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Chalmette Refining (1376), Chalmette

Releases of Nitrogen Oxide

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
92491

2006-12-08
Number 2 Flare
Cause: Under investigation

Followup: No

Notes: Relief valve will be inspected; Pressure was lowered on First Stage Stripper. The inlet block valve was closed and flow to the #2 Flare stopped, ending the incident. The block valve was reopened.
48.0 pounds
92469

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

Followup: No

Notes: Letter written to rescind notification of 12/7/6
92440

2006-12-05
#2 Flare - AE-AOA-05-0109 EPN 29
Cause: Quench pump G-7621 was down which increased gas production and caused a sudden increase in off gas from crude 2 vacuum tower.

Followup: No

Notes: Unknown why quench pump was down. Will install a switch guard to prevent unintentional shutdown.
119.0 pounds
92412

2006-12-04
#1 Flare
#2 Flare
Cause: shut down of interstage cooler causing trip of WGC

Followup: No

Notes: Resetting alarms to appropriate levels; reinforced training of the operators on WGS operations at low temperatures.
6.0 pounds
92394

2006-12-02
#1 Flare AE-AOA-05-0109 EPN 28
#2 Flare - AE-AOA-05-0109 EPN 29
Cause: WGCs K-402 and 406 tripped due to an instrument air leak on the K-402 control panel. Leak was fixed and WCGs turned back on

Followup: No

Notes: Investigation ongoing.
61.0 pounds
92383

2006-12-01
AE-AOA-05-0109 EPN 28
Cause: WGC (K-8101) tripped due to low seal Oil pressure. Main pump was shut down due to erratic operation due to wet steam. WGC restarted ending incidend. Liquid level indicator in the GRU condensate drum was not working.

Followup: No

Notes: put in work order for liquid level indicator.
7.0 pounds
92194

2006-11-21
#1 Flare - AE-AOA-05-0109 EPN 28
#2 Flare
Cause: Compressor K-406 tripped for unknown reasons.

Followup: No

Notes: Under investigation.
21.0 pounds
92158

2006-11-18
#1 Flare - AE-AOA-05-0109 EPN 28
Cause: WGC K-406 tripped due to high vibrations. The shutdown caused the pressure in the WGS to increase and hydrocarbon gas with Hydrogen Sulfide was routed to the number 1 flare

Followup: No

Notes: cause of vibration is unknown at this time. K-406 will be inspected for damage.
15.0 pounds
92095

2006-11-15
AE-AOA-05-0109 EPN 28
Cause: FCC tripped due to a blown fuse and a malfunctioning component within the FCC multi lin and fuse system. A second mechanical failure (currently under investigation) dropped the remaining voltage to below the sct point.

Followup: No

Notes: Investigation ongoing. Unit feed rates reduced to a minimum and reactor severity was reduced. In addition, moves were made to minimize the main fractionators overhead receiver pressure. Process gas was routed to the #1 Flare while troubleshooting was performed.
374.0 pounds
91727

2006-10-29
AE-AOA-05-0109 EPN 28
Cause: mechanical failure in the check valve servicing the K-7702 Compressor. Make-up Discharge Check Valve mechanically failed and allowed the system to pressure back into the compressor. The resulting surge in pressure to the compressor caused the pressure safety valve on the first and second stage to relieve.

Followup: No

Notes: PSV was isolated until it rescated and lined back up to the compressor. During the next turnaround on the CFHT or shutdown, the valve for the K-7702 compressor will be replaced.
24.0 pounds
91605

2006-10-24
AE-AOA-05-0109 EPN 29
Cause: Pressure safety valve (PSV) malfunctioned, causing it to relieve below the set pressure.

Followup: No

Notes: PSV and related equipmt were isolated and taken out of service to end the flaring. PSV was inspected and found to be in need of repair. But, found that o-ring was bad and needed replacing, etc. Letter sent 12 18 06 rescinds prior notifications and revises amts emitted to those listed at left. Had been NOx 564 lbs ; VOC 1925 lbs
20.0 pounds
91457

2006-10-17
AE-AOA-05-0109 EPN 29
Cause: release occurs during major turn around of refinery. Planned system outages created higher than usual operating pressure on the WGS and AMU. Additionally, on 10/13, the stream was re-routed (misaligned) through a line with an unidentified check valve. Subsequent attempts to push liquid through the AMU line resulted in increased pressure on the WGS.

Followup: No

Notes: Investigation ongoing. PSV set pressure was raised to allow for higher head pressure events at WGS without flaring. Detailed investigation ongoing.
8,293.0 pounds
91273

2006-10-10
Thermal Oxidizer and Flare 1 - AE-AOA-05-0109 EPN 46
Cause: Discharges came from THOX and Flare 1. The Amine and Sulfur Recovery Units were upset. It was determined that hydrocarbons contaminated the Diglycolamine (DGAš) and required both units to be taken offline. The upset caused excess emissions from the SRU 1 Thermal Oxidizer (THOX). Sulfer Plant feed was diverted to the refinery safety flare system while the conditions which cause the upset were isloated and remedied. CRLLC reduced the rates of acid gas productin units to minimum and lowered total sufer content of remaining feed, within refinery capability.

Followup: No

Notes: CITIZEN COMPLAINT COINCIDES WITH INCIDENT - all acid gas producing units were cut back to minimum rates. The source of hydrocarbon in the DGA system was isolated and then purged. The refinery has initiated an investigation into the cause of this incident. Based on the result of that investigation, appropriate measures will be take in order to prevent a recurrence dut ot the same cause.
3,198.0 pounds
91000

2006-09-29
#2 Flare - AE-AOA-05-0109 EPN 29
Cause: pressure safety valve on the F-402 bOiler fuel gas drum was found intermittently lifting fuel gas to the flare. The pressure indicator was out of calibration and reading low. The false readings in fuel pressure resulted in the PSV lifting to the flare.

Followup: No

Notes: pressure controller set pressure point was reduced. The pressure control indicator will be calibrated during the next turnaround (Feb. 2007)
66.0 pounds
90842

2006-09-22
No information given
Cause: No information given

Followup: No

Notes: Letter written to rescind notification of 9/22/6
90624

2006-09-12
#1 Flare - AE-AOA-05-0109 EPN 28
Cause: No information given

Followup: No

Notes: Letter written to rescind notification of 9/12/6
90535

2006-09-08
#1 Flare - AE-AOA-05-0109 EPN 28
Cause: during Coker 1 startup the top of the fractionator tower flooded due to an unstable flow from the heavy gas Oil pump around (typical during startup). The end result was an overpressure to the emergency flare system.

Followup: No

Notes: the k-2800 will be reconnected to the Number 2 Flare for use in emergency situations only until the FGR System is commissioned. Communication to employees on what constitutes and emergency situation will occur.
10.0 pounds
90486

2006-09-06
#1 Flare - AE-AOA-05-0109 EPN 28
Cause: Flooding in the Crude 2 Gas Oil Tower caused by a false reading from a level controller (74LC503). Ultimately lead to backflush and overpressure.

Followup: No

Notes: Flushing medium valve was reopened. Process adjustments were made to restore product quality for Crude 2 to the CFHT. Distillate quench was added to cool down the FCCU regeneration bed temperature.
36.0 pounds
89604

2006-07-31
AE-AOA-05-0109 EPN 46
Cause: loss of instrument air pressure resulting in upset and shutdown of multiple process units within the refinery

Followup: No

Notes: Process adjustments were made to restore refinery instrument air and steam systems. Process units were stabilized, ending the incident.
548.0 pounds
87647

2006-05-04
Flare No. 1 AE-AOA-05-0109
Cause: malfunctioning chiller, bad coil (report not legible). Release from Flare No. 1

Followup: No

Notes: sphere chiller was switched, which ended flaring.
35.0 pounds
87269

2006-04-19
No information given
Cause: coker compressor failed

Followup: No

Notes: Letter states that emissions were BRQ
86695

2006-03-24
Flare
Cause: power failureblip on shared electrical system resulted in 14 minute outage

Followup: No

Notes: Letter written to rescind notification of 3/24/6
11.0 pounds
86447

2006-03-13
AE-AOA-05-0109
Cause: loss of power resulted in the unplanned upset of the refinery. External power supplied by Entergy was lost due to activity external to refinery operations. Release from Nos. 1 and 2 Flares.

Followup: No

Notes: Specific action taken: met with Entergy to stress the impact of this incident and request that appropriate measures be taken in order to prevent a recurrence.
16,393.0 pounds
85834

2006-02-15
Waste Gas Compressor
Cause: process equipment allowed light ends to enter Tank 75 during an upset. The tank vent ignited briefly during this period.

Followup: No

Notes: Letter written to rescind notification of 2/15/06
85198

2006-01-15
Flare
Cause: leak in the LPG line

Followup:

Notes: DEQ report with no corresponding letter from CRLLC
100419

2007-10-23
Tank 1024
Cause: due to heavy rain, personnel were filling Tank 1024 to manage excessive storm water for processing. The tank overflowed.

Followup: No

Notes: Isolated the tank. 3rd party environmental clean up firm called in to do clean up. Vacuum trucks deployed; foam applied to minimize volatilization of spilled material and absorbent materials used to contain the discharge to the vicinity of the tank.
99999

2007-10-05
Emergency Flare System
Cause: power failure.

Followup: No

Notes: CRLLC followed the Loss of Power Emergency Shutdown Procedures for each unit.
99557

2007-09-18
#1 Flare
Cause: Malfunctioning FCC PGC seal oil level controller. I/E was requested. While I/E's were making adj. the compressor shutdown and excess gas was sent to #1 flare.

Followup: No

Notes: Compressor was restarted ending the flaring. The seal oil level control was replaced.
98210

2007-07-29
#2 Flare
Cause: No information given

Followup: No

Notes: No information given
97457

2007-06-27
Emergency Flare System
South Flare
Cause: LPG recovery compressor shut down on a high interstage level due to a faulty level indicator

Followup: No

Notes: Temporary modifications made to LPG interstage level bridle. A new LPG Interstage level indication and shut down system has been designed and the parts have been ordered.
97329

2007-06-22
No information given
Number 2 Flare
Cause: chain operator on the sour waste gas block valve on the #3 Deoctane Overhead Off-Gas Line failed allowing waste gas to go to flare

Followup: No

Notes: CRLLC repaired the malfunctioned chain operator on the #3 Deoctane Overhead Off-Gas sour waste gas block valve.
96641

2007-05-30
Number 1 Flare
Cause: failure of the central processing unit within the ignition control system for the engine driver for K-402.

Followup: No

Notes: Central Processing Unit within the ignition control system was replaced
96227

2007-05-15
No information given
Cause: No information given

Followup: No

Notes: Letter written to rescind notification of 5/15 concerning release of SO2, NO, NO2
96051 / 96092

2007-05-10
#1 Flare
Cause: after renovation, a low point develops in flare line. Liquid accumulation is blown to flare during coker cycle blow down.

Followup: No

Notes: Letter written to rescind notification of 5/10 concerning release of SO2. Letter states that NO and NO2 were BRQ. Layout of the flare line is being checked to allow the plant to eliminate the problem
24.0 pounds
95652

2007-04-25
No information given
Cause: No information given

Followup: No

Notes: Letter sent to rescind notification of 4/25 concerning release of SO2, NO, NO2, H2S,
17.0 pounds
93412

2007-01-21
No information given
Cause: No information given

Followup: No

Notes: Letter sent to rescind notification of 1/21/07 concerning release of NO and NO2
2.0 pounds
93200

2007-01-10
1st Stage Fin Fan E2415 tube
Cause: leak in tube on 1st stage fin fan

Followup: No

Notes: Root cause analysis initiated. Tube has been sent offsite for analysis. Measures will be taken based on result of analysis.
1.0 pounds
No information Given

2008-08-30
Flare
Cause: shutting down units due to hurricane

Followup: No

Notes: All incidents grouped in one report concerning activities surrounding start up and shut down near the arrival of Hurricane Gustav. CRLLC reports requesting a variance for all emissions resulting from these events.
1,024.0 pounds
103126

2008-02-17
Flare
Cause: conducting functionality test for acid evacuation system. On of vent valves opened to flare.

Followup: No

Notes: Letter states that emissions were BRQ.
11.0 pounds
102953

2008-02-08
No information given
Cause: pump seal failed on G8111 at the #2 Coker causing a fire

Followup: No

Notes: Letter states that emissions were BRQ.
1.0 pounds
142422-142489-143217

2012-08-27
Coke Conveyor Facilities
flare
isolated areas of standing stormwater
Wastewater treatment Unit
Cause: Chalmette Refining LLC shut down operations because of the approach of Hurricane Isaac. Following established shutdown procedures and protocols, CRLLC was safely and systematically shutdown due to the approach of Hurricane Isaac. Likewise, CRLLC followed standard startup procedures and protocols and minimized excess emissions during recovery and startup efforts.

Followup: Yes

Notes: There are three LDEQ incident numbers assigned for the events at Chalmette Refining LLC surrounding Hurricane Isaac: 142422, 142489, 143217. On August 27, 2012 the CRLLC began to safely shut down unit operations due to Hurricane Isaac. The emergency shut down resulted in potential permit deviations and reportable quantity exceedances. However CRLLC believes that this event qualifies as an upset as defined in LAC 33:III.507.J. Below are the detailed quantities released from each unit during the startup/shutdown activities: Acid Gas and Hydrocarbon Flaring: During the shutdown and equipment preparation, excess process gases were vented to the flare system in order to reduce emissions to the atmosphere. The duration of flaring was approximately 21.1 hours. Below are the emissions which occurred during shutdown activities: 23.6 Tons S02 126 lbs H2S 133 lbs NO 133 lbs N02 714 lbs CO 558 lbs VOC 72 lbs PM10 On August 31, 2012, CRLLC began start-up operations and equipment preparation which required periodic hydrocarbon flaring. There were temporary visible emissions of smoke from flaring activities. Further, during startup of the SRU, there was a transient period which resulted in flaring amine acid gas prior to directing to the SRU. Below are the estimated emissions during startup of refinery operations. The duration of the amine acid gas flaring was 89 minutes and the duration of the intermittent hydrocarbon flaring during startup was 84 hours. Actual emissions were: 10.03 Tons S02 (> 500 lbs RQ) 0.03 Tons H2S (> 100 lbs RQ) 0.28 Tons NO/N02 (> 1000 lbs RQ) 1.52 Tons CO 0.69 Tons VOC (>5000 lbs RQ) 0.08 Tons PM10 <1 00 lbs Benzene (> 10 lbs RQ) There were approximately 9 hours where the H2S 162 ppm 3-hour rolling flare limitation was exceeded during shutdown and startup activities. These excess emissions are covered under startup/shutdown provisions provided in NSR CD Paragraph 58. As such, no additional action is required by agency. Flare Gas Recovery equipment was being repaired and so no FGR was used during this process. Tail Gas Incident: On August 27, 2012 the CRLLC Sulfur Recovery Unit was safely shut down and equipment was prepared. During this process Tail Gas Incident resulted from Source ID EIQ193. Predicted emission estimates were approximately 25 tons S02 for the shutdown. On September 5-6, 2012 the Sulfur Recovery Unit was started-up. There were no tail gas incidents during this process. As such, no additional action is required by agency. Sulfur Pit Venting: Emission estimates were expected to be less than 200 pounds H2S during shutdown and start-up operations. It is important to note that these exceedances occurred during the period when CRLLC was shutting down equipment and subsequently starting up and lining out operations. Actual emissions were -72 lbs. H2S and -50 lbs. S02. These excess emissions are covered under startup/shutdown provisions provided in NSR CD Paragraph 58. As such, no additional action is required by agency. H2S Concentration of 162 ppm in Fuel Gas: During shutdown on August 27, 2012 the refinery had the potential to exceed the H2S concentration of 162 ppm in the fuel gas system. FCCU NOx, S02, CO, PM, and Opacity Permitted Emission Limits: During shutdown and subsequent start-up operations, the refinery exceeded the emission concentration limit for CO for 14 hours and the differential pressure parameter for 32 hours at the FCCU. There were no Title V permit limit lb/hr exceedences during these times. SRU Permitted Emission Limits (lbs/hr & concentration): During the shutdown and subsequent start-up operations, the refinery exceeded the permitted emission limit of 95 lbs/hr for S02 for three (3) hours at the Sulfur Recovery Unit. The 250 ppm concentration limit was exceeded for approximately 48 hours. It is important to note that these exceedances occurred during the period when CRLLC was starting up and lining out operations. These excess emissions are covered under the start-up/shutdown provisions provided in NSR CD Paragraph 23 and 29. Flare Pilot Outages: During the shutdown due to the higher than normal rain and wind volumes, flare pilots experienced temporary outages. Data Availability from Continuous Emission Monitoring Systems (CEMS): The CEMS analyzers at the CRLLC may be adversely affected by nitrogen constraints. Some selected CEMS may have reduced data availability during the time period of storm landfall, recovery, and start-up activities. The specific duration of reduced data availability will be provided in the 30- day follow-up report. Missing LDAR Monitoring: CRLLC is subject to several Louisiana & Federal Regulations requiring Leak Detection and Repair (LDAR) as noted below. Hurricane Isaac and its aftermath have not allowed completion of some of the timing obligations, and will prevent us from meeting all the timing obligations of the required August monitoring. Approximately 250 components will receive delayed monitoring, but will be monitored in September. Details of the number of components subject to delay will be provided in the 30-day follow-up report. Consistent with USEPA's decision for Hurricane Gustav, CRLLC requests that the delayed monitoring and repair be exempted from enforcement under the applicable Force Majeure provisions. Approximately 255 monthly LDAR components received delayed monitoring, but were monitored in September. In addition, 7 leaks that missed the 5 day attempt and 6 leaks that missed the 15 day attempt due to Hurricane Isaac. Isolated Areas of Standing Stormwater: There were isolated pockets of stormwater in the refinery which contained some sheen material and potential hydrocarbon. All of these areas were contained within the refinery boundaries and no material migrated offsite. Areas include tank firewall areas, overflow of sumps, and low-lying areas. There is the potential to exceed more than one (1) barrel of total oil accumulative across the complex from all the isolated areas. All hydrocarbon and sheen material was removed and properly disposed/treated. Any contaminated soil has been remediated. This information is reported in accordance with the site waste management plan. Coke Conveyor Facilities: The coke conveyor facilities sustained some minor damage which resulted in loss of covers over portions of the conveyor belt system. There are also minor amounts of coke material on the ground which is being collected. Some small particulate emissions may result from recovery and re-start Operations. Covers will be repaired/replaced as soon as possible. The 30-day follow-up report will describe the specific repairs and dates of completion. The conveyor covers that were damaged during the hurricane have been repaired/replaced. This accident is linked to Bypass of Wastewater Treatment Unit (LSP incident # 12-05781; NRC Incident # 102-2486). Actual storm rainfall was 30". In consideration of personnel safety and increasing weather severity, the refinery initiated the emergency discharge bypass for Outfall 004 from wastewater treatment facilities to MS River on August 28, 2012. It is important to note that the refinery process operations were shutdown previously which mitigated wastewater hydrocarbon content. Water discharge was essentially storm water. Samples were collected to document wastewater quality. On August 29, 2012 all parameters were within current permit limits with the exception of Total Suspended Solids. Preliminary analysis indicates a potential exceedance of 4,444 lbs/day versus permitted limit of 3,180 lbs.
693.0 pounds