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Chalmette Refining (1376), Chalmette
Releases of Volatile Organic Compounds (VOCs)
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 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 Chalmette Refinery rescinded the 11/17/05 notifications for NO, NO2, VOC, SO2 and H2S since the estimated amounts were less than the reportable quantity of 10lbs.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. | 3,681.0 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. | 9.3 pounds |
| 83685 2005-11-07 | Tank 72 (D-72) | Cause: During periodic rounds and gauging of tank 72 (D-72), refinery operations personnel observed slop oil overflowing from tank 72. It was determined that the tank had experienced an unanticipated sure in inventory between manual gauging events. The release was caused by the unanticipated malfunction of tank gauge equipment. Followup: Yes Notes: Chalmette Refining reported a release of oil (Slop Oil) and Benzene on 1/7/05. Calculations performed after the incident indicate the greater than a reportable quantity of Volatile Organic Compounds (VOCs) was also released during this incident, as such, emissions calculations for VOCs are included in this follow-up report. Hurricane Katrina caused damage to the electronic tank gauge (telepulse) system for tank 72 (D-72). As mitigation step, periodic manual gauging of D-72 was implemented based on anticipated tank inventory movement. At approximately 2345 hours on 11/7/05 during periodic rounds and gauging of tank 72, refinery operations personnel observed slop oil overflowing from tank 72. It was determined that the tank had experienced an unanticipated surge in inventory between manual gauging events. Since the tank receives inventory from multiple sources the reason for the unexpected increase in inventory was no immediately evident. Oil (as slop oil) released from refinery tank 72 (D-72) via overflow. Slop oil and water was released to the carthen tank containment dike. A portion of the slop oil components evaporated to the air. Transfer to tank the was stopped ending the incident. Transfer out of the tank to the other storage was initiated, lowering the level. Vacuum Trucks were dispatched in order to recover released liquids. The electronic tank gauge for tank 72 has been repaired and placed back in service. Liquid released was contained within the tank dike area and recovered via vacuum truck. Refinery personnel have begun removing soils that appear to have come in contact with spilled slop oil and will remove all stained soil for off site disposal. Currently, migration outside of the tank dike or to groundwater is not suspected. Released liquids that did not volatilize were contained within the tank dike area. Liquids were recovered via vacuum truck and placed into refinery tankage for re-processing. Excavated soils are being placed in roll-off containers, characterized and properly disposed of. | 1,862.0 pounds |
| 83087 2005-10-13 | Flare No. 2 | Cause: #2 flare was smoking. In an attempt to reduce the smoke, the flare steam was engaged. Repairs to the flare steam system from the Hurricane Katrina shutdown were still ongoing. The steam was engaged with allowance for draining the lines of condensate prior to putting the steam to the flare.. there was some water carryover, resulting in intermittent steam and a surge of steam which extinguished the flare and pilots. Followup: No Notes: This letter is in regard to calls made by the Chalmette Refinery, notifying of a release of compressed flammable gas/volatile organic compounds (VOCs) on 10/13/05.At 15:00, the #2 flare was smoking. In an attempt to reduce the smoke, the flare steam was engaged. Repairs to the flare steam system from the Hurricane Katrina shutdown were still ongoing. The steam was engaged with allowance for draining the lines of condensate prior to putting the steam to the flare. There was some water carryover, resulting in intermittent steam and a surge of steam which extinguished the flare and pilots. Initial investigation indicated that too few drains were present on the steam line to eliminate the quantity of water created, and there were leaking isolation valved on the steam line. Chalmette will establish review the procedure for commissioning steam to the flare after shutdown to ensure that the line is drained prior to putting steam to the tip of the flare and that the line is checked for valve leaks and pluggings. affected refinery personnel will be trained regarding updates to applicable procedures. The refinery anticipates that these measures will minimize the likelihood of a recurrence of an incident due to the same root cause in the future. The flare was re-lit and the steam was adjusted and stabilized, ending the incident. Initial investigation indicates that too few drains were present on the steam line to eliminate the quality of water created, and there were leaking isolation valves onthe steam line. CRLLC will establish and review the procedure for commissioning steam to the flare after shutdown and will train affected personnel for updated procedures. These measurements should minimize the likelihood of a recurrence | 4,800.0 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. | |
| 81244 2005-08-12 | No information given | Cause: Leaking relief valve released naphtha. Followup: No Notes: BELOW REPORTABLE QUANTITIES. Chalmette Refining rescinded its notification after further review since it was determined that the event that prompted notification was not a reportable event as the amount released was below reportable quantities. | 36.0 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. | 72.0 pounds |
| 80548 2005-07-12 | Coker 2, gas then vented to Tank 304 | Cause: During tropical storm Cindy there was a power failure. This release happened upon re start. Followup: No Notes: The line which allowed the gas to go to the tank was isolated and the incident was ended. The flow indication was calibrated and process logic updated to minimize recurrence. No time given for which the release was stopped, but the event occurred on 07/12/05 at 16:33 hours, was identified at 21:06 hours, and subsequently emission estimates were completed on 07/14/05 at 17:25 hours. No information was given on the amount released of refinery fuel gas in this report. | 12,779.0 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. | 1,736.0 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. | 2.0 pounds |
| 76040 2005-01-07 | D-6305 | Cause: During a transfer of gasoline to tank 6303 (D-6303), gasoline was observed leaking from the side of tank 6305 (D-6305). Tank 6305 later was determined to have been unintentionally filled past capacity, causing overflow to leak through tank side vent. 123,836 pounds of gasoline released to the ground. Report documents amounts volatilized. However, total amounts released to environment in report attached do not add up to 123,836. States 123,836 lbs of flammable organic liquid 'including' the benzene, xylene, and VOCs. Followup: Yes Notes: Contained liquid in tank area and recovered via vacuum truck. Water and foam applied to minimize volatilization and migration into soil. Note that report attached to letter contains information about other compounds released to the environment. Air monitoring report and soil sampling report were requested and provided by letters dated 1/18/05 and 2/28/05, which are attached to the report file. Field interview form states that 582 bbls of gasoline were released, but everything else states 481 bbls. The quantities of pollutants listed in this report were the portion that Chalmette Refinery claims were volatilized; under the Reportability of Liquid Product and Chemical Spills, the Notification Instructions lists that the quantities released were 123,836 lbs of oil (gas), 2748 lbs flammable gases, 980.8 lbs benzene, 8173.2 lbs xylenes. Further in report it is declared that 2747.7 lbs of pollutants were released offsite. Accutest Lab summary of soil testing adds Toluene and TPH-GRO to pollutant list. | 2,544.0 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. | 1,370.0 pounds |
| 92494 2006-12-08 | Number 1 Flare | Cause: heavy oil entered Flare drum and was released as droplets Followup: No Notes: #2 Flare was quickly relit and steam controller placed in manual mode to stop the pulsating until the #2 Flare System could be stabilized. Spill cleanup was initiated for the heavy oil ffrom the #1 Flare to the batture and the Mississippi River. Heavy Oil was removed from the #2 Flare Drum. | 18,597.0 pounds |
| 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. | 463.0 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. | |
| 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. | 1,429.0 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. | 1,228.0 pounds |
| 91605 2006-10-24 | AE-AOA-05-0109 EPN 29 | Cause: Pressure safety valve (PSV) malfunctioned, causing it to relieve below the set pressure. Followup: No Notes: PSV and related equipmt were isolated and taken out of service to end the flaring. PSV was inspected and found to be in need of repair. But, found that o-ring was bad and needed replacing, etc. Letter sent 12 18 06 rescinds prior notifications and revises amts emitted to those listed at left. Had been NOx 564 lbs ; VOC 1925 lbs | 74.0 pounds |
| 90319 2006-08-29 | No information given | Cause: No information given Followup: No Notes: Letter written to rescind notification of 8/29/06 | 44.0 pounds |
| 90163 2006-08-22 | No information given | Cause: first stage recycle finfan leak in HCU Followup: No Notes: Letter written to rescind notification of 8/22/06 | 270.0 pounds |
| 89056 2006-07-05 | No information given | Cause: leak occurred during feed composition change on #1 Pretreater Followup: No Notes: DEQ report with no corresponding letter from CRLLC. Channel bolts tightened. The exchanger gasket surface will be repaired in August during the next schedule pretreater catalyst change-out. | 3,259.0 pounds |
| 88541 2006-06-12 | Feed/Effluent Exchanger (E7502 A-f) | Cause: automatic shutdown due to interruption in electrical current, water leak following thunderstorms. Followup: No Notes: Feed to the #1 Pretreater was shut off, steam was applied to the channel head, and water was used to flush naphtha to the refinery oily water system | 3,399.0 pounds |
| 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. | |
| 99999 2007-10-05 | Emergency Flare System | Cause: power failure. Followup: No Notes: CRLLC followed the Loss of Power Emergency Shutdown Procedures for each unit. | |
| 99496 2007-09-16 | Cat Feed Hydrotreater Unit | Cause: piping failure due to corrosion from leak of DGA and H2S into piping system from DGA contactor. Drop in reactor pressure on the CFHT unit. Leak on outlet piping of the Fin Fan. Emer. shutdown due internal corrosion from a leak of diglycolame/Hydrogen Sulfide Followup: No Notes: Emergency shutdown was initiated. Water spray was applied to decrease emissions until the unit could be safely depressured. CRLLC inspected entire piping system and ID' other corroded areas. CRLLC plans to increase frequency of outlet piping system inspections. DEQ letter of 10/11/07 indicates that incident will be referred to enforcement because it is preventable. | 24,066.0 pounds |
| 99117 2007-09-04 | #1 Flare | Cause: No information given Followup: No Notes: Letter states that no RQ's were exceeded | |
| 100575 2007-09-04 | #2 Coker Unit | Cause: flare isolation unit on coke drum didn't seal when closed. Opened drum to cut it, flare gas backed into drum to atmosphere. Followup: No Notes: No information given | |
| 98704 2007-08-16 | # 3 reformer debutanizer tower | Cause: The LEP absorber tower was shutdown & the #3 debutinizer tower could not send overhead vapor to the LEP therefore #3 towerincr. and PSV was exceed. PSV on the # 3 reformer debutanizer tower reached the PSV set pressure causing a release. The LEP was shutdown due to an unstable steam rate. Followup: No Notes: The feed rate was reduced to the units to stop the release until the PSV was reseated and confirmed not leaking. Follow up letter indicates that human factors also played a role; an operator did not respond appropriately to a series of alarms. | 6,362.0 pounds |
| 98248 2007-07-31 | Flare | Cause: No information given Followup: No Notes: Letter states that no RQ's were exceeded | |
| 98210 2007-07-29 | #2 Flare | Cause: No information given Followup: No Notes: No information given | |
| 96571 2007-05-27 | Naphtha Storage Tank #36 | Cause: see notes. Small hole develops in floating roof of tank permitting vapors to escape. Followup: No Notes: Letter written to rescind notification of 5/27 concerning release of VOCs, Benzene, Xylene | |
| 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 | 0 |
| 94461 2007-03-08 | Tank 66 | Cause: CRLLC inspects Tank 66 and discovers compacted material and holes at the bottom. Performs investigation. Followup: Yes Notes: File contains report from Arcadis, firm hired by ExxonMobil to perform soil assessment. Results of investigation indicate that releases were BRQ. DEQ letter of 10/24/07 states that the Tank 66 investigation will supplement results of an additional RFI assessment and will be evaluated. It is unclear what happens after this letter is received. | Under Investigation |
| 93451 2007-01-24 | No information given | Cause: No information given Followup: No Notes: Letter sent to rescind notification of 1/24/07 concerning release of VOC | 781.0 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 | 647.0 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 | |
| 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. | 469.0 pounds |
| 93102 2007-01-06 | Exchanger E2321 on 2nd Stage Effluent Cooler of Hydrocracker Unit | Cause: leak in the tube sheet on the E2321 Exchanger Followup: No Notes: CRLLC will replace Exchanger E2321 with an upgraded new exchanger. | 50.0 pounds |
| 111122 2008-11-28 | Desalter relief valve header piping | Cause: desalter relief valve header piping developed aleak Followup: No Notes: Release was isolated, line depressurized and scanned, and a clamp was installed. As of 12/1/08 the line was back in service | 9.0 pounds |
| 110959 2008-11-21 | Light ends plant de-propanizer overhead condenser | Cause: leak from light ends plant de-propanizer overhead condenser Followup: No Notes: CRLLC shutdown the LEP ending the leak. Under investigation. 12/15 letter rescinds prior notification. | |
| 110720 2008-11-09 | No information given | Cause: No information given Followup: No Notes: Letter states that emissions were BRQ. | |
| 110004 2008-10-10 | Once Through Cooling Water System | Cause: heat exchanger leaking Followup: No Notes: Letter states that emissions were BRQ. | |
| 109521 2008-09-23 | Outfall 003 | Cause: tube leak on overhead exchanger Followup: No Notes: Shut down the cooling unit and isolated the exchangers. Letter states that emissions were BRQ. Verbal report indicates emission of 1000 lbs of compressed gas. | |
| 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: | |
| 108416 2008-08-28 | HDS Unit | Cause: No information given -leak in fin fans Followup: No Notes: Claims emission was below RQ. | |
| 108528 2008-08-20 | Flare | Cause: shutting down units due to hurricane Followup: No Notes: No Information Given | |
| 107017 2008-07-06 | flange on the Number 3 Reformer Exchanger leaking at the channel head | Cause: flange leak, cause investigation is ongoing; design on the face of the gasket surface of the exchanger. Followup: No Notes: Lowered the system pressure to help mitigate the leak and shutdown the Unit. | 700.0 pounds |
| 103126 2008-02-17 | Flare | Cause: conducting functionality test for acid evacuation system. On of vent valves opened to flare. Followup: No Notes: Letter states that emissions were BRQ. | 31.0 pounds |
| 102968 2008-02-10 | FCC Fractionator Overhead Receiver | Cause: process gases escaped to the atmosphere through the FCC Fractionator because gas in the flare gas header was allowed to reach the overhead receiver due to inadequate isolation between the two systems Followup: No Notes: CRLLC immediately closed the valve on the Overhead Receiver and conducted a check of all the remaining valves on the unit to verify that all the valves were closed. | 9,826.0 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. | |
| 120390 2009-12-28 | #3 Pretreater overhead accumulator | Cause: #3 Pretreater overhead accumulator had leak on site glass. Followup: No Notes: RQ not exceeded. | |
| 117789 2009-09-01 | 10" pipe | Cause: pinhole leak in 10" pipe. Followup: No Notes: RQ not exceeded. | |
| 116591 2009-07-20 | Desulphurization unit clamp | Cause: Desulphurization unit clamp leaked. Followup: No Notes: RQ not exceeded. | |
| 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. | 7.0 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. | 7.0 pounds |
| 114850 2009-05-09 | HDS unit | Cause: HDS unit leak on outlet of E3301. Shut down to do repairs causing release.. Followup: Notes: RQ not exceeded. | 198.0 pounds |
| 112971 2009-02-24 | No Information Given | Cause: No Information Given Followup: No Notes: Below reportable quantities. | 60.0 pounds |
| 112467 2009-02-02 | No Information Given | Cause: No Information Given Followup: No Notes: Below reportable quantities. | 131.0 pounds |
| 112269 2009-01-24 | #1 Flare | Cause: No Information Given Followup: No Notes: Below reportable quantities. | 2.2 pounds |
| 112239 2009-01-23 | No Information Given | Cause: No Information Given Followup: No Notes: Below reportable quantities. | 890.0 pounds |
| 112124 2009-01-19 | No Information Given | Cause: No Information Given Followup: No Notes: No Information Given | 593.0 pounds |
| 111871 2009-01-07 | No Information Given | Cause: No Information Given Followup: No Notes: No Information Given | |
| 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. | |
| 126170 2010-09-07 | Fin Fans | Cause: LDEQ report states the event released hydrogen sulfide and VOC for 163 minutes. CRLLC had a tube failure on the inlet side of an exchager at the hydrodesulfurization unit. Gas was released into the atmosphere.
Follow-up report states that the leak was the result of thermal cycles on the fin fans which occurred during a power interruption. The unit was shutdown and fin fan exchanger was purged with nitrogen. Followup: Yes Notes: RQ. Unit was shutdown and exchanger purged with nitrogen. LDEQ report states that DEQ database was checked several times for a 60 day follow-up notification but no report was sent within 60 days. When contacted they stated no knowledge of 60 day notification requirement. The facility then submitted the second follow-up report notification with root cause analysis. According to the report, the event was not preventable. This facility referred to circuit rider for not submitting the second follow-up notification in accordance with LAC 33.I.3925.A.3 | 2,714.0 pounds |
| 126093 2010-08-19 | Tank 6344 Tank 6344 in the East Tank | Cause: LDEQ report states that a seven day follow report was received from the facility for a release that occurred stating that gasoline was released as a liquid to the roof of a tank and to the ground adjacent to the tank. The transfer of material into the tank was stopped and the roof drain closed. VOC emissions from the release exceeded reportable quantities. Report stated the release was not preventable by the facility investigating the root cause of the release. Operator checking equipment noticed gas smell.
FOLLOW-UP: Report from facility states, that incident was preventable and resulted operators not following written procedures causing an uncalibrated level controller.
Discharge was released to air. Followup: Yes Notes: RQ. LDEQ report states DEQ database was checked several times in November for a 60 day follow-up notification report. No report found in the systems. Chalmette Refinery environmental representative stated he was not aware of the 60 day notification requirement. The facility referred to circuit rider for not submitting a follow-up notification in accordance with LAC 33.I.3925.A.3. On 12/16/2010, the facility submitted a second follow-up notification report. The report states that the leak was preventable and was due to operators not following written procedures causing an uncalibrated level controller. The facility failed to have control facilities in place to prevent to overflow. This is an area of concern with LAC 33:III.905.Control Facilities to be Installed when Feasible." | 2,987.0 pounds |
| 123894 2010-06-01 | FLARE: #1 Flare (Solenoid Valve) | Cause: LDEQ states that the failure was caused by corrosion in the solenoid. An unplanned activation of the solenoid valve occurred, and the FCC Process Gas Compressor was shut down. Eventually, gasses were vented to the flare. Followup: No Notes: Process rates were decreased, and the incident was given to the unit engineer for review. The solenoid was replaced, and the weatherization of the system was updated. LDEQ Report included. No Refinery Letter. | |
| 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. | |
| 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 | |
| 122541 2010-04-02 | no information given | Cause: Verbal DEQ report states: "vapor coming out of ground - Butane." No further details in written report. Followup: No Notes: no info given | |
| 121281 2010-02-04 | storage tank | Cause: floating storage tank roof tilted during heavy rains, released gasoline to roof and roof drain, traveled down drain to soil. Release picked up by air monitor at Chalmette HS.
DEQ report only in this file--references a "seven-day notification" but it's not included. Followup: No Notes: RQ. gasoline foamed to reduce volatilization, recovered from soil with vacuum truck, contaminated soil excavated, bioremediation agent applied to soil. | 633.0 pounds |
| 120686 2010-01-10 | TANK 56; fast loop sampling pump G3832 | Cause: Leaking gasoline blend pump. Gasoline release adjacent to Tank 56. Followup: No Notes: Liquid removed with vacuum truck, contaminated soil removed & disposed of. Report stated that no groundwater impact or health effects were identified as a result of incident. | 512.0 pounds |
| 133679 2011-09-06 | Tank Roof Leak | Cause: Emission values included in the later report of 134390. All values in notes for this report. On August 9, 2011, at approximately 0930 hours, oil was discovered on the roof of Tank 71. The roof was cleaned and visually inspected, and though no leaks were discovered, it was determined that additional inspection was required, including mechanical thickness readings. Additional cleaning was necessary for this to occur. Concurrently, it was determined that the source of the oil was likely a failed check valve on the tank roof drain. This drain was plugged to ensure no oil could back up onto tank roof.
On Friday, October 7, 2011 at approximately 1040 hours, while cleaning the roof of Tank 71 to allow the inspection group to access the roof for mechanical thickness reading, scale was removed and a hole developed in the roof. Cleaning was stopped at that point and personnel exited the roof and notified Refinery personnel. The initial leak estimate determined it to be potentially in excess of 1000 lbs of hydrocarbon and 10 lbs of benzene. Prompt notifications to the agencies were made upon discovery.
In a separate event at 0915 hours on October 11, 2011, approximately 20 gallons of gasoline were released to the soil when a cam lock fitting did not seal properly at Tank 403. The emissions associated with this event were approximately 116 lbs hydrocarbon and 1 lb of benzene. In combination with the above incident, the RQ for benzene was exceeded. Followup: No Notes: Mitigation efforts to reduce emissions potential commenced promptly, as tank level was reduced, however, the product could not be removed from the tank roof. Foam was applied to the tank roof at 1540 hours, greatly reducing the emissions from the event. The tank roof was landed Sunday, October 9, and the oil was able to be removed from the floating roof. Additionally, the tank contents were drained and water was introduced into the tank, however a thin oil layer is still present as repairs progressed. There were multiple complaints associated with this incident; a. Terrible odor coming from the direction of the river where there is a barge parked, and several facilities in that direction as well. t134349 b. Terrible odor coming from the direction of the river making several people in area sick. Vomiting, headache, and child exposure. t133866 c. Barge that has been tied up at the docks for 2 days is producing terrible odors. No tempo # d. Incredibly strong and foul odor coming from the direction of the river. No Tempo # | |
| 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." | 146.0 pounds |
| 131805 2011-06-13 | fin fan on the Cat Feed Hydrotreater | Cause: Aire release of hydrogen sulfide and compressed flammable gas from fin fan on Cat Feed Hydrotreater at Chalmette Refining. According to the refinery letter, "the Cat Feed Hydrotreater (CFHT)Unit lost power during a transformer switch, resulting in a pressure increase, and the subsequent leak on the E-7778 fin fan."
It was determined that the cause was premature corrosion in the overhead fin fans of the CFHT Unit. Followup: No Notes: RQ of hydrogen sulfide. BRQ of VOCs. Inventory was removed from the unit and system pressure was reduced in order to stop the leak and make necessary repairs Chalmette Refining retained U.S. Risk Management to perform community monitoring during the event. The fin fan tube was isolated until repairs and/or replacement are completed. | |
| No LDEQ Reported 2012-10-10 | no information given | Cause: Followup: No Notes: Preliminary air monitoring was observed. | |
| 143640 2012-10-05 | no information given | Cause: Release of Volatile organic compounds (VOC) on October 5, 2012. Followup: No Notes: No information given. Report states that no reportable quantities were exceeded for VOC during this event. | |
| 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. | 1,938.0 pounds |
| 152220 2013-11-07 | No Information Given | Cause: Reported release of volatile organic compounds and hydrogen sulfide that occurred on November 7, 2013. No reportable quantities were exceeded during this event. Followup: No Notes: | |
| 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. | |
| 148156 2013-04-16 | Alkylation Unit | Cause: A hydrofluoric acid leak at a flange on the alkylation unit was discovered during start up on April 16, 2013 at approximately 12:45 hours. Followup: No Notes: A clamp isolated the leak on the evening of April 17, 2013. The initial report estimated 26 pounds of flammable gas was released along with less than 1 pound of hydrogen fluoride. The refinery letter states that no reportable quantities were exceeded during this event. | |
| 147793 2013-04-03 | discharge pipe from the Flare 1 knockout drum | Cause: On Wednesday, April 3, 2013 at approximately 0145, a Chalmette Refining, L.L.C. (CRLLC) operator noticed odors around the waste water treatment plant (WWTP) shelter. At 0225, CRLLC was notified by St. Bernard Parish Sheriff's Office of a community complaint regarding a potential odor. The potential odor issue was communicated to relevant supervisors during the 0400 shift change, and operators continued to investigate the cause of odor during initial rounds. At approximately 0600, CRLLC personnel detected and reported potential odors, and intensified the investigation to identify the source and possible root cause.
Personnel identified a leak from a pipe near Tank 5502 at 0645 and positively identified the source as a discharge pipe from the Flare 1 knockout drum at 0708. Moderate to heavy rain water and insulation covering the pipe, made it difficult to identify the leak source.
The root cause of failure was determined to be highly localized internal pipe corrosion. Followup: Yes Notes: The pipe section with the leak was completely isolated at 0745, then vacuum trucks were utilized to clean up the spilled material. An engineered pipe clamp was installed to eliminate the pipe leak. To minimize any further potential community impacts from the odor, firefighting foam and suppressants were applied to the area possibly affected by the leak. Contaminated soil was remediated. In addition to determining root cause and actions regarding the pipe failure CRLCC has identified two actions to be taken to improve odor management and response: 1. Update guidelines for addressing community odor complaints. 2. Refresh personnel involved in this incident on expectations for documenting odor complaint activities/ observations on written shift change reports. The accident did result in offsite impact because ExxonMobil officials released this claims number for any community members affected: 866-752-6339. The facility made a small mention of the bad smell that permeated throughout the metro area in their letter to LDEQ. According to Exxon's April 10th report, "While there was no impact to ambient air quality standards set by the LDEQ and EPA to protect health and environment, the leak was malodorous given the 245 parts per million mercaptan levels of the sulfur compounds. While there was no impact to ambient air quality standards set by the LDEQ and EPA to protect health and the environment, the leak was malodorous given the 245 parts per million mercaptan levels of the sulfur compounds. The May 30th follow up updates this value to 127 parts per million. According to the 30 day follow up on May 30, 2013: On July 9, 2013 - CRLLC has pledged to participate in the Jefferson Parish LEPC meeting. | |
| 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. | 1,380.0 pounds |
| 156412 2014-06-03 | Tank 61 | Cause: Personnel observed a material leaking at Tank 61 from the roof drain area in the dike area. Upon identification, personnel mobilized and safely blocked in the roof drain and dike valve in the containment area. Due to heavy rains the roof drain and dike valve were open for draining the area per normal work practice. CRLLC personnel noticed some hydrocarbon had entered the concrete drain ditch, where it was contained. While blocking in the roof drain, personnel noted that hydrocarbons and water partially covered the north side of the tank roof. The tank immediately began to be pumped down to empty the contents. The tank was pumped down to a level that completely exposed the tank roof. After identification of the issue, the area was foamed to minimize emissions, and cleanup began immediately. CRLLC is conducting a failure analysis of the tank roof to determine the cause of the failure. Followup: Yes Notes: After isolating the leak, operators used foam to minimize volatilization and vacuum trucks were utilized to clean up the area. All material in Tank 61 was transferred to Tank 60 to allow operators to address the Tank 61 floating roof. | 3,775.0 pounds |
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