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Phillips 66 (2418), Belle Chasse

Releases of Nitrogen Oxide

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
No LDEQ Reported

2005-08-02
308F-D-2 High pressure flare
Cause: An unusually severe thunderstorm caused an upset in the unit 491 Depropanizer Tower

Followup: Yes

Notes: The level of NOX exceeded that of a reportable level. The 43 minutes included two seperate times of the day including 19 minutes and 24 minutes). They also claimed corrective actions will be implemented.
20.0 pounds
No LDEQ Reported

2005-07-29
308F-D-1 Low pressure flare
Cause: The liquid/gas pressure relay on transformer XFR 5CE at electrical substation 5C unexpectedly tripped breaker VCB 3CG.

Followup: Yes

Notes: Claimed preventative maintenance could have been used, but the failure was unforeseeable. The level of SO2 exceeded that of a reportable level.
22.5 pounds
No LDEQ Reported

2005-07-25
Low Pressure Flare
Cause: A contractor came into contact with the instrument air supply line for the FCC Unit's K-2A Supplemental compressor. This caused the lines to separate and for air to leak.

Followup: No information given

Notes: It was immediately repaired and they claimed to go over similar air supplies.
8.2 pounds
No LDEQ Reported

2005-06-07
X-4 and X-5 exchangers in the coke fractioner
Cause: The compressor second state knockout drum received a high level alarm. Inadequate cooling of verhead vapors at the X-4 and X-5 exchangers in the coke fractioner caused the 891-K-1 compressor to trip offline

Followup: No information given

Notes: They claimed they changed operational procedures and the compressor was restarted.
8.7 pounds
No LDEQ Reported

2005-05-10
(308F-D-1) Low Pressure Flare; (308F-D-2) High Pressure Flare; (301-D-3) CO Bypass Stack; (591-D-21X) SRU Incinerator
Cause: Entergy experienced a ground fault and the backup supply failed to switch in a timely manner. Forced most process units to shutdown resulting in flaring and venting of CO. Two pressure valves relieved to the atmosphere.

Followup: No

Notes: With most of the process units down, there was isufficient feed to keep the SRU tail gas treater online. The tail gas from SRU 591 was routed directly to the SRU incinerator until other refinery process units restarted to provide sufficient feed to support stable TGT operation. There was some smoking form the flares.
668.0 pounds
No LDEQ Reported

2006-11-23
301-D-3 FCC Regenerator Flue Gas Bypass Stack; 308F-D-1 Low Pressure Flare; 308F-D-2 High Pressure Flare
Cause: The FCC process control system malfunctioned causing upset operating conditions at the FCC Unit. This malfunction caused an immediate and unecpected shutdown of the entire FCC Unit.

Followup: yes

Notes: According to the report: "Although preventative maintenance procedure exist, conditions of this type cannot be anticipated. An investigation is continuing to determine the root cause of this accident."
36.1 pounds
No LDEQ Reported

2006-11-15
308F-D-2 High Pressure Flare
Cause: The HF Acid Rerun Tower in the HF Alkylation Unit was being taken out of service to replace fouled packing. The normal procedure for preparing this equipment for maintenance includes a flush with isobutane to the High Pressure FLare

Followup: No

Notes: An attempt was made to reduce the flare flow but it was not sufficient enough. Further occurrence of this maintenance activity will be planned in a manner to allow a variance request to be submitted prior to the event. For a linger term solution, the flare permit will be modified to add this specific maintenance activity.
36.7 pounds
No LDEQ Reported

2006-08-18

308F-D-2 High Pressure Flare
Cause: The bottom recirculation pump for the HDS Hydrotreater Column tripped off line due to unexpected seal failure and sudden pressure surge within the column.

Followup: No

Notes: Executed all shutdown mechanisms for the Low Sulfur Gasoline Unit safely, stablized HDS Column product streams and isolated L3 pump. The Alkylation Unit operation was adjusted to the available cooling water supply and stop the flaring.
55.7 pounds
No LDEQ Reported

2006-08-17
308F-D-1 Low Pressure Flare; 308FD2 High Pressure Flare
Cause: An electrical fault caused a loss of power to the Alkylation Unit cooling tower and tripped the Delayed Coking Unit compressor and other equipment off line.

Followup: No

Notes: Stabilized unit allowing restart of the 891K1 compressor and stopping of the flaring off of 491V9
13.7 pounds
No LDEQ Reported

2006-08-15
308F-D-2 High Pressure Flare
Cause: An oil circuit breaker in the electrical substation supplying electricity to the Alkylation Unit and its cooling tower failed. This power interruption caused a loss of cooling water and tripped several pumps offline.

Followup: No

Notes: Plant personnel stabilized the unit to prepare AU 491 for restart.
267.8 pounds
No LDEQ Reported

2006-08-15
308F-D-2 High Pressure Flare
Cause: During restart of Alkylation Unit a pressure surge triggered an automatic shutdown. Pressure safety valves relieved on 491V8.

Followup: No

Notes: Plant personnel stabilized unit operations to prepare AU 491 for restart
112.7 pounds
No LDEQ Reported

2006-07-08
308F-D-2 High Pressure Flare
Cause: The Process Safety Valve relieved to the HP flare causing the Pressure Swing Absorption unit to trip off line.

Followup: No

Notes: The entire 1792 Unit including the PSA portion of the unit was shutdown to allow inspection of the hot spot in the heater.
11.8 pounds
No LDEQ Reported

2006-06-19
308F-D-2 High Pressure Flare
Cause: The Pressure Swing Adsorption Unit tripped off line due to leaking of the Repssure Safety Valve to the HP Flare System.

Followup: No

Notes: PSV was isolated from the unit. An investigation is continuing to determine the root cause of this accident.
60.8 pounds
No LDEQ Reported

2006-06-12
308F-D-2 High Pressure Flare
Cause: The reflux pump 294L4B att he Low Sulfur Gasoline Unit experienced a seal failure.

Followup: No

Notes: The Low Sulfur Gasoline Unit was taken off line and shutdown.
57.9 pounds
No LDEQ Reported

2006-06-07
308F-D-1 Low Pressure Flare
Cause: Coke fine particles clogged downstream of the valve causing liquid levels in V16 to increase.

Followup: No

Notes: It seems these coke particles had accumulated failry quickly near the valve due to the manner in which the outlet valve had been operating over the past several drum switch cycles.
6.5 pounds
No LDEQ Reported

2006-06-06
308F-D-1 Low Pressure Flare
Cause: The level float column in the 1291 V 15 Sour Water Drum malfunctioned causing its level controller OLC 180 to open and caused a higher than normal rte of sour water and hydrocarban to inter the Sour Water Stripper Flash Drum v12.

Followup: No

Notes: The OLC 180 controller valve was manually closed and then re opened to establish a proper water level in the Sour Water Drum.
8.1 pounds
No LDEQ Reported

2006-05-18
308F-D-1 Low Pressure Flare
Cause: The 891-K-1 compressor tripped off line due to a faultry level indicator on the high level alaerm in the compressor interstage drum. There was foreign material collecting and plugging the level bridle on V-16.

Followup: No

Notes: The liquid levels in the interstage drum were drained manually and the circuit breaker for the compressor was reset and the compressor put back on line. A periodic flush of the V16 level bridle with fresh water is the corrective action.
15.9 pounds
No LDEQ Reported

2006-05-16
308F-D-1 Low Pressure Flare
Cause: Malfunction with the bus bar caused the main circuit breaker supplying power to the Crude Unit 191, Saturated Gas Unit 7991 and the WWTP to trip. The power interruption caused unit upsets at the Crude Unit and Hydrotreating Unit 292.

Followup: No

Notes: Immediately switched power source to an alternative feeder.
29.5 pounds
No LDEQ Reported

2006-04-26
308F-D-1 Low Pressure Flare
Cause: Problems with the coke cutting system required a switch of drums which reduced the flow to the compressor and caused a compressor kickback valve to open to the flare.

Followup: No

Notes: Pressures were stabilized and the valve was closed.
16.6 pounds
100206

2007-10-16
292-FF, 308F-D-1 Low Pressure Flare
Cause: Vapor leak coming from a tube at the exchanger. Unit 292 was depressurized and shut down which caused flaring.

Followup: Yes

Notes: Determined that preventative maintenance procedures could not prevent this accident.
5.0 pounds
99785

2007-09-27
308F-D1 Low Pressure Flare
Cause: The Delayed Coking Unit was in hot circulation and preparing for startup after unexpectedly losing its coke cutting water pumps and its compressor (891 K-1) tripped off line due to high liquid level in the compressor suction drum 891-V-12, unexpectedly carried over to V-15. The compressor's suction stream is automatically diverted to the Low Pressure Flare during an emergency shutdown.

Followup: Yes

Notes: Investigation to determine the cause of liquid carryover from the Delayed Coking Unit combination tower overhead drum. The refinery claims that there was no offsite impact.
4.5 pounds
99023

2007-08-29
308F-D-1 Low Pressure Flare, 308F-D-2 High Pressure Flare
Cause:

Followup: Yes

Notes:
14.0 pounds
96490

2007-05-23
410-PSV-62
Carbon Monoxide Bypass Stack
Induction gas relief valve (APC-105), Low Pressure Flare, High Pressure Flare
Low Pressure Flare (308F-D-1), High Pressure Flare, 191 APC-105
Low Pressure Flare, High Pressure Flare, 191-PV-105
Low Pressure Flare, High Pressure Flare, SRU incinerator Stack, 191-PV-105, Heaters
Cause: During a rain storm the line from Entergy's substation tripped. The loss of power forced most of the refinery's process units to shutdown resulting in flaring. While shutting down the 191 crude unit the pressure controller relieved vapors and liquid hydrocarbons from a vent at the top of the Vacuum Tower. The hydrocarbons ignited and caused a fire at the top of the Vacuum Tower. With most of the process units down there was insufficient feed to keep the SRU tail gas treater online. The tail gas was routed to the SRU incinerator. When units were started up again they required more flaring for prepare for recommissioning.

Followup: No

Notes: Determined that although there are back up systems there are no ways to prepare for these types of power outages. Electrical department will preform preventative maintenance and replacement of components. 191-PV-105 pressure controller at the crude unit no longer vents to the atmosphere. Piping was installed that routes gases from this vent directly to the flare.
138.0 pounds
110898

2008-11-19
308F-D-1 (Low Pressure Flare); 308F-D-2 (High Pressure Flare); 191-FF (191-PSV-009A); 191-FF (191-PSV-011)
Cause: On 11/19/09, the refinery "experienced an unexpected internal electrical power phase to ground fault." This fault caused a power interruption from internal Substation 5D to the Crude Unit 191 and resulted in the loss of most of the Crude Unit's pumps and several fin fans causing a major unit upset and emergency shutdown. These upset operations subsequently caused the Atmospheric Tower's pressure relief valve (191-PSV-009A) to open to protect the upper section of the Atmospheric Tower. An attempt to circulate the liquid inventory in the Vacuum Tower (VT) back to the Crude Tanks caused as unexpected high liquid level and the VT pressure relief valve (191-PSV-011) opened up to protect the upper section of the VT. This relief valve relieved vapors, liquid hydrocarbons, and crude oil from a vent at the top of the VT. The loss of the Crude Unit forced most of the refinery's process units to shutdown resulting in intermittent flaring. Following the shutdown and the re-establishment of power to substation 5D, the process of restarting several refinery units was initiated. The Coker Unit's Compressor (891-K-1) motor amp limit controller (PJC-404) unexpectedly opened the flare valve (PPC-998) due to a very high motor amperage surge at its initial start. Flares smoked intermittently throughout shutdown and startup events. Fenceline monitoring indicated "no offsite impact." Fenceline monitoring

Followup: No

Notes: Immediate: Units were shut down until electrical supply was repaired. After a formal investigation, the cause of the incident was determined to be a loose connection between the bus and runback rod that put enough electrical load on the connecting bolt to melt it thus creating the ground fault. Connecting bolts are now inspected and replaced as necessary, COP electricians are being further trained, and a QC checklist and testing procedures to verify proper electrical connections have been implemented. Discharge classified as "Extremely Hazardous Substance" Regulated by OSHA HazCom
5.0 pounds
No LDEQ Reported

2008-06-03
Fluid Catalytic Cracker (FCC) Unit, 308-D-1 Low Pressure FLARE, 308F-D-2 High Pressure FLARE, 301-D-3 CO Bypass Stack
Cause:

Followup: Yes

Notes: FCC shut down to repair a crack. During repairs, a broken valve was discovered and also repaired (#106247). Emissions released during startup of FCC and below reportable quantities. Investigation into procedures to prevent flarting during shutdown/startup
107.5 pounds
114566

2009-04-30
308F-D-1 (Low Pressure Flare)
Cause: On April 30, 2009 at approximately 2:40 AM, the Coker compressor unexpectedly tripped off-line. At approximately 2:41 AM the suction drum flare valve opened, which it is designed to do when the compressor experiences an unexpected complete shutdown. The suction stream is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown.

Followup: No

Notes: The compressor was started and brought online following review of alarm and trip logs.
5.1 pounds
114066

2009-04-08
308F-D-1 (Low Pressure Flare)
308F-D-1 (Low Pressure Flare); 191-PSV-009
Cause: The 891-K-1 Compressor tripped off-line due to a high liquid level inside the first stage suction drum (891-V-15). This was caused by high liquid levels in the fractionator tower's reflux drum (891-V-12) due to coke fines plugging the filters of the L-11 reflux pumps and L-13 Sour Water pumps at an unexpectedly rapid rate. The compressor's suction steam is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown of the compressor. Monitoring at the refinery permitter was performed and "there was no offsite impact."

Followup: No

Notes: The compressor was started and brought online as soon as proper levels could be established in the first stage suction drum. An investigation is in process to determine the cause of the high levels in the first stage suction drum (which caused the compressor to trip).
5.0 pounds
113974

2009-04-06
308F-D-1 (Low Pressure Flare); 191-PSV-009
Unit 191-PSV-009
Cause: A power failure occurred as a result of grid failure due to scheduled maintenance by Entergy. Entergy's method did not allow for ConocoPhillips to secure an alternative source while the main grid was down. The refinery thus had to initiate an emergency shutdown. As a result, the refinery had to employ the low pressure flare.

Followup: No

Notes: Entergy has proposed a three phase project that will build additional substations within the electrical power grid over the next five to eight years to improve its reliability. Entergy is currently seeking federal funding for this project.
53.0 pounds
113242

2009-03-08
308F-D-1 (Low Pressure Flare)
Cause: Problems with the Coker drum steam condensate operations caused inadequate heating of the"inactive Coke drum. To avoid shutting down the Coker Unit, Operations personnel switched Coker feed from teh "active" drum into the "inactive" drum that was much cooler than normal operating systems. The switch into a cooler coke drum reduced the flow to the 891-K-1 compressor and caused the "compressor kickback" control scheme to activate. This scheme caused the compressor kickback valve to open, sending additional flow to the compressor's suction drum (891-V-15). The pressure in the compressor suction drum increased to the point that the pressure control system opened the valve to the Low PRessure Flare (308F-D-1).

Followup: No

Notes: Coker unit operations and pressure were stabilized and the valve to the flare was closed.
5.0 pounds
126678

2010-09-24
308F-D-1 (low pressure flare) and various process heaters
Cause: During maintenance activities, "amine stripper vessel experienced unexpected level swings" and "SRU (sulfur recovery unit) waste heat boiler unexpectedly tripped offline due to its flame scanner no longer detecting a flame at the burner. Several attempts that were made to re-light the burner were unsuccessful due to igniter malfunction" -- had to flare excess.

Followup: No

Notes: "Routed acid gas feed stream to the LP flare and immediately implemented the sulfur shedding plan...root cause investigation has been initiated." Detailed refinery letter only in this file. No LDEQ Report.
7.0 pounds
123185

2010-05-02
Cooling water exchanger & Coker compressor (891-K-1), Low-pressure flare (308F-D-1)
Cause: Report states that the release occurred as a result of a breaker trip in the Coker Compressor. Which seems to have originated within the compressor's motor.

Followup: Yes

Notes: RQ. Reportable quantity for sulfur dioxide was exceeded. LDEQ report states that "The facility will be referred to the Circuit Rider Review process for failure to submit an updated notification within 60 days of the initial 7 day letter as required by LAC 33:I.3925.A.3." An investigation is in process to determine the cause of the electrical breaker trip after which, corrective actions will be implemented.
52.7 pounds