogen Oxide: 3.6 pounds Particulate Matter: 0.7 pounds Sulfur Dioxide: 257.4 pounds Volatile Organic Compounds (VOCs): 9.7 pounds Benzene: 0.4 pounds Cyclohexane: 0.2 pounds Ethylene: 0.1 pounds Propylene: 0.2 pounds Highly Reactive Volatile Organic Compounds: 0.2 pounds |
| 88170 2006-05-26 | West Ops Ground Flare (EPN 9-84) GO-1 Process Unit ; West Ops Ground Flare (EPN 9-84) | Cause: Shell Chemical's GO-1 Process Unit experienced a small pipe leak on a line at the base of a process vessel. The leak developed during an online abrasive blasting job. In order to relieve pressure on this line, operations had to reduce rates at the GO-1 process unit. The reduction of rates caused flaring at Motiva's West Operations Ground Flare (EPN 9-84). Followup: No Notes: Shell Chemical installed a clamp to stop the leak then returned operations to normal conditions. | Benzene: 14.0 pounds Toluene: 1.0 pounds Nitrogen Oxide: 105.0 pounds Particulate Matter: 20.0 pounds Carbon Monoxide: 569.0 pounds Volatile Organic Compounds (VOCs): 157.0 pounds 1,3-Butadiene: 23.0 pounds |
| 85967 2006-02-21 | DU-5 Unit | Cause: An atmospheric leak of light naphtha gasoline material was identified in Motiva's Distilling unit due to a piping failure on the crude column overhead line. Initially, operations personnel identified the line dripping in two locations, and vaporizing before reaching grade. Followup: Yes Notes: Operations developed a plan to safely remove insulation so that the leak could be stopped. Operations installed barricade tape around affected area and monitored the leak for benzene. A catch tray was fabricated and mounted directly to the crude overhead piping to contain atmospheric emissions while the associated insulation was removed from the crude overhead line. Once the insulation was removed, a pipe clamp was installed to permanently stoped the leak. The overhead piping will be replaced during the next unit turnaround in October 2006. | Benzene: 1,532.0 pounds n-Hexane: 4,197.0 pounds Toluene: 1,266.0 pounds Xylene: 614.0 pounds Volatile Organic Compounds (VOCs): 60,571.0 pounds Highly Reactive Volatile Organic Compounds (HRVOCs): 1,885.0 pounds Flammable Gas: 60,583.0 pounds Ethylbenzene: 124.0 pounds 1,3-Butadiene: 6.0 pounds Hydrogen Sulfide: 0.2 pounds |
| 85653 2006-02-06 | RCCU Flare (EPN 8-84) | Cause: The Wet Gas Compressor at Motiva's RCCU slowed down due to a site-wide loss in steam pressure. The loss in steam-pressure was due to the shutdown of Shell Chemical's Utilities East Boil #8 after a tube rupture. The slow down of the compressor resulted in hydrocarbon flaring at the RCCU Flare. Followup: No Notes: RCCU made a reduction in feed rate during the initial upset in order to stabilize operations. RCCU operations personnel reacted accordingly to the loss in steam pressure. Corrective actions to prevent future boiler shutdowns will be addressed in a separate letter by Shell Chemical. Flaring was not continuous throughout the start and end dates. | Carbon Monoxide: 253.0 pounds Sulfur Dioxide: 476.0 pounds Volatile Organic Compounds (VOCs): 150.0 pounds Nitrogen Oxide: 44.0 pounds Particulate Matter: 5.0 pounds |
| 101464 2007-12-05 | Cause: Leak in pipeline--slop oil header at a point of external corrosion. Followup: Yes Notes: Motiva emergency personnel immediately cut feed to reduce pipe flow. Vacuum trucks removed slop oil from ground. Motiva personnel clamped the 4" metal pipe 10" above ground level. Slop oil pickup transported to slop oil Tank 409. Impacted soil removed and disposed of at industrial landfill site. Quantity of slop oil released is initially reported to be 3 barrels (126 gallons). The follow-up report claims that the amount of slop oil released was 0.91 barrels (38.33 gallons). | Slop Oil: 38.2 gallons Benzene: 0.2 pounds | |
| 99302 2007-09-07 | Fresh acid line to Alkylation unit reactors | Cause: The fresh acid line to the Alkylation unit reactors developed a leak originating from a Furmanite manufactured box installed to control a prior leak. Followup: Yes Notes: Upon discovery of the leak, Furmanite was contacted and the manufactured box was re-pressurized and sealed. The leak was corrected and the line was returned to normal service duty. | Sulfuric Acid: 616.0 pounds |
| 98320 2007-08-01 | Sanitary sump pumps serving RCCU and DU-5 units | Cause: Discharge piping on the sanitary system sump pumps serving the RCCU and DU-5 units leaked sewage due to plugged pipe. Material drained to a nearby stormwater sewer and was discharged into the refinery wastewater treatment system bypassing normal sewage treatment routing.
See also incidents 96492 and 97505, reports of the same date. Followup: Yes Notes: Vacuum truck was called out to pick up material and prevent additional leakage to the wastewater system. Operations blew line free of plug, reestablishing flow. Motiva will make permanent repairs once evaluation of lines is complete. Routine emptying of the sanitary sump via vacuum truck is being conducted until repairs to the discharge line are completed. The material was routed directly to the refinery wastewater treatment system and received full treatment through this system prior to discharge. | |
| 97930 2007-07-17 | Heat exchanger piping on DU-5 unit | Cause: An "off-spec" section of piping failed and leaked while operators were putting a heat exchanger into service on the DU-5 unit. Followup: Yes Notes: No information given. | |
| 97505 2007-06-28 | Interface piping of wharf structure | Cause: Pipefitting located on the sewage and steam condensate interface piping of the wharf structure leaked sewage and steam condensate into the Mississippi River.
See also incident #s 96492 and 98320, reports of the same date, and follow-up inspection reports on file for the three incidents combined. Followup: Yes Notes: The lines were 30' above the batture, making them difficult to access. A scaffold platform had to be built before repairs could take place. The lines were blocked and the release was contained with secondary containment at ground level until repairs could be made. Upon completion of scaffold platform, maintenance repaired the line, thus stopping the leak and returning the discharge to its normal routing to the site's wastewater treatment facility. The released steam condensate and sewage did not go through this wastewater treatment facility. | |
| 96492 2007-05-24 | System clean-out hub near RCCU control room | Cause: Plugged sewer line from restrooms to lift station caused sewage leak from a system clean-out hub near the RCCU Control Room. Sewage drained to a stormwater sewer and was discharged into the refinery wastewater treatment system bypassing normal routing for treatment before release.
See also incident #s 97505 and 98320, reports of the same date, and follow-up inspection reports on file for the three incidents combined. Followup: Yes Notes: Plumber unclogged line. To prevent recurrence, Motiva plans to have the line routinely cleaned on a quarterly basis. | |
| 95320 2007-04-11 | Collection line | Cause: A clogged collection line resulted in the backup and release of raw sewage to an area of soil at Motiva's Norco Facility. Followup: No Notes: Spilled sewage was absorbed in soil. Clog was removed. | Sewage: 25.0 gallons |
| 94667 2007-03-15 | Sewer sump servicing DU-4 and DU-5 Units | Cause: A sewer pump servicing the DU-4 and DU-5 Units overflowed due to plugging of the discharge line. Followup: Yes Notes: The overflow material was drained into a nearby storm water sewer and was discharged into the refinery wastewater treatment system. The material was then discharged through LPDES Outfall 002. Normally the effluent goes through a small sanitary sewage treatment plant prior to mixing with the main refinery effluent, but with the plugging of the line, the effluent bypassed this treatment. Once the leak was discovered, a vacuum truck was placed to pick up the material and to prevent additional leakage. Once the piping was accessible, the plugging was cleared and the sump returned to normal operations. | Sewage: 10.0 gallons |
| 109940 2008-10-08 | RCCU unit CO heater | Cause: RCCU unit discovered several tube leaks in the CO heater, necessitating a controlled shutdown of the heater and RCCU and the diversion of all regenerator flue gas to the atmosphere and away from the flue gas scrubber to mitigate safety concern.
Even went on over 5 days--RQs exceeded.
No DEQ report in this file--follow-up only. Followup: No Notes: 76 tubes that were in poor condition replaced in the CO heater. | Carbon Monoxide: 806,024.0 pounds Nitrous Oxide: 1,694.4 pounds Particulate Matter: 21,166.0 pounds Sulfur Dioxide: 21,640.0 pounds |
| 106936 2008-07-03 | Sewer pump house, LPDES Outfall 002 | Cause: A PVC pipe failure inside the sewer pump house caused the sanitary sewage to fill the dry well of the sewer pump house and to spill out of the building. The spare pump also failed, causing a second unauthorized discharge. Followup: Yes Notes: The pumps were disabled and the spilled sanitary sewage was recovered via vacuum truck. A bypass was necessary to complete the repairs on the damaged piping. The sanitary sewage was directed to the refinery wastewater treatment system prior to mixing with the main refinery effluent. The discharge of sewage was cleaned up and treated. | |
| 103758 2008-03-08 | Tank F-455 rundown line | Cause: A leaking flange on the rundown line of tank F-455 was discovered during refill operations. Followup: Yes Notes: Operations personnel halted product transfer, tightened the flange to stop the release, called out additional personnel to begin containment and vapor suppression foaming, began clean up operations, and notified the Norco Site Supervisor. All material released to the ground was picked up via vacuum trucks and stored in fractionation tanks to facilitate source control sampling. All hydrocarbon impacted soil was excavated and disposed of in Motiva's on-site landfill. Regarding remedial actions, each tank within the logistics organization will be evaluated on a case-by-case frequency to determine the need to excavate rundown lines during scheduled tank turnaround activities. The work scope of the tank turnaround process will be revised to include excavation and inspection of all flanges and to include flange make-up requirements that ensure an adequate seal is maintained at the flange interface. | Benzene: 25.5 pounds Xylene: 101.7 pounds Oil: 267.0 gallons |
| 117729 2009-09-04 | hole in pipe of CR-2 unit | Cause: There was a hole in the CR-2 unit's Caustic and Water Wash column overhead piping allowing gas to be released into the air. Note: they are also labeling this incident as a reactor failure Followup: Yes Notes: After the hole in the piping was discovered, the CR-2 regeneration section was shut down and the piping was replaced | |
| 114485 2009-04-26 | hole in bleach tank TM-5694 | Cause: there was corrosion of stainless steel piping on the bleach tank TM-5694 that resulted in the release of Sodium Hypochlorite solution into both the tanks concrete containment and surrounding soil. Followup: Yes Notes: the impacted soil was washed with water and a vaccum truck was used to recover the standing material. | Sodium Hypochlorite: 730.0 pounds |
| 113913 2009-04-02 | 3-inch de-watering hose line | Cause: After de-watering a RU gasoline take (F-456) and 2 crude oil tanks (A-413 and A-416) it was noticed that there was a leak coming from a 3 inch de-watering hose. This leak was linked to a corrosion in that 3-inch de-watering line. As a result of the incident, both crude oil and benzene vapor were released Followup: Yes Notes: the corroding line was isolated and clamped while booms were put in the ditch as a way to prevent further migration of the released material. A pumper truck was used to recover the compounds released, and these compounds were discharged into the refineries slop oil system. contaminated soil was disposed of sent to an on-site landfill. Waste water that was contaminated received full treatment before being discharged | Crude Oil: 42.0 pounds |
| 113517 2009-03-19 | tank water draw line servicing crude oil storage tanks | Cause: oil/water mixture discovered leaking from above ground pipeline--out-of-service tank water draw line. Mixture migrated in an earthen (diked) pipeway 800' east and stopped.
Heavy rains occurred a few days into cleanup, flooding contained area where spill occurred.
No DEQ report in this file, follow-up letter only. Followup: Yes Notes: Clamped leak. Four vacuum trucks dispatched to remove free liquid, brought to Motiva's recovered oil sump for reprocessing in the refinery. Contaminated soil excavated and placed into plastic bags for disposal. Will add "Micro-Sorb(tm)" to the ground to further promote biodegradation of any low-level residual hydrocarbons once area dries out after the heavy rains. Will flush line then blind and isolate it. | Crude Oil: 84.0 gallons |
| 113296 2009-03-10 | firewater system | Cause: It was reported that there was a leak in the firewater line part of the firewater distribution system. Some of the water was captured by the wastewater treatment system but some was also sprayed onto Airline Hwy as a result of this leak. Followup: Yes Notes: the appropriate block valves were used to isolate the leaking firewater header | Water or Wastewater: 50.0 gallons |
| 113158 2009-03-05 | piping from two bleach tanks: T-M5693 and T-5694 | Cause: Piping connected to 2 bleach tanks: T-M5693 and T-5694,had a joint problem which resulted in a leak of sodium hypochlorite (NaClO) solution into the containment dike and surrounding soil. Followup: Yes Notes: Soil contaminated with the NaClO solution was washed with water and a vacuum truck was used to recover the standing material. When the compound was release,d wind conditions were reported at a wind movement from the south at 12mph | Sodium Hypochlorite: 48.1 pounds |
| 122119 2010-03-13 | HCU absorber surge drum PV-829 HCU oil absorber surge drum PV-829 | Cause: Operator on rounds discovered stain on nozzle bottle of vessel of hydrocracking unit. Plug missing, visible vapors, and there is a quarter inch hole leaking. Followup: No Notes: BRQ. Refinery letter states that "final calculations confirm that no reportable quantities were exceeded." Steam lanced the leak initially, then got advice from piping inspectors for leak repair. Repaired with nipple and isolation valve with cap. | |
| 134787 2011-10-20 | Sour Water Stripper Plant (SWS) #1 | Cause: On 10/20/11 at approximately 3:35pm a release of hydrogen sulfide occurred at Motiva's Sour Water Stripper Plant (SWS). The release was attributed to a leak that was concealed behind insulation of the 14" outlet piping downstream of the SWS #1 overhead fans. Followup: No Notes: Immediately upon discovery this system was shutdown and depressured to allow for inspections and repairs to be made. Additionally, the overhead piping at SWS #2 was function tested and put online where repairs were being made to the overhead piping at SWS #1. | |
| 134693 2011-10-15 | level bridle at sulfur plant S-3 | Cause: On 10/15/11 at approximately 1:40 pm, a release of hydrogen sulfide occurred at Motiva's Sulfur Plant No. 3 (S-3) from a leaking level bridle. Immediately upon discovery, the leaking level bridle was isolated and the leak stopped. A maintenance work ticket was generated to fabricate a new spool piece to replace the leaking section of pipe on the level bridle. The new spool piece was then installed and the level bridle was put back in service with no issues. Followup: Yes Notes: The report says that immediately upon discovery the level bridle was isolated and the leak stopped, yet the duration shows the leak went on for more than 1 day. | |
| 130202 2011-03-26 | Logistics Berth 2 | Cause: Initially, leaking pipe unable to be contained until the leaking pipe was isolated. A small pinhole developed on the firewater piping at Logistics Berth 2 causing a leakage of firewater into the Mississippi River. Followup: No Notes: LDEQ and Follow-Up Report provided, but no Refinery Report included. Motiva states that they were unable to contain spill, but isolated the leaking piping to stop the leak. The Follow-Up report stated "Motiva Norco is permitted to release firewater to the Mississippi River from the Wharf". All required monitoring requirements for the permitted discharge were met and were within permit limits. | |
| 145652 2012-12-30 | Naphtha vapor return line DU-5 process unit | Cause: On December 30, 2012 a leak was discovered in a naphtha vapor line in the DU-5 Process Unit. The leak was from a pinhole that developed in a weld on the line. The leak on a vapor control line resulted in the release of 1, 3 butadiene and benzene. Followup: No Notes: The vapor return line was immediately isolated and a nitrogen purge was established. Plans have been developed to complete repairs to the line before the line is safely returned to service. They initially reported over 10 lbs of both Butadiene and benzene being released. Motiva later reported that no reportable quantities were exceeded. | |
| 145521 2012-12-23 | Finished butadiene line | Cause: At 23:45 on December 23, 2012 a contractor reported a leak on the finished butadiene line. Maintenance removed the insulation from the line and a pin-hole leak was located. Followup: Yes Notes: Operations de-pressured the line to the flare and installed a temporary clamp to stop the leak. An engineered box was installed on Decembrer 26, 2012. There was an undetermined amount of 1,3 butadiene released reported in initial report. A follow up report written on February 21, 2013 indicates that the reportable quantity for 1, 3 butadiene was exceeded. | 1,3-Butadiene: 50.8 pounds |
| 144121 2012-10-23 | 4" Butadiene line | Cause: At 10:50 on October 23, 2012 during maintenance work to clean and paint a corroded area of the 4" Butadiene line, a contractor discovered an ice ball on the 4" butadiene line. The line was out of service and 95% depressurized for maintenance activities. Followup: No Notes: The area was cleared and the PEI inspector was called to investigate the leak. Upon investigation a pin hole in the pipe was discovered. At 13:30 there was no material detected exiting the pin hole. A clamp was installed and the leak officially stopped at 17:05. No mention of any pounds or gallons. | |
| 138462 2012-04-02 | Rubber boot in sewer line on Berth 1 | Cause: Through a small hole in a rubber boot on the sewer line in Berth 1, sewer water was spilled to the Mississippi River. The released material did not go through the wastewater treatment facility. Normally, the sewer line is routed to the refinery wastewater treatment facilities and then to the Mississippi River via LPDES Outfall 002. Followup: No Notes: Operations isolated the sewer line, stopping the release. Maintenance replaced the rubber boot on the sewer line at Berth 1 with a new rubber boot. | Sewage: 1.0 gallons |
| 147591 2013-03-25 | Propane pipeline | Cause: On March 25, 2013 at 1830 hours operations personnel in Logistics discovered a liquefied propane gas leak. Immediately after discovery the pipeline was depressured and isolated to stop the leak. Upon investigation, the source of the leak was determined to be a failed piece of piping at the discharge of a relief valve on the propane pipeline. Followup: Yes Notes: Immediately after discovery, the pipeline was depressured and isolated to stop the leak. The leaking piping system was reviewed by Pressure Equipment Inspections (PEI) and repair recommendations provided. The short term repairs have been implemented. To prevent reoccurrence, the plan is to increase monitoring of this piping system. Upgrades to the piping system to meet engineering standards will be addressed in the future. | Propane: 1,542.0 pounds |
| 146746 2013-02-04 | berth number 1 | Cause: An unauthorized discharge of raw sewage into the Mississippi River resulted from the unanticipated bypass of the Norco Refinery wastewater treatment facility on February 4, 2013. No reportable quantities were exceeded.
At 1027 hours on February 4, 2013, Operations discovered a sewage leak into the Mississippi River from a sewage line at Berth number 1. The leak was identified at a connection point where a PVC and metal pipe are joined with a rubber clamp. After noticing the loose pipe coupling, operations isolated the water and closed the bathroom to stop any further leakage. Followup: No Notes: The released material was approximately one gallon and did not go through a wastewater treatment facility; therefore, we are reporting an unauthorized discharge as a result of the bypass of the treatment process. The damaged pipe has been repaired with a new rubber clamp. | Sewage: 1.0 gallons |
| 146188 2013-01-19 | S3 Incinerator (EPN 2-90) | Cause: On January 19, 2013, Motiva's Sulfur Plant No. 2 (S2) experienced an unexpected lube oil piping leak on a turbine driven main air blower causing the process unit to trip offline. At this time, all of the acid gas that S2 was processing was routed to Motiva's Sulfur Plant No. 3 (S3). Subsequently, the acid gas header at S3 surged sending an additional flow of tail gas through the unit to the S3 absorber. The S3 absorber was not able to adequately treat the sudden increase in flow at this time, and sulfur dioxide was released through the S3 incinerator exceeding the maximum pound per hour permit limit.
Motiva has determined that the root cause of the piping leak on the main air blower lube oil system at S2 was due to a fatigue of a threaded connection that contributed to the fatigue condition, and this will serve as a final repair of the leak. Followup: No Notes: Operations responded immediately to the incident by starting an electric blower at S2, to safely restart the process unit and recover the additional acid gas set to S3. Once the acid gas was routed back to S2 utilizing the electric blower, the release stopped. Operations also tripped the Sour water stripper column to reduce feed flow to S3 and help reduce incinerator SO2 emissions. There were no reportable quantities exceeded during the release. However, the maximum pound per hour permit limit for sulfur dioxide was exceeded. | Sulfur Dioxide: 80.1 pounds |
| 145719 2013-01-05 | RCCU Elevated Flare (EPN 8-84), 1-90(GO-1 Elevated Flare FE-602) 1-90(GO-1 Elevated Flare, FE-602) | Cause: On January 5, 2013, Motiva's Residual Catalytic Cracking Unit (RCCU) discovered a catalyst leak from a section of piping on the unit's West Secondary Cyclone Dip Leg. Operations responded immediately and worked to isolate this section of line. However, due to the location of the leak it was determined the line could not be isolated without shutting down the RCCU process unit. RCCU Operations then initiated a controlled unit shutdown following all operating and safety procedures. As part of the RCCU shutdown process, catalyst circulation within the West Secondary Cyclone Dip Leg was halted and the leak stopped.
During this event, GO-1 flared RCCU Dry Gas at the GO-1 Elevated Flare (EPN 1-90) on January 6, 2013, January 9, 2013, and January 10, 2013. The GO-1 flaring resulted in reportable quantities exceeded during the release for Sulfure Dioxide and permit limit exceeded of Hexane on January 9, 2013 and January 10, 2013.
Emission Calculations were performed using process data and appropriate AP-42 emission factors.
Final update report 4/10/13 corrects cover letter of 3/7/13 report, which inaccurately stated that no reportable quantities were exceeded. Followup: Yes Notes: Immediate remedial actions: Operations worked to identify the source of the leak and made preparations for a repair. RCCU operations initiated a controlled unit shutdown to allow for maintenance repairs. As part of the RCCU shutdown process, catalyst circulation within the West Secondary Cyclone Dip Leg was halted and the leak stopped. Once this system was secure, Motiva contract maintenance personnel began welding repairs at the catalyst leak point. On January 8, 2013, the weld repairs on this system were completed and the system was returned to service. Motiva operations restarted the RCCU process unit following all operational and safety procedures on January 14, 2013. Additionally, there were no reportable quantities exceeded during the release. However, the maximum pound per hour limit for sulfur dioxide, carbon monoxide, nitrogen oxides, volatile organic compounds and particulate matter were exceeded. All materials routed to flare were combusted with an appropriate destruction efficiency of 99.5%, released from the RCCU Elevated Flare to the atmosphere, and dispersed naturally. To prevent recurrence of the incident, a field weld was made as a final repair to the leak. A release at Shell Chemicals resulted in flaring at the Shell facility as well as the Motiva facility. Motiva states that the flare release was not a reportable quantity, while Shell's release was. | Carbon Monoxide: 24,487.6 pounds Nitrogen Dioxide: 4,500.4 pounds Particulate Matter: 847.1 pounds Sulfur Dioxide: 30,043.3 pounds Volatile Organic Compounds (VOCs): 11,466.2 pounds Hexane: 72.7 pounds |
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