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ExxonMobil Refinery (2638), Baton Rouge

Releases of Butene

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
05-BB009-1805

2005-06-20
FLARE
Cause: flaring occurred when the wrong fan was shutdown on No35 cooling tower; the breakers were labeled 'A' and 'B' instead of 'East' and 'West' so one was mistakingly shut down

Followup: No

Notes: pressure was reduce in No12 depropanizer by temporarily returning the West Cell to service. The flare was relit, which reduced the emissions of propylene and propane to the atmospher
2.0 pounds
05-BB009-1787

2005-06-13
tank 766
Cause: level gauge on tank 766 was not responding correctly. Chemicals began flowing out of the drain on the tank.

Followup: Yes

Notes: foam was sprayed on the tank to reduce exposure and fire potential. The tank was slowly emptied to ensure the roof did not shift and damage the tank.
75.0 pounds
05-BB009-1746

2005-03-24
E3A- & E3B
Cause: safety valves lifted

Followup: No

Notes: There were 2 incidents involved- the 1st did no exceed any reportable quantities, the 2nd incident started on 3/24/05 at 11:21pm and ended at 11:30pm the same day; furnace reboiler was shut down to reduce tower pressure and allow safety valves to reseat; the actual release lasted 9 minutes (from 11:21pm to 11:30pm); the report stated that the safety valve release on 4 LEU was preventable, but the reboiler leak on E-3A was not expected as it was a newer bundle than E-3
693.0 pounds
05-BB009-1737

2005-03-09
FLARE (Nos. 5, 7, 8, 9, 17, 19, 20 and 23)
Incinerators, Sites 68 and 69
Waste Water Treatment Unit
Cause: 30 minute power failure on Bulk Power Station #2. See Notes

Followup: No

Notes: Information for both LDEQ Incident Report numbers included on same report. Electrician doing work in the area injured. Investigation underway and findings will be implemented. May put automatic bypasses around filters in case they plug. Emissionswere minimized because some units shutdown; the vent gas from TGCU was sent through the incinerators emitting sulfur dioxide instead of the more harmful hydrogen sulfide. Power failure caused the following refinery units to shut down: No. 10 PipestilSLA-10), West Coker, 200 and 400 Trains on the Sulfer Plant, the Tail Gas Clean-up Unit, No. 2 Powerformer, Heavy Cat Napatha Units, No.1 and No.2 Sour Water Strippers, and some Depronanizers. The following Chemical Plant Units also shut down: Linea
102.0 pounds
05-BB009-1721

2005-02-27
FLARE
Cause: the controller responsible for the operation of the Refinery Gas Compression Unit (RGCU) began experiencing problems

Followup: No

Notes: C-50 was started up to eliminate the flaring and was run on manual. Incident not preventable because normal preventative precautions not used due to concern over clanging noises.
5.0 pounds
92695

2006-12-17
FLARE - #17 and #19 Flares
Cause: -compressors had to be shut down for repair - compressor trip.

Followup: No

Notes: This incident was not preventable because the compressor trip that caused the flaring incident was unexpected. If the findings of this investigation indicate that the cause of the trip was preventable, a modified report will be issued. Remedial Measures - an investigation is ongoing and the appropriate follow-up actions will be completed. an assistant operator at the Refinery Gas Compression Unit (RGCU) noticed an unusual noise coming from one of the refinery gas compressors C-50. These was evaluated by compressor specialists and it was determined that the compressor had to be shut down for repair. An advanced notification was made in anticipation of the flaring event since the spare compressor was unavailable due to other mechan
16.0 pounds
91379

2006-10-16
FLARE - #17 and #19 Flares
Cause: the cause of the flaring was high pressure in the refinery gas collection system due to a high volume of vent gas from the other refinery units. The source of the high vent gas rate was unable to be determined.

Followup: No

Notes: This incident was not preventable because the remedial actions were initiated before the flaring incident. These actions should have been sufficient to reduce vent gas rates. Two primary actions were initiated to reduce refinery vent gas rates. First, the compressor at the Hydrocracker was lined with the Refinery Gas Compression Unit Compressors to assist with processing refinery vent gas. Secondly, the crude feed rate to Pipestill #10 was decreased. Remedial Actions -an invgation is ongoing and the appropriate follow-up actions will be completed. The reportable quantity for nitrogen oxide has been exceeded.
2.0 pounds
91339

2006-10-13
5 light ends unit T-2 Depropanizer
Cause: the 5 Light Ends Unit T-2 Depropanizer tower reboiler had a leaking channel box. This leak is thought to have been caused by the failure of the channel box seal.

Followup: No

Notes: This incident was not preventable because this reboiler channel box seal failure was unexpected. Remedial Measures - The seal will be replaced. The reportable quantity for butenes has been exceeded.
265.0 pounds
90901

2006-09-26
FLARE - #5, #9, #17, #19, #23, #24 Flares
Cause: a control system power failure at the Refinery Gas Compression Unit caused a reduction in compressor capacity due to poor compressor control. As a result of the reduced capacity, the compressors were unable to process all of the refinery gas and the excess gas was routed to the refinery flare syste

Followup: No Information Provided

Notes: This incident was not preventable because the failure of the compressor control system was a result of a failure in both the primary and alternate power supply systems. The back-up power system should have supplied power to the compressor control systemwhen the primary failed to do so because of an electrical malfunction. Remedial Measures - an investigation is ongoing and the appropriate follow-up actions will be completed. Reportable quantities for nitrogen oxide and sulfur dioxide were exceeded.
5.0 pounds
90788

2006-09-21
E-515 B Exchanger on the 2 Light Ends Unit
Cause: the E-515 B Exchanger on the 2 Light Ends Unit was leaking to Cooling Tower #25. The leak is form corrosion on the tube bundle.

Followup: No

Notes: This incident was not preventable because inspection records for this exchanger indicate no history of leaks or premature failure. Records also show that this equipment was last inspected/tested 3 years ago and found to be in good condition. Remedial Measures - the exchanger bundle will be inspected and repaired or replaced, as appropriate. Reportable quantities for propylene and butene have been exceeded
139.0 pounds
90267

2006-08-26
FLARE - #17 and #19 Flares
Cause: the level indicator on the #4 Light Ends T-103 amine scrubber tower failed to function properly. Excess gas was flared in the #17 and #19 flares.

Followup: No

Notes: This incident was not preventable because failure of the level instrumentation was unexpected. Remedial Measures - an investigation is ongoing and the appropriate follow-up action will be completed. As a result of the faulty level indication, hydrocarbons were carried under to the amine regeneration unit and subsequently the refinery gas collection unit. The gas collection unit was unable to handle the increased load and therefore the excess gas was flared in the #17 and #19 flares.&##34;Reportable quantities for sulfur dioxide, nitrogen oxide, nitrogen dioxide, butenes, and propylene were exceeded
307.0 pounds
89850

2006-08-04
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
1,011.0 pounds
87051

2006-04-08
FLARE - C-30 and C-40 compressor
Cause: at the time of this report, the cause of the flaring incident was unknown and was under investigati

Followup: No

Notes: The only information provided is that the preventability of the incident had not been determined and was under investigation. Remedial Measures are listed the same way. The reportable quantities for nitrogen oxide were exceeded.
3.0 pounds
86548

2006-03-16
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.
121.0 pounds
86248

2006-03-06
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
237.0 pounds
85618

2006-02-04
F-600 furnace at No. 2 Reformer / Powerformer Feed Hydrotreater (RHLA-2) / No. 2 Powerformer
Cause: an instrument malfunction caused the F-600 furnace on the No. 2 Reformer to shut down. The shutdown of F-600 resulted in the Powerformer Feed Hydrotreater (RHLA-2) and the No. 2 Powerformer shutting down. The Powerformer is a major supplier of hydrogen to the refinery, and with the reduction in hydrogen supply, several units were forced to significantly reduce rates or shut down. The Feed Preparation Unit feeds RHLA-2 and with this unit shut down a valve was opened to send this stream from Feed Preparation to tankage. There is a second valve in this line that is normally open, but during this time it was closed. The second valve being closed led to a pressure increase in T-31 and caused the safety valve to release. The towe pressure was returne

Followup: No

Notes: Remeidal Measures - An investigation is ongoing and appropriate follow-up actions will be completed. Exxon states in their report that the accident was preventable. Their explanation is that the safety valve did not restart as it should have, nor did the operator know the second valve was closed. Could this be human error in addition to Instrument failur
27.0 pounds
85270

2006-01-19
#2 Light Ends Unit (E-568)
Cause: #2 Light Ends Unit experinenced a leak from their rebolier exchanger. The failure mechanism causing the leak in the exchanger is listed as unknown.

Followup: No

Notes: Incidents 06-00380, 06-00401 occurred simultaneously on January 19th and on Jan. 20th 06-00406 occurred, overlapping with the first two. The reportable quanitites for highly reactive volitile organic compounds and flamable vapors were exceeded whenthe emissions from these three events were summed over the first 24 hour period beginning with the initiantion of the rlease from the No. 2 Powerformer Unit. With regard to the 24 hour period beginning with the release at the MTBE Unit, there were nportable quanity exceedances for this period of time. The emissions limit exceeded the reportable quanitity threshold only during the time when all three incidents were taking place simultaneously. The mortar in T-4X will be replaced with a Furan re
16.0 pounds
100459

2007-10-23
Exchanger leak-E514A leak
Cause: corrosion of tube bundle

Followup: No

Notes: Exhanger was blocked and removed from service.
911.0 pounds
98141

2007-07-25
Leak at Alkylation unit
Cause: no information given

Followup: No

Notes: no information given
480.0 pounds
96849

2007-06-06
flange leak
Cause: OTHER-Overpressure of flange line

Followup: No

Notes: unit was depressurized immediately in accordance with emergency procedures.
215.0 pounds
95842

2007-05-02
Flare
Cause: broken air supply line was closed to control valve

Followup: No

Notes: Closed valve was bypassed until repairs,it was then replace
496.0 pounds
95549

2007-04-22
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.
3,041.0 pounds
94172

2007-02-23
Exchanger leak
Cause: underdeposit corrosion

Followup: No

Notes: Leaking exchangers were removed from service. The metallurgy of the exchangers is being evaluated for upgrading.
312.0 pounds
93441

2007-01-23
Leak
Cause: loose bolt on flange

Followup: No

Notes: Insulation pulled form #10 depropanizer reboiler and flange bolt tightened to stop leak
290.0 pounds
93020

2007-01-03
FLARE-Flare #5,7,17,19
Cause: OTHER-Electrical failure of Coker units

Followup: No

Notes: Personnel initiated startup of idle compressor recovering most of coker gas. Alternate electrical coordination settings and power supply designs are being evaluated for this system.
34.0 pounds
105542-105544

2008-05-11
safety valve release/ FLARE-Flare 17,23
Cause: process upset/under investigation

Followup: Yes

Notes: In response to the suspected exchanger tube leak, the unit was shut down per appropriate procedures. Safety valve inlet line was cleaned and replaced.
2.0 pounds
102960/102918

2008-02-08
FLARE-Flare 5,17,19
Cause: Process Upset-recycle gas compressor shut down due to process upset./Other-high pressure in the refinery gas collection system due too a high volume of vent gas from other refinery units.

Followup: No

Notes: Process upset conditions at the catalytic cracking unit were resolved and recycle gas compressor was restarted to stop flaring. When the high pressure burner line overpressured, efforts were made to reduce the amount of gas sent to HPBL and increase gas amount taken by Enterg
6.0 pounds
102686

2008-01-29
FLARE-Flare 9
Cause: equipment failure

Followup: No

Notes: Written report from Exxon Mobile surrounding the flaring accident stating that the source was found to be several leaking evacuator valves on the flare gas compressor system. Steam was injected into the flare drum, and RGCU gas gointo to the flare drumwas blocked out. The leaking evacuator valves were also replace
3.0 pounds
102529

2008-01-23
FLARE-Flare 9
Cause: Equipment Failure( leaking RGCU evacuator valve)

Followup: No

Notes: Report from Exxon Mobile surrounding the flaring incident stated that steam was injected into the flare drum, and the RGCU gas going to the flare drum was blocked out. The #9 flare was isolated from the rest of the flaring system. Report stated the leaking evacuator valve would be replace
3.0 pounds
102274

2008-01-15
no informaiton given/leak
no information 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.
144.0 pounds
102233

2008-01-11
Flange leak
Cause:

Followup: No

Notes: DEQ detected vapors containing pollutants with a HAWK camera after receiving odor complaint from citizen. Leaking flange was replaced on 01/11/08. See citizen complaint 01/10/08,Incident #10221
117096

2009-08-06
No Information Given
Cause: Leak occurred, but no information provided about the cause.

Followup: No

Notes: Release is BRQ. Secured leak and will de-pressurize line then replace pipe. LABB does not have access to the LDEQ incident report.
116840

2009-07-28
Alkyl Unit
Cause: Ongoing pinhole leak in piping in Alkyl Unit.

Followup: No

Notes: RQ not exceeded. Blocked the hole, but continues to leak gas.