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Chalmette Refining (1376), Chalmette

Releases of Nitric Oxide

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
84745-84794

2005-12-22
Sulfur Recovery Unit Train 2
Cause: Instrument malfunction caused the automatic shutdown of the refinery sulfur recovery unit train 2, resulting in the routing of refinery acid gas to the flare system (No. 1). Equipment malfunction on SRU 2...leak ongoing...NOX, SO2, H2S. Siting the related incident, ldeq # 84794: According to the refinery, an electrical supply malfunction on the Rich DGA Pump G-8291 caused the automatic shutdown of the refinery Sulfur Recovery Unit Train 2. The shutdown resulted in routing of refinery acid gas to the flare system Loss of one of the amine circulating pumps #g8291 on SRU train 2...NOX, NO2, SO2, H2S

Followup: No

Notes: The following details are for LDEQ incident # 84745, but there is another event (ldeq 84794) which will be discussed in further detail in the 2nd section below: Operations were conducted in order to minimize emissions while maintaining a safe and orderly stabilization of refinery operations and restart of the impacted process unit. Repairs were made to applicable instrumentation and SRU Train 2 was restarted, ending the incident. The refinery has initiated an investigation into the cause of this incident. Based on the result of that investigation, appropriate measures will be taken in order to prevent a recurrence due to the same cause. SO2, H2S, nitric oxide, NO2 released to atmosphere through the refinery number 1 flare and to a lesser extent via the refinery sulfur recovery unit thermal oxidizer stack. Operations were conducted in order to minimize emissions while maintaining a safe and orderly stabilization of refinery operations and restart of the impacted process unit. Repairs were made to applicable instrumentation and SRU Train 2 was restarted, ending the incident. In a separate but related incident report that is linked to the event detailed above (LDEQ # 84794) the following details pertain to that release, but the pollutant totals have been combined: pollutants from incident number 84794 have been combined in the pollutant totals in the table below, but the original report for 84794 had listed these quantities which have all been added to the totals mentioned in report 84745: Hydrogen Sulfide 273.0 pounds Nitric Oxide 239.0 pounds Nitrogen Dioxide 27.0 pounds Sulfur Dioxide 103,560.0 pounds Operations were conducted in order to minimize emissions while maintaining a safe and orderly stabilization of refinery operations and restart of the impacted process unit. Repairs were made to applicable electrical equipment and SRU train 2 was restarted, ending the incident. The refinery has initiated an investigation into the cause of this incident. Based on the result of that investigation, appropriate measures will be taken in order to prevent a recurrence due to the same cause. The Sulfur recovery unit train 1 (SRUTR1) which included the release of 33375 lbs of sulfur dioxide to the atmosphere through the facility's Refinery Sulfur Recovery Unit Thermal Oxidizer Stack. The emissions occurred intermittently from 12/22-25/05 over 35 hour time frame. The unit was shutdown over this timeframe to make necessary repairs. An investigation concluded that a dip-leg of srut1 unit was identified and the unit had to be shutdown. Further investigations revealed that SRUTR1 unit was shutdown prior to katrina and was brought back on line on 12/22/05 when the incident occurred. The shutdown to the SRUT2 resulted in the routing of refinery acid gas to the flare system from 12/22-23/05 for 13.5 hour timeframe. The unit was shutdown over this timeframe to make necessary repairs. Operations were conducted in order to minimize emissions while maintaining a safe and orderly stabilization of refinery operations and restart of the impacted process unit. Repairs were made to applicable electric equipment and SRU Train 2 was restarted, ending the incident. Appropriate measures will be taken in order to prevent a recurrence due to the same cause. These releases of sulfur dioxide exceed reportable quantity. Incident #84745 occurred 12/22 to 12/23 and Incident #84794 occurred from 12/24 to 12/25. The two reports here are also linked to a third report, LDEQ Incident #84723 which is separate on our database.
888.0 pounds
84681

2005-12-19
Hydrocracker (HCU) Second Stage Make-up Hydrogen Compressor (K-2302)
Cause: Operation personnel determined that the Hydrocracker (HCU) Second Stage Make-up Hydrogen Compressor (K2302) alignment and unit conditions were causing a pressure safety valve (PSV) to relieve refinery grid hydrogen to the flare.

Followup: No

Notes: A notification was made regarding a release of Nitric Oxide (NO) on 12/19/2005. At approximately 1758 hours on 12/19/05, excess flare volume was identified and a search of process units was initiated to locate the source. At approximately 2224 hours the source of the flaring was identified and isolated. Upon identification of the flaring source emissions calculations were completed and agency notifications made. A search located the source of excess flare gas. The situations which caused the PSV to relieve the flare were modified, ending the incident. Normal procedures for HCU startup will be reviewed in order to evaluate line-ups that could result in flaring and modify them if appropriate.
79.0 pounds
No LDEQ Reported

2005-12-18

Coker 2 Wet Gas Compressor K8101
Cause: Compressor went into high alarm for high vibration. It was determined that the vibration probe had provided a false alarm due to a faulty connection. Coker 2 Wet Gas Compressor K8101 went into alarm for high vibration on 12/18/2005.

Followup: No

Notes: This is a letter rescining the notification made relative to Hydrogen Sulfide (H2S). Upon further review, the total amount of H2S is estimated to be less than the reportable quantity (RQ= 100 lbs). Chalmette refinery estimates that approximately 70 lbs of H2S was released to the atmosphere during the 12/18/05 event. In order to avoid equipment damage and associated emissions, refinery personnel shut down the machine in order to evaluate and develop a repair strategy. The vibration probe was repaired and the machine was put back in service, ending the incident. Instrument and electrical connections directly related to K8101 were double checked for proper connections in order to avoid a recurrence due to the same root cause. It was determined that the vibration probe had provided a false alarm due to a faulty connection. The vibration probe was repaired and the machine was put back in service, ending the incident. Instrument and electrical connections directly related to K8101 were double checked for proper connections in order to avoid a recurrence due to the same root cause. Although the facility claims that this was a false alarm, there must have been some type of equipment failure to result in the release of 26,127 lbs of sulfur dioxide. The incident released 26,127 lbs of S02, which exceeds the reportable quantity for S02 (RQ= 500 lbs).
254.0 pounds
84474

2005-12-10

Wet Gas Compressor K8101
Cause: Coker 2 Wet Gas Compressor K8101 shutdown on multiple occasion for uncertain reasons. On December 13, 2005 it was determined that some shutdown relay wiring on K8101 had become less secure than required for consistent operations.

Followup: No

Notes: Chalmette Refinery notified the office regarding a release of Nitric Oxide, Nitrogen Dioxide, Sulfur Dioxide, and Hydrogen Sulfide on December 10,12, and 13. This is a notification by CRLLC rescinding the notification made relative to Hydrogen Sulfide (H2S). Upon further review, the total amount of Hydrogen Sulfide is estimated to be less than the reportable quantity. The RQ for H2S is 100 pounds. Chalmette Refinery estimates that approximately 25 pounds of H2S was released to the atmosphere during the combination of the events. The incident occurred on four separate occasions, during three days. Due to incremental emissions caused by downtime of K8101, the compressor was re-started as quickly as possible during the trips on 12/10 and 12/12. On 12/12, when the compressor once again tripped, the machine was left off-line and refinery instrument and electrical resources were mobilized to conduct more extensive evaluation of the machine before re-start. Coker 2 rates were reduced in order to reduce emissions. It was determined on 12/13/05 that some shutdown relay wiring on K8101 had become less secure than required for consistent operations. The wiring was reinstalled, and the machine was re-started ending the incident. The machine was left off-line until refinery instrument and electrical resources could be mobilized to conduct more extensive evaluation of the machine before re-start. K8101 was repaired in order to minimize recurrence due to the same root cause. Sulfur Dioxide, Nitric Oxide and Nitrogen Dioxide released to atmosphere through the refinery No. 1 flare.
91.0 pounds
84328

2005-12-05
Sulfur Recovery Unit Thermal Oxidizer Stack
Cause: Loss of power triggered upset of refinery and shutdown of the refinery's operating sulfur recovery unit.

Followup: No

Notes: A power outage and refinery shutdown resulted in flaring, including a release of Sulfur Dioxide, Hydrogen Sulfide, Nitric Oxide, and Nitrogen Dioxide beginning 12/5/05 and continuing intermittently during the repair of equipment damaged by the outage. The power outage occurred when Entergy was doing some work at the Meraux substation. The entire refinery lost power. The units are now back on line but at minimal rates while repairs are being performed. The refinery is still flaring S02 and H2S because there was damage to the sulphur plant. Operations were conducted in order to minimize emissions while maintaining a safe and orderly stabilization of refinery operation and restart of some refinery process units. Refinery Management has met with Entergy to stress the impact of this incident and request that appropriate measures be taken in order to prevent a recurrence. Operations were conducted in order to minimize emissions while maintains a safe and orderly stabilization of refinery operations and restart of some refinery process units. This is clearly far exceeding the reportable quantity for sulfur dioxide (RQ=500 lbs).
2,070.0 pounds
84247

2005-12-02
Pressure Safety Value
Cause: Unexpected blockage caused backpressure in the unit causing a PSV to relieve to the flare.

Followup: No

Notes: A relief valve failed..NOX The refinery reported a release of Nitric Oxide (NO) on 12/2/05 at approximately 0743 hours causing flaring. The cause of the flaring was identified and isolated at approximately 0923 hours. Total duration was approximately one hour and 41 minutes. Excess flare volume was identified and a search of process units was initiated to locate the source. At 9:23am the source of the flaring was identified and isolated. Operations personnel determined that an unexpected blockage (liquid and/or hydrate) caused back pressure in the unit, causing a Pressure Safety Valve (PSV) to relieve to the flare. Upon identification of the flaring source, emissions calculations were completed and agency notifications made. The search located the source of excess flare gas. The PSV which relieved to the flare was isolated, ending the incident. The incident will be reviewed with affected operations personnel to make them aware of the potential implications of unusual line-ups and their potential environmental implications.
57.0 pounds
84073

2005-11-23
No. 2 Coker Wet Gas Compressor
Cause: The wet gas compressor shut down due to the axial thrust alarm, resulting in emissions from the No. 1 Flare. Following investigation, refinery personnel believe the Wet Gas Compressor shut down due to a momentary loss of lube oil.

Followup: No

Notes: In an effort to stop the release, the compressor was restarted, but the alarm remained. Following determination by refinery personnel that maintenance was required on the compressor, K-8101 was taken out of service and sent out for repair. A variance was applied for with the LDEQ to authorize the emissions associated with the compressor maintenance. The variance was approved on November 29, 2005, ending this release.
2,490.0 pounds
81776

2005-08-27

FCC debutanizer overhead condenser
no.1 and no.2 flares
Cause: HURRICANE KATRINA (storm) Release of sulfur dioxide, nitric oxide, nitrogen dioxide, and hydrogen sulfide was due to overpressurization of the FCC debutanizer overhead condenser, resulting in flaring and a small ground fire.

Followup: Yes

Notes: This follow-up letter has been delayed due to Hurricane Katrina. This is a notification that the total refinery shutdown resulted in an evacuation of the refinery and the potential emergency release of wastewater from the wastewater treatment plant outfall. Chalmette Refining conducted a detailed analysis of emissions resulting from the refinery shutdown for Hurricane Ivan in September 204. Since the refinery shutdown for Hurricane Katrina was similar, they have assumed that the quantities released during Katrina shutdown are the same as the Ivan shutdown. Chalmette Refinery is rescinding the 8/27/05 notifications for S02, H2S, NO2, and hydrocarbons (non-speciated VOCs). Upon further review, the facility claims that the total amounts were estimated to be less that the reportable quantities (RQ= 100 lbs). The original estimated quantity of NO was 467 lbs, and was later changed to be estimated at 74 lbs. Shutdown was undertaken in preparation for the forecasted potential for Hurricane conditions. Operations were conducted in order to minimize emissions while maintaining a safe and orderly shutdown. Emissions resulted from gas flaring, fuel gas quality changes, and standby operation modes necessitated by the shutdown. Sometime after Hurricane Katrina, the pilots on the flares were extinguished. By that time, predominantly natural gas was being flared and no reportable quantities were exceeded.The pilots were re-lit on all flares by September 8, 2005 At approximately 12:00 hours on 8/27/05, the FCC debutanizer overhead condenser overpressured due to a failure with a pressure controller, resulting in flaring and a small ground fire. For the FCC, the tower was returned to normal pressure and the pressure transmitter on the overhead condenser was repaired. The small ground fire was extinguished.
74.0 pounds
81795

2005-08-27
FCC Debutanizer Overhead Condenser
Cause: Condenser overpressured due to a failure with the FCC debutanizer overhead condenser, resulting in flaring and a small ground fire.

Followup: No

Notes: For the FCC, the tower was returned to normal pressure and the pressure transmitter on the overhead condenser was repaired. The small ground fire was extinguished. This follow-up letter was delayed due to Hurricane Katrina This is a letter rescinding the 8/27/2005 notification for Sulfur Dioxide (S02), Hydrogen Sulfide (H2S), Nitrogen Dioxide (NO2), and Hydrocarbons (non-speciated VOCs). Upon further review, the total amounts were estimated to be less than reportable quantities. Nitric oxide was released to the atmosphere through the refinery Number 1 flare.
74.0
81586

2005-08-23

LPG compressor K-9200
Cause: At 7:52am on 8/23/2005, the LPG compressor, K-9200, tripped on high suction drum level due to a problem with the suction drum instrumentation, causing the fuel system to overpressure to the #2 flare. Nitric oxide was released to the atmosphere through the no.2 flare. An unexpected increase in fuel pressure caused fuel system to divert to the #2 Flare.

Followup: No

Notes: The suction drum instrumentation was repaired and the compressor was restarted. The instrumentation causing the compressor trip was repaired in order to prevent recurrence. This letter has been delayed due to Hurricane Katrina. The event is considered as reasonably unforeseeable, and qualifies as an upset. No further action warranted at this time.
20.0 pounds
81016

2005-08-05
Coker 1 Heavy Gas Oil pump G2804 problem led to release at the No. 2 Flare
Cause: Seal on coker 1 Heavy Gas Oil pump G2804 failed, causing a localized fire at the pump. Caused coker 1 wet gas compressor K2800 to shutdown due to high drum level. Flare to no. 2.

Followup: No

Notes: Unit throughput was reduced to minimum and attempts to restart required process equipment were made. Unit feed was changed from sour (high H2S concentrations) to sweet (lower H2S concentrations) to minimize emissions. The unit was stabilized and the flaring ceased.
68.0 pounds
80685

2005-08-03
No information given
Cause:

Followup: No

Notes: BELOW REPORTABLE QUANTITIES
80865

2005-07-22
Hydrocracker
Cause: Hydrocracker overpressured

Followup: No

Notes: BELOW REPORTABLE QUANTITIES
2.6 pounds
80590

2005-07-18
No information given
Cause:

Followup: No

Notes: BELOW REPORTABLE QUANTITIES
4.0 pounds
80568

2005-07-17
Wet Gas Compressor K 2800 shut down and went to the No. 2 Flare
Cause: Coker 1 wet gas compressor (K2800) shut down due to high knock-out drum level. Resulted in flaring of process gasses until it could be re-started.

Followup: No

Notes: Process adjustments were made in order to minimize the likelihood of fractionators liquid carryover and high knock-out level, prior to the re-start of the compressor. K2800 was re-started, ending the incident.
22.0 pounds
80533

2005-07-15
Cat feed hyrdrotreater unit problem caused release to the No. 2 Flare
Cause: Cat feed hydrotreater (CFHT) developed a leak due to a failure in the piping. The unit was shut down in order to eliminate the lead and safely conduct repairs. Vented through flare 2

Followup: No

Notes: Cat Feed hydrotreater (CFHT) was shut down and hydrogen and process gas vented to the refinery flare system. Operations were conducted in order to minimize emissions while maintaining a safe and orderly shutdown and restart of the CFHT. Chalmette Refinery rescinded its notifications of both gas oil and sulfur dioxide, stating that there was not a reportable amount of gas oil spilled on the concrete slab, and also that 0 lbs of sulfur dioxide was released.
127.0 pounds
80502

2005-07-13
Transformer power outage - emitted at No. 2 Flare
Cause: Loss of a refinery power transformer resulted in unplanned shut-down of coker 1, resulting in flaring to no. 2

Followup: No

Notes: Backup transformer was placed in service to replace the one that failed.
266.0 pounds
80322

2005-07-06
No information given
Cause: Power failure due to Tropical Storm Cindy, resulting in an unplanned shutdown.

Followup: No

Notes: Due to the multi-day nature of the event CRLLC was unable to give a comprehensive report at this time. As of this report, equipment repairs were still ongoing and addition emissions may occur. Operations were conducted to minimize emissions while maintaining a safe and orderly shutdown.
167.0 pounds
80288

2005-07-04
Hydrocracker Light Ends Plant Butane Splitter Tower & LEP Depropanizer
Cause: LEP Butane Splitter Tower began to overpressure. Moves in operating temperature and pressure on LEP Depropanizer, actuated by the refinery advanced controls system, allowed propane to exit via Depropanizer Bottoms, to the Butane Splitter, which is not designed to off-gas light materials such as propane. Personnel mode moves to lower tower pressure, including the venting of Propane in the Butane Splitter, to the refinery flare system in order to lower the pressure of the tower to safe levels.

Followup: No

Notes: Cooler back flushing was conducted in order to ensure that maximum cooling was available. Refinery personnel made operational adjustments that ended the incident. Various level controllers and analyzers associated with the LEP Depropanizer and Butane Splitter were checked for proper operation. The refinery has initiated an investigation into the cause of this incident.
19.0 pounds
79977

2005-06-20
No. 2 Flare
Cause: The LPG compressor tripped; the alarm panel showed a high suction drum level. Upon investigation no high drum was detected. The machine was restarted and tripped again on a high level indication. A this time the high level alarm was calibrated by the operators and again restarted.

Followup: No

Notes: The level in the suction drum was checked and upon tripping a second time the operators checked the high level shutdowm switch chamber for liquid. Finding none, the machine was restarted.
11.4 pounds
79529

2005-06-02
Hydrocracker Light Ends Plant Butane Splitter Tower
Cause: The Hydrocracker Light Ends Plant (LEP) Butane Splitter Tower began to overpressure; moves in operating temperature and pressure on the LEP Depropanizer, actuated by the refinery advanced system controls system, allowed propane to exit via Depropanizer Bottoms, to the Butane Splitter, which is not designed to off-gas light materials such as propane.

Followup: No

Notes: Cooler back flushing was conducted in order to ensure that maximum cooling was available. Refinery personnel made operational adjustments that ended the incident. Various level controllers and analyzers associated with the Lep Depropanizer and Butane Splitter were checked for proper operation.
11.0 pounds
79189

2005-05-19
Hydrocracker Light Ends Plant - Butane Splitter Tower
Cause: Unit upset, pressure increase: Excess feed to the Depropanizer Tower caused overpressure. Hydrocracker Light Ends Plant Butane Splitter Tower overpressured, which caused propane to exit to the Butane Splitter from the excess feed in the Depropanizer Tower via the Depropanizer Bottoms. The material was vented to the refinery flare system to reduce pressure.

Followup: No

Notes: Moves to reduce temperature and pressure were made in effort to prevent the depressurization of the Butane Splitter to the refinery flare system. Cooler back flushing was conducted in order to ensure that maximum cooling was available, heater firing was reduced in order to reduce tower temperatures and pressures.
77.0 pounds
78980

2005-05-11
K3304
Cause: Leak on the Hydrodesulphurization (HDS) Unit Off0gas Compressor K-3304

Followup: No

Notes: Sweet streams (lower Sulfur content) were routed to the flare to minimize sour gas flaring. Process unit output was adjusted in order to minimize the total amount of waste gas being sent to the flare. No mention of pollutant other than Nitric Oxide in official report, but attached Summary of Emissions lists multiple pollutants.
64.0 pounds
78900

2005-05-08
K-4301
Cause: After starting the propane compressor the first and second stage releif valves opened to the flare.

Followup: No

Notes: Below reportable quantities. Initial report said 12 lbs/hour released; report states that incident occured at 14:35 hours and was secured at 15:00 hours.
4.5 pounds
05-BB005-206

2005-05-07
No information given
Cause:

Followup: No

Notes: Below reportable quantities
5.0 pounds
78674

2005-04-29

Coke drum
Cause: Coke drum got too hot, causing gases to be sent to flare

Followup: No

Notes: Below reportable quantities. LDEQ notes that the event that prompted the call was part of a Continuous Release Report filed October 14, 2002.
78541

2005-04-26
Sulfur Recovery Unit, Hydrocracker, #2 Coker, #2 Crude
Cause: A loss of power to the Refinery's Boiler Instrumentation System caused the shutdown of the three plant boilers which generate the Refinery's 600 lb. steam. The loss of 600 lb. steam production caused upset conditions at a series of Refinery Process Units including the Sulfur Recovery Unit, Hydrocracker, #2 Coker and #2 Crude

Followup: No

Notes: The refinery has initiated an investigation into the cause of this incident. Based on the result of that investigation, measures will be taken in order to prevent a recurrence due to the same cause. The report's Summary of Emissions also states 692 lbs. of HC, 1131 lbs of CO, and 36 lbs of PM were also released at this time.
326.0 pounds
78361

2005-04-19
K-401 (waste gas compressor number 2)
Cause: Waste gas compressor number 2 (K-401) automatically shut down, automatically diverting waste gas to the flare system.

Followup: No

Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize total amount of waste being sent to the flare. Same language about doing an investigation to understand the underlying cause and prevent future incidents.
3.0 pounds
78341

2005-04-17
K-401 (waste gas compressor number 2)
Cause: Waste gas compressor number 2 (K-401) automatically shut down, automatically diverting waste gas to the flare system.

Followup: No

Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize total amount of waste being sent to the flare.
2.0 pounds
78226

2005-04-13
K-401 (waste gas compressor number 2)
Cause: Waste gas compressor number 2 (K-401) automatically shut down, automatically diverting waste gas to the flare system.

Followup: No

Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize total amount of waste being sent to the flare. Letter rescinds report of nitric oxide because below reportable quantity.
7.0 pounds
78042

2005-04-06
K-402 (Refinery waste gas compressor number 3)
Cause: K-402 unexpectedly shut down. Shortly after shutdown, refinery personnel identified the cause of the shutdown as a malfunction of the compressor motor ignition system.

Followup: No

Notes: The compressor motor was repaired and the compressor restarted, ending the incident.
108.0 pounds
77978

2005-04-02
No information given
Cause: NOx was flared so that maintenance could be done on a vessel.

Followup: No

Notes: Initial report states that there was no release of NO to the atmosphere, and thus it was not reportable.
77936

2005-03-31
K-400 (Refinery waste gas compressor number 1)
Cause: Refinery waste gas compressor number 1 (K-400) unexpectedly shut down. Refinery waste gas automatically diverted to the flare system.

Followup: No

Notes: Adjustments made to the fuel/air mixture and K-400 restarted.
2.0 pounds
77649

2005-03-16
No information given
Cause: Waste gas compressor number 2 (K-401) automatically shut down due to a high temperature.

Followup: No

Notes: Letter rescinds verbal report because incident was not reportable. No release to atmosphere.
7.0 pounds
77549

2005-03-13
C-2307 (Second Stage High-Pressure Separator) level controller; K-2303 (HCU Second Stage Recycle Compressor)
Cause: During maintenance, the Hydrocracker (HCU) Second Stage High-Pressure Separator (C-2307) level controller was inadvertently left in the manual position. Later, HCU Second Stage Recycle Compressor (K-2303) shut down due to high level in C-2307. Shutdown of K-2303 caused automatic depressurization of C-2307 to the refinery flare system.

Followup: No

Notes: Letter rescinds report of Sulfur Dioxide because below reportable quantity.
29.0 pounds
77290

2005-03-02
Waste Gas Compressor Number 4 (K-406); Copper tubing connecting C-435 (first stage suction drum) to high-level instrumentation
Cause: Waste gas compressor number 4 (K-406) shut down due to failure of piece of copper tubing connecting C-435 to high-level shutdown instrumentation. When it failed, a false high level reading was recorded, causing automatic safety shutdown system to become engaged.

Followup: No

Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize amount sent to the flare. C-435 was retubed, K-406 was checked and restarted.
30.0 pounds
76869

2005-02-11
No information given
Cause: Power failure caused many of the processes to shut down.

Followup: No

Notes:
6.0 pounds
76795

2005-02-07
Unintended over pressurization of the Hydrocracker Light Ends Plant (HCU LEP) Depropanizer surge drum
Cause: Due to the isolation of the sight glass of the hydrocracker light ends plant depropanizer, the automatic level indication equipment was disabled and false reading was transmitted; this condition caused an unintended over pressurization of the HCU LEP Depropanizer surge drum, which was venter to the refinery flare system (No. 2 flare)

Followup: No

Notes: Refinery personnel evaluated the process operation, identified the source of the problem and made appropriate corrections, ending the incident.
90.0 pounds
76775

2005-02-04
Electrical breaker G-457; Waste gas compressor number 2 (K-401)
Cause: Electrical breaker for G-457 malfunctioned, unexpectedly cutting power to all pumps and fin-fans within the refinery waste gas compressor area. Waste gas compressor number 2 (K-401) shut down as a result of the electrical power outage and refinery waste gas was diverted to safety flare system.

Followup: No

Notes: Low-Sulfur content streams were routed to the flare to minimize sour gas flaring. Output was adjusted to minimize total amount of waste being sent to the flare. Note: the breaker for G-457 had been identified for repair and was supposed to be replaced that week.
13.0 pounds
76595

2005-01-30

Pressure Safety Valve (PSV) on the Hydrocracker Light Ends Plant (LEP) A stripper as the source of the increased flame at number 2 flare
Cause: An abrupt increase in light material to the LEP A Stripper exceeded the tower overhead condenser cooling capacity, causing tower to overpressure.

Followup: No

Notes: After identifying the LEP A Stripper PSV flaring, cooling water in the A Stripper overhead was increased which condensed additional light materials in the tower; this lowered the pressure on the tower to end the incident.
15.0 pounds
76382

2005-01-24
Waste gas compressor shut down and caused an over pressure situation
Cause: Waste gas compressor shut down and an over-pressure situation.

Followup: No

Notes: Rescinding notification for below reportable quantities. (There is a hand-written T76382 on incident # 76355 PDF, but LABB believes that they are unrelated).
8.0 pounds
76355

2005-01-22
K-406 (waste gas compressor number 4)
Cause: Waste gas compressor number 4 (K-406) unexpectedly shut down. Waste gas was automatically diverted to refinery safety flare system.

Followup: No

Notes: Rescinding notification for NO2. The refinery waste gas system and refinery operations were adjusted in order to minimize the amount of waste gas being sent to the flare. Sweet streams were routed to the flare in order to minimize sour gas flaring. K-406 was removed from service on 01/27/05 to complete an evaluation of the machine and perform other maintenance. Additional emissions listed in the Summary of Emissions were not mentioned in the report. This incident is related to incident # 76362.(There are two hand-written incident numbers, T76377 & T76382, on the PDF, but LABB believes they are not related to this event).
23.0 pounds
76362

2005-01-21
Hydrocracker Light Ends Plant Butane Splitter Tower & LEP Depropanizer Tower Bottoms Flow Control Valve 50FC060
Cause: (1) 0600 hrs: Hydrocracker Light Ends Plant (LEP) Butane Splitter Tower began to overpressure because LEP Depropanizer Tower Bottoms Flow Control Valve (50FC060) had failed in the open position, letting propane to exit to the Butane Splitter. (2) 1700 hrs: Butane Splitter again began to overpressure due to the presence of propane. The level indication on the level instrument was detecting a false reading.

Followup: No

Notes: Letter speaks of two incidents on same day at 0600 hrs and 1700 hrs but attached report shows three incidents: (1) 4:05 a.m. lasting 3h 42m; (2) 3:15 p.m. lasting 41m; (3) 4:30 p.m. lasting 1h 25m. Amounts of compounds are only given in totals for all 3incidents. This incident is related to incident # 76355. LDEQ states that it is also related to incident # 76395.
77.0 pounds
76033

2005-01-06
K-406 (waste gas compressor number 4)
Cause: K-406 unexpectedly shut down and waste gas was automatically diverted to refinery safety flare system.

Followup: No

Notes: Sweet streams (lower Sulfur content) were routed to the flare to minimize sour gas flaring. Process unit output was adjusted in order to minimize the total amount of waste gas being sent to the flare. Shortly after shutdown, personnel re-started K-406 restoring the systems ability to process available refinery waste gas streams, ending the incident.
2.0 pounds
92464

2006-12-07
Lube Oil Cooler on Waste Gas Compressor K-406
Cause: leak in lube oil cooler tubing on WGC

Followup: No

Notes: Lube oil cooler on compressor was shut down. Leaking cooler tubing was repaired and all of the tubing was hydro-tested.
91726

2006-10-29
Flare
Cause: Compressor tripped and the safety valve on first-stage suction relieved to flare

Followup: Yes

Notes: DEQ report without corresponding letter from CRLLC
34.0 pounds
91667

2006-10-29
AE-AOA-05-0109 EPN 28 and 29
Cause: electrical switchgear failure.

Followup: No

Notes: DEQ report indicates that unknown amounts of the pollutants were released.
467.0 pounds
90530

2006-09-08
#1 Flare - AE-AOA-05-0109 EPN 28
Cause: during shutdown of GRU, gas had a higher BTU value than usual and the refinery furnaces automatically reduced the volume of gas consumed. The fuel drum was limited in its capacity to absorb fluctuationsin quality/auntity. The combination caused the fueldrum to vent excess pressure to the flare

Followup: No

Notes: CRLLC will evaluate prerequisites in GRU shutdown procedure.
14.0 pounds
90319

2006-08-29
No information given
Cause: No information given

Followup: No

Notes: Letter written to rescind notification of 8/29/06
1.0 pounds
90326

2006-08-29
#1 Flare - AE-AOA-05-0109 EPN 28
Cause: primary seal on recycle pump failed and resulted in venting to no. 1 flare. Later another primary seal failed

Followup: No

Notes: Spare Pump G-7913 was repaired and put in service, ending the incident. refinery has initiated an investigation into the cause
22.0 pounds
89293

2006-07-17
AE-AOA-05-0109 EPN 29
Cause: the process of startup and shutdown of the FCC resulting in apparent variability of FCC to Alky feedstock product quality with accumulation of noncondensable materials. Personnel allowed a controlled partial depressurization to avoid overpressure.

Followup: No

Notes: this incident will be reviewed by FCC and Alky process team leaders in order to increase awareness of the potential impacts of FCC shutdown/startup operations on Alky feed composition.
23.0 pounds
89266

2006-07-14
Flare
Cause: compressor shut down on the Hydrocracker Unit

Followup: No

Notes: Letter written to rescind notification of 7/14/6
2.0 pounds
89057

2006-07-06
No information given
Cause: No information given

Followup: No

Notes: Several pages missing from report!
88847

2006-06-23
Emergency Flare System - AE-AOA-05-0109 EPN 28
Cause: chiller malfunction. excess flare volume identified, search to identify source, as D9007 sphere as having relieved pressure to the emergency flare system. Sphere's chiller (ME9002) malfunctioned, heated up and overpressured.

Followup: No

Notes: sphere chiller was restarted which ended flaring.
19.0 pounds
89431

2006-06-21
#2 Flare AE-AOA-05-0109 EPN 29
Cause: alarm was improperly set allowing motor to operate above its design load leading to shut down of #1 Coker WGC

Followup: No

Notes: K-2800 high amperage alarm has been reset to 208 amps.
22.0 pounds
88694

2006-06-18
No information given
Cause: malfunction on fuel drum

Followup: No

Notes: Letter written to rescind notification of 6/18/6
88600

2006-06-14
#2 Flare - AE-AOA-05-0109 EPN 29
Cause: compressor shut down due to a low level reading in the lube Oil reservoir which was caused by the discharge of Oil from the west seal Oil trap to the refinery Oily water sewer system.

Followup: No

Notes: refinery has initiated an investigation into the cause
27.0 pounds
88492

2006-06-11
#2 Flare - AE-AOA-05-0109 EPN 29
Cause: thermal overload from direct sunlight, automatic shut down of WGC

Followup: No

Notes: temporary roof installed over the motor starter / thermal load protection system. This will prevent direct sunlight from contributing to excess temperature on the thermal over arm protection system.
29.0 pounds
88280

2006-06-02
No information given
Cause: malfunction in a control valve causes a clearing incident

Followup: No

Notes: DEQ report with no corresponding letter from CRLLC
8.0 pounds
87979

2006-05-19
Process unit
Cause: leak in a fan in a process unit

Followup: No

Notes: No information given
1.0 pounds
87763

2006-05-11
Flare
Cause: light ends sent to flare during start up

Followup: No

Notes: Letter written to rescind notification of 5/11/6
87256

2006-04-18
No information given
Cause: Cat Feed Hydrotreater Compressor tripped on overamp

Followup: No

Notes: Letter states that emissions were BRQ
7.0 pounds
86835

2006-03-29
AE-AOA-05-0109
Cause: Plant de-ethanizer tower (2410) relieved pressure to the emergency flare system after that propane treater (C7402) had plugged causing backpressure on the system leading to venting to emergency flare system. Release from Flare no. 2.

Followup: No

Notes: the refinery has initiated an investigation, appropriate measures will be taken in order to prevent a recurrence due to the same cause.
25.0 pounds
85953

2006-02-21
AE-AOA-05-0109
Cause: during startup of liquefied Petrol. Gas compressor, an unexpected liquid was present in the compressor discharge piping. This caused an unexpected upset resulting in over pressurization of the refinery fuel system. No. 2 Flare.

Followup: No

Notes: the refinery has initiated an investigation, appropriate measures will be taken in order to prevent a recurrence due to the same cause.
25.0 pounds
85641

2006-02-06
No information given
Cause: No information given

Followup: No

Notes: Letter written to rescind notification of 2/6/06
7.0 pounds
84904

2006-01-01
No Information Given
Cause: No information given

Followup:

Notes: Letter written to rescind notification of 1/1/06.
99870

2007-09-30
#2 Flare
Cause: pressure safety valve release

Followup: No

Notes: Letter states that no RQ's were exceeded