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ExxonMobil Refinery (2638), Baton Rouge

Releases of 1,3-Butadiene

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

E-552B exchanger

Followup: No

Notes: an exchanger crew was called out to return E-552A to service; they plan to evaluate if a metallurgy upgrade is needed on this exchanger; was not preventable because the exchanger was retubed in June of 2003 and historically has a longer run life
13.0 pounds
No LDEQ Reported

F-3 furnace
Cause: furnace smoked for 3 minutes because the fuel gas rate to the furnace increased. This was due to the controller typing 3200 instead of 2300 kscf.

Followup: No

Notes: Other controllers were informed of the consequences and were asked to double check manual inputs prior to execution; fuel gas rates were immediately cut back and the air damper was opened.
1.0 pounds

E-552A and E-553A Exchangers on the Coker
Cause: the E-552A and E-553 Exchangers on the Coker were discovered leaking into Cooling Tower #44. The leak on the E-553A was stopped 20 mins. Later while the leak on the E-552A continued until August 26th, 2006. The leaks are believed to have been caused by accelerated corrosion

Followup: No

Notes: This incident was not preventable because inspection reports on these exchanger bundles indicate that both failed prematurely. Remedial Measures - The existing tube bundles will be repaired/replaced as necessary. Metallurgy of these exchangers will be upgraded. Reportable quantities for volatile organic compounds, hydrogen sulfide, and benzene were exceeded. Note: in the follow up report, it was found that the reportable quantities for hexane, 1,3 Butadiene, and highly reactive volatile organicpounds were exceeded as well. The previously reported level of volatile organic compounds was 8800 and was later found to be 66388, for hydrogen sulfide it was 901/4578, and for benzene it was 59/43
96.0 pounds

E-513 A exchanger on the 2 Light Ends Unit
Cause: E-513 A exchanger on the 2 Light Ends unit was leaking hydrocarbon to Cooling Tower #25. The leak is believed to have come from corrosion on the hydrocarbon side of the tube bundle.

Followup: No

Notes: This incident was not preventable because previous inspection reports indicate that this exchanger bundle is less than 6 years old and in serviceable condition. Remedial Measures - this bundle will either be replaced with a new bundle or repaired. A metallurgy upgrade to 410 stainless steel is being evaluated. Replacement and/or upgrade of exchanger bundles in similar is also being considered. LDEQ reportable quantities for butenes, propylene, highly reactive volatile organic compounds, and 1,3adiene were exceeded
727.0 pounds

E-3 exchanger on the Coker
Cause: the leak is believed to have been caused by corrosion and erosion

Followup: No

Notes: There is no information whatsoever as to why the accident was preventable. Remedial Measures- the bundle was replaced with a new bundle. In the letter to LDEQ, Exxon states that the reportable quantities for hydrogen sulfide and benzene were exceeded
3.0 pounds

FLARE - Alkylation Feed Preparation Unit
Cause: The Methyl Tertiary-Butyl Ether Unit was converted to an Alkylation Feed Preparation Unit (AFP). The AFP was beginning its initial start up. As the level in one of the towers increased, steam was added to the reboiler to begin producing overhead product. During this time, the safety valves on the tower began relieving to the flare system, which resulted in the reported flare. During the conversion of the unit the overhead pressure meter was reranged in the field, but was no reranged in the control room. Due to this oversight the operator believed he was at a significantly lower pressure and did not immediately discover that the safety valves on the tower had lifted to the flare system. The calculations automtically completed by the flare system

Followup: No

Notes: The cause of the accident is listed as preventable in the company's report, but there is no explanation whatsoever as to why it was preventable - that section is blank. The only remedial measure listed is that the pressure meter range was corrected in the control room. The letter to LDEQ states that reportable quantities of nitrogen oxide and butenes were exceeded.
288.0 pounds

E-553B Exchanger at the coker
E-553B Exchanger leak at the coker
Cause: -the E-553B exchanger on the Coker was leaking to Cooling Tower #44. The leak is believed to be from the corrosion on the tube bundle.

Followup: No

Notes: Remedial measures - The leaking tube on the E-553 exchanger will be plugged and the exchanger will be pressure tested before it is returned to service. The accident was not preventable because the exchanger had not leaked previously and the tube bundle was approximately 18 months old. The report letter to LDEQ states that the reportable quantities for benzene, hydrogen sulfide, volatile organic compounds, and 1,3-butadine were exceeded.
39.0 pounds

E-515A exchanger on the No. 2 Light Ends Unit
Cause: The E-515A exchanger on the No.2 Light Ends Unit leaked hydrocarbon to a cooling tower. From the cooling tower the hydrocarbon was released to the atmosphere.

Followup: No

Notes: Remedial measures - The leaking tube on the exchanger will be plugged. In their letter to LDEQ, ExxonMobil states that LDEQ reportable quantities for propylene and butene were exceeded
4.0 pounds

flange leak
Cause: OTHER-Overpressure of flange line

Followup: No

Notes: unit was depressurized immediately in accordance with emergency procedures.
29.0 pounds

Flare/Safety valve release
Cause: leaking seal/safety valve release

Followup: Yes

Notes: Several actions were taken to avoid or reduce the environmental impacts from this incident. The different gas streams were redirected in a manner appropriate to minimize emissions.
18.0 pounds


Followup: No

Notes: Due to the presence of a film on the surface of the water in the cooling tower basin, it was suspected that an exchanger was leaking oil into the cooling water. After diligent searching over the last week, no leaking exchanger has been identified. Since the initial sighting, the film has disappeared. Exxon will continue to closely monitor the water quality in the cooling tower through regular sampling and unit observations. No reportable quantities have been exceeded.

no information given/leak
no informaiton given/leak
Cause: no information given

Followup: No

Notes: Written notification from Exxon Mobile surrounding the leak that occurred at the facility stating that no reportable quantities had been exceeded.
2.0 pounds

No Information Given
Cause: Leak occurred, but no information provided regarding the cause.

Followup: No

Notes: Release is BRQ. LABB does not have access to the LDEQ incident report. The SPOC report indicates the release occurred on 05/07/09, but the refinery letter states the incident occurred on 04/11/09.

Cooling Tower Water System
Cause: There was an exchanged leak into a cooling tower water system resulting in a release.

Followup: No

Notes: This release was BRQ. The leak was stopped. 346 pounds of material were released. More than 100 pounds of hydrogen sulfide and more than 10 pounds of 1,3-butadiene may have been released as a result of this incident.
10.0 pounds

Pipe band on PCLA unit
Cause: A pinhole leak was discovered on the top of a pipe band on the PCLA unit.

Followup: No

Notes: Due to prompt incident response, no RQs were exceeded. LABB does not have access to the LDEQ or SPOC reports. 158 pounds of flammable vapor, .44 pounds of benzene, and .05 pounds of 1,3-butadiene were released as a result of this event.
0.1 pounds

Unspecified 3/4" line
Cause: A leak was discovered on a 3/4" line. No other information given.

Followup: No

Notes: The line was isolated and the leak was secured. Initially, 10 lbs of benzene, 10 lbs of 1,3-butadiene, and 1000 lbs of flammable vapors were reported as being released, but in the written report, Exxon reports that only 209.22 pounds of flammable vapor, 0.85 pounds of benzene, and 0.14 pounds of 1,3-butadiene was released.
0.1 pounds