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Chalmette Refining (1376), Chalmette
Releases of Sulfur Dioxide
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 84723 2005-12-22 | Dip-leg of SRUTR1 | Cause: At approximately 0200 hours on 12/22/05 plugging on a dip-leg SRUTR1 was identified and the unit was shut down. During shutdown and hot stand-by of the unit emissions occur via the THOX. Followup: No Notes: The Chalmette Refinery notified regarding malfunction of the refinery sulfur recovery unit train 1 (SRUTR1), including release of sulfur dioxide (S02) beginning 12/22/05 and continuing intermittently until 12/25/05 during the shutdown and preparation of impacted equipment. Sulfur dioxide released to atmosphere through the Refinery Sulfur Recovery Unit Thermal Oxidizer (THOX) Stack. Operations were conducted in order to minimize emissions while maintaining a safe and orderly shutdown of the impacted unit. 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 SO2 emissions of 33,375 lbs exceed reportable quantity. This amount is a part of the total SO2 emissions found in LDEQ incident #84745-84794. This Incident is closely related to LDEQ incident # 84745-84794 in our database. | 33,375.0 pounds |
| 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. | 381,000.0 pounds |
| 84684 2005-12-20 | No information given | Cause: Followup: No Notes: Chalmette Refinery is rescinding the December 20, 2005 notification. Upon further review, the event that prompted the call was not a reportable incident. The incident did not result in a reportable release as defined by the applicable regulations. CELLC is rescinding the notification made relative to Sulfur Dioxide. Upon further review, the total amount of S02 released is estimated to be less than the reportable quantity. The reportable quantity for S02 is 500 pounds. They estimate that approximately 77 pounds of S02 was released during the December 20, 205. The release did not cause an emergency condition. Therefore, notification was not required. | 77.0 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). | 26,127.0 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. | 9,361.0 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). | 900,344.0 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. | 255,680.0 pounds |
| 84015 2005-11-21 | No. 2 Crude Unit Prefractionator (Prefrac) Tower | Cause: Pressure spikes on the No. 2 Crude Unit Prefractionator Tower coupled with increased Overhead Accumulator levels, and problems maintaining tower bottoms circulation. The tower pressure exceeded the process relief valve set pressure, ad the Prefrac Towerrelieved to the No. 2 Flare resulting in Sulfur Dioxide emissions in excess of reportable quantity. Followup: No Notes: In an effort to stop the release, bypasses were opened o the water boot level controllers on both the Atmospheric and Prefrac Towers, and the Prefrac Overhead fin-fans were started. Prefrac Bottoms product was slopped due to water content and the Stabilizer Tower was also shutdown. Following determination by Refinery Personnel that the problem was due to a false Prefrac Bottoms level indication, the level was dropped by increasing the flow to slop, returning tower operation to normal. The level tritter is scheduled for repair in order to reduce the likelihood of a recurrence. | 841.0 pounds |
| 84013 2005-11-21 | Sulfur Recovery Unit Thermal Oxidizer Stack | Cause: Refinery personnel diverted acid gas from Train I of the SRU due to mechanical issues on the unit. Diverting the acid gas resulted in Sulfur Dioxide emissions from the Thox stack in excess of the permit limit, resulting in a reportable release. Followup: No Notes: Sulfur dioxide to atmosphere through the SRU Thox Stack. | 8,632.0 pounds |
| 83924 2005-11-17 | Hydrodesulphurization (HDS) Unit Fans | Cause: Leak on the HDS Unit fans caused spill to the ground. Emissions resulted from the spill to the ground, the release to the atmosphere and from the unit de-pressure to the No. 2 flare. Followup: Yes Notes: At approximately 04:07 hours on 11/17/05, refinery personnel discovered a leak on the Hydrodesulphurization (HDS) Unit fin-fans. Approximately 9.3 barrels of Distillate range material spilled to the ground. Emissions resulted from the spill to the ground, the release to the atmosphere, and from the unit de-pressure to the no. 2 flare. Chalmette Refinery rescinded the 11/17/05 notifications for NO, NO2, VOC, SO2 and H2S since the estimated amounts were less than the reportable quantity of 10lbs. They estimate that approximately 1.93 and 0.21 pounds of Nitric Oxide (NO) and Nitrogen Dioxide (nO2), respectively, were released to the atmosphere during the 11/17/05 event. Therefore, notification for Nitrous Oxides (NOx) was not required. Calculations performed after the incident indicated that a greater than reportable quantity of oil was spilled to the ground during this incident, and as such, emissions calculations for the oil spill are included in the follow-up report. Hydrogen Sulfide and Compressed Flammable Gas/Non-speciated VOCs released to atmosphere through the leak; Sulfur Dioxide and compressed flammable gas/non-speciated VOCs released to atmosphere through the NO. 2 flare; oil spill to ground with VOC volatilization to atmosphere. The HDS Unit was shutdown and de-pressured to the no. 2 flare to minimize the impact of the leak. A pipe clamp was installed, stopping the leak. Liquid released from the leak was contained and recovered. Soils that appeared to have come in contact with spilled slop oil were removed for off site disposal. | 783.0 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. | 34,400.0 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. | |
| 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. | 6,968.0 pounds |
| 80865 2005-07-22 | Hydrocracker | Cause: Hydrocracker overpressured 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. | 155.0 pounds |
| 80566 2005-07-16 | Hydrodesulphurization (HDS) Unit problem went to No. 2 Flare | Cause: Leak in the HDS due to failure in the piping. Sulfur dioxide released into atmosphere through the refinery Number 2 Flare. Followup: No Notes: The unit was shut down so that the leak could be isolated and repaired. Although Chalmette Refinery listed the release of hydrogen sulfide as below reportable quantities, LDEQ's final report states that the minimum reportable quantity was released. | 1,126.0 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. | 1,096.0 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. | 50,599.0 pounds |
| 80291 2005-07-04 | No information given | Cause: Followup: No Notes: Rescind notification since it was below reportable quantities. | 309.0 pounds |
| 79721 2005-06-09 | Compressor K-2800 | Cause: Overfill of lube oil reservoir resulted in compressor K-2800 tripping offline. Off gas was routed to the no. 2 flare. Followup: No Notes: Reservoir level lowered and compressor restarted. Additional training conducted to ensure operator is always observing filling. | 538.0 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. | 1,176.0 pounds |
| 79008 2005-05-11 | K7402 No. 2 Crude Unit Thermal Oxidizer Stack on the API | Cause: Gas oil tower overhead compressor tripped. The bypass was a result of a mechanical malfunction of the flame arrestor. Attempts to restart were impeded by plugging on the pilot gas line. LDEQ report adds that the Gas Oil Tower overhead compressor tripped on high knock-out-drum level. Followup: No Notes: Below reportable quantities. Appropriate maintenance and preventive maintenance were followed in order to minimize plugging on the flame arrestor. | 189.0 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. | 31.0 pounds |
| 78808 2005-05-05 | No information given | Cause: Followup: No Notes: Below reportable quantities. In calculations section of report addition releases of 1 lb of NO and 1 lb of H2S are also listed. | 402.0 pounds |
| 78760 2005-05-02 | K7702 Cat Feed Hydrotreater | Cause: Cat Feed Hydrotreater make-up compressor automatically shut down due to thermal overload. The shutdown caused excess acid gas loading at the refinery Sulfur Recovery Unit (SRU) which lead to increased Sulfur Dioxide emission from the SRU Thermal Oxidizer (THOX) Followup: No Notes: K7702 was restarted and SRU and CFHT operations were stabilized and efforts were made to reduce SRU THOX Sulfur Dioxide concentrations | 856.0 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. | 79,817.0 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. | 970.0 pounds |
| 78345 2005-04-18 | No information given | Cause: Compressor tripped offline Followup: No Notes: Below reportable quantities | 332.0 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. | 707.0 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. | 2,161.0 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. | 33,873.0 pounds |
| 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. | 706.0 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. | 888.0 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. | 12.0 pounds |
| 77659 2005-03-12 | Cause: This is a rescinding notification for an event that was closed on 03/12/05, which was reported on 03/17/05. Upon further review, it was determined that there was an analyzer issue and not a release. Followup: Notes: | ||
| 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. | 6,322.0 pounds |
| 76869 2005-02-11 | No information given | Cause: Power failure caused many of the processes to shut down. Followup: No Notes: | 454.0 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. | 401.0 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. | 4,075.0 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. | 1.0 |
| 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). | 0.9 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). | 4,543.0 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. | 46.3 pounds |
| 76224 2005-01-18 | No information given Number 2 Flare -- Pressure Safety Valve (PSV) on Fuel Drum for Number 10 Boiler | Cause: From the verbal report: False pressure indicator on tower, caused relief value to open and gases to mix. Followup: No Notes: | |
| 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. | 726.0 pounds |
| 92940 2006-12-29 | Waste Gas Compressor | Cause: Waste Gas System Compressor shut down due to water contamination of the oil in the crank case. Followup: No Notes: Rates at the HDS and CFHT units were reduced and CRLLC routed sweet hydrocarbons streams to the flares to minimize flaring. Oil was drained from the crank case and replaced. The K-406 Compressor was restarted. | 31,282.0 pounds |
| 92642 2006-12-14 | Flare No. 2 EPN 29 | Cause: Crude 2 K-7601 Compressor shut down Followup: No Notes: Machinists restarted the compressor and an investigation of the incident is underway. | 3,236.0 pounds |
| 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. | 2.0 pounds |
| 92484 2006-12-08 | Number 1 Flare AE-AOA-05-0109 EPN 28 | Cause: valves were misaligned in the field leading to acid gas being sent to #1 Flare Followup: No Notes: refinery has reviesed the procedure for switching a SRU tran to acid gas and will train unit operators on the revised procedures. | 2,988.0 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. | |
| 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. | 5,505.0 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. | 1,946.0 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. | 19,224.0 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. | 722.0 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. | 3,723.0 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. | 4,607.0 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. | 8,190.0 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. | 22,226.0 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. | 30.0 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 (DGA¨) 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. | 1,068,405.0 pounds |
| 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. | 1,005.0 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. | 800.0 pounds |
| 90319 2006-08-29 | No information given | Cause: No information given Followup: No Notes: Letter written to rescind notification of 8/29/06 | 37.0 pounds |
| 89699 2006-08-03 | AE-AOA-05-0109 EPN 29 | Cause: gas compressor tripped due to a sudden change in feed composition and or compressor suction pressure Followup: No Notes: refinery has initiated an investigation into the cause | 695.0 pounds |
| 84697 2006-08-02 | AE-AOA-05-0109 EPN 46 | Cause: loss of instrument air pressure resulting in upset and shutdown of multiple process units within the refinery. Resulted from July 31, 2006 upset and the resultant restart and passivation of SRU Train 2 Followup: No Notes: refinery has initiated an investigation into the cause | 3,173.0 pounds |
| 89716 2006-08-02 | AE-AOA-05-0109 EPN 46 | Cause: No information given Followup: No Notes: This incident tied to 84697. Both listed in same incident report from CRLLC. | |
| 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. | 7,184.0 pounds |
| 89597 2006-07-29 | No information given | Cause: loss of flow in the tail gas compressor Followup: No Notes: Letter written to rescind notification of 7/29/06 | 46.0 pounds |
| 89555 2006-07-27 | No information given | Cause: upset on amine unit. Followup: No Notes: Letter written to rescind notification of 7/27/06 | 25.0 pounds |
| 89470 2006-07-21 | SRU Thermal Oxidizer Stack | Cause: inadequate oxygen flow to SRU2 due to lack of manual adjustments by refinery personnel Followup: No Notes: LDEQ was not notified of the release within the 24 hour nonemergency notification period. Process adjustments were made to bring the unit back on ratio. | 1,577.0 pounds |
| 89255 2006-07-13 | AE-AOA-05-0109 EPN 46 | Cause: section circulation impeded when an exchanger is plugged resulting in diversion from train 2 to train 1 Followup: No Notes: Repairs to Train 2 MDEA Lean/Rich Exchanger (E8062) are being scheduled in order to return Train 2 tail gas section to service. | 1,136.0 pounds |
| 89525 2006-06-26 | No information given | Cause: No information given Followup: No Notes: Letter written to rescind notification of 6/26/06 | 46.0 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. | 2,287.0 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. | 2,926.0 pounds |
| 88381 2006-06-07 | Flare | Cause: off gas compressor tripped on overload and released to flare Followup: No Notes: Letter written to rescind notification of 6/7/06 | 288.0 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 | 0 |
| 88213 2006-05-31 | Number 2 Flare | Cause: cracked tubing caused an instrument to malfunction and caused WGC to trip Followup: No Notes: The cracked copper tubing was replaced with stainless steel tubing in order to improve durability. The refinery will evaluate installations on the Low Pressure Waste Gas system where copper tubing is utilized for instrument connections and make upgradesto that tubing, if deemed appropriate, during the next unit turnaround. | 782.0 pounds |
| 88173 2006-05-28 | No information given | Cause: No information given Followup: No Notes: Letter states that emissions were BRQ | 100.0 pounds |
| 87979 2006-05-19 | Process unit | Cause: leak in a fan in a process unit Followup: No Notes: No information given | 301.0 pounds |
| 87626 2006-05-04 | Thermal Oxidizer at SRU Train 1 | Cause: tail gas analyzer malfunctioned Followup: No Notes: Malfunctioning analyzer was repaired | 706.0 pounds |
| 87269 2006-04-19 | No information given | Cause: coker compressor failed Followup: No Notes: Letter states that emissions were BRQ | 346.0 pounds |
| 87236 2006-04-17 | No information given | Cause: No information given Followup: No Notes: Letter states that emissions were BRQ | 378.0 pounds |
| 87121 2006-04-11 | AE-AOA-05-010,9AE-AOA-05-0109 EPN 46 | Cause: contamination in the air system Followup: No Notes: updated unit operating procedures to remove potential impurities from the line prior to future use. | 32,624.0 pounds |
| 86878 2006-03-31 | Emergency Flare System AE-AOA-05-0109 EPN 29 | Cause: waste gas compressors 4 and 3 (K406 and 402) automatically shut down, lowering the refinery capacity and causing overpressure to the emergency flare system. Liquid level pump (G476) switch was in the off position. Followup: No Notes: A mechanical guard was placed on the pump switch in order to avoid the unintentional movement of the switch | 3,174.0 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. | 472.0 pounds |
| 86612 2006-03-20 | Emergency Flare System AE-AOA-05-0109 EPN 29 | Cause: compressor 1(K-400) automatically shut down, lowering waste gas processing capacity and causing overpressure to the emergency flare system. Later, waste gas compressor number 2 (K-401) automatically shut down causing the waste gas system to further overpressure to the emergency flare system. 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. | 2,204.0 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. | 680.0 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 | |
| 85837 2006-02-14 | No information given | Cause: No information given Followup: No Notes: Letter written to rescind notification of 2/14/06 | 322.0 pounds |
| 85454 2006-01-29 | Thermal Oxidizer AE-AOA-05-0109 EPN 46 | Cause: steam leak into SRUTR1 prcoess necessitated shutdown and transfer to another unit Followup: No Notes: refinery has initiated an investigation into the cause. Operations were conducted to minimize emissions. Safe and orderly shutdown to reduce impact. | 3,141.0 pounds |
| 101895 2007-12-21 | Flare | Cause: upset of FCC; overhead pressure opened to flare Followup: No Notes: No information given | |
| 101836 2007-12-19 | #1 Flare | Cause: #4 Waste Gas system shut down because of misalignment of a sensor and magnetic pick-up. CRLLC technicians also found a bad bearing for the cam shaft idler sprocket. Followup: No Notes: Operators immediately tried to start a second compressor. Restarted the shutdown compressor and removed gas flow from flare, ending event. | 1,955.0 pounds |
| 101812 2007-12-18 | Flare | Cause: power failure caused Reformer #1 to overpressure and vent to flare. Followup: No Notes: No information given | |
| 101744 2007-12-17 | No information given | Cause: #1 prefract loss feed to tower, tower over pressured released SO2 Followup: No Notes: No information given | |
| 101404 2007-12-02 | Flare | Cause: compressor problem leads to release to flare Followup: No Notes: No information given | |
| 101331 2007-11-29 | No information given | Cause: #1 prefract loss feed to tower, tower over pressured released SO2 Followup: No Notes: No information given | |
| 101270 2007-11-27 | #2 Flare | Cause: frozen material in a pipe prevented material from the HCU and Pretreater to leave towers. Pressure was relieved to flare. Followup: No Notes: CRLLC repaired the level gauge and the level transmitter on the De-ethanizer | 763.0 pounds |
| 101165 2007-11-19 | #2 Flare | Cause: No information given Followup: No Notes: No information given | |
| 101150 2007-11-18 | #1 Flare | Cause: HGO Pump around failed, causing a shut down of #2 Coker Off Gas Compressor Followup: No Notes: Operators established the HGO Pump Around before restarting the K-8101 Compressor. When compressor restarted, gas flow removed from flare, ending incident. | 4,484.0 pounds |
| 100423 2007-10-22 | Emergency Flare System | Cause: Number 1 Coker Wet Gas Compressor shutdown on high amperage when water entrained in the feed line to the compressor caused the compressor to overheat. Followup: No Notes: Operators closed the valve to the feed line to the compressor and restarted the K-2800 compressor. The line was again dewatered and lined back up to the compressor K-2800 without shutting down the compressor. | 958.0 pounds |
| 100358 2007-10-20 | Emergency Flare System | Cause: incident occurred during shut down of the Sulfur Recovery Unit train 1 for maintenance. Train 2 also shut down, initiating release. Followup: No Notes: Operators restarted Train 2 twice before they were able to route acid gas through Train 2 and out of the Emergency Flare System ending the flaring. | 211,810.0 pounds |
| 100315 2007-10-19 | Emergency Flare System | Cause: Train 2 shut down due to low oxygen flow Followup: No Notes: Operators restarted Train 2 to end the flaring. | 12,020.0 pounds |
| 100171 2007-10-14 | #2 Flare | Cause: #2 crude unit prefractionator tower reflux pump tripped Followup: No Notes: Letter states that no RQ's were exceeded | |
| 100093 2007-10-11 | Sulfur Plant | Cause: power failure. Followup: No Notes: Letter states that no RQ's were exceeded | |
| 99911 2007-10-02 | No information given | Cause: No information given Followup: No Notes: Letter written to rescind notification of 10/2 concerning release of SO2. DEQ letter indicates there was an SO2 release of 1500 lbs. | |
| 99861 2007-09-30 | No information given | Cause: pressure safety valve release Followup: No Notes: Letter from CRLLC states that no RQ's were exceeded; DEQ letter estimates that there was a release of 2718 lbs of SO2 | |
| 99870 2007-09-30 | #2 Flare | Cause: pressure safety valve release Followup: No Notes: Letter states that no RQ's were exceeded | |
| 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. | 1,979.0 pounds |
| 99492 2007-09-16 | #1 Flare | Cause: hole in the pipeline Followup: No Notes: Letter states that no RQ's were exceeded | |
| 98732 2007-08-12 | No information given | Cause: No information given Followup: No Notes: High SO2 readings at Chalmette Vista site and AAM site. Both CRLLC and CII state normal operations with no malfunctions. | |
| 98232 2007-07-29 | Flare | Cause: upset on hydrocracker Followup: No Notes: No information given | |
| 98137 2007-07-24 | No information given | Cause: No information given Followup: No Notes: High SO2 reading at Chalmette Vista air site | |
| 98089 2007-07-22 | No information given | Cause: compressor had a problem with the coency of water, unable to carry load, flare staged releasing Followup: No Notes: Algiers AAM site had readings of 134 ppb | |
| 97897 2007-07-15 | No information given | Cause: No information given Followup: No Notes: Chalmette Vista ambient air site had high SO2 readings from 7/15=7/17. Voluntary response from CRLLC and CII was that everything was operating normally. | |
| 97720 2007-07-09 | No information given | Cause: No information given Followup: No Notes: High SO2 readings at Chalmette Vista site. CRLLC found no problems within the facility. | |
| 97504 2007-06-28 | No information given | Cause: No information given Followup: No Notes: High SO2 readings at Chalmette Vista site. CRLLC found no problems within the facility. | |
| 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. | 1,815.0 pounds |
| 97539 2007-06-25 | Flare | Cause: LPG Compressor tripped and K-3304 compressor R/V had over pressured resulting in some excess flaring and SO2 emissions Followup: No Notes: CITIZEN COMPLAINT. | |
| 98127 2007-06-25 | Fluidized Catalytic Cracking Unit Process Gas Compressor (FCC) (PGC) -- EPN 28 | Cause: The FCC PGC tripped due to a blown fuse that was corroded. Due to the loss of the PGC the overhead vapors were released to the #1 flare. Followup: No Notes: Immediate restart was attempted when attempsts to restart failed, feed was diverted from the FCC reactor to m. flaring. Fuses were replaced due to corrosion. | 5,471.0 pounds |
| 97334 2007-06-23 | Flare | Cause: LPG Compressor tripped and K-3304 compressor R/V had over pressured resulting in some excess flaring and SO2 emissions Followup: No Notes: No information given | |
| 97329 2007-06-22 | Number 2 Flare No information given | 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. | 509.0 pounds |
| 97329 2007-06-22 | Number 2 Flare No information given | 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. | 495.0 pounds |
| 97235 2007-06-19 | No information given | Cause: No information given Followup: No Notes: No information given | |
| 96950 2007-06-09 | No information given | Cause: false reading from DGA flow controller leads to shutdown of Waste Gas System Compressor K-400 Followup: No Notes: CRLLC will initiate a routine maintenance check of the DGA flow controller transmitter and communicate the need for maintenance to the process personnel and instrument techs. | 2,735.0 pounds |
| 96736 2007-06-04 | # 2 Flare | Cause: while lining up tower to vent, they opened up & a pocket of light hydrocarbons got into flare line Followup: No Notes: Letter written to rescind notification of 6/4 concerning release of SO2 | |
| 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 | 8,132.0 pounds |
| 96498 2007-05-23 | EPN 28 - #1 flare | Cause: The HDS unit off-gas compression system pressure valve had relieved causing gas to go to the #2 flare after operators failed to verify a prerequisite step of the off-gas compressor start-up procedure. Followup: No Notes: attempted to reduce the discharge pressure of the HDS off-gass compressors by water washing the system. HDS charge rates were reduced. | 523.0 pounds |
| 96369 2007-05-20 | No information given | Cause: No information given Followup: No Notes: SO2 above trigger levels at Algiers AAM site. | See notes. |
| 96304 2007-05-16 | Bullet #6 | Cause: DEQ report states that the flaring is required, indicating that it is part of normal procedures Followup: No Notes: Letter written to rescind notification of 5/16 concerning release of SO2 | 30.0 pounds |
| 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 | |
| 95928 2007-05-05 | No information given | Cause: new flare gas recovery system that the compressor tripped on Followup: No Notes: Letter written to rescind notification of 5/5 concerning release of SO2. File includes flare assessment report for month of April. | |
| 95937 2007-05-04 | No information given | Cause: shut the compressor down due to potential for significant refinery upset Followup: No Notes: Letter written to rescind notification of 5/4 concerning release of hydrocarbons | |
| 95843 2007-05-03 | No information given | Cause: small fire starts when hot coke ignites during coking process Followup: No Notes: Letter written to rescind notification of 5/3concerning release of VOC | 18.0 pounds |
| 95667 2007-04-26 | No information given Amine Regeneration System | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 4/26 concerning release of SO2 | 75.0 pounds |
| 95689 2007-04-26 | No information given | Cause: No information given Followup: No Notes: Letter written to rescind notification of 4/26 concerning release of SO2 | 499.0 pounds |
| 95667 2007-04-26 | No information given Amine Regeneration System | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 4/26 concerning release of SO2 | 75.0 pounds |
| 95622 2007-04-25 | No information given | Cause: No information given Followup: No Notes: DEQ voluntarily investigates site and takes SO2 readings. According to the report, the Chalmette Vista site had the highest 24hr average of SO2 that LDEQ has seen to date. There were 10 hrs of readings over 100 ppb with a final 24 hr avg of 108 ppb. The highest hourly reading was 248 ppb. | See notes. |
| 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, | 186.0 pounds |
| 95360 2007-04-15 | Sox Scrubber Stack | Cause: see notes. the FCC gas expander triggered a shutdown of the FCC. The pressure in the unit discharged to the atmosphere via the Sox scrubber stack. Followup: No Notes: Letter sent to rescind notification concerning release of SO2 and PM. Cleared the valves of catalyst. Expander was restarted at a reduced rate. | 265.0 pounds |
| 94950 2007-03-28 | #2 Flare | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 3/28/07 concerning release of SO2 | 425.0 pounds |
| 94692 2007-03-18 | Gas Recovery Unit - # 1 flare | Cause: see notes. #2 coker wet gas compressor and the GRU experienced pressure swings causing the temp. in the comp. to increase and shutdown. Followup: No Notes: control valve in the GRU was out of calibration. Control valve was sending false signals to the control room indicating that the valve was 100% open. The valve was replaced. | 1,572.0 pounds |
| 94536 2007-03-11 | #2 Coker Unit | Cause: see notes. Fire in the #2 Coker Unit. Followup: No Notes: Letter sent to rescind notification of 3/11/07 concerning release of SO2 | 380.0 pounds |
| 94538 2007-03-11 | Waste Gas Compressor | Cause: The WGC tripped due to low seal oil pressure Followup: No Notes: the charge rates on the #2 coker WGC were cut. The turbine main pump was restarted and is running in parallel with the auxiliary electric pump. | 659.0 pounds |
| 94017 2007-02-18 | No information given | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 1/24/07 concerning release of SO2 | |
| 93996 2007-02-15 | Emergency Flare System | Cause: Under investigation Followup: No Notes: Sweet hydrocarbon gas streams were routed to the flare to reduce the flaring of the sour hydrocarbon gas streams. HDS-rate was lowered to reduce the off-gas rate to the WGS. | 1,062.0 pounds |
| 93908 2007-02-12 | Cat Feed Hdyrotreater Unit (CFHT) / EPN 28 | Cause: CFHT shutdown due to a short in the wiring system. The compressor k-7702 had blown a gasket. The unit depressurized through the emergency flare Followup: No Notes: Feed to the CFHT was reduced and the k-7702 compressor was manually isolated. The unit was depressurized to the flare system, ending the incident. CRLLC sends another letter indicating on 3/22 indicating that investigation continues and revisions to prior reports are pending the results. | 3,249.0 pounds |
| 93700 2007-02-03 | Emergency Flare System | Cause: operator adjusted cooling water system, leading to a shut down of the Waste Gas System Compressor K-400 Followup: No Notes: Sweet hydrocarbon gas streams were routed to the flare to reduce the flaring of the sour hydrocarbon gas streams. The WGS was restarted and reloaded. CRLLC will reinforce training of operators on the impact of adjustments to the cooling water system. | 784.0 pounds |
| 07-BB005-482 2007-02-03 | Waste Gas Compressor / Emergency Flare System | Cause: The WGS compressor k-400 shutdown due to an operational adj. that caused high jacket water temp. Sour hydorcarbons were detected Followup: Notes: Sweet hydrocarbon gas streams were routed to the flare to reduce the flaring of the sour hydrocarbon gas streams. The WGS was restarted and reloaded. | 784.0 pounds |
| 93419 2007-01-21 | Coker B Drum | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 1/21/07 concerning release of VOC and SO2 | 0 |
| 93384 2007-01-19 | No information given | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 1/21/07 concerning release of SO2 | 10.0 pounds |
| 93337 2007-01-17 | No information given | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 1/17/07 concerning release of VOCs and SO2 | 3.0 pounds |
| 93240 2007-01-11 | #2 Flare | Cause: #2 prefractionator tower bottoms level controller malfunctioned causing resulted in venting to #2 flare Followup: No Notes: Refinery has issued a work order to repair the Prefractionator Tower bottoms level controller (741C012) | 822.0 pounds |
| 07-BB005-469 2007-01-11 | # 2 Crude Unit | Cause: #2 prefactionator tower bottom level controller malfunctioned which resulted in venting to the #2 flare Followup: No Notes: | |
| 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. | 25.0 pounds |
| 93101 2007-01-07 | Sulfur Recovery Unit | Cause: the governor control arm was sticking which caused a problem with the blower. Followup: No Notes: Initial report indicates emissions were: SO2 - 500 lbs and H2S - 100 lbs, but letter from Chalmette states that further investigation indicates amt released of both substances was 0 lbs. Follow-up letter adjusts emissions to numbers listed here. | 433.0 pounds |
| 110843 2008-11-18 | #1 Flare | Cause: start up of the alkylation unit Followup: No Notes: Letter states that emissions were BRQ. | |
| 110391 2008-10-25 | #1 Flare | Cause: upset condition in a process unit Followup: No Notes: Letter states that emissions were BRQ. | |
| 108944 2008-09-12 | Flare #2 | Cause: Hurricane Ike causes a scaffold to fall and damage a power line. Power outage causes shut down of Crude 1 and Crude 2 Units Followup: Yes Notes: | 6,180.0 pounds |
| 108882 2008-09-11 | No information given | Cause: pressure safety valve released Followup: No Notes: No Information Given | |
| 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. | 671,171.0 pounds |
| 108453 2008-08-29 | No information given | Cause: shutting down units due to hurricane Followup: No Notes: Letter states that emissions were BRQ. | |
| 108528 2008-08-20 | Flare | Cause: shutting down units due to hurricane Followup: No Notes: No Information Given | |
| 108123 2008-08-16 | thermal oxidizer stack | Cause: No information given - train trippedÉhit switch to train oneÉtrain one become overloaded Followup: No Notes: Claims emission was below RQ. | |
| 108301 2008-08-02 | Sulfur Recovery unit THOX stack | Cause: the air demand analyzer became plugged and a breaker was switched off Followup: No Notes: Issued a work order to investigate equipment. Unable to confirm if workers bumped the breaker. Reported as a Tail Gas Incident. Letter of 10/24 includes checks to the DoJ and LDEQ as paymt of penalty for incident. | 5,454.0 pounds |
| 107279 2008-07-17 | Flare | Cause: the level controller on the slurry pump around system malfunction and the FCC fractionator overpressured Followup: No Notes: Corrected the level indicator | 734.0 pounds |
| 107088 2008-07-09 | No information given | Cause: No information given Followup: No Notes: Claims emission was below RQ. | |
| 105915 2008-05-23 | #2 Flare | Cause: excess light material in the feed stream caused the Crude 2 Atmospheric Tower to over pressure. CRLLC began processing a new type of crude that caused the upset. Followup: No Notes: CRLLC reduced the Crude 2 Feed rate and made adjustments to the feed rate to reduce the pressure in the atmospheric tower and in the Prefractionator Tower. | 922.0 pounds |
| 103974 2008-03-15 | No information given | Cause: high winds blew a tarp into a power line; cooling water pumps were lost Followup: No Notes: Letter states that emissions were BRQ. | |
| 103563 2008-03-01 | Emergency Flare System | Cause: operator over-adjusted flow to the inter-stage cooler after receiving a high temperature alarm on the Process Gas Compressor Followup: No Notes: When PGC lost suction, the board operator immediately directed the outside gas operator to decrease the cooling water flow. The intercooler temperature returned to normal operating range and the PGC was able to compress and pump the process gases again | 1,026.0 pounds |
| 103437 2008-02-26 | No information given | Cause: power failure in FCC Unit Followup: No Notes: Letter states that emissions were BRQ. | |
| 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. | 231.0 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. | 3.0 pounds |
| 102818 2008-02-04 | #2 Flare | Cause: excess light material in the feed stream caused the Depropanizer Tower to experience processing difficulties that resulted in a pressure increase in the Tower. Followup: No Notes: Operators reduced the feed rate to the Debutanizer Tower and cut back the production of overhead liquids from other units supplying the Light Ends Plant | 1,205.0 pounds |
| 102577 2008-01-25 | #2 Flare | Cause: liquid from Crude 2 Stabilizer Overhead Receiver carried over into the Waste Gas System Line and froze, plugging the line and initiating a series of problems. Followup: No Notes: CRLLC repaired the level indicator and changed the alarm points on the gas line to the WGS reducing the probability of such an event and enabling faster identification of such an event. The combined activities will prevent future plugging of the line. | 1,461.0 pounds |
| 102455 2008-01-19 | Flare | Cause: taking a flare out of service because they have to burn product out so they can install blinds Followup: No Notes: Letter states that emissions were BRQ. | |
| 102436 2008-01-18 | Flare | Cause: taking a flare out of service because they have to burn product out so they can install blinds at the FCC Followup: No Notes: Letter states that emissions were BRQ. | |
| 102088 2008-01-04 | No information given | Cause: Vacuum compressor at #1 crude tripped Followup: No Notes: Letter states that emissions were BRQ. | |
| 118804 2009-10-17 | flare #2 | Cause: Level indicator in the Light Ends Plant over head had malfunctioned. Causing the #3 Pretreater and Hydrocracker (HCU) 1st Stage Stripper overhead off gas flow to suddenly decrease. This caused the pressure to increase and release emissions through flaring (#2). Followup: No Notes: Lowered drum level and stablizied the HCU and PT 3. Repaired indicator by refilling leg with glycerin. | 1,172.0 pounds |
| 118643 2009-10-09 | Waste Gas Compressor | Cause: Waste Gas Compressor lost high pressure and failed. Sent gas to FLARE #1. Followup: No Notes: RQ not exceeded. Flare gas recovery system prevented excessive flaring. | |
| 117083 2009-08-06 | SRU 1 and 2 | Cause: Sulfur Recovery Unit Train (SRU 2) shutdown due to a steam excursion in the refinery. The steam excursion had caused the SRU 2 to shutdown from low boiler water level. The acid gas loading from SRU 2 was added to SRU 1 which caused the emissions.
A second incidence occurred when the refinery lost its hydrogen supply from Air Products. This caused the shutdown of the refinery hydrotreaters and a significant decrease in refinery acid gas production. SRU 1 shutdown due to the insufficient acid gas leading to a second emission. Followup: Yes Notes: acid gas was routed from SRU 2 to SRU 1. Acid gas flaring was avoided and DGA strippers was contained until SRU 1 was restarted. SRU 1 was run at minimal air flow rates to avoid excess H2S consumption due from insufficient acid gas rates. Caustic addition was maximized in tail gas section to mitigate additional SO2 formation. | 1,136.0 pounds |
| 116434 2009-06-12 | coker #2 coke pit and fire lanes | Cause: Failure of the coker fines lane pump discharge check valve resulting from accumulated coke fines, which allowed oil from the coker cutting water tank to back flow into the fines lane. Once the oil came in contact with the hot coke in the pit, a fire resulted. Followup: Yes Notes: Fire was extinguished with foam. Secondary check valve was installed and a cautionary procedure was developed and implemented. | 3,569.0 pounds |
| 115487 2009-06-08 | hose from waste water tank | Cause: Contractor pulled cap off of hose leading to a wastewater tank causing sludge to be released. Followup: No Notes: RQ not exceeded. Release cleaned up for future disposal. | 267.0 pounds |
| 115514 2009-06-07 | PSV lift, tanks 9000, 9006, and 9007 | Cause: Unscheduled release of PSV lift, tanks 9000, 9006, and 9007. Followup: No Notes: RQ not exceeded. | 267.0 pounds |
| 114985 2009-05-14 | flare | Cause: High differential pressure across gas oil feed filters to Cat Feed Hydrotreater (CFHT) prevented feed from entering the unit. Loss of feed to CFHT combined with malfunctioned level indicator (instrument failure) in hot separator resulted in the total loss of liquid level in the hot separator. This created high pressure vapor from the hot separator that was fed to the fractionator. This result in the overheating and over pressuring of the fractionator and increased gas rates to the fractionator overhead. Followup: Yes Notes: RQ exceeded. CFHT rates reduced to a minimum and stopped using propane to minimize temperature and pressure excursions. Level indicator malfunction ocrrected by replacing the anti-freeze. | 2,138.0 pounds |
| 114229 2009-04-16 | No Information Given | Cause: No Information Given Followup: No Notes: Below reportable quantities. | 77.7 pounds |
| 113148 2009-03-04 | No Information Given | Cause: No Information Given Followup: No Notes: Below reportable quantities. | 18.7 pounds |
| 112269 2009-01-24 | #1 Flare | Cause: No Information Given Followup: No Notes: Below reportable quantities. | 151.0 pounds |
| 128197 2010-12-16 | No Information Given | Cause: LDEQ report states that it is an air release. No information given regarding cause. Followup: No Notes: BRQ. According to the follow-up notification letter, this is a courtesy notification. No reportable quantities were exceeded as a result of this release. Refinery equipment was shut down for repairs. | |
| 127974 2010-12-04 | No Information Given | Cause: Planned and controlled release to shutdown Alky Unit.
LDEQ repor states that "according to the 7-day notification report submitted by the facility, no reportable quantities were exceeded as a result of this release. The release is considered a courtesy notification. No further action at this time." Followup: No Notes: BRQ. Release is considered a courtesy notification. | |
| 126946 2010-10-08 | flare | Cause: Flaring due to isolation of a line involved in a prior incident on 10/4/10 -- see incident #126868. Reportable quantity for Sulfur dioxide was exceeded three times during incident, beginning on 10/10/10. Followup: No Notes: RQ. "Valve was fully seated to achieve complete isolation." "No chronic or acute health risks are anticipated as a result of this release..." | 78,395.0 pounds |
| 126762 2010-09-29 | no information given | Cause: This file only has a brief refinery report with no specific info. Followup: No Notes: No information given | |
| 126163 2010-09-06 | FCC regenerator flue gas scrubber vent FLARE: Thox stack, Flare # 1 and 2 FLARE: Flare #1 | Cause: Bus bar short to ground due to unsealed air gaps created a voltage dip which resulted in power loss to multiple units which then had to flare. Pressure imbalance in the FCC regenerator resulted in loss of catalyst through the regenerator flue gas scrubber vent. FLARE. Followup: Yes Notes: "To reduce the likelihood of recurrence, sealant was installed between the bus bars and supports in PS 7711 and acoustic inspection is being performed at another power station that was designed and installed by the same contractor." Refinery letter states that "there was no emergency condition related to this release and the resulting community exposures would not be expected to have acute or chronic health impacts." | 106,646.0 pounds |
| 125331 2010-08-02 | no information given | Cause: SO2 release when system depressurized for maintenance
"permitted release, and not a reportable incident" Followup: No Notes: no information given | |
| 123156 2010-04-30 | no information given | Cause: "Waste gas compressor shut down causing SO2 to flare"--no details given.
File contains DEQ report only, refinery letter dated 8/17/10 referred to but not included. Followup: No Notes: no information given. | |
| 123040 2010-04-27 | flare #1 | Cause: Compressor inadvertently tripped while executing Emergency Block Valve Prevention Maintenance Program procedure on it--sent material to flare. Followup: No Notes: Operations team secured the unit and started up the compressor, full evaluation and troubleshooting will be addressed during next shutdown. Will not perform EBV maintenance program in the meantime. | 1,359.0 pounds |
| 122546 2010-04-03 | no information given | Cause: "Unloading olefin truck--vent line to flare left open"--no details. Followup: No Notes: no information given | |
| 121183 2010-01-31 | no information given | Cause: verbal report states "petroleum coke fire on conveyor." No detailed description in written report. FIRE. Followup: No Notes: no information given | |
| 120629 2010-01-08 | SOX scrubber | Cause: Fluid Catalytic Cracking (FCC) SOX scrubber circulating water pumps failed due to catalyst pluggage. Followup: No Notes: RQ. had difficulty dislodging the catalyst--tried switching pumps off & on, using portable air compressor, increased grid wash, FCC charge rate decreased continuing to monitor performance of SOX scrubber | 1,956.0 pounds |
| 135438 2011-11-20 | #1 Flare | Cause: The flare gas machines lost its pumping ability. The stages on the #1 flare overpressured and burned the gas into the atmosphere. The cause is under investigation. Followup: No Notes: Chalmette Refining provided a courtesy notification to your office regarding a release of Sulfur Dioxide on November 20, 2011. After further review, there were no RQ exceedances or permit violations as a result of this event. | |
| 135259 2011-11-14 | No. 1 Flare | Cause: On November 14, 2011, the high pressure side waste gas compressors were down for scheduled piping replacement. At approximately 1705 hours, the Flare Gas Management (FGM) system compressors stalled, at which time gas that would have been routed to the FGM contractor, was instead routed to the No 1 Flare. The FGM system would have contained the release; however, the FGM seal water was contaminated with hydrocarbon, which is believed to have been a potential result of the Alky Feed PSV overpressure on November 5, 2011 reported under separate cover. The result was intermittent flaring at the No. 1 Flare through November 15, 2011, at 22:01 hours, consequently resulting in emissions of sulfur dioxide in excess of the reportable quantity of 500 lbs. Followup: No Notes: The seal water on the FGM compressors was changed out. CRLLC is investigating the root cause of the release. Based on the results of the Refinery's investigation, appropriate measures will be taken to minimize the likelihood of a recurrence. | 5,296.0 pounds |
| 135184 2011-11-09 | Flare: Flare No. 1 | Cause: The low pressure side waste gas compressor shutdown due to a fuel control valve failure. This routed the low pressure side waste gas to the Flare Gas Management (FGM) system. Followup: No Notes: The fuel control valve was repaired. The low pressure side waste gas compressor was restarted, and the stream was removed from the FGM system. The seal water on the FGM compressors was changed out. There is no SPOC report and no LDEQ report in the file. | 5,484.0 pounds |
| 135138 2011-11-05 | No information given | Cause: No information given. Followup: No Notes: Chalmette Refining provided a courtesy notification to the LDEQ regarding a release of Sulfur Dioxide on November 5, 2011. After further review, there were no RQ exceedances or permit violations as a result of this event. The release did not cause an Emergency Condition or require Offsite Protective Action. | |
| 134471 2011-10-10 | FLARE-No. 1 Flare; SRU 1 | Cause: There was sudden unexpected loss of O2 supply from Air Products causing SRU1 to immediately shut down. Acid gas (SO2 and H2S) was released intermittently through Number 1 Flare. SRU 1 was sole operating SRU at the time of incident, as SRU 2 was shutdown for maintenance. Followup: No Notes: Steam controllers have been repaired and rebuilt. There was also an evaluation of alarm changes to provide more response time. EPA Acid Gas Flaring report included. LDEQ conducted an investigation in response to this incident on 12/8/11. | 164,891.0 pounds |
| 134066 2011-09-18 | No information given | Cause: Sulfur dioxide released to atmosphere with no RQ/BRQ Followup: No Notes: Chalette Refining provided a courtesy notification to your office regarding a release of sulfur dioxide to the atmosphere on September 18, 2011. After further review, there were no RQ exceedances as a result of this event. | |
| 133880 2011-09-11 | FLARE: Flare No. 1 | Cause: A packing leak developed on the seal of the fire eye cleaning device causing it to malfunction during routine maintenance and allowed combustion gases to escape to the atmosphere and shutting down Train 1 of the SRU (Sulfur Recovery Unit) sending acid gases to the FGM. Flared from flare 1 at a reportable quantity of H2S/SO2. Followup: No Notes: Unit operations were adjusted to minimize the duration and severity of flaring. The SRU Train 1 was switched to oxygen mode so it could process refinery acid gas. Sulfur pit vents on both trains were opened until SRU 1 could process them. To prevcnt this from happening again a re-engineered fire-eye cleaning tool will be constructed. This is expected to be completed by December 31, 2011. CRLLC will not utilize the fire-eye cleaning tool until modification to the tool has been completed. Two employees received first aid treatment. No chronic or acute health risks are anticipated as a result of this release. There was no emergency condition as a result of this release. NO SPOC or LDEQ report. | 36,579.0 pounds |
| 133625 2011-09-01 | No information given | Cause: A heavy rain occurred then the sulfur plant started having problems around 1130 hrs. They started seeing emissions. They believe it is due to an instrument malfunction. Followup: No Notes: Chalmette Refining LLC provided a courtesy notification to the LDEQ regarding a release of sulfur dioxide to the atmosphere on September 1, 2011. After further review, there were no RQ exceedances or permit violations as a result of this event. | |
| 133061 2011-08-11 | FLARE: Unspecified location | Cause: A high pressure waste gas flaring system shut down. The flare gas recovery compressor could not handle the load and sulfur dioxide was released into the atmosphere. Followup: No Notes: The unit rates were reduced to lower the amounts going to the flare. | |
| 132776 2011-07-29 | Flare 1 | Cause: On 01/28/11, at approximately 9:00am, the amine unit was being taken out of service for a planned maintenance activity. During the course of the shutdown, the DGA circulation in the contactor decreased. The reduced flow occurred concurrent with the loss of the LPG compressor. As a result, there was an H2S breakthrough to the refinery fuel gas system at approximately 1 minute. This event resulted in 86 lbs of excess SO2 emissions. Followup: No Notes: Fuel Gas incident- The shift leader recognized the problem within 15 minutes of the start of the event and immediately increased circulation to stop the H2S breakthrough and mitigate the SO2 emissions potential. Updated procedures to ensure shutdown activities include awareness of circulation rate and interaction with other unit operators. Refresher training will be conducted with unit personnel on revised procedure. In a separate event at 12:58am, the flare gas management compressors briefly shutdown due to elevated molecular weight (MW) gas which resulted in increased SO2 emissions from the fired combustion units of 481 lbs excess SO2 | 567.0 pounds |
| 132721 2011-07-23 | Flare | Cause: On July 23, 2011 at approcimately 23:33 hours, a safety valve on the propane/polypropylene mix drum, D9007 relieved to the No. 1 Flare, resulting in intermittent flaring, and consequently resulting in emission of sulfur dioxide in excess of the reportable quantity of 500 lbs. Incident 11-04337 occurring on July 21, 2011 caused a buildup of hydrocarbons in the compressor seal water decreasing the capacity of the compressors which normally have the capacity to contain this volume. Followup: No Notes: The seal water on the FRM compressors was changed out as the hydrocarbon buildup contributed to the flaring. Pressure build up in the spheres occurred before the seal water could be changed out in the compressors causing intermittent flaring. The venting could not be delayed as it would have been a process safety issue. Flaring does not normally occur from these procedures. | 1,010.0 pounds |
| 132609 2011-07-20 | Flare: Unspecified location | Cause: A sphere over pressured and dumped to the flare. Pressure safety valve lifted and went to flare. Followup: No Notes: The sphere was isolated away from the flare. | |
| 132188 2011-07-09 | No Information Given | Cause: Planned unit shutdown for maintenance operations. Followup: No Notes: BRQ: According to the Refinery Letter, "unit operations and shutdown timing were adjusted to minimize environmental impact." | 1,949.0 pounds |
| 131213 2011-05-13 | FLARE-No. 1 Flare; Sulfur Recovery Unit (SRU) Train II | Cause: Air Products, third party oxygen supplier, experienced a malfunction of an emergency safety device. Oxygen supply was lost to Train II of SRU. The Flare Gas Management System shutdown because of acid gas from the DGA strippers. Two follow-up letters dated 10/25/11 and 11/15/11. Followup: Yes Notes: Report states that Air Products re-secured a loose control relay and has ordered a new relay that will fit more securely. EPA Acid-Gas Flaring incident report included. Follow-up letters: A new control relay has been obtained and will be installed in Q4 2012 during a planned outage. | 117,344.0 pounds |
| 130963 2011-04-27 | No. 2 Coker and Cat Feed Hydrotreater (CFHT) | Cause: Unscheduled outages of the No. 2 Coker and Cat Feed Hydrotreater resulted from a temperature change due to operating on combustion air resulted in the release of sulfur dioxide. Followup: Yes Notes: RQ. EPA Consent Decree report included. Immediate remedial actions taken: Upstream unit rates were reduced, the Sour Water Stripper unit was shut down, and SRU conditions were adjusted. Further action: 1)Refresher training has been conducted with increased emphasis on the importance of monitoring the No. 1 Converter temperature closely during train transitions to combustion air with pit vapor to prevent recurrence. 2)Procedure to switch from O2-mode to air-mode was modified. 3)MDEA lean loading field testing to be moved to refinery lab, with upgraded analysis procedures 4)Evaluate project to operate SRU units in partial O2-enrichment mode to reduce environmental vulnerability On January 6, 2012 the refinery sent follow-up notification that all action items related to the April 27, 2011 Tail Gas Incident has been completed. | 1,150.8 pounds |
| 130697 2011-04-18 | Fluid Catalytic Cracker (FCC) Unit | Cause: According to LDEQ, there was "a pump shut down due to a power trip. After thepump shut down, pressure levels built in the absorber column," which resulted in a release of sulfur dioxide. Followup: No Notes: BRQ According to LDEQ, "There is a back-up pump in case of emergency where flow was restored during the... flaring." No further information given. | 187.0 pounds |
| 129573 2011-03-01 | Flare | Cause: Malfunction of the compressor spillback valve. The Fluidized Catalytic Cracker (FCC) main fractionator overhead accumulator pressure control valve (79PC502F) began to open to flare due to a sudden increase in pressure in the accumulator, which led to flaring at the #1 Flare. The sudden pressure increase was the result of a stuck compressor spillback valve. Followup: No Notes: Feed rate to the unit was reduced, pressure was reduced and the pressure control valve setpoint was raised. CRLLC has determined the cause of this release to be a malfunction of the compressor spillback valve. The valve has been evaluated by a technician and the pressure control valve setpoints are being reviewed. | 1,014.0 pounds |
| 129381 2011-02-23 | PSV Valve | Cause: State Police report states a PSV valve may be leaking and that cause of leak is under investigation.
LDEQ Report states PSV valve was leaking to flare system. Followup: No Notes: BRQ | |
| 144301 2012-10-30 | Flare # 1 | Cause: On 10/30/12, Chalmette Refining conducted a planned maintenance activity to test a high integrity protective system. The activity resulted in a release at Flare #1.
Release at Flare # 1 resulting from a planned and controlled maintenance activity. According to the follow-up notification letter submitted by Chalmette Refining, this was a courtesy notification. Followup: Yes Notes: Follow-up report states that refinery has completed the installation of the new low-molecular-service PSV. The original incident report committed the refinery to this implementation. | |
| No LDEQ Reported 2012-10-10 | no information given | Cause: Followup: No Notes: Preliminary air monitoring was observed. | |
| 143192 2012-09-25 | NIG | Cause: Flaring began September 25, 2012 at approximately 05:36 hours with intermittent flaring occurring until September 28, 2012 at 02:54. The refinery lists this event as a permitted flaring event associated with a planned unit shutdown.
Cumulative flaring time was approximately 8 hours and 48 minutes. Followup: No Notes: Unit operations and shutdown and timing were adjusted to minimize environmental impact. | 3,014.0 pounds |
| 143258 2012-09-10 | #1 Flare | Cause: The flare gas management compressors tripped due to high molecular weight and staged the #1 Flare intermittently for 5.02 hours. Sulfur Dioxide was released to the air.
Incident was caused by the Number 2 Coker Unit Naptha Splitter overhead safety relief valve relieving to the FGM compressors causing the shutdown. Followup: Yes Notes: Started the third FGM compressor and added hydrogen to the flare to decrease the molecular weight to expedite the FGM compressors recovery. FGM compressors water seals were also re-inventoried with fresh water. PSV was sent out for maintenance, retested and calibrated. | 3,696.0 pounds |
| 142422-142489-143217 2012-08-27 | Wastewater treatment Unit Coke Conveyor Facilities isolated areas of standing stormwater flare | 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. | 117,310.0 pounds |
| 142387 2012-08-24 | No Information Given | Cause: Power trip caused flare gas compressors to power down temporarily causing Sulfur Dioxide release. Followup: No Notes: According to facility representative, the release was minimal and did not result in the need for flaring. | |
| 140083 2012-05-26 | Cause: The facility experienced malfunctions when the high pressure waste gas system was shut down in the Coker unit, releasing sulfur dioxide to the flare. High Pressure Waste Gas System (HPWGS) compressors K402 and K406 were unavailable due to mechanical issues and the Flare Gas Management System was used instead. This usually works but the depropanizer surge drum water boot sprung a leak and heavy material entered the shut down HPWGS. Followup: No Notes: The high pressure waste gas system had been restored by the time of the LDEQ Incident Report. | 5,769.0 pounds | |
| No LDEQ Reported 2012-04-27 | Sulfur Recovery Unit Thermal Oxidizer | Cause: Tail Gas incident due to Sulfur Recovery Unit Train 1 being shut down due to low refinery acid gas production following unscheduled outages of the No.2 Coker and the Cat Feed Hydrotreater. the Sulfur Recovery Unit on Train 2 was forced to switch to combustion air-mode to avoid the possibility of acid flaring.The temperature of the Sulfur Recovery Unit Train 2 No.1 Converter dropped ue to uncombusted pit vapors, resulting in an increase in Sulfur Dioxide from the Thermal Oxidezer Followup: No Notes: - Refresher training has been conducted with increased emphasis on the importance of monitoring the No. 1 Converter temperature during train transitions to combustion air with pit vapor to prevent recurrence. - Procedure to switch from O2-mode to air-mode was modified to ensure temperature is adequate to handle pit vapors on air-mode. - MDEA lean loading field testing will now include upgraded analysis procedures and will be moved from the field to the lab. - Evaluate project to operate Sulfur Recovery Units in partial O2-enrichment mode to reduce environmental vulnerability. | 1,150.8 pounds |
| 138541 2012-04-03 | #1 Flare | Cause: A high molecular weight gas was routed to the flare gas management system, which prevented the compressor from being able to pump the gas and caused the flare to open. Followup: Yes Notes: To stop the discharge, feed rate to the unit was reduced, reducing pressure, and eventually ending the release. A representative from Chalmette Refining contacted LDEQ Emergency Response on 4/4/12 when an all-clear was called, also providing the total release quantity of sulfur dioxide. No fire, injuries, or fatalities resulted from this incident | 1,022.0 pounds |
| 152005 2013-10-31 | D acid cooler Flare #1 | Cause: On October 30, personnel identified increased fluoride levels of routine samples at the battery limits of the Alkylation unit in the cooling water return system from 0.39 parts per million (ppm) to 0.5 ppm. Based on preliminary findings, the "D" acid cooler at the alkylation unit appears to have developed a leak. Sampling conducted at Outfall 013, which measures fluoride concentration, suggests a neutral pH, dilute solution of HF was leaking from a heat exchanger in the cooling water system and discharged through the outfall. CRLLC personnel began to shutdown the unit in order to isolate the cooler on October 31. As a result of the leak and subsequent shutdown of the unit, intermittent flaring occurred at the #1 Flare beginning on October 31 and ending on November 2. Followup: No Notes: The Alkylation Unit was shut down in a safe and controlled manner in order to isolate the acid cooler. The acid cooler is being inspected and repaired to minimize the risk of recurrence. The rates were reduced and the acid was evacuated from the unit. Fluoride samples were measured from the cooling water effluent throughout the shutdown of the unit. The pH of Outfall 013 was continuously monitored. | 10,360.0 pounds |
| 151403 2013-10-07 | No Information Given | Cause: On Monday, October 7, 2013 at approximately 09:03 hours, the flare gas management (FGM) compressors overpressured from a planned maintenance shutdown of the waste gas system (WGS) resulting in the intermittent staging of the #1 Flare. The WGS was being taken temporarily out of service for maintenance of the electrical switchgear. During the WGS outage, the waste gas is routed to the FGM compressors for recovery. The increased flow of the waste gas to the FGM compressors caused an overpressure of the recovery system and staged the #1 Flare.
According to the 01/10/14 follow up letter the WGS was being taken temporarily out of service for maintenance of an electrical switchgear. During WGS outage, waste gas is routed to the flare gas management (FGM) system compressors for recovery system, resulting in the intermittent staging of the # 1 Flare. Followup: Yes Notes: The maintenance of the electrical switchgear was completed and the compressors were returned to service to eliminate the gas being routed to the recovery system. All three flare gas recovery compressors were online to minimize flaring during the event. The planned maintenance activity for the WGS will increase the reliability of the system and reduce the likelihood of waste gas being routed to the flare gas recovery system. According to the LDEQ incident report "this event is considered reasonably unforeseeable, therefore qualifies as an upset in accordance with LAC 33:507J Upset Conditions" | 2,442.0 pounds |
| 150508 2013-08-21 | No Information Given | Cause: Followup: No Notes: Reported release of sulfur dioxide and volatile organic compounds that occurred at Chalmette Refining, L.L.C. on August 21, 2013. After further evaluation, we have determined that no reportable quantities were exceeded during this event. | |
| 150004 2013-07-29 | Flare #1 | Cause: On Thursday, July 29, 2013, at approximately 1352 hours, the flare gas management (FGM) compressors over pressured from a planned maintenance shutdown of the waste gas compressor (K406) resulting in the staging of the #1 Flare. K406 was being taken temporarily out of service to repair piping on the sight glass and bottom drain piping for the cooling water day tank. During the K406 outage, the waste gas is routed to the FGM compressors for recovery. The increased flow of the waste gas to the FGM compressors caused an overpressure of the recovery system and stages the #1 Flare.
On 8/28/2013 LDEQ conducted "onsite discussions" with Chalmette supervisors about three accidents relating to the WGC and FGC unit between 7/25-7/28 (149927, 149989, 150004). Followup: No Notes: K406 was repaired and returned to service to eliminate the gas being routed to the recovery system. The planned maintenance activity for K406 will increase the reliability of the waste gas system and reduce the likelihood of waste gas being routed to the flare gas recovery system. | 1,666.0 pounds |
| 149989 2013-07-28 | Flare #1 | Cause: On Sunday, July 28, 2013, at approximately 0349 hours, the flare gas management (FGM) compressors began to lose suction and stopped pumping resulting in the staging of the #1 Flare for approximately 7 minutes. With the inability of the compressors to pump reliably, a water change out was required to get the system back in normal and stable operation. This process intermittent flaring between 10:44 and 18:11. Followup: Notes: Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. An ongoing evaluation of the equipment during the event revealed the flare gas recovery water purge capability was restricted. This resulted in increased unreliability of the compressors due to the reduced discharge rate of the high molecular weight water recirculating in the system. The water purge capability was restored on 7/29 and should result in faster recovery times from unplanned high molecular weight gas events. LDEQ conducted "onsite discussions" with Chalmette Environmental and business supervisor related to three accidents related to the FGC and WGC units between 7/25-7/28 (149927, 149989, 150004) on 8/28/2013. | 1,548.0 pounds |
| 149927 2013-07-25 | Flare #1 | Cause: On Thursday, July 25, 2013, the flare gas management (FGM) compressors began to lose suction and stopped pumping resulting in the staging of the #1 Flare. Prior to this even, a planned venting of pump G7908 occurred and is suspected to have caused an increased flow of higher molecular weight material to the compressor system. Concurrently, waste gas compressor (K406) was out of service from a prior malfunction causing waste gas to be routed to the FGM system. The increased flow of the waste gas caused an overpressure of the recovery system and staged the #1 Flare. Followup: No Notes: Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. K406 was repaired and returned to service to reduce the gas being routed to the recovery system. An evaluation of the equipment during the event revealed the flare gas recovery water purge capability was restricted. This resulted in increased unreliability of the compressors due to the reduced discharge rate of the high molecular weight water recirculating in the system. The water purge capability was restored on 7/29 and should result in faster recovery times from unplanned high molecular weight gas events. Waste gas system compressor reliability and water purge capability will be reviewed to identify and evaluate improvement options. LDEQ conducted "onsite discussions" with Chalmette Environmental and business supervisor related to three accidents related to the FGC and WGC units between 7/25-7/28 (149927, 149989, 150004) on 8/28/2013. | 10,860.0 pounds |
| 149707 2013-07-16 | No Information Given | Cause: CRLLC reported release of sulfur dioxide that occured on July 16, 2013. Followup: No Notes: It was determined that no reportable quantities were exceeded during this event. No additional information was provided in addition to not exceeding reportable quantities of sulfur dioxide. | |
| 149561 2013-07-10 | Flare | Cause: On Wednesday, July 10, 2013, at approximately 0422 hours, the flare gas management (FGM) compressors began to lose suction intermittently due to mechanical issues. The root cause of the mechanical issues was determined to be residual high molecular wight material entrained in the flare gas compressor circulating water from the reported events on July 7, 2013. To mitigate long term issues, the circulating water was changed out in the system which resulted in the staging of the flare during the process. Followup: No Notes: Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. To mitigate long term issues, the circulating water was changed out in the system which requires the staging of the flare during this process. CRLLC claimed that no reportable quantities were exceeded during this event although they did release over 500 pounds of sulfur dioxide which is RQ. | 1,396.0 pounds |
| 149525 2013-07-07 | FGM compressor | Cause: On July 7, 2013, the flare gas management (FGM) compressors began to lose suction intermittently due to mechanical issues caused by high molecular weight material being routed to the compressors. A comprehensive investigation determined that controlled venting from Tk-9005 and a PSV leaking from the FCC Unit and relieving to the FGM system were the cause of the FGM compressor mechanical issues. The two identified sources were blocked in and the compressors were brought back online. Community monitoring was conducted during the event and all results were zero. Followup: Yes Notes: Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. TK-9005 vent and the FCC PSV were blocked in to isolate the materials from being routed to the flare gas compressors. | 1,854.0 pounds |
| 149521 2013-07-06 | No information given | Cause: On July 6, 2013, mechanical problems with the FGR compressors caused a release of sulfur dioxide. No reportable quantities were exceeded as a result of this release. Followup: Notes: No information was provided in addition to the release being below reportable quantity. | 50.0 pounds |
| 149333 2013-06-22 | No Information Given | Cause: On June 22, 2013, sulfur dioxide released to air due to compressor trip. Followup: No Notes: The refinery letter only included that the incident was below reportable quantity. No information regarding duration or point source were included. | |
| 149037 2013-06-06 | No Information Given | Cause: Release of sulfur dioxide that occurred at the Chalmette Refinery, L.L.C. (CRLLC) on June 6, 2013. After further evaluation, they have determined that no reportable quantities were exceeded during this event. Followup: No Notes: No information was provided in the refinery letter regarding the duration or point source of the release. | 133.0 pounds |
| 148913 2013-05-25 | No Information Given | Cause: Followup: No Notes: | |
| 148731 2013-05-15 | FGM compressors | Cause: On Wednesday, May 15, 2013, at approximately 13:53 hours, the flare gas management (FGM) compressors were shut down due to high molecular weight materials being purged to the system during the Alky Unit startup. There was the potential to cause long-term damage if the FGM compressors continued to be used during this process which would result in the recovery system being out of service for an extended period of time. Followup: No Notes: The compressors were returned to service immediately after equipment preparation and maintenance activities were completed. Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. | 20,020.0 pounds |
| 148700 2013-05-12 | FGM compressor, #1 Flare | Cause: On Sunday, May 12, 2013, at approximately 19:25 hours, the flare gas management (FGM) compressors tripped on a high inlet separator drum liquid level which resulted in material being routed to the #1 Flare. An investigation revealed the liquid level instrumentation that controls the levels in the inlet separator drum had malfunctioned causing the liquid level control valve to close and the liquid level to rise. This occurred when the level instrument was reading at lower than the setpoint value and the valve closed to raise the liquid level although the level was already rising but could not be seen by the operator board. The computer logic is designed to shut down the flare gas compressors during high level liquid alarms which were detected by a triplicated high level system which is independent of the liquid level that controls the control valve to prevent damaging the equipment. Followup: Notes: Steps were taken to minimize emissions as much as possible and return the FGM compressors to normal operation. The inlet separator drum level instrumentation was repaired and is now operating normally. Additional systems are being evaluated which would provide backup indicators of conditions that would fill the inlet separator drum. | 1,049.0 pounds |
| 148358 2013-04-26 | FGM compressor | Cause: On Friday, April 26, 2013, at approximately 14:33 hours, the flare gas management (FGM) compressors stopped pumping during the startup of the fluidized catalytic cracking (FCC) unit due to high molecular weight in the system. The FGM compressors are not able to pump correctly with high molecular weight in the water interface. There was also the potential to cause long-term damage if the FGM compressors continued to be used during this process which would result in the recovery system being out of service for an extended period of time. Followup: No Notes: The compressors were returned to service after equipment preparation and maintenance activities were completed on April 27, 2013 at 15:49 hours. All efforts were taken to minimize emissions as much as possible during the compressor outages. Community monitoring was conducted during the events and all results were non-detect. Steps were taken to minimize emissions as much as possible and operations are being adjusted to return the FGM compressors to normal operation. | 6,866.0 pounds |
| 148142 2013-04-16 | NIG | Cause: On April 16, 2013 Chalmette Refining experienced a leak of hydrogen sulfide and sulfur dioxide. The refinery letter stated that no reportable quantities were exceeded. No additional information was provided. Followup: No Notes: | |
| 148111 2013-04-14 | FGM Compressors | Cause: On Sunday, April 14, 2013, at approximately 0843 hours, the flare gas management (FGM) compressors were shut down due to high molecular weight materials being purged to the system during the Alky Unit startup. Sulfur dioxide was released to the air. Followup: No Notes: Emissions were minimized as much as possible and the FGM compressors were returned to normal operation as soon as possible. A similar event labeled "not preventable" occurred on March 2, 2013, LDEQ number: 147101. | 6,744.0 pounds |
| 147803 2013-04-03 | Coker 2 Gas Compressor | Cause: A lightning strike caused a temporary loss of power from Entergy resulting in a shutdown of the K8101 wet gas compressor. On Wednesday, April 3, 2013, at approximately 1026 hours, Chalmette Refinery experienced a disruption in power service causing the coker 2 gas compressor to trip (K8101). This resulted in the fractionator overhead valve opening to the flare system to control the pressure. K8101 restart attempts failed and the flare gas management (FGM) compressors stopped pumping from the increased molecular weight. Flare 1 was out of service for maintenance activities and the gas was routed to the #2 Flare system to ensure safe operations. K8101 was restarted at 1420 hours and at approximately 1640 hours the FGM compressors were restarted and H2S levels decreased. All systems were normal at 1800 hours. Followup: Yes Notes: After several attempts to restart K8101 flare gasses were routed to the #2 Flare to ensure safe operations. All efforts were taken to get the flare system back in normal operation as quickly as possible. | 24,480.0 pounds |
| 147101 2013-03-02 | Flare Gas Compressor | Cause: On Saturday, March 2, 2013, at approximately 21:03 hours, the flare gas management (FGM) compressors could not be returned to service following a permitted maintenance activity due to high molecular weight in the system. The FGM compressors were not able to pump correctly with high molecular weight in the water interface and due tot he cold weather conditions the high weight material was not able to be flushed from the system.
This event is considered reasonably unforseeable, therefore qualifies as an "upset" in accordance with LAC 33:507.J.Upset Conditions. Followup: No Notes: This event resulted in a release of 4724 pounds of sulfur dioxide. This exceeded sulfur dioxide's reportable quantity of 500 pounds. | 4,724.0 pounds |
| 159929 2014-11-08 | #2 Coker Wet Gas Compressor | Cause: On Wednesday, November 8, 2014, at approximately 13:27 hours the #2 Coker Wet Gas Compressor K-8101 tripped on an electrical outage and routed all gas to the flare gas recovery (FGR) system. The FGR system was unable to handle the excess gas and flaring occurred intermittently for 277 minutes until K-8101 could be restarted.
Duration is listed as 4h 36m, however calculated duration from incident start time and incident end time is 11h 59m.
An investigation into the root cause of the event is still ongoing and results will be provided in a 60-day followup letter. Followup: Notes: #2 Coker rates were reduced to minimize the amount of excess gas being routed to the flare gas recovery system. An investigation into the cause of the trip started and was determined to be a tripped fuse. The fuse was replaced and the compressor was restarted as soon as possible. Chalmette refining is conducting a failure analysis of K-8101 to determine the cause of the failure and preventability determinations. | 7,480.0 pounds |
| 159885 2014-11-05 | #2 Coker Wet Gas Compressor | Cause: On November 5, 2014 at approximately 04:25 hours, the #2 Coker Wet Gas Compressor K-8101 tripped on an electrical outage and routed all gas to the flare gas recovery (FGR) system. The FGR system was not able to handle the excess gas and the flaring occurred intermittently for 364 minutes until K-8101 could be restarted.
During this time, only one of the three flare gas compressor was available due to mechanical failures were down for repairs. With two flare gas compressors offline for repairs there was not sufficient capacity to recover all of the excess gas.
An investigation into the root cause of the event is still ongoing and results will be provided in a 60-day follow up letter. Followup: No Notes: # 2 Coker rates were reduced to minimize the amount of excess gas being routed to the flare gas recovery system. An investigation into the cause of the trip started immediately and was determined to be a tripped fuse. The fuse was replaced and the compressor was restarted as soon as possible. Chalmette Refining is conducting a failure analysis of K-8101 to determine the cause fo the failure and preventability determinations. Results will be provided in a 60-day follow up letter. | 21,700.0 pounds |
| 159191 2014-10-02 | K406 waste gas compressor | Cause: On Thursday, October 2 2014, at approximately 01:47 hours, Waste Gas Compressor K-406 tripped an overspeed and routed all gas to the flare gas recovery (FGR) system. The FGR system was unable to handle the excess gas and flaring occurred intermittently for 25 minutes until K-406 could be restarted. While investigating the cause of the K-406 compressor trip, another overspeed trip occurred at approximately 23:42 hours on October 2, 2014. All waste gas was routed again to the FGR system which was unable to recover the excess gas and intermittent flaring occurred for approximately 22.06 hours after several attempts to restart the compressor failed.
During this time Waste Gas Compressor K-402 was also down for repairs after a mechanical failure had previously occurred. With both waste gas compressors down there was no ability to recover any of the waste gas to relieve some of the flow to the FGR system.
Investigation of the accident determined that the cause of the K-406 trip was a sticking butterfly valve which regulates the fuel gas flow to the compressor. Personnel conducted extensive analysis and troubleshooting on K-406 to determine potential causes for the compressor trip.
The initial compressor trip was reported under LDEQ # 159284, however the emissions for both events were reported under 159191. Followup: No Notes: Flow rates to the flare system were minimized as much as possible throughout the refinery until Waste Gas Compressor K-406 could be returned to service. After K-406 was returned to service the FGR system also returned to normal operation and flaring ceased. Once it was determined that the butterfly valve was the leading root cause the valve was lubricated and returned to service. Chalmette Refining is developing an equipment procedure to add the butterfly valve as a potential failure scenario and conduct annual preventative maintenance on the valve to prevent any future recurrences. | 30,620.0 pounds |
| 156690 2014-06-10 | Compressor K81-01 | Cause: K 81-01 shut down - the compressor that usually pumps this gas, located in the #2 Coker Unit. Followup: No Notes: Shut down unit. | |
| 155017 2014-04-03 | Alkylation Unit | Cause: Flaring at the No. 1 Flare during maintenance on the Alkylation Unit. Maintenance required the refinery to de-inventory the unit. Report states that the flaring is authorized for safe operation of refinery processes and all emissions are permitted. Followup: No Notes: No incident date was given, only the date of the courtesy notification. Notification was not required as per NSR Consent Decree Paragraph 56.c. | |
| 154535 2014-03-17 | Outfall 013 Flare #1 | Cause: On Monday, March 17, 2014, at approximately 05:11 hours, the analyzer at the battery limits of the Alkylation unit indicated slightly elevated fluoride levels at the battery limits in the cooling water return system. At approximately 10:30, unit personnel identified that the "D" acid cooler at the unit had developed a leak. Shift super was notified of the potential of a small hydrogen fluoride leak in the cooler. This cooling water return is combined with, and diluted by, the once through cooling water system from other process units which discharges at Outfall 013 into the Mississippi River.
As a result of the leak and shutdown of Alkylation unit, flaring occurred at the #1 flare beginning on March 18 at approximately 17:00 in order to safely shut down the unit. During the permitted flaring event, the waste gas compressor K-406 tripped on March 19 at 20:26 and routed waste gas to the #1 flare. Flaring was completed on March 20 at 19:00. Followup: No Notes: Sampling was conducted at Outfall 013 to measure the fluoride concentration. It was determined that a neutral pH, dilute solution of HF was being discharged through the outfall. Agencies were notified of a potential HF reportable quantity exceedence on March 17 at approximately 16:25. The refinery conservatively estimated all measured fluorides as neutralized HF. All releases of HF were in a diluted water phase and no HF was released to the atmosphere. No reportable quantities were exceeded for HF during the event on a 24-hour rolling basis. This release did not result in any known impacts to the community or environment. | 23,300.0 pounds |
| 154310 2014-03-06 | Cause: A release of compressed flammable gas, benzene, and sulfur dioxide occurred on March 6, 2014. No further information about accident is given. Followup: No Notes: Only document provided about accident is one page refinery letter. | ||
| 153798 2014-02-22 | Sulfur Recovery Unit, reactor bed | Cause: During start up, personnel was putting air through the sulfur recovery unit when the sulfur on the reactor bed lit off causing emissions. The small fire inside the unit was caused due to induction of air through the train. Followup: No Notes: Nitrogen was utilized to remove fire from the reaction bed. Notification letter on 2/17/14 with same state police number references an accident on 2/10/2014. No information about that accident. | |
| 153414 2014-01-17 | Coker 2 Unit | Cause: On January 17, 2014, there was a release of SO2 to air due to a unit shut down. Chalmette Refining reported that Coker 2 unit shut down causing a flare event. Followup: No Notes: According the refinery letter, it was determined that no reportable quantities were exceeded during the event. Prior to the refinery letter, it was estimated that 500 lbs of SO2 was emitted in the SPOC report. Note: A Citizen Complaint (#153347) cites this event as a contributing factor for 3 days of odor, which the citizen described as "terrible." |
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