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Valero (1238), Meraux
Causal Factor: Maintenance/Procedures
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 77020 2005-02-18 | North Flare 20-72 | Cause: of the Sour Gas Compressor in the Distillate Hydrotreater Followup: No Notes: No information Given | Sulfur Dioxide: 13,397.0 pounds |
| 76817 2005-02-09 | North Flare 20-72 | Cause: of the Sour Gas Compressor in the Distillate Hydrotreater Followup: No Notes: They replaced gaskets. Note the second letter in the file that corrects the incident date in the original letter. | Sulfur Dioxide: 8,250.0 pounds |
| 75946 2005-01-03 | #3 Sulfur Recovery Unit | Cause: Conducted a bypass of the Tail Gas Treater as part of routine start up Followup: No Notes: BELOW REPORTABLE QUANTITIES | Sulfur Dioxide: 288.0 pounds |
| 76080_a 0200-01-10 | South Flare Sulfur Recovery Unit Incinerator #3 | Cause: It was hard to figure out what is going on. The report stated that it happened because they re started the Sour Water Stripper but it didn't say why it needed to be re started. Followup: No Notes: Note that this is additional information to the incident reported on 1.10.05 | Sulfur Dioxide: 40,761.0 pounds Sulfur Dioxide: 451.0 pounds |
| No LDEQ Reported 2007-06-26 | #2 FCC Slurry Cooler | Cause: the cause of the release was a leak in the #2 FCC Slurry Cooler during startup of the #2 FCC following a 30-day maintenance outage. Followup: No Information Provided Notes: There is no information as to whether this event was preventable or not. Remedial Measures - The refinery and O'Briens Group deployed absorbent and hard booms to minimize the impact to the river. According to Murphy, there was no adverse impact to wildlife in the area. Within approximately 24 hours, Outfall 001 and the cooling water return pond were free of material. Representatives from USCG and LDEQ observed clean-up efforts on June 26 and 27. The FCC slurry leaked into the Mississippi R via Outfall 001 (Once Through Cooling Water discharge). The leak was discovered by visual inspection of the cooling water return pond | FCC Slurry Oil: 15.0 gallons |
| 127860 2010-11-22 | FLARE: #2 SRU [#1-93]; North Flare [EPN 20-72] | Cause: Refinery letter indicates that facility flared sulfur dioxide from the North Flare due to the shutdown of the #2 SRU. Emissions were also released from the incinerator stack. A root cause analysis will be conducted to determine the trigger for the shutdown.
FOLLOW-UP: Level indicator failed at #1 SWS Overhead Receiver and #1 SWS Off-Gas knockout Pot (SA-V-102). This caused erratic flame at SRU furnace ultimately causing safety shutdown. Root cause was formation of ammonia salts plugging the level indicators; this was "the result of insulation and steam tracing on these level indicators that did not conform to design conditions. Some insulation was not in place and some steam tracing was not in contact with the process piping." DEFERRED MAINTENANCE. Followup: No Notes: RQ. Shut down unit and steamed out level indicators. Restored the insulation and steam tracing on the level indicators to design conditions. | Sulfur Dioxide: 1,391.0 pounds Hydrogen Sulfide: 15.0 gallons |
| 120544 2010-01-05 | FLARE - South Flare (EPN #3-77) | Cause: Pressure increase in sulfur plant due to series of unit shutdowns, automatic safety diversion of naphtha vapors, pressure relief valve opened, released via South Flare. Letter states that "the pressure increase was apparently due to naptha vapors venting into the vessel during shutdown of the Hydrocracker Unit for a month-long refinery-wide maintenance turnaround." FLARE. Followup: No Notes: BRQ. Refinery letter states that "reportable quantity of a regulated material was not exceeded." Followed operating procedures in "Startup, Shutdown, and Malfunction Plan." Reviewing event to see if procedures need to be updated. Refinery letter only. No LDEQ report. | Sulfur Dioxide: 12.0 pounds |
| 145281 2012-12-12 | North Flare | Cause: Two steam vents were opened to the atmosphere during the first week of the month. On December 11, 2012, there was a release of steam from the North Flare. Followup: Yes Notes: Citizen complaining of multiple days of flaring and different disturbing noises emanating from Valero refinery throughout December, 2012. | |
| 143377 2012-09-28 | South Flare | Cause: Excess propane was intermittently discharged to the South Flare when the Depropanized on the Alkylation Unit was shut down for repairs. Followup: No Notes: Citizen complaint on 9/28/12. On 9/27 complainant observed flaring and steaming. Observed a very deep orange flame, black streaks and some smoke after a heavy rain event. There was a flaring and steaming noise. Both flares were in use. Could hear steaming noises in house. The South Flare was large and bright orange with a noise continuing throughout the night and flaring during the early morning hours of 9/28. The flaring was a deeper orange flame and had an associated noise. Sunrise lighting made the black smoke of the flare more easily visible. The material is very low in sulfur. No reportable quantities were exceeded and there was no upset conditions at the plant. | |
| 138274 2012-03-24 | South flare | Cause: Above normal flaring occurred when the naphtha reformer experience an unplanned shutdown. Adjustments were being made to change operating conditions and the unit tripped. Followup: No Notes: Recycle gas was vented to the South flare until unit conditions were stabilized. The unit was immediately restarted. No significant sulfur dioxide emissions from the flare due to this event. Large dark orange flare with a much black smoke was seen. | |
| 137785 2012-03-06 | NIG | Cause: Operations personnel were making adjustments to the steam systems to eliminate the venting of excess steam to the atmosphere. A pressure relief valve on the system opening to the atmosphere for approximately 3 to 5 minutes, a possible source for the noise/whistle listed in the complaint. LDEQ report states that the large pressure release caused constant flaring for hours after initial discharge. Followup: Notes: Citizen Complaint: March 6th around 2pm and 7pm it was observed what may have been a continuous use of north flare with dark streak and sooty trailing smoke and associated flaring noise through neighborhood that was audible inside homes. March 7th around 830 am pressure relief valve jolted residents, some had windows open, big pressure was released creating sounds like jet engines, damaging ear drums. It was followed by very loud, extremely high-pitched constant tone for over 5 minutes hurting ears. Around 1-2 pm on March 7th a deep orange flaring with sooty trailing smoke was observed. It contained match-burnt fuel smell in neighborhood with odors getting strong as you approach Valery. At 7pm on March 7th the flare is still in use. A video of the flare was viewed for March 7th. It was noted that it was deep orange in color but not with a sooty trail as listed in the complaint. Facility did not experience any upset conditions that resulted in emissions in excess of permit limits or violations of regulatory requirements at this time. | |
| 137051 2012-02-07 | North Flare | Cause: The emissions occurred during startup of the Hydrocracker Unit after a planned maintenance turnaround. The exact cause is under investigation, as of 02/14/12. Followup: No Notes: The refinery made some pressure adjustments in the unit to reduce the emission rate at the flare, and then the startup was completed. The incident is under investigation, which will result in a plan to prevent recurrence. | Sulfur Dioxide: 3,000.0 pounds Hydrogen Sulfide: 30.0 pounds |
| 148777 2013-05-20 | None Reported | Cause: Loud noise due to depressurizing the HCU due to a previous incident that occurred on 5/17/13 (LDEQ #148798). Operations directed as much material as possible to other process units. However, to complete the depressure process, gas had to be routed to the north flare. The HCU valve heading to the flare cannot be throttled, it is either 'full open' or 'full closed'. Between the high gas flows to the flare, and what they believe to be excessive assist steam, a deep, helicopter - like noise emanated from that flare. Followup: No Notes: No information given about release of chemicals | |
| 148798 2013-05-17 | North Flare, #2 and #3 SRU, Heaters, Reboilers | Cause: On May 17, 2013 at approximately 15:43, Valero experienced excess emissions of Sulfur Dioxide at the North Flare, the #2 and #3 Sulfur Recovery Units, and several refinery fuel gas-fired sources due to an unexpected shutdown of the #3 SRU. The #3 SRU shut down on high burner pressure caused by a plugged condenser seal leg.
After several unsuccessful attempts to unplug and restart the #3 SRU, Valero determined that the unit could not be restarted and completely shut down the unit. The Gas-Oil Hydrocracker/Hydrotreater was also shut down and refinery charge rates were reduced accordingly.
Valero opened up the unit for inspection and discovered that catalyst from one of the reactor beds had migrated into the condenser and caused the plugging in the seal legs. Valero could not definitively identify the exact cause of the catalyst migration, but believes that it was most likely due to improper catalyst loading during the last catalyst replacement in 2010. Followup: Yes Notes: Valero immediately initiated its sulfur shedding procedure and attempted to unplug the #3 SRU condenser and restart the #3 SRU. Valero transferred as much of the remaining sulfur load to the #2 SRU as the unit's capacity would allow. Before the sulfur shedding procedure reduced the sulfur load to within the capacity of the #2 SRU, hydrogen sulfide entered the refinery fuel gas system and was combusted to sulfur dioxide in the refinery heaters and boilers. Hydrogen sulfide concentrations in the refinery fuel gas system returned to less than the 162 ppm NSPS Subpart J limit at approximately 05:14 on May 18, 2013. To prevent recurrence, Valero reloaded the #3 SRU with new catalyst and ensured that the catalyst was properly loaded and supported with additional support media. Valero plans to install a smaller mesh screen on top of the existing quarter inch screen that currently supports the catalyst bed and support media. | Sulfur Dioxide: 2,708.0 pounds Hydrogen Sulfide: 10.0 pounds |
| 148510 2013-05-03 | Cold Separator PSV in the Gas Oil Hydrocracker/Hydrotreater Unit | Cause: On May 3rd 2013, starting at approximately 2:00, Valero experienced excess emissions of sulfur dioxide and Hydrogen Sulfide at the north flare during startup of the gas oil Hyrdocracker/ Hrydrotreater Unit (HCU) following a planned maintenance outage and catalyst replacement.
Excess emissions during the HCU startup were associated with the following events:
1. The Pressure Safety Valve (PSV) on the Fractionator Tower opened to the flare
2. The PSV on the cold seperator was found to be opened to the flare
3. The Recycle Gas Compressor (RGC) tripped and activated an automatic unit depressurization to the flare.
4. The PSV on the Cold Seperator Opened to the Flare
5. The PSV on the Fractionator Tower opened to the flare a second time
Valero determined the root cause of the PSV actuations to be inadequate startup procedure.
Valero determined the root cause of the RGC trip to be an instrument technician lifting the instrument wires for a thermocouple that provided a shutdown interlock. Contributing factors to this root cause were:
1. Neither the operator nor the instrument technician was aware that this thermocouple provided a shutdown interlock
2. The instrument technician did not reference any documentation to verify that this transmitter was a possible Safety Critical Instrument
3. The reference documentation was inadequate
4. The instrument was not labeled in the field as a Safety Critical Instrument contrary to Valero standard procedure
7/2/2013 report states that written notification was submitted on 5/10/2013. This documentation is not available on the LDEQ document database. Followup: Yes Notes: Valero reduced pressure to reseat PSVs that had lifted and attempted to stop the leakage on the Cold Separator PSV. Valero shut down the HCU on 5/13/13 and replaced the Cold Separator PSV. Valero will revise HCU startup procedure to include a maximum charge rate limit and maximum Cold Separator pressure limit during sulfiding and also to ensure that the Cold Separator pressure control valve is initially lined up for feed introduction into the unit. Valero repaired the thermocouple and corrected the documentation to reflect that it is a Safety Critical Instrument. Valero has also labeled this instrument in the field. Valero will also finalize a Safety Critical Instrument List in the HCU to provide a reference document for all critical instruments and to label these instruments in the field. | Sulfur Dioxide: 10,007.0 pounds Hydrogen Sulfide: 109.0 pounds |
| 147265-147182-147183-147185 2013-03-09 | NIG | Cause: On March 9, 2013, a caller complained of a sulfur like odor. A fire company and a chief reponded ot the area and confirmed the odor, sulfur like and source unknown. The area is right outside of a refinery (Valero) the strongest odors were at Judge Perez and Jacob Dr.
Additionally, 3 other complaints were made: 9:55pm on 3/9, 8:09pm on 3/10, 4:30pm at 3/10. All three complaints report an odor. One complaint mentions flaring.
On March 9th and 10th, the Meraux Refinery prepared several process units for a planned maintenance turnaround. Process equipment on the Merox Unit was de-inventoried, water-washed, and steamed in preparation for entry. When the wash water and steam condensate was drained to the refinery sewer system, some residual process material (including malodorous reduced-sulfur compounds) volatilized to the atmosphere. This is believed to be the source of the odor complaints received by LDEQ and the refinery. When this drained material reached the refinery's waste water treatment plant, it may have also generated odors from that location.
Both flares were operating during this period. The Valero Environmental Manager stated that the flow rate and sulfur content of the flare gas were within normal ranges. No reportable quantity exceedences or emergency conditions resulted from this activity.
An LDEQ inspector conducted surveillance of the area on 3/14/13 and did detect an odor at the time of the inspection. Followup: No Notes: During the cleaning of the equipment on the Meraux Unit in a preparation for entry, the wash water was sent to the treatment plant. Agitation of the water released sulfur containing fumes to the atmosphere. The draining of the wash water was slowed down to prevent the agitation of the fumes. Four separate LDEQ numbers were assigned to this incident and complaints: 147265, 147182, 147183, 147185. When the odors became apparent, draining activity was suspended. Draining was resumed on March 11 at a reduced rate and no further odor complaints were received. Valero will review its turnaround plans to ensure that future drainage events are less likely to contribute to off-site odors. | |
| 147203 2013-03-08 | North Flare | Cause: On March 8, 2013, at approximately 01:34, Valero experienced excess emissions of Sulfur Dioxide at the North Flare during the start up of the Hydrocracker/Hydrotreater Unit.
On March 5, 2013, Valero discovered an oil leak on an electrical transformer in the Reformer Unit. In order to de-energize and repair the transformer, Valero conducted a controlled shutdown of the refinery. The root cause of excess SO2 emissions from the Hydrocracker/ Hydrotreater during start up has been identified from previous incidents to be inherent to the original design of the unit. The most recent previous incident, SERC Incident # 12-05963, occurred on 9/3/12.
As a corrective action for the 9/3/12 incident, Valero designed a vent line that will direct the gases vented from the Hydrocracker/Hydrotreater Fractionator Overhead Receiver to the refinery's HiJet so that these gases will no longer need to be flared during startup. Valero was planning to shutdown the Hydrocracker/Hydrotreater on 3/15/13 and install this vent line prioer to this unplanned shutdown to repair the transformer. Followup: No Notes: Valero completed the start up of the Hydrocracker according to procedure. Valero will shut down the Hydrocracker/Hydrotreater on 3/15/13 as originally planned and install the vent line designed to prevent the start up gases from being flared. | Sulfur Dioxide: 564.0 pounds Hydrogen Sulfide: 6.0 pounds |
| 158573 2014-09-08 | None Reported | Cause: According to the e-mail from Mr. Stubbe (Manager Environmental Engineering), the project and turnaround activities that commenced in late July continue. No Reportable Quantities (RQ) were exceeded, no emergency condition existed, and no odor complaints were received from inside or outside the plant.
DEQ inspectors conducted a survey of the area on 9/16/14 and 9/24/14. The first survey found no odors in the area during surveillance, the second survey conducted found some odors in the neighborhood located on the north side of the facility.
*Starting 7/28/14, the refinery executed a planned shutdown of several process units for project work and scheduled maintenance. Affected units include the Hydrocracker, the FCCU, the Alkylation Unit and the ROSE unit. Followup: No Notes: Related to incidents #158394, 158330, 158905, 158516, 158452. | |
| 158516 2014-09-03 | None Reported | Cause: Inspector contacted the Valero Mereax facility representative Mr. Justin Stubbe in response to a community complaint of flaring on 9/3/14. According to Mr. Stubbe, they have no records of any upsets, malfunctions, or unplanned discharges. However, project and turnaround work that started in late July continues. Valero has been preparing its flare headers for blinding and tie-in work associated with the upcoming Flare Gas Recovery project. The flares' appearance (flame size, color, etc.) has varied more than normal due to these activities. Inspector spoke with complainant on 9/5/14 regarding results from investigation. Followup: No Notes: No Information Given | |
| 158452 2014-08-31 | None Reported | Cause: Complaint of smoke being emitted from a Flare at Valero Mereaux on 8/31/14. According to a facility representative the #2 Amine Regenerator tower was being drained and prepared for planned maintenance, During this process, a small volume of liquid amine flowed into the #3 SRU Incinerator, where it was combusted. This generated black smoke at the incinerator stack for a period of approximately 2-3 minutes. A valve was closed and the smoke stopped. There was no emergency condition and no Reportable Quantities (RQs) were exceeded. Followup: No Notes: A valve was closed and the smoke stopped. According to e-mail correspondence, the flare's appearance (flame size, color, etc.) has varied more than normal due to a flare gas recovery project and turnaround activities. | |
| 158394 2014-08-28 | Gas Condensation Unit | Cause: Community complaint of foul odors from near Valero submitted on August 28.
According to the e-mail from Mr. Stubbe (Manager Environmental Engineering), the project and turnaround activities that commenced in late July continue. The letter explained that a review of refinery operations from the evening of 8/28-29 revealed only a single incident that occured approximately half an hour after the complainant's call to SPOC. While demolishing a section of piping on the Gas Condensation Unit, a small quantity of liquid exited a flange. This is believed to have set off the alaram on the nearby worker's personal H2S detector. No Reportable Quantities (RQ) were exceeded, no emergency condition existed, and no odor complaints were received from inside or outside the plant.
During this period, the wind was blowing from the ESE at approximately 3-5 mph. Background levels of H2S and SO2 were measured at the Community Air Monitoring Station on Ventura Drive.
*Starting 7/28/14, the refinery executed a planned shutdown of several process units for project work and scheduled maintenance. Affected units include the Hydrocracker, the FCCU, the Alkylation Unit and the ROSE unit. Followup: No Notes: Related to incident #'s 158330, 158905, 158516, and 158452. | |
| 158905 2014-08-27 | None Reported | Cause: Investigated a complaint by the Bucket Brigade on behalf of various citizens of flaring at Valero Refining, Mereaux on 8/27/14, 8/30/14, and 9/2/14-9/5/14. Spoke with the facility representative Mr. Stubbe. The facility representative stated that they have no records of any upsets, malfunctions or unplanned discharges on these dates. However, the project turnaround work that began in late July continues. Due to this, the flares, appearance has varied more than normal. I spoke with the complainant on 9/25/14 to discuss the results of this investigation.
No further action. Followup: No Notes: No Information Given. Along with LDEQ #'s 158452 and 158516, blame is put on flare gas recovery project and unit turnaround. | |
| 158330 2014-08-26 | Cause: According to the e-mail received from Mr. Stubbe, the project and turnaround activities that commenced in late July continue. Valero has been preparing its flare headers for binding and piping tie-in work associated with the upcoming Flare Gas Recovery Project. In order to ensure stable combustion at the flares, Valero has periodically introduced NSPS J-compliant fuel gas into the headers. The flares appearance (flame size, color, etc) has varied more than normal due to these activities. No unusual odor or noise has been observed. There were no reportable upsets or malfunctions during this period. The wind was variable. It blew from ESE during the evening of the 26th, later switched to northeasterly, and then returned to ESE during the afternoon of the 27th. Hydrogen sulfide concentrations measured at the Ventura Drive air monitoring station remained within their normal band (0.003-0.006 ppm). One citizen complaint was received during this period regarding vehicle and pedestrian noise along the refinery's eastern fence line. This appears to be unrelated to the complaints received by your office.
*Starting 7/28/14, the refinery exectued a planned shutdown of several process units for project work and scheduled maintenance. Affected units include the Hydrocracker, the FCCU, the Alkylation Unit, and the ROSE unit. Followup: No Notes: related to previous incidents with LDEQ#s 158905, 158516, and 158452 | ||
| 158125 2014-08-16 | Ultra Low Sulfur Diesel Hydrotreater Pressure Safety Valve | Cause: On August 16, 2014 at approximately 22:00, Valero exceeded the reporting threshold for sulfur dioxide (SO2) emissions at the South Flare. Valero calculates flare SO2 emissions based on continuous monitoring of flow and total sulfur concentration in the flare header. The reporting threshold is exceeded when the 24-hour aggregate exceeds the baseline average SO2 emissions by 500 pounds.
Sour water generated in the Ultra Low Sulfur Diesel Hydrotreater (ULSDHT) is accumulated in the High Pressure Stripper Receiver before flowing to one of the two Sour Water Strippers. At approximately 20:00 on August 16th, Valero personnel began redirecting sour water from the #2 Sour Water Stripper to the #1 Sour Water Stripper. During this process, the liquid level increased in the Stripper Receiver and sour water entered the ULSDHT Fractionator, where it flashed into steam. This caused a sudden pressure increase in the overhead line which, in turn, caused a Pressure Safety Valve (PSV) to open to the South Flare.
The root cause of this incident was an improper valve line-up. Operators lacked a clear and adequate procedure for switching between the two Sour Water Strippers, and the high-high alarms did not allow sufficient time to respond to the rising liquid level in the Receiver. Followup: Yes Notes: The feed to the ULSDHT was reduced and sour water was drained from the Stripper Receiver. The sulfur concentration in the South Flare returned to normal. Level alarms in the Stripper Receiver were set to a lower level, allowing additional response time during an upset. Operations procedures were revised to more clearly describe the process of rerouting sour water from one stripper to another. | Sulfur Dioxide: 831.0 pounds Hydrogen Sulfide: 9.0 pounds |
| 156601 2014-06-07 | South Flare | Cause: Leaking PSV on compressor in Diesel Hydrotreater Unit to blame for the release.
On June 8, 2014 at approximately 12:00 hours, Valero exceeded the reporting threshold for Sulfur Dioxide (SO2) emissions at the South Flare. Valero calculates flare SO2 emissions based on continuous monitoring of flow and total sulfur concentration in the flare header. The reporting threshold is exceeded when the 24-hour aggregate exceeds the baseline average SO2 emissions by 500 pounds.
Sulfur concentration in the south flare began to increase at 2100 on 6/7/14. At 0830 on 6/8/14, Valero began to flare sweet (low sulfur) propane while starting up the depropanizer section of the alkylation unit, which had been shut down for a week for repairs.
At the same time as this startup, SO2 mass emissions increased to 100-120 lbs/hr. Valero executed its procedure for checking high sulfur sources (Process Safety Valves) and identified a leaking PSV in the diesel hydrotreater unit. Compressor was shut down, and the sulfur concentration returned to normal. Followup: No Notes: There remains some uncertainty about the accuracy of the monitoring at the south flare, as sulfur-free flaring from the alky depropanizer should not have increased SO2 emission rate. Valero provided verbal notification before reaching the emissions threshold. Valero implemented its procedure for checking high sulfur sources (process safety valves (PSV), process vents, etc) and identified a leaking PSV on a compressor in the Diesel Hydrotreater Unit. The compressor was shut down and the sulfur concentration in the South Flare returned to normal. | Sulfur Dioxide: 1,583.0 pounds Hydrogen Sulfide: 17.0 pounds |
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