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Phillips 66 (2538), Lake Charles

Releases of Sulfur Dioxide

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
80241

2006-06-30
FLARE-South Flare (EP-31)
Cause: Incident due to combustion of sour gases at the flare which were diverted from the South Flare Gas Recovery system. The SFGR compressors were operating at reduced gas compression volumes as a result of the presence of excess steam in th

Followup: No Information Provided

Notes: As soon as the problem was resolved the compressors resumed operating at full capacity and the release ended. Emissions didn't exceed permit limits and no reportable quantities were exceeded, therefore the notification was made as courtesy only.
639.0 pounds
84653

2005-12-18
Leak
Cause: No information Given

Followup: Yes

Notes: Called maintenance to fix it, replace lube oil plunge
768.0 gallons
84402

2005-12-08
FLARE-South Flare Gas Compressor
Cause: South Flare Gas Compressor shut down due to maintenance

Followup: Yes

Notes: This report serves as the follow up to the telephone notification of the incident which occurred on December 8th.
55.0 pounds
84367

2005-12-07
FLARE (Area A, South Flare)
Cause: South Flare Has Recovery Compressors shut down due to planned maintenance.

Followup: No

Notes: Emissions didn't exceed permit limits, and no reportable quantities were exceeded, notice as courtesy only.
53.0 pounds
84329

2005-12-05
FLARE (Area A North Flare)
Cause: The Gas Recovery Plant COmpressor malfunctioned, resulting in a release of Sour Gas to the North Flare.

Followup: No

Notes: Shutdown of SFGR. The high temps experienced were a result of a surge of has flow from another process unit. This has stream flow rate was corrected and the GRP compressor returned to its normal status.
3,080.0 pounds
84330

2005-12-05
FLARE (South Flare Are B EP-31)
Cause: The South Flare Gas Recovery Compressor was shutdown in an attempt to get the GRP compressor to run.

Followup: No

Notes: Compressor started back as soon as possible.
1,780.0 pounds
84284

2005-12-03
FLARE (Area B South Flare EP-31)
Cause: South Flare Gas recovery Compressor was shutdown to perform relief valve maintenance.

Followup: No

Notes: No excess emissions above permit limits, and no reportable quantities were exceeded, therefore the notification was made as courtesy only.
650.0 pounds
84196

2005-11-30
C-Szorb Unit
Cause: Fire due to a flange leak on the feed exchanger to the S-Znob Unit.

Followup: No

Notes: Fire was extinguished, the course was isolated and the unit was shut down. Incident was preventable; flake leak caused by unequal heat expansion due to incorrect application of insulation.
83599

2005-11-02
FLARE-(Area A South Flare Gas Reciovert C-1430)
Cause: South Flare Gas Recovery Compressor was Shut down due to nipple failure.

Followup: No

Notes: Emissions didn't exceed permit limits, and no reportable quantities were exceeded, therefore this notification was made as a courtesy only. Compressor was shut down.
1.0 pounds
83574

2005-11-01
FLARE (Area A South Flare EP-31)
Cause: Export Compressor shutdown.

Followup: No

Notes: Release over reportable quantities. Operators shut down export compressor. Incident unpreventable due to compressor spillback problems.
702.0 pounds
83596

2005-11-01
Release
Cause: corrosive liquid in vessed of the de-ethanizer boiler

Followup: Yes

Notes: report serves as follow up to incident on November 1st. Reboiler was repaired and de-ethanizer was put back in service.
245.0 pounds
83518

2005-10-29
FLARE (Area B-South Flare EP-31)
Cause: Incident due to shutdown of the SOuth Flare GAs Recovery System. the SFGR System compressors were shutdown as a result of a compressor upset condition in the Has Recovery Plant.

Followup: No

Notes: Once normal operation of the Gas Recovery Plant was restored, the SFGR compressors were restarted and the release ended. Permit limits not exceeded for the period of the release. The incident was determine dto be unpreventable as the compressor upset
2,200.0 pounds
83522

2005-10-29
FLARE (North Flare Area A EP-64)
Cause: Incident due to an upset at the No. 2 Coker Unit. A suction strainer on compressor C-3301 had plugged an caused the compressor to shutdown. The gazes normally handled by the compressor were rerouted and the release ended.

Followup: No

Notes: Incident determined to be unpreventable as the plugging of the compressor strainer could not be foreseen.
30,400.0 pounds
83456

2005-10-27
FLARE (Area B South Flare EP-31)
Cause: Incident due to excessive flaring associated with FCC unit Start-up.

Followup: No

Notes: Facility personnel were having difficulty in starting a compressor during the FCC start up due to faulty instrumentation on the compressor suction drum. Once the instrumentation was repaired, operations completed start yp of the unit and the release en
9,514.0 pounds
83419

2005-10-25
FLARE (North Flare Area A EP-64)
Cause: combustion of gases from start up of refinery units following Hurricane Rita.

Followup: No

Notes: During the flaring period, unit operators were making the necessary adjustments to provide an adequate amount of gas at the compressor suction and the line our C-3301 compressor. The release ended upon completion of start up of process units in Area A.
1,008.0 pounds
82367

2005-09-21
FLARE (North Flare EP-64)
Cause: release occurred due to shutdown of the refinery in preparation for Hurricane Rita.

Followup: No

Notes: In addition to the flaring from the North flare, there was possible visible flaring from the South and West Flares, however no excess emissions were noted from the South or West Flares. Refinery indicated that their hurricane shutdown plan will be upda
3,400.0 pounds
82372

2005-09-21
FLARE (Area A South Flare EP-31)
Cause: release due to a loss of 2 compressors located at the South Flare location that became inoperative due to high oxygen levels in the compressor's suction.

Followup: No

Notes: Incident Secured by purging the lines on the date of notification. emissions didn't exceed reportable quantities, therefore the notification shall serve as a courtesy call. No further action required
300.0 pounds
05-BB007-1484

2005-09-02
FLARE-(Are A, South Flare EP-31)
Cause: OTHER-Incident occurred during the replacement of the SOuth flare gas recovery compressor.

Followup: No

Notes: Multiple attempts made to contact the State police, DEQ and National Response Center but unsuccessful during all times. Release didn't exceed the permit limit nor the Sulfur Dioxide reportable quantities.
244.0 pounds
81725

2005-08-28
FLARE (South Flare EP-31)
Cause: The incident occurred due to the impaired capability of the South Flare Gas Recovery System. The impairment in the gas recovery system was caused by high inlet temperature resulting from high blowdown system temperature.

Followup: No

Notes: Facility took immediate corrective action to make the necessary adjustments and return the SFGR system to normal operation. The letter states that no reportable quantities were exceeded and the notification was made as a courtesy only.
341.0 pounds
81485

2005-08-19
FLARE (South Flare EP-31)
Cause: The incident involved a release of Sulfur Dioxide from he SOuth Flare due to a shutdown of the SOuth Flare Gas Recovery System for scheduled relief valve maintenance on a vessel. Upon completion of the work, the SFGR System was r

Followup: No

Notes: Upon completion of the work, the SFGR system was returned to normal operation and the release ended. Letter stated that there were no excess emissions above permit limits, and no reportable quantities were exceeded. Notification made as a courtesy onl
430.0 pounds
81422

2005-08-18
FLARE (South Flare EP-31)
Cause: The incident involved a release of sulfur dioxide due to a shutdown of the South Flare Gas Recovery System for a scheduled relief valve maintenance on a vessel.

Followup: No

Notes: Upon completion of the work, the SFGR system was returned to normal operation and the release ended. Letter stated that there were no excess emissions above permit limits, and no reportable quantities were exceeded. Notification made as a courtesy onl
440.0 pounds
81473

2005-08-18
FLARE (South Flare EP-31)
Cause: The Incident involved a release of Sulfur Dioxide from the South Flare due to a shutdown of the South Flare Gas Recovery System (SFGR) resulting from a faulty O2 analyzer on the compressor inlet gas.

Followup: No

Notes: The O2 analyzer was repaired thus the SFGR system was returned to operation and the release ended.
472.0 pounds
80427

2005-07-10
FLARE (North Flare EP-64)
Cause: Release due to shutdown of the #4HDS, #5HDS, and C-3301 Wet Gas Compressor.

Followup:

Notes: Operations took immediate corrective action to minimize emissions by curing unit charge rates, The unit rates were reduced until equipment could be repaired and brought back online. Incident determined to be unpreventable. Refinery indicated that the
13,200.0 pounds
79470

2005-05-31
FLARE (South Flare EP-31)
Cause: South Flare Gas Recovery Compressors shutdown.

Followup: No

Notes: Release ended as soon as the compressor was restarted. Emissions were not in excess of permit limits and no reportable quantities were exceeded, therefore the notice was made as a courtesy only.
8.0 pounds
79466

2005-05-30
FLARE (South Flare EP-31)
Cause: STORMS-Incident occurred as a result of a process upset at the FCC which occurred due to a heavy rainstorm.

Followup: No

Notes: Release ended once unit operators regained control of the process. Emissions not in excess of permit limits and no reportable quantities exceeded, therefore notice as courtesy.
9.0 pounds
79451

2005-05-29
FLARE (South Flare EP-31)
Cause: STORMS-Incident occurred as a result of an upset on the product fraction section of the FCC unit due to a rainstorm.

Followup: No

Notes: Release ended once unit operators regained control of the process after the rain subsided. Emissions were not in excess of permit limits and no reportable quantified were exceeded, therefore notification made as courtesy only
13.0 pounds
79400

2005-05-27
FLARE (South Flare EP-31)
Cause: released caused due to shutdown of the SOuth Flare Gas recovery System in order to replace C-1431 compressor.

Followup: No

Notes: As soon as work was completed, the system was restarted and the release ended. According to the company, emissions didn't exceed the permit limits and no reportable quantities were exceeded. Notice made as courtesy.
79328

2005-05-24
FLARE (South Flare EP-31)
Cause: This incident resulted due to combustion of excess vent gases from he South Flare Gas recovery System.

Followup: No

Notes: Emissions not in excess of permit limits and no reportable quantities were exceeded. The notice was sent as courtesy.
360.0 pounds
79166

2005-05-18
FLARE (South Flare EP-31)
Cause: Incident occurred due to shutdown of the South Flare Gas recovery System.

Followup: No Information Provided

Notes: Emissions didn't exceed permit limits and no reportable quantities exceeded, therefore notice only as courtesy.
296.0 pounds
77888

2005-05-08
FLARE (South Flare EP-31)
Cause: The oxygen analyzer sample plugged up causing a false reading in the analyzer which triggered a shut down of the flare recovery system.

Followup:

Notes: Instrument craftsmen cleaned out the sample system and the compressors were restarted.
3,200.0 pounds
78898

2005-05-07
FLARE (South Flare EP-31)
Cause: Failure of O2 Analyzer; failed and tripped out the South flare gas recovery system.

Followup: No

Notes: Instrument craftsmen is repairing the analyzer. Previously identified capital project w/in days of completion installs 2 redundant, non-intrusive 02 analyzers with 2 of 2 voting required for shutdown.
8,400.0 pounds
77846

2005-03-28
FLARE (North Flare)
Cause: planned and controlled release associated with turnaround maintenance on the South Flare. The gas normally routed to the S Flare was transferred to the North Flare during the maintenance period.

Followup: No

Notes: No emission excesses therefore the notification was as courtesy.
77849

2005-03-28
FLARE (North EP-64)
Cause: Compressor C-1202 shut down due to mechanical problems. As a result they had to shur down No. 4 and 5 and 5 HDS Units. Had to depressor the unit to flare to sweep the reactors. The shutdown was caused by burned-out motor leads at the

Followup: No

Notes: Corrective action was taken immediately to replace the damaged electrical components and return the compressor to service. This incumbent was found to be unpreventable as the equipment failure could not be anticipated. No reportable quantities were exce
445.0 pounds
77838

2005-03-24
FLARE (South Flare EP-31)
Cause: planned outage of the SFGR compressors for removal of RV's and installation of blinds associated with FCC T/A

Followup: No

Notes: Plan to restart compressor. No excess emissions above permit limits, therefore notification only as courtesy.
74.0 pounds
77792

2005-03-23
FLARE (South Flare Ep-31, Area B)
Cause: Shutdown SFGR Compressors for removal of RV'S and installation of blinds associated with the FCC T/A.

Followup: No

Notes: Plan to start compressors. No excess emissions above permit limits, therefore notification only as courtesy.
233.0 pounds
77765

2005-03-22
FLARE (North Flare)
Cause: No. 4/5 HDS Recycle Compressor, C-1202, motor tripped off-line. Could not reset the motor to restart the compressor and proceeded to shutdown both units. Per the emergency shutdown , they removed the charge from each unit and purges

Followup: No

Notes: Shutdown both HDS units immediately. Removing the charge from the reactor sections stops H2S production.
542.0 pounds
77719

2005-03-21
FLARE (South Flare EP-31)
Cause: SFGR compressor shutdown from high pressure, due to FCC steaming and No 2 Coker going to blowdown early due to hitting a 94% source (drum level). Undetermined if Area A or B will be the one to calculate the volume of emissions.

Followup: No

Notes: Better coordination between areas when steaming equipment during T/A. Ensure coordination of high steam-out activity with coker drum switches. No excess emissions above permit limits, therefore notification only as courtesy.
74.0 pounds
77739

2005-03-21
FLARE (South Flare EP-31)
Cause: SFGR compressors shut down on high flare header pressure. FCC steaming for turnaround elevated flare header pressure (along with 2CTU gas) and when No. 2 Coker went to the blowdown at normal time (not early), it spiked the header pressure up high enough

Followup: No

Notes: Cut FCC steaming back and started SFGR compressors. No excess emissions above permit limits, therefore notification only as courtesy.
420.0 pounds
77636

2005-03-16
FLARE (South Flare EP-31)
Cause: release for sulfur dioxide due to shutdown of the south flare gas recovery (SFGR) system to allow the FCC Unit to remove a relief valve onto he flare line and install a block valve for turnaround work. Shut down increased the amoun

Followup: No

Notes: Refinery said the incident was not preventable because it was necessary for unit turnaround maintenance. No permit limits were exceeded during the event and the notification was made as courtesy.
902.0 pounds
77768

2005-02-24
FLARE (South Flare EP-31)
Cause: planned outage of the SFGR compressors for removal of RV's and installation blinds associated with the FCC T/A.

Followup: No

Notes: Planned maintenance. No excess emissions above permit limits, therefore notification only as courtesy.
438.0 pounds
77768

2005-02-24
FLARE (South Flare EP-31)
Cause: planned outage of the SFGR compressors for removal of RV's and installation blinds associated with the FCC T/A.

Followup: No

Notes: Planned maintenance. No excess emissions above permit limits, therefore notification only as courtesy.
438.0 pounds
76779

2005-01-26
FLARE (South Flare and Refinery Process Heater/s Boilers)
Cause: Release of sulfur dioxide from the Refinery Process Heaters/Boilers and the south Flare due to an upset of the No.3 Amine Unit.

Followup: No

Notes: Corrective action to end the release entailed repairing a defective level indicator and stabilizing the amine system to return to normal operation. No permit limits were exceeded and the notification was made as a courtesy only.
298.0 pounds
76181

2005-01-13
FLARE (South Flare EP-31)
Cause: incident involved release of sulfur dioxide from the south flare due to a shutdown of the South Flare Gas recovery (SFGR) System. The SFGR compressor was shutdown in order to replace a faulty pressure indicator.

Followup: No

Notes: Upon completion of the replacement, the compressor was resorted and the release ended. According tot he facility's report the incident was preventable, however there were no excess emissions above reportable quantities and the notification was madeas
624.0 pounds
92372

2006-12-01
Area A- North Flare (EP64)
Cause: see notes. RV lifting in the #5 HDS & releasing to the flare. Overhead pressure controller froze up due to cold weather snap pressured up 5 HDS overhead & stripper

Followup: No Information Provided

Notes: WEATHER. Put steam on pressure controller and bypassed process around overhead cooling water condenser to heat up 5 HDS overhead. Potentially add low temp alarm on overhead drum to adjust operation during cold weather
2,074.0 pounds
92036

2006-11-17
Sulfuric Acid Plant
Cause: Acid strength analyzer failed

Followup: No

Notes: Letter states that emission was BRQ. No information given
76.0 pounds
91237

2006-10-09
Area A-North Flare (EP-64)
Cause: A relief valve on the stripper is the 6HDS lifted due to a process upset caused by a hydrogen compressor shutdown & consequent unit upset.

Followup: No Information Provided

Notes: A management environmental review will develop a plan to identify leaking RVs and troubleshoot the flare system during relied events/upsets so that future releases do not exceed permit limits. HAZMAT#0606318
861.0 pounds
91101

2006-10-04
Area A- North Flare EP64
Cause: RV leakage

Followup: No Information Provided

Notes: Relief Valve is being changed to prevent further leakage to the flare. HAZMAT#0606201
3,026.0 pounds
90166

2006-08-21
Area A- North Flare (EP-64)
Cause: Compressor was shutdown due to an external trip. The cause of the trip is unknown and is currently being investigated to prevent future occurence

Followup: Yes

Notes: The cause of the trip will be identified using the RCFA process and the area will take action - using engineering controls if possible - to ensure that trip never happens again. HAZMAT#0605264
1,721.0 pounds
89157

2006-07-10
Area B - South Flare (EP-31)
Cause: Low suction pressure on C-1430, south flare gas recovery compress

Followup: No Information Provided

Notes: Installing low and low-low level alarm on caustic level to prevent future shutdown of the SFGR compressor. HAZMAT #
88915

2006-06-27
#1/2 Sulfur Recovery Unit (SRU)
Cause: An instrumentation malfunction occurred which resulted in a unit upset.

Followup: No Information Provided

Notes: No information given
40.0 pounds
88848

2006-06-24
Area B - South Flare (EP-31)
Cause: Planned maintenance to reinstall RV on #1 Amine Regeneration Unit (ARU) required shutdown of the South Flare Gas Recovery system.

Followup: No Information Provided

Notes: South Flare Gas Recovery Compressor was restarted following completion of work. HAZMAT #06-03981
1.0 pounds
88648

2006-06-16
Area A - Other
Cause: SFGR Compressor was shutdown to perform relief valve work.

Followup: No Information Provided

Notes: None needed since exceedance did not occur HAZMAT # 06-038
15.0 pounds
88547

2006-06-13
South Flare
Cause: Release caused by a Flare Gas Recovery shutdown, associated with Turnaround activitie

Followup: No Information Provided

Notes: No information given
88503

2006-06-12
Area B - South Flare (EP-31)
Cause: The South Flare Recovery Compressor was shutdown to perform relief valve inspection work.

Followup: No Information Provided

Notes: Once inspection was complete, compressor was put back in service. HAZMAT#
46.0 pounds
88366

2006-06-06
Area B- South Flare (EP31)
Cause: see notes. Intermittent power surge due to malfunctions at the Entergy Power Company. Emissions resulted from power failure.

Followup: No Information Provided

Notes: Power failure. Restarted and/or isolatedpertinant units to prevent further impact. HAZMAT#
2,360.0 pounds
88297

2006-06-04
Area A- North Flare (EP-64)
Cause: A refinery process unit (#7 HDS) was being depressured and steamed to the flare as part of a pre-turnaround shutdown procedure.

Followup: No Information Provided

Notes: Letter from CP indicates that an instrument malfunctioned causing an incorrect reading that indicated an excessive release of SO2
<10
87173

2006-04-16
Area A- South Flare (EP-31)
Cause: see notes.

Followup: No Information Provided

Notes: SFGR tripped due to high O2 right after a #2 Coker blow down event. SFGR was started back 30 minutes after the incident. HAZMAT#
50.0 pounds
86847

2006-03-29
Excel -Sulfur Plant (EP-111)
Cause: see notes. Based on temperature trends & air demand analyzer readings, the SO2 was being formed in the 3rd converter bed of the Claus reactor. Excess O2 from the reaction furnace was reacting with sulfur on the catalyst creating SO2 and hea

Followup: No Information Provided

Notes: Discuss learnings with operations. HAZMAT#
220.0 pounds
86572

2006-03-18
Area B- South Flare (EP31)
Cause: Emissions occurred when the SFGR compressor system was shut down to install relief valves.

Followup: No Information Provided

Notes: South Flare Caustic Scrubber was in service during this outage. HAZMAT#
less than 1
86430

2006-03-13
Area B- South Flare (EP31)
Cause: -The SFGR compressor was shut down to facilitate the installation of the RV for W-10.

Followup: No Information Provided

Notes: Once work completed, the SFGR compressor will be started up. In the future, STL's must plan around routine operations. HAZMA
86154

2006-03-02
Area C- North Flare (EP-64)
Cause: The No. # Crude Unit shut down for turnaround resulted in excess emissio

Followup: No Information Provided

Notes: No Information given.
1,120.0 pounds
86076

2006-02-27
Area B -South Flare (EP31)
Cause: South Flare Gas Recover compressor was shutdown to facilitate flare work on W-10.

Followup: No Information Provided

Notes: Work is planned to minimize duration of compressor outage thus minimizing quantity of pollutants releases. HAZMAT #06-01195
55.0 pounds
85943

2006-02-24
Area B- South Flare (EP31)
Cause: Release caused by poor NaHS operation and south flare caustic scrubber startup not completed.

Followup: No Information Provided

Notes: South Flare Caustic Scrubber is in full operation. HAZMAT # 06-01158
5,600.0 pounds
86019

2006-02-23
Area B- South Flare (EP31)
Cause: The suction pressure on the SFGR compressors dropped below the low-low suction pressure trip point and shutdown the compressor that was running. The suction pressure dropped due to commissioning activites or the South Flare caustic scrubber project.

Followup: No Information Provided

Notes: Compressor restarted. Troubleshooting performed subsequent to the event reveled that the caustic scrubber level was not sufficient to hold enough backpressure or the recovery compressor suction. The level instrumentation will be revised to prevent reoccurence of this event. HAZMAT #06-01120
85927

2006-02-19
Area C- North Flare (EP-64)
Cause: see notes. Overpressure of W-1150 and W-1301, due to plugged offgas line, resulting in relief valves lifting to North Flar

Followup: No Information Provided

Notes: WEATHER - near freezing ambient temperatures initiate chain of events that produce release.Reroute PB liquid from going through offgas line to prevent line freezing/hydrate formation.
7,438.0 pounds
85778

2006-02-11
North Flare (EP-64)
Cause: see notes. A loss of electrical power occurred caused by failure of an Entergy own electrical transformer. The electrical power loss resulted in emergency shutdown of the majority of process units. Emergency shutdown instrumentation directed hydrocarbon gas streams to the refinery complex flares resulting in excess emissions of SO2, H2S, and NOx from the complex's North and South Flares. Additional flaring of gas streams resulted from the staggered process unit and various start up once electrical power was restore

Followup: Yes

Notes: POWER FAILURE. A root cause failure analysis is being conducted on this incident. Its results will be used to develop actions that will potentially preclude a recurrence.
6,600.0 pounds
85778

2006-02-11
North Flare (EP-64)
Cause: see notes. A loss of electrical power occurred caused by failure of an Entergy own electrical transformer. The electrical power loss resulted in emergency shutdown of the majority of process units. Emergency shutdown instrumentation directed hydrocarbon gas streams to the refinery complex flares resulting in excess emissions of SO2, H2S, and NOx from the complex's North and South Flares. Additional flaring of gas streams resulted from the staggered process unit and various start up once electrical power was restore

Followup: Yes

Notes: POWER FAILURE. A root cause failure analysis is being conducted on this incident. Its results will be used to develop actions that will potentially preclude a recurrence.
1,280.0 pounds
85654

2006-02-06
North Flare (EP-64)
Cause: Crude Tower pressure control valve, instrument air line was blocked in by a contractor. The control valve opened and the crude tower started depressing to the flare. The air line block valve was opened and the control valve closed of

Followup: Yes

Notes: Instrument air lined back up to valve to close off from flare.
1,820.0 pounds
85529

2006-02-01

Excel Paralubes SRU (EP-111)
Failed check valve
South Flare (EP-31)
West Flare (EP-110)
Cause: Loss of containment occurred due to the structural failure of check valve on the discharge of Heater H-11001, which allowed a hydrocarbon release to the atmosphere. The hydrocarbons ignited causing significant damage to the process piping and insturmentation associated with the heater

Followup: Yes

Notes: root cause failure analysis is being conducted. Its results will be used to develop actions that will preclude a recurrence of this event.
140.0 pounds
85529

2006-02-01

Excel Paralubes SRU (EP-111)
Failed check valve
South Flare (EP-31)
West Flare (EP-110)
Cause: Loss of containment occurred due to the structural failure of check valve on the discharge of Heater H-11001, which allowed a hydrocarbon release to the atmosphere. The hydrocarbons ignited causing significant damage to the process piping and insturmentation associated with the heater

Followup: Yes

Notes: root cause failure analysis is being conducted. Its results will be used to develop actions that will preclude a recurrence of this event.
4,260.0 pounds
85529

2006-02-01

Excel Paralubes SRU (EP-111)
Failed check valve
South Flare (EP-31)
West Flare (EP-110)
Cause: Loss of containment occurred due to the structural failure of check valve on the discharge of Heater H-11001, which allowed a hydrocarbon release to the atmosphere. The hydrocarbons ignited causing significant damage to the process piping and insturmentation associated with the heater

Followup: Yes

Notes: root cause failure analysis is being conducted. Its results will be used to develop actions that will preclude a recurrence of this event.
27,600.0 pounds
85529

2006-02-01

Excel Paralubes SRU (EP-111)
Failed check valve
South Flare (EP-31)
West Flare (EP-110)
Cause: Loss of containment occurred due to the structural failure of check valve on the discharge of Heater H-11001, which allowed a hydrocarbon release to the atmosphere. The hydrocarbons ignited causing significant damage to the process piping and insturmentation associated with the heater

Followup: Yes

Notes: root cause failure analysis is being conducted. Its results will be used to develop actions that will preclude a recurrence of this event.
3,000.0 pounds
85452

2006-01-28
High Pressure Fuel Gas Heater Stacks
Cause: Exchanger leak caused the H2S in the High Pressure Fuel Gas (HPFG) System to increase. This resulted in SO2 being released from all heater stacks on that system.

Followup: Yes

Notes: Investigating the root cause of the leak. Adjusted the pressure balance of the process as to not leak H2S into the Lean Amine System. Repair the heat exchangers at the next until shutdown.
340.0 pounds
84930

2006-01-04
South Flare, Compressor C-1430
Cause: C-1430 had a release valve which was leaking in the reverse direction. This caused an increase in the flare gas to the South Flare header.

Followup: No

Notes: A DCS alarm to indicate run status of C-1430 is proposed.
5,880.0 pounds
101739

2007-12-16
North Flare
Cause: No information given

Followup: Yes

Notes: No information given
1,100.0 pounds
100875

2007-11-08
North Flare
Cause: relief valve lifted

Followup: No

Notes: No information given
6,517.0 pounds
100243

2007-10-17
Sulfuric Acid Plant duct
Cause: hole developed in duct work

Followup: No

Notes: No information given
34.0 pounds
100021

2007-10-07
South Flare
Cause: unit shut down for flare header maintenance

Followup: No

Notes: Restablished level in South Flare scrubber and restarted South Flare Gas Recovery Compressor
2,083.0 pounds
99970

2007-10-04
North Flare
Cause: loss of flare analyzer

Followup: No

Notes: Report states no excess emissions from North Flare during loss of flare analyzer
99837

2007-09-28
North Flare
Cause: multiple units were being shut down for turnaround, and caused steam to build to flare resulting in the analyzer being water logge

Followup: No

Notes: Steam purging rate reduced to lower emissions.
8,881.0 pounds
98135

2007-07-26
Sulfur Recovery Unit
Cause: Hydrocarbons were entrained into feed and a loss of containment occurred.

Followup: No

Notes: Incident is related to 07-4185, occurred within 24h of each other, and have the same root cause. Units producing sour water/acid gas rates were reduced and feed was shifted to #4/5 SRU and NaSH plant. #2 SRU was shut do
930.0 pounds
98116

2007-07-25
Sulfur Recovery Unit
Cause: Hydrocarbons were entrained into feed and a loss of containment occurred.

Followup: No

Notes: #1 SRU feed was redirected to #2 SRU, #1 SRU was shut down for repai
2,269.0 pounds
98116

2007-07-25
Sulfur Recovery Unit
Cause: Hydrocarbons were entrained into feed and a loss of containment occurred.

Followup: No

Notes: #1 SRU feed was redirected to #2 SRU, #1 SRU was shut down for repai
142.0 pounds
97829

2007-07-13
North Flare
Cause: see notes

Followup: No

Notes: a root cause failure analysis will be completed to determine the cause of the equipment failure. Once emissions were noticed, unit was shut dow
21,950.0 pounds
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.
798.0 pounds
97272

2007-06-20
Sulfur Recovery Unit
Cause: Gas header tripped due to loss of fuel gas

Followup: No

Notes: No information given
386.0 pounds
96694

2007-05-31
South Flare
Cause: instrument malfunction on a drum on the scrubber on the flare header

Followup: Yes

Notes: Cause analysis being performed to determine cause and prevent recurrence.
1,329.0 pounds
95940

2007-05-07
South Flare
Cause: OTHER-Low seal pressure in C-103 Compressor when switching pumps

Followup: No

Notes: No information given
153.0 pounds
95414

2007-04-17
#1 RGG furnace
Sulfur Recovery Unit
Cause: operator pressed button that shut down #1 RGG furnace causing release

Followup: No

Notes: No information given
29.0 pounds
95414

2007-04-17
#1 RGG furnace
Sulfur Recovery Unit
Cause: operator pressed button that shut down #1 RGG furnace causing release

Followup: No

Notes: No information given
29.0 pounds
95203

2007-04-09
West Flare
Cause: Sat Gas plant experiences upset that results in flaring

Followup: No

Notes: No information given
456.0 pounds
95165

2007-04-07
Excel Paralubes West Flare (EP110)
Cause: see notes

Followup: No

Notes: The shut down of the Sat-Gas compressor caused the release of sulfur dioxide. Shut down resulted from pressure transmitter producing a false reading of a compressor seal leak.
3,967.0 pounds
93272

2007-01-14
South Flare
Cause: OTHER-Sub 109 lost power resulting in shutdown of gas compressor

Followup: No

Notes: No information given
92923

2006-12-29
North Flare
Cause: wet gas compressor tripped and shut down

Followup: No

Notes: Facility is conducting root cause failure analysis to prevent future recurrence and ensure extra insulation on the bus is adequate during shutdowns
27,964.0 pounds
108894

2008-10-02
004 Outfall
North Flare
Cause:

Followup: No

Notes: See incident 08-06535
244.0 pounds
108898

2008-09-07
North Flare
Cause: courtesy notification pollutants released during facility start

Followup: No

Notes: Letter concerns possible flare outage, states that accumulation of steam concealed flare and no pilot outage occurred. Courtesty notification onl
No LDEQ Reported

2008-09-07

Cause: Facility start up released SO2 and H2S to flare.

Followup: Yes

Notes: No information given.
No LDEQ Reported

2008-09-07

Cause: Facility start up released SO2 and H2S to flare.

Followup: Yes

Notes: No information given.
108466

2008-08-31
West (Excel) Flare, North Flare
Cause: Hurricane Gustave - impending landfall of hurricane causes emergency shutdown of multiple process unit

Followup: No

Notes: Accordint to C-P, All reasonable steps taken to minimize emissions, air pollution control equipment, process equipmt and processes were at all times maintained and operated in a manner consistent with good practices for minimizing emissions. Letter provides rolling emissions rates but not emissons totals. Presumptive total (21324 lbs of SO2 released) calculated here by multiplying emissions rates and incident durations as listed in C-P letter dated 9/5/08. Follow-up letter from C-P indicates thherewas an instrument malfunction causing an incorrect assessment of SO2 emissions. Per this letter, no RQ's were exceede
108145

2008-08-19
North Flare
Cause: instrument fails due to high temperatures from steaming out process

Followup: No

Notes: Technicians worked on 02 analyzer and the compressors were brought back to service
105820

2008-05-21
#10 Reformer West flare
Cause: release occurred during shut down; no further info giv

Followup: No

Notes: Letter states that emissions were BRQ.
104365

2008-03-30
North Flare
Cause: release occurred during #3 CTU start

Followup: No

Notes: Steaming the unit out slower would have reduced the environmental impact. DEQ report indicates that steaming the unit out slower would not have made a difference
1,406.0 pounds
103064

2008-02-13
South Flare - EQT 080
Cause: malfunction of south flare gas caustic scrubber level due to a plugged drain line

Followup: No

Notes: Caustic line unplugged and spent caustic replaced with fresh caustic
1,317.0 pounds
103301

2007-07-05
South Flare - EQT 080
Cause: upset in the ARU

Followup: No

Notes: Level indicator on #2 regenerator tower malfunctioned and there isn't a redundant level indicator. Root Cause analysis estimates release at 19,800 lbs - approx 3,000 lbs more than original repor
19,800.0 pounds
103590

2007-07-05
West Flare
Cause: shut down for turnaround and steamed to fla

Followup: No

Notes: V. little info given in DEQ report. NO info on pollutants released or amounts.
108581

2007-07-05
see notes
Cause: see notes

Followup: No

Notes: ANONYMOUS CITIZEN COMPLAINT - sulfur odor. DEQ rep visits site and C-P rep indicates that odor may stem from flaring after post-Gustav startup of facility or from the Hot Resid tanks located in the Sour Crude/Resid Tank farm (Area A). Tanks T-2003, T-2004, and T-2005 are not equipped with a water scrubber for odor contro
108607

2007-07-05
Excel Paralubes Sulfur Recovery Unit Stack
Cause: start up post-Gustav causes flari

Followup: No

Notes: Abnormally high concentration of light hydrocarbons in the Reaction Furnace. The change in feed composition reduced the unit's effectiveness at converting H2S to sulfur. As a result, the concentration of H2S went beyond the hourly permit limits fromthe SRU sta
276.0 pounds
118896

2009-10-21
No information given
Cause: SO2 emissions were elevated due to units being shut down in preparation of a turnaround.

Followup: No

Notes: No information given
116265

2009-07-05
West Flare
Cause: A 2A fuse blew which caused the five control valves in the Hydro-cracker unit to fail closed. The safety system worked as designed, and dumped the reactor pressure to the flare.

Followup: No

Notes: No information given
115990

2009-06-25
West Flare
Cause: Wet gas compressor tripped on low lube oil pressure. Report makes note that lube oil pressure should be verified by operators prior to switching pumps to prevent unit shutdown.

Followup: No

Notes: Modify anti-surge controller pressure transmitter set-points to allow restart or alert operation that pressure is reading top of scale.
1,707.0 pounds
115150

2009-05-21
#4/5 Sulfur Recovery Unit
Cause: While starting up the unit after a turnaround, problems were encountered. An instrument use for operating the unit was not responding properly resulting in a unit upset.

Followup: No

Notes: No information given.
354.0 pounds
114646

2009-05-03
#64/65 SRU stack
Cause: In the process of shutting down the #64 sulfur train,a loss of steam to the amine regenerator occurred. This caused an increase of SO2 released from the #64/65 SRU stacks.

Followup: No

Notes: Exceeds RQ. No additional information given.
22.0 pounds
112924

2009-02-21
Area A, B, and C heater stacks
Cause: The skimming of hydrocarbons at the #3 Flash Drum led to a foaming upset of the regenerator and inefficient H2S removal from the amine utilized in the high pressure fuel gas (HPFG). This caused a #3 Amine Regeneration Unit (ARU) system upset that resulted in combustion of refinery fuel gas with high H2S in the HPFG system. Ultimately, this caused SO2 to be released from fired heater stacks in Areas A, B, and C.

Followup: Yes

Notes: NOTE: Follow-up occurred on 3/31/09. Exceeds RQ. Immediate action taken was to add anti-foam to get the system back to normal and cleaning up the amine. Firing rates of heaters reduced to decrease SO2 released. Planned remedial action include increase frequency of skimming the #3 Amine Flash Drum to prevent sending large amounts of hydrocarbon to the regenerator all at once.
716.0 pounds
111828

2009-01-07
North Flare
Cause: Net gas compressor in No. 10 reformer was shutdown due to high vibrations. The shut down caused high volumes of gas and liquids to the North Flare. This resulted in a surge of high pressure on the flare header line to the North Flare.

Followup: Yes

Notes: Immediately after the discharge, Conoco Phillips shut down Old Spanish Trail Roadway, and the North Flare was taken out of service. A Conoco personnel did a FLIR camera monitoring of the flare header line for VOC leakage. No leaks were found. LDEQ personnel were dispatched to the site later in the day after the discharge. They collected a summa canister air sample offsite and downwind of the North Flare. The canister did not detect any readings. Samples of ditch water was collected by Conoco Phillips on the north side of Old Spanish Trail on Sasol property. The water samples of SO2 was detected to be 0.7-4.0ppm, while H2S and VOCs levels were not detectable. During the collection, the inspectors described a pungent, sulfuric odor. CITIZEN COMPLAINT (T111853)- Ms. Debra Ramirez stated concern over the Conoco Phillips discharge. The LDEQ inspector's observations stated that the release was caused by a malfunction of the net gas compressor in the No. 10 reformer, which relieves to the North Flare. In an attempt to mitigate the release, operations began cutting charge rates to the units and diverting vent streams from the North Flare to the South Flare system.
111853

2009-01-07
North Flare
Cause: A net gas compressor shut down due to high vibrations, this resulted in a high volume of material being sent to the north flare.

Followup: Yes

Notes: No information given
128016

2010-12-07
amine gas feed line to #1 ECC
Cause: Leak on the amine gas feed line pipe at the #1 ECC #1 sulfur recovery unit. LDEQ report states that "leak was originally discovered when an internal H2S monitor picked-up an unknown quantity from inside the refinery."

Followup: No

Notes: Feed taken out of the line and nitrogen introduced to purge amine gas; #1 SRU unit shut down; line replaced.
1,050.0 pounds
127251

2010-10-25
Sulfur Recovery Unit (SRU)
Cause: Upset in the sulfur recover unit; the "tail gas unit experienced a foaming incident," which allowed SO2 and SO3 to escape into the atmosphere.

Followup: No

Notes: No information given
126826

2010-10-02
West flare EQT330
Cause: "During start-up of the HDC [hydrocracker] unit, the amine contactor foamed leading to amine carryover and a high liquid level in the knockout drum which shutdown the recycle hydrogen compressor and triggered depressurizing of the unit to the flare." SO2 release above permitted amounts of 500lbs/hr but below RQs Flame carryover from flaring resulted in a "small" grass fire along the right-of-way of PPG Drive which was extinguished by the Westlake Fire Dept.

Followup: No

Notes: "Amine flow to the contactor has been reduced from typical to prevent recurrence."
949.0 pounds
122272

2010-03-21
A4X45003--sump relief valve
Cause: API sump relief valve (A4X45003) leaked, allowing gases high in H2S to bypass the scrubber on the Area B - API flare, allowing for elevated H2S levels released from the flare.

Followup: No

Notes: Verified elevated emissions
1,300.0 pounds
121788

2010-02-26
FLARE: West flare
Cause: Foaming event in hydrocracker amine contactor (W-11001) resulted in liquid carryover into the knock-out drum of a compressor, which caused the compressor to shut down, opening the dump valve to flare. FLARE.

Followup: No

Notes: BRQ. Liquids drained from knock-out drum and compressor was restarted.
152.0 pounds
130644

2011-04-12
air-demand analyzer
Cause: According to the refinery letter, during the start-up of the sulfur reaction furnace, an air-demand analyzer malfunctioned causing excess air to the hydrogenation bed resulting in elevated SO2 emissions.

Followup: No

Notes: BRQ: No further information on remedial actions was given. Refinery letter and SPOC report only; no LDEQ report.
144262

2012-10-27
1/2 SRU
Cause: Instrumentation failure caused the No. 1 SRU unit to shutdown.

Followup: No

Notes: An instrument tech repaired the instrument. Operations started the unit back up. Determined that the amount of sulfur dioxide released during the upset was less than the reportable quantity. The incident began at 0339 hours and was secured at 0742 hours on October 27, 2012.
138385

2012-03-28
#4 SRU
Cause: Due to a shutdown of the #1 SRU, additional amine gas was sent to the #4 SRU, resulting in elevated sulfur dioxide emissions. This caused a flare.

Followup: No

Notes: The flare was less than the RQ in SO2 and the notice was a courtesy notification
137276

2012-02-17
FLARE: SRU Stack No.1 and No.2
Cause: Excess hydrocarbons in the feed composition to the No.1/No.2 SRU caused the reducing gas generators (RGGs) to shutdown. SO2 was released.

Followup: No

Notes: Air monitoring was conducted.
2,623.0 pounds
No LDEQ Reported

2012-02-16
FLARE: South Flare System
Cause: A third party vendor was preparing a line for maintenance by isolating and purging it. During the maintenance activity a high concentration H2S containing gas was sent to the South Flare System.

Followup: No

Notes: Fresh caustic solution and water were added to the South Flare Scrubber during the event to keep the scrubber as effective as possible. There is no SPOC report and no LDEQ report attached to this file.
600.0 pounds
No LDEQ Reported

2012-02-16

Cause: TDC was preparing a line for maintenance by isolating and purging it, and during this maintenance activity, TDC sent a high concentration of hydrogen sulfide containing gas to the South Flare System. Sudden spikes in flow from the third party NASH plant of a stream with high hydrogen sulfide concentration and sufficient flow overwhelmed the capacity of the South Flare Caustic Scrubber to adequately treat the material.

Followup:

Notes: The flow of high hydrogen sulfide gas to the system from a third party was enough to overwhelm the caustic scrubber system. Fresh caustic solution and water were added to the South flare scrubber during the event to keep the scrubber as effective as possible.
600.0 pounds
153015

2013-12-25
caustic scrubber pump
Cause: Sulfur Dioxide was released from the facility's API/CPI flare due to the unexpected failure of a pump on the caustic scrubber system due to low temperatures.

Followup: No

Notes: Refinery personnel reestablished circulation through the scrubber using steam to heat the pump and associated piping. Causal factor could also be Equipment design if the currently used equipment is not able to support the low temperatures that are occurring.
152618

2013-11-28
#1 and #2 Sulfur Recovery Units
Cause: On November 28, there was a unit upset due to cold weather which caused a loss of the sour water gas flow indication and a release of sulfur dioxide (SO2) and hydrogen sulfide (H2S). Report states that the amount of pollutants released were less than the reportable quantities, and no further action will be taken.

Followup: No

Notes:
152440

2013-11-16
T-71001
Cause: On November 16, a fire occurred within the vapor space of the roof on T-71001, the Sour Water Stripper feed tank at Excel Paralubes. Immediately after the incident, process changes were made to minimize the flow to the tank. The process of removing feed from the tank was completed at 3pm on November 17. Deinventory of the tank contents is nearly complete with an estimated 2 feet of material left in the tank. The process of diluting and removing the remaining material is expected to be completed throughout the next week. Once the tank is completely emptied, a damage assessment will be completed for the tank and any associated equipment. The cause of the incident is under investigation.

Followup: No

Notes: The fire was extinguished quickly and no offsite impact occurred. Based on engineering calculations, it is estimated that the combustion emissions of sulfur dioxide and volatile organic carbons from the first did not exceed the respective reportable quantities.
268.0 pounds
157528

2014-07-18
C-3301 Wet Gas Compressor
Cause: The wet gas compressor shut down due to high amps, emitting Sulfur dioxide from the flare.

Followup: No

Notes: Unit rates were cut to minimize flaring, and work on the compressor started immediately to get it running and back in service. Began cutting rates and working the electrical issue. Restarted C-3301 Wet Gas Compressor.
2,995.0 pounds
156644

2014-06-10
South Flare
Cause: A temporary loss of power resulted in multiple units venting to the South Flare for pressure release purposes. Based upon engineering calculations, amount of sulfur dioxide released should be below RQ.

Followup: No

Notes: Courtesy notification only. Only refinery letter included in this report.
188.0 pounds
156201

2014-05-25
Sour Crude Recycle Hydrogen Compressor (C-3702)
Cause: The Sour Crude Recycle Hydrogen Compressor (C-3702) has a failure of the rheostat, which is a component that controls the DC current to the compressor motor. This component failure caused the compressor to shut down. This was not operator error, according to facility reports. Shut down of the compressor resulted in flaring at the Area A North Flare.

Followup: No

Notes: Rates were immediately reduced to stabilize the units and reduce flare. Permit levels were exceeded for the North Flare EQT0539.
1,246.0 pounds
155814

2014-05-07
#7 HDS
Cause: On 5/7/14 there was a release from the Area A North Flare (EQT 0539) caused by a process upset in the #7 HDS, likely due to feed contamination.

Followup: No

Notes: Reduced charge rate / changed barge off load tank.
1,358.0 pounds
153335

2014-01-07
North Flare
Cause: A sudden loss of the Hydrogen supplied from another facility caused a process upset in the PSA unit.

Followup: No

Notes: Telephone notification was made on 1/7/2014 regarding a release of SO2 from the North Flare. A sudden loss of the Hydrogen supplied from another facility caused a process upset in the PSA unit. Based upon engineering calculations, it was determined that the amount of SO2 released during the upset was less than the RQ. There was no information given on the duration.
153147

2014-01-06
North Flare
Cause: Facility initially reported release of unknown quantities of H2S and Liquified Petroleum Gas. Follow-up letter from the company stated that the release was from the North Flare, due to sudden loss of electrical power in Area C Desalters, causing process upset.

Followup: No

Notes: Facility initially reported release of unknown quantities of H2S and LPG. Letter stated release of SO2 was below the reportable quantity (RQ) and later confirmed via telephone by a Phillips 66 representative that the amount release was 22 lbs. It was noted that there is no RQ for SO2 under CERCLA regulations but rather the RQ for SO2 under EPCRA regulations is 500 lbs for which reporting to the Louisiana State Police is required. There is documentation of what caused the power outage or duration of the emission.