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ExxonMobil Refinery (2638), Baton Rouge
Releases of Sulfur Dioxide
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 05-BB009-1907 2005-12-09 | FLARE | Cause: repairs were being done on an exchanger which caused the events to occur Followup: No Notes: the MEA from the scrubber was temporarily diverted to the slop system where it would not cause additional upsets. The tail gas from the tail gas clean up unit was diverted to the incinerators to reduce hydrogen sulfide emissions; the procedures for removing the absorber tower from service will be updated to reflect the potential to have hydrocarbon condense in the MEA system; . Air monitoring completed outside facility. | 27,695.0 pounds |
| 05-BB009-1884 2005-11-07 | FLARE- No. 20 & 5 | Cause: power failure caused compressor C-551 to shutdown resulting in flaring from No20 and No5 flares Followup: No Notes: A smaller compressor was started up to reduce flaring and the feed rates to the Cokers were reduced until C-551 could be restarted; an investigation was underway to determine why the automatic transfer to the backup power supply failed | 4,451.0 pounds |
| 05-BB009-1859 2005-08-04 | FLARE- No. 19 | Cause: controls for the REA regenerators were switched to the control backup panel, so part of a controller could be repaired. The REA regenerators had difficulty operating and carried over liquid to the SRLA knockout drums triggering an overabundance of chemical releas Followup: No Notes: the refinery reduced rates to reduce the production of CAG.Ammonia acid gas production was stopped to allow the maximum amount of CAG to be processed. | 64,400.0 pounds |
| No LDEQ Reported 2005-07-25 | FLARE- No17 & 19 | Cause: the sulfur plant shut down causing refinery upset and causing flaring from No17 and No18. Followup: No Notes: significant rate reductions were made to refinery units that send hydrogen sulfide to SRLA to reduce flaring. | 35,257.0 pounds |
| 05-BB009-1801 2005-06-17 | F-101 & F-102 tail gas conversion unit | Cause: the sour water strippers had a larger than normal oil layer. Followup: No Notes: the controller diverted the tail gas to the incinerators to reduce personnel exposure and the SWS evaluated levels in the feed spheres to ensure no more hydrocarbon would be sent to the SWS and SRLA; the first page of the report states that the hydrogensulfide level was exceeded from 9AM to 9PM on June 17th, and the sulfur dioxide limit from the F-101 and F-102 incinerators was exceeded- even though the actual report only states the levels of sulfur dioxi | 12.0 pounds |
| 05-BB009-1798 2005-06-15 | FLARE | Cause: caused by the safety valve malfunction Followup: No Notes: this report involved 3 events over the course of 3 days; the source of the additional gas to RGCU was determined and the vapor pulldown line was opened to reduce pressure in the sphere. This allowed to safety valve to reseat; 63 pounds of nitrogen oxide was released during the incident on the 15th and 16th, and an additional 18 pounds were released on the 17th- making the total pounds released of nitrogen oxide | 1,365.0 pounds |
| 05-BB009-1784 2005-06-08 | C-102 compressor | Cause: flare was caused by a leaking block valve that had been opened when work was being done on the compressor Followup: No Notes: the leaking block valve that was allowing additional hydrocarbon to be fed to the Refinery Gas Compression Unit was tightened down to stop the flaring | 651.0 pounds |
| No LDEQ Reported 2005-04-30 | FLARE- GLA-3x compressor | Cause: the MEA scrubber on No. 2 Light Ends Unit experienced an operational upset due to a high level in the MEA scrubber to overhead drum; GLA-3x compressor shut down causing the RGCU to become overloaded and a gas leakage which flared Followup: No Notes: operations attempted to restart GLA-3x and then reduced rates to the FCCU to eliminate flaring; a new alarm was added that is more visible and will alert the controller of increased level in the interstage drum; other items identified by the ongoing investigation will be evaluated and implemented; flaring occurred from 3:20 PM to 4:40 PM on April 30th; the Wet Gas Scrubber exceeded its regulatory limit of 500 PPM of carbon monoxide from 4-6PM; the carbon monoxide concentration increased to 639 PPM fhe hour from 1-2 on May 1st | 5,903.0 pounds |
| No LDEQ Reported 2005-03-31 | FLARE: GLA-3x compressor | Cause: flaring occurred due to an instrument problem on the Fluid Catalytic Cracking Unit Followup: No Notes: an alternate compressor was started up and the feedrate to the unit was reduced | 2,922.0 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 | 30,244.0 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. | 503.0 pounds |
| 05-BB009-1716 2005-02-19 | FLARE | Cause: Control valves created excessive back pressure on the compressors at PCLA, which resulted in the compressor pressure control valve opening to the flare syste Followup: No Notes: Corrected controls for the pressure control valves for the first part of the flaring event and closed a block valve for the second part of the flaring event; report stated that the release was preventable, but eplained that the flaring from 10:17am to 1:49pm was not preventable because a level instrument was reading incorrectly, which allowed the gas to the flare system. | 734.0 pounds |
| 05-BB009-1711 2005-01-31 | FLARE | Cause: faulty electrical connection caused the compressor to trip on the No. 2 Reformer (RHLA-2); Followup: No Notes: Restarted PHLA-2 and RHLA-2 and diverted HHLA's tail gas to lower pressure system. Refinery will investigate improvements to shutdown facilities. | 743.0 pounds |
| 05-BB009-1710 2005-01-24 | No.3 Fluid Catalytic Cracking Unit | Cause: fresh caustic being blocked away from the WGS when the No.3 fluid catalytic cracking unit, PCLA-3, was shutdown for squa Followup: No Notes: Fresh caustic was lined up to the system to bring sulfur dioxide emissions down. | 3,476.0 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 | 1,743.0 pounds |
| 06-BB009-2231 2006-10-27 | Tail Gas Clean -up Unit (TGCU) - valves 101, 738 | Cause: possible heavy rain storm could have caused 738 to open due to a malfunction associated with heavy rain storm. Followup: No Notes: This accident was not preventable because it is the result of a malfunction of the 738 valve and a leak on the 101 valve. These failures were unexpected. Remedial measures - an investigation is ongoing and the appropriate follow up actions will be completed. Reportable quantities for sulfur dioxide were exceeded. | 944.0 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. | 228.0 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. | 593.0 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 | 2,964.0 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. | 315.0 pounds |
| 86722 2006-03-24 | FLARE - as a result of a leak from the ammonia gas line to the No. 100 Sulfur Plant (SRLA-100) | Cause: the pipe leaked due to new corrosion hole that had developed under the edge of a clamp that was installed in November. The existing clamp was tightened which did not stop the leak so it was replaced with a new clamp which also did not stop the leak. Since the newly installed clamp did not stop the leak, the old clamp was then reinstalled with a new gasket which still did not stop the leak. The feed spheres to the Sour Water Strippers became full which required the start up of the Sour Water Strippers to the flare syste Followup: No Notes: The incident was not preventable because, The clamp was installed in Nov. 2005 due to a pinhole leak from condensate corrosion. At that time, the line was x-rayed and no areas of concern were discovered outside the area under the clamp. Therefore, the corrosion hole that led to the release could not have been predicted. Remedial actions- a similar line exists to the SRLA-200 unit. This line will be inspected and repaired while the SRLA 200 unit is down. The letter to LDEQ ss that the reportable quantities for ammonia, hydrogen sulfide, sulfur dioxide, nitrogen oxide, and nitrogen dioxide were exceeded. Note: there is a time discrepancy - the report states that the incident started at 2:30pm on 03/24/2006 but was discov | 83,580.0 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. | 180.0 pounds |
| 86687 2006-02-23 | No.200 Sulfur Plant (SRLA-200) | Cause: emissions released during the planned shutdown of the No. 200 Sulfur Plant (SRLA-200) were regulated under the Clean Air Act requirements and the unit's MACT II Startup, Shutdown, and Malfunction Plan (SSMP) from 40 CFR 63 Subpart UUU which requiresfacilities to minimize excess emissions during periods of startup, shutdown, or malfunction Followup: No Notes: The incident occurred as a result of a scheduled, planned, and properly executed event. It was not preventable. Remedial measures are cited as appropriate procedures were followed. The emissions are federally permitted and were minimized in accordance with the MACT II SSMP. Note: there is a time discrepancy - the report states that the incident started at 1:00pm on 03/23/2006 but was discovered at 2:00pm on 03/23/2006. May 2nd follow up later states that this was a scheduledus train shutdown and this type of shutdown is expempted from the 250 ppmvd under the consent decree (paragraph 67(c)). This is not a tail gas incident because of the above mentioned exemption. The root cause of the emissions is an unavioid | 16,400.0 pounds |
| 86001 2006-02-22 | FLARE | Cause: the 100, 200, 400 Sulfur Trains shut down due to high pressure on the primary burners. The 100 Train started up after 2min., the 200 Train started up after 3min., and the 400 train started up after 10min. During the time the Sulfur Trains were shutdown,the pressure increased on the MEA Regenerators, so clean acid gas was flared for 17min. Equipment failed due to a a failure to operate and maintain that equipment in a manner consistent with good engineering practice. Followup: No Notes: This event was not preventable -SEE Follow Up Consent Decree letter dated 04/07/2006 - Had the limit switch for valve 182 not been connected in the manner in which it was to the valve posistioner, then the AG Flaring Incident would not have occurred. The fact that valve 192 lacks valve posistion feedback to the Controller to indicate the actual posisiton of the valve was a signifigant contributing factor in this incident. A second contributing factor was that there as no visual checkitiated by the Controller, on the valve to provide absolute certainty that valve 182 was actually open. This was considered, for purposes of stipulated penealties under the consent decree, equipment failed due to a failure to oper | 8,171.0 pounds |
| 101896 2007-12-26 | FLARE-Flare #19 FLARE-Flare 19 | Cause: Motor operated valve found in open position and upstream control valve was leaking acid gas to flare Followup: Yes Notes: Report states that incident is still under investigation and follow up report will be completed once investigation is complete. | 1,423.0 pounds |
| 101896 2007-12-26 | FLARE-Flare #19 FLARE-Flare 19 | Cause: Motor operated valve found in open position and upstream control valve was leaking acid gas to flare Followup: Yes Notes: Report states that incident is still under investigation and follow up report will be completed once investigation is complete. | 1,424.0 pounds |
| 100050 2007-10-09 | FLARE-Flare #5,17,19,20,24 | Cause: air supply line broke Followup: Yes Notes: feed to both PCLA units were reduced. Air to the regenerator was adjusted to increase CO concentration in the flue gas and return CO combustion to the normal level in furnace. | 1,139.0 pounds |
| 100015 2007-10-06 | FLARE-Flare #17 | Cause: Safety valve released to flare due to overpressure Followup: No Notes: Valve outlet line removed from service and D-105 was opened to relieve pressure | 6,963.0 pounds |
| 99374 2007-09-12 | Release FLARE-Flare #5,8,9,17,23 | Cause: c-101 Recycle Compressor on the HCLA unit shutdown due to an instrumentation tubing failure. Compressor trip activated the units emergency depressureization procedure. Followup: Yes Notes: The unit was depressurized immediately in accordance to emergency procedures. Tubing on the seal oil pump was replaced and properly connected. The investigation is ongoin so an appropriate follow up will be completed. Under Investigation. | 7,176.0 pounds |
| 97340 2007-06-23 | steam line leak | Cause: leak in steam line Followup: Yes Notes: Under investigation/line was repaired and piping in area was visually inspected for similar occurences. Tail gas diverted from incinerators back to TGCU. | 167,093.0 pounds |
| 96991 2007-06-11 | FLARE-Flare #19 | Cause: Followup: No Notes: Initially the flare was not noticed but when it was operating crews attempted to locate the source of the excess gas but by 2:37pm the system returned to normal, thus ending the flar | 568.0 pounds |
| 96828 2007-06-06 | Flare | Cause: cooling tower pump failed Followup: No Notes: Several units were shut down to avoid a serious safety incident or property damage. The pump was repaired and returned to service | 14,921.0 pounds |
| 95990 2007-05-08 | FLARE-Flare #5,20 | Cause: Followup: Yes Notes: Attempts were made to restart compressor and without success a back up compressor was started. Feed rates were reduced to stop flaring. | 4,659.0 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. | 1,505.0 pounds |
| 94413 2007-03-07 | furnace permit deviations | Cause: valve misalignment Followup: Yes Notes: Once alignment was noticed, hydrogen sulfide stream was blocked from the high pressure burner line. 8 furnaces were involved(F1-4 at Powerformer2, F-31 at Feed Prep, F1 at 4-Light Ends East, F1-2 at 4-Light Ends Wes | 1,054.0 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. | 14,881.0 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. | 8,752.0 pounds |
| 111426 2008-12-15 | unspecified flare PCLA Furnace F-301 | Cause: The refinery PCLA furnace F-301 developed holes in it which caused a release of 421 pounds of sulfur dioxide/day. On the same day, a flaring incident released 107 pounds of sulfur dioxide. Combined, these two sources released 528 pound of sulfur dioxide which is above RQ.
The flaring incident occurred due to the depressurizing of the Alky unit for mechanical work after an unexpected shutdown. The unit was depressured after shutdown. This was an unplanned shutdown, which resulted in more light hydrocarbon loading for the vapor recovery system. The vapor recovery system was subsequently overloaded, resulting in a flaring incident. This incident was caused by a process upset. Followup: No Notes: Additional cooling tower cells started and rebalanced operations to reduced gas sent to the vapor recovery system. SO2 was leaked at a rate of 421 pounds per day from the furnace failure, but no information given as to the duration of the incident. Combined with the flare SO2 release, this incident surpasses the 500 pound RQ for SO2. | 107.0 pounds |
| 111426 2008-12-15 | unspecified flare PCLA Furnace F-301 | Cause: The refinery PCLA furnace F-301 developed holes in it which caused a release of 421 pounds of sulfur dioxide/day. On the same day, a flaring incident released 107 pounds of sulfur dioxide. Combined, these two sources released 528 pound of sulfur dioxide which is above RQ.
The flaring incident occurred due to the depressurizing of the Alky unit for mechanical work after an unexpected shutdown. The unit was depressured after shutdown. This was an unplanned shutdown, which resulted in more light hydrocarbon loading for the vapor recovery system. The vapor recovery system was subsequently overloaded, resulting in a flaring incident. This incident was caused by a process upset. Followup: No Notes: Additional cooling tower cells started and rebalanced operations to reduced gas sent to the vapor recovery system. SO2 was leaked at a rate of 421 pounds per day from the furnace failure, but no information given as to the duration of the incident. Combined with the flare SO2 release, this incident surpasses the 500 pound RQ for SO2. | 421.0 pounds |
| 111454 2008-12-14 | flare #17 | Cause: Flaring at #17 flare. Followup: No Notes: Official letter from Exxon missing. | |
| 110601 2008-11-05 | Furnace F-301 | Cause: Multiple holes have developed in the F-301 CO furnace box at the Catalytic Cracking Unit. The initial leak rate evaluation was completed 07/28/08 and SO2 emissions were BRQ. However on 11/5/08, the number of holes and hole size increased, and SO2 emissions were 726 pounds a day which exceeds RQ. On 11/21/08, the SO2 emissions reduced to 566 pounds a day which still exceeds RQ. On 12/5/08, the SO2 emissions were BRQ at 493 pounds/day. On 12/9/08, emissions reduced to 421 pounds per day. No further work will be perform on furnace due to the locations and personnel exposure of the remaining leaks.
Air monitoring for SO2 was conducted at the furnace and near the fenceline after the RQ was exceeded. Readings of 13ppm, 25ppm, and 85ppm SO2 were detected at various levels 1 foot away from the furnace. Fenceline readings were all below detectable limits. Followup: Yes Notes: The lower temperature exposure and several of the higher temperature areas were patched to reduce the SO2 emissions to BRQ. The F-301 furnace will be shut down and repaired during the turnaround which is scheduled to begin January 2009. This release is RQ and ongoing. | 19,395.0 pounds |
| 110037 2008-10-13 | Flare | Cause: An Emergency Isolation Valve (EIV) on the suction to GLA-2X compressor at the Catalytic Cracking unit unexpectedly closed. As a result, gases that normally feed the compressor were sent to the Refinery Gas Compression Unit as capacity allowed, and the remainder was flared. The flares burned for 14 minutes while unit personnel investigated the source of the flare. When the EV was found in the closed position, the controller immediately opened it to resume flow to the compressor and stop the flaring. Followup: No Notes: The flares burned for 14 minutes while unit personnel investigated the source of the flare. When the EV was found in the closed position, the controller immediately opened it to resume flow to the compressor and stop the flaring. Feed rates to the Cat unit were reduced from 117 to 104 KBD. The EIV was reopened to resume flow to the compressor. This release exceeded the RQ for SO2. | 627.0 pounds |
| 108842 2008-09-09 | NIG | Cause: According to the verbal report, Exxon lost their primary control device on the Sulfur Recovery Unit so they diverted to the secondary control device. They reduced rates to minimize flaring amounts. Followup: Yes Notes: LABB only has access to the SPOC verbal reports. These initial reports estimate that both sulfur dioxide and hydrogen sulfide were released above reportable quantity. Material went offsite. LABB only has access to the SPOC verbal report. | 500.0 pounds |
| 108690 2008-09-05 | Flare | Cause: STORMS-startup brought on flaring after rapid shutdwon due to Hurricane Gustav Followup: Yes Notes: refinery is undergoing startup operations. All efforts are being made to minimize environmental impacts. A follow up report will be submitted when startup flaring has ended. | 368,396.0 pounds |
| 108484 2008-09-02 | FLARE-Sour Water Stripper routed to flare | Cause: STORMS-Hurricane Gustav Followup: No Notes: no information given | 506,946.0 pounds |
| 108485 2008-09-01 | FLARE- All 8 flares FLARE-All 8 flares | Cause: STORMS-Hurricane Gustav Followup: No Notes: Refinery was safely and sytematically shutdown due to the hurricane. Learning from this even will be incorporated into future hurricane preparations. | 28,656.0 pounds |
| 107771 2008-08-05 | compressor | Cause: Flaring occurred when a compressor depressurized for maintenance. Followup: No Notes: Amount of sulfur dioxide released is unknown. | |
| 107711 2008-08-02 | flare gas compressor | Cause: Flare gas compressor tripped off. Back up compressor started back up which stopped the other from flaring. This in turn secured the incident Followup: Notes: No additional information given. | 500.0 pounds |
| 107172 2008-07-12 | Hydrocracker unit safety valve | Cause: Safety valve lifted on the hydrocracker unit and went to flare. Followup: No Notes: The compressor was unloaded and pressure was brought down. | |
| 107124 2008-07-10 | Cause: The flaring was caused by a unit start up. Followup: No Notes: No reportable quantities were exceeded. | ||
| 107052 2008-07-08 | flare | Cause: They are starting up some units at the refinery which requires them to flare intermittently until midnight and possibly into the early morning tomorrow. Followup: No Notes: It requires them to flare intermittently until midnight and possibly into the early morning tomorrow which may result in the release of the gas to the air from the flare. | |
| 106981 2008-07-07 | flare | Cause: Cause of release to the air form the flare is unknown. Followup: No Notes: Written report states no reportable quantities were exceeded. | 500.0 pounds |
| 106842 2008-06-30 | flare #7 | Cause: The indicator is not functioning properly, so they do not know the exact amount released to the flare. Followup: No Notes: They normally have instrumentation that tells what the values are when they are flaring. This occurred at Flare #7. | |
| 106840 2008-06-29 | flare | Cause: Experiencing intermittent flaring. Instrument does not appear to be functioning properly. Followup: No Notes: May exceed reportable quantity of sulfur dioxide. | |
| 106262 2008-06-07 | Atmospheric release/FLARE-Flare 17,19,23 | Cause: The C-101 Recycle Compressor on the HCLA unit shut down due to a fault in the transformer that supplies power to the compressor motor. The compressor trip automatically activated the units emergency depressurization procedures, which caused gases in the HCLA reactor system to be vented to the atmosphere via the condensable blow down drum. The transformer failed due to overheating. The air conditioner in the substation was found to have failed causing the temperature in the building to increase and the transformer to overheat. FLaring also occurred. Followup: Yes Notes: The unit was depressurized automatically in accordance with the emergency procedures. Temporary ventilation conditioning was installed in the substation to cool the remaining electrical equipment. Total amount of flammable vapor released was 108,206 pounds. Total amount of VOC's released was 93,904 pounds | 163.0 pounds |
| 106230 2008-06-06 | Furnace emmision deviation | Cause: The hydrogen sulfide analyzer for the NSPS fuel gas system indicated that the hydrogen sulfide levels in the fuel gas system increased. It was not initially known if the analyzer reading was accurate because there was no alarm indication for the operator of any unit malfunction that could have caused the elevated hydrogen sulfide levels. The source of the high hydrogen sulfide was due to a valve misalignment on the T-301 MEA scrubber at the #2 Light Ends Unit. Sour gas was inadvertently lined up through the scrubber, which had been down for repairs, without introducing MEA into the tower. The unscrubbed gas entered the NSPS fuel gas system and caused 33 furnaces in the NSPS system to exceed their maximum permitted limits for sulfur dioxide. Followup: Yes Notes: The high hydrogen sulfide stream was blocked away from the scrubber and the hydrogen sulfide level in the NSPS system dropped below the maximum allowable limit. | 1,255.0 pounds |
| 106154 2008-06-03 | flare | Cause: Chemicals are flaring. Followup: No Notes: They are in the process of trying to resolve which process unit the chemicals are coming from. | |
| 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. | 241.0 pounds |
| 104962-104935 2008-04-20 | leak/FLARE-Flare 5,9,19,20,24 | Cause: Equipment failure-Hydrocracker unit down; Pressure Swing Absorber out of service Followup: No Notes: Safety valve released itself once the pressure stabilized. Lights end section was depressured to stop H2S leak, which caused many flares to burn. Light ends depressured. Stream was lined up to the tower to stop flarin | 1,445.0 pounds |
| 104832 2008-04-17 | FLARE | Cause: They are doing a planned power outage at the Methylethylketone (MEK) Unit and sending natural gas to the #5 flare. Followup: No Notes: There was potential to have pilot outages. They added natural gas to keep the pilots lit because the ignitors are electric. | |
| 103859 2008-03-12 | no information given | Cause: A reactor is being brought back on line. Followup: No Notes: They are pre-treating the reactor. As a result of this, they have high hydrogen sulfide in their fuel gas which results in high sulfur dioxide in the furnace gas flue. The three hour average of hydrogen sulfide is more than 160 ppm. | |
| 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 | 445.0 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 | 372.0 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 | 367.0 pounds |
| 111957 2008-01-11 | flare and PCLA F-301/F-201 furnace | Cause: Emergency isolation valve on GLA-2X compressor failed to close. This caused pressure build up in PCLA system, in which the control valve routed the excess gas to the flare system. Followup: No Notes: Under investigation. Exceeded RQ due to the combination from the flare and the PCLA F-301/F-201 furnace leaks (LSP Incident #08-07087). | 633.0 pounds |
| 119501 2009-11-16 | flares | Cause: Compressor tripped at RGC unit. Followup: No Notes: RQ not exceeded. Will re-start compressor and minimize gas that will be sent to the flare. | |
| 119021 2009-10-10 | spent catalyst line | Cause: Leak occurred in spent catalyst lines. Followup: No Notes: RQ not exceeded. Evaluating to make repairs. | |
| 118272 2009-09-28 | Flare # 17 and 19 | Cause: Flare #17 and #19 ignited due to an unknown reason Followup: Yes Notes: RQ not exceeded. | |
| 117459 2009-08-22 | no information given | Cause: Compressor malfunctioned leading to flares. Followup: No Notes: RQ not exceeded. Company reports and State Police HAZMAT report differs in pollutants. | |
| 116863 2009-07-28 | flare system | Cause: PCLA-2 Fluid Catalytic Cracking Unit restart caused discharge. Unit unexpectedly shutdown earlier in the day. Restart caused pressure to build and ultimately flaring. Followup: No Notes: RQ for SO2 exceeded. State Police HAZMAT report and company reports differ in pollutants. Feed was reduced o the unit, temperatures within unit was decreased and compressor was restarted. | 1,161.0 pounds |
| 116539 2009-07-17 | 7 unspecified flares 7 flares | Cause: Compressor lost which caused flaring for 7 of the flares. Followup: No Notes: RQ not exceeded. | |
| 116430 2009-07-14 | unspecified flare | Cause: Coker compressor failed which caused flares to burn. Followup: No Notes: RQ not exceeded. | |
| 116294 2009-07-07 | flare system | Cause: Safety valve lifted in the plant which caused 6 different flares to ignite. Followup: No Notes: This release estimate exceeds RQs. The incident was secured. LABB only has access to the SPOC verbal report, and all of these quantities are the initial estimates. | 500.0 pounds |
| 114924 2009-05-12 | flare system | Cause: Personnel was making valve alignment changes when a block valve on the suction of the coker compressor was inadvertently closed. This caused the pressure to build in the overhead system until the pressure exceeded that of pressure vent set point. The pressure vents opened, resulting in overhead vapor to be released to the flare system, which resulted in the flaring of the hydrocarbon. Followup: No Notes: The RQ for SO2 was exceeded. The valve was reopened. Additional training and discussion was held for the personnel about the importance of valve misalignment. Company letter and State Police HAZMAT report differs on pollutant released. | 836.0 pounds |
| 114803 2009-05-11 | No Information Given | Cause: According to the SPOC verbal report, a meter read a high SO2 concentration, but no information about what caused this high reading. Followup: No Notes: The RQ not exceeded, and there was a fluctuation in pressure for SO2. LABB does not have access to the LDEQ incident report. | |
| 114733 2009-05-07 | bypass stack | Cause: The Wet Gas Scrubber had a malfunction which led to failure of an expansion joining at CO Furnace, F-301. The malfunction required venting of PCLA 2 and 3 to bypass stacks and shutdown of Wet Gas Scrubber. Followup: Yes Notes: This incident exceeded RQs. PCLA-3 vented to bypass stack until shutdown was completed. All of the Wet Gas Scrubber nozzles were replaced. Root cause is under investigation. | 115,215.0 pounds |
| 114479 2009-04-27 | FLARE | Cause: Flaring occurred when compressor tripped off line. Followup: No Notes: RQ not exceeded. Restarted compressor. No LDEQ report or follow up. | |
| 114103 2009-04-11 | GLA-3X compressor flare | Cause: Level instrument of GLA-3X compressor was plugged which caused the reading to be erroneously high. Compressor tripped which caused pressure to build up and a flare to be emitted. Followup: No Notes: Release exceeded RQ. Unit rates decreased to stop flaring. Cause of compressor trip is under investigation. High level alarm is bypassed to prevent recurrence. | 5,104.0 pounds |
| 113891 2009-04-01 | unspecified flare | Cause: Flaring was caused by an overhead condenser leak at the PCLA complex. The overhead material at the PCLA fractionator is cooled using cooling tower water. A leak developed in these condensers which caused cooling tower water to enter the shell side of the overhead condensers. When the cooling tower water evaporated, salts and foulant were deposited in the process side of the overhead condensers, causing an increase in pressure drop. This increase in pressure drop caused the fractionator pressure to increase, and eventually exceed the set pressure of the pressure relief valves. The pressure relief valves released fractionator overhead into the flare gas recovery system, resulting in flaring. Sulfur Dioxide was released to the atmosphere in exceedance of the reportable quantity. Followup: No Notes: Unit pressure and unit feed rates were reduced to minimize overhead gas rates and eliminate flaring. Release exceeds RQ. | 857.0 pounds |
| 113842 2009-03-31 | make-up hydrogen compressor (C-102B) | Cause: Make-up hydrogen compressor (C-102B) malfunctioned which caused a higher rate of hydrogen into C-102 compressor. This increased pressure which resulted in a safety valve release and caused flaring. Followup: No Notes: Release exceeded SO2 RQ. The safety valve was removed from service. Pressure maintained by companion safety valve. Compressor will be repaired. Company report and State Police HAZMAT report differs on pollutants released. | 978.0 pounds |
| 113150 2009-03-05 | #20 flare | Cause: Flaring occurred at #20 flare. Followup: No Notes: RQ not exceeded. | |
| 113123 2009-03-04 | No Information Given | Cause: According to SPOC verbal report, a leak occurred on CO furnace. Followup: No Notes: RQ not exceeded. | |
| 112587 2009-02-08 | No Information Given | Cause: According to the SPOC verbal report, the sulfur dioxide 12 hour limit was exceeded and the incident is still under investigation. No information provided regarding the cause. Followup: No Notes: Under investigation. May be related to another unit that is in a turnaround. Release is BRQ. | |
| 112184 2009-01-02 | #17 flare and PCLA furnaces | Cause: As a result of flaring at flare #17, 139 pounds of sulfur dioxide was released into the atmosphere. The SO2 release, in conjunction with the continuous SO2 release of 431 pounds/day from the PCLA Furnaces (State Police Number 08-07187), resulted in a release exceeding the RQ for SO2.
No information given regarding the cause of these releases. Followup: No Notes: Combined release of SO2 from #17 flare and PCLA furances exceeded RQ. PCLA unit rates were reduced and critical overhead condensors were backwashed, and the PCLA furnaces were repaired during the unit turnaround scheduled for the first quarter of 2009. | 570.0 pounds |
| 128404 2010-12-30 | Flare | Cause: An unknown quantity of sulfur dioxide release due to flaring to correct levels within a steel drum. Liquid contains hydrogen sulfide and when combusted sulfur dioxide was released. Followup: No Notes: This release is below reportable quantity. | |
| 128351 2010-12-27 | Flares #17 and #19 | Cause: The alkylation unit was being shutdown and a compressor at the hydrocracker unit was starting up, this helped the flare gas recover unit to receive higher than normal hydrocarbon vapor rates. This exceeded the vapor recovery system capacity leading to temporary flaring of flare #17 and #19, and the leaking of sulfur dioxide. Followup: No Notes: "Unit operations were adjusted to end the flaring." "Increased monitoring will be conducted on gas vent rates to prevent recurrence" | 1,127.0 pounds |
| 128094 2010-12-10 | FLARE | Cause: Upset in light ends unit caused high pressure, had to flare. FLARE. Followup: No Notes: BRQ. LDEQ report states that this incident was below reportable quantities. No information given. LDEQ report only. No refinery letter included. | 500.0 pounds |
| 128095 2010-12-10 | weld | Cause: Crack in a weld caused a small fire that burned SO2. Followup: No Notes: A box was placed around the cracked weld to repair the leak and nitrogen was used to maintain an extinguished flame. LABB only has access to the LDEQ incident report. This release is BRQ. | 100.0 pounds |
| 128030 2010-12-07 | No Information Given | Cause: The cold weather may have prevented the gas from reaching the compressor and caused the flare to burn which released sulfur dioxide. Followup: No Notes: The LDEQ incident report says that an estimated 500 pounds of sulfur dioxide was released due to flaring. This amount is reportable quantity. However, the refinery letter states that no releases exceeded reportable quantity. | |
| 127934 2010-11-30 | FLARE: Refinery MEA Scrubbing Tower (T-585) | Cause: FOLLOW-UP REPORT: Root cause determined to be incorrectly calibrated level instrument.
INITIAL REPORT: Refinery letter incidents that a process upset was the cause. MEA is used in several towers in the refinery to remove hydrogen sulfide from the hydrocarbon streams. A refinery MEA scrubbing tower, T-585, lost its MEA liquid level, allowing hydrocarbon vapor to enter the MEA system. This malfunction caused flaring. Combined incident involving both the ExxonMobil refinery and ExxonMobil Chemical Plant in Baton Rouge. Followup: Yes Notes: INITIAL RESPONSE: Tower T-585 was isolated from the MEA system to eliminate the root cause of incident release potential. Unit operations were adjusted to minimize emissions potential and incident duration. The tower was isolated, and liquid level was restored to stop the incident. FOLLOW-UP RESPONSE: LDEQ states it will investigate further during next facility inspection. | 4,392.0 pounds |
| 127376 2010-10-28 | FLARE | Cause: Pressure instrument failed & resulted in flaring. FLARE. Followup: No Notes: BRQ. Below Reportable Quantities. | |
| 126270 2010-09-10 | flare | Cause: The Alky Unit was shut down, and while preparing equipment, isobutane released to flare system. Followup: No Notes: Release was Below Reportable Quantities [BRQ]. | |
| 125914 2010-08-24 | flares # 17 and 19 | Cause: An upset on the process unit caused flaring. Followup: No Notes: No further information provided, | |
| 125843 2010-08-21 | Flare | Cause: Two flaring incidents in one 24hr period: on 8/21, water boot level instrument malfunction on the Hydrocracker Unit Low Pressure Separator Drum D-105; on 8/22, level instrument on Sponge Absorber Tower's reflex drum D-114x failed.
These releases exceeded RQ for sulfur dioxide. Followup: No Notes: The water boot was isolated and the drum liquid level lowered. | 3,084.0 pounds |
| 124285 2010-06-18 | FLARE: vapor recovery system | Cause: All cooling towers are over temperature limit and will be flaring at the coker unit. Followup: No Notes: Feed rates reduced to stop temporary flaring. 1,039 pounds of SO2 were released through the flare which is RQ. LABB only has access to the LDEQ incident report. | 1,039.0 pounds |
| 123244 2010-05-05 | PCLA-2 Unit | Cause: The PCLA-2 unit was following start up procedures when one of the unit's air blowers tripped due to an erroneous upstream level instrument reading. Reduced air flow rates caused an increase in light material production, which resulted in a compressor shutting down. This in turn caused hydrocarbon to be sent to the flare system, by design, until unit operations could be restored. The flaring resulted in a sulfur dioxide RQ exceedance. The original amount reported was 969 lbs, but an updated amount increased the estimate to 1,052 pounds of SO2 released.. Followup: Yes Notes: This release is RQ. Instrument level was adjusted to prevent erroneous readings. A citizen complaint ( T-13243) was also logged in by SPOC [State Police]. | 1,052.0 pounds |
| 122774 2010-04-14 | FLARE: PCLA-2 [CCU] | Cause: Facility was called after smoky flare was noticed. A level instrument critical to unit operations that malfunctioned caused flaring.
Exceeded RQ for SO2. Follow-up letter states that a recent analysis of the refinery flare system resulted in updated release amount: 1653 lbs Followup: No Notes: The unit was shut down to end the release. This incident is under investigation to determine the root cause in order to prevent reoccurrence. This release exceeded the 1,000 pound RQ value for SO2. LDEQ incident report indicate that this incident is #122774 and State police #10-01932. However, the refinery letter indicates that this incident is incident #s 122774, 123224, and 124285 and state police numbers 10-01932, 10-02386, 10-03389. | 1,653.0 pounds |
| 120862 2010-01-19 | sulfur recovery unit | Cause: Sulfur Recovery Unit process upset. No further details provided. Followup: No Notes: Release is BRQ. | |
| 120611 2010-01-08 | flare | Cause: Over pressure to flare due to cold weather. LDEQ indicates it is a safety issue and flared with smoke.
No information given as to amounts of releases. Followup: No Notes: LABB only has access to LDEQ incident report. No information provided if release was BRQ. | |
| 135838 2011-12-10 | Furnace from a burner line | Cause: At the time of initial notification, Exxon personnel was attempting to find the source of the problem. No information given about the cause in the written report after the release was all clear. Followup: No Notes: No remedial actions mentioned. Initial reports indicated a release of over 500 lbs of sulfur dioxide, but Exxon determined that no RQs were exceeded in the written report. The RQ for sulfur dioxide is 500 pounds. | |
| 134945 2011-10-26 | Flare at the tower compressor pump | Cause: ExxonMobil was trying to bring the rates up on a unit. The tower pressure exceeded what the compressor could pump. This resulted in flaring of SO2. Followup: No Notes: Another compressor was attached until the pressure went back down. | 25.0 pounds |
| 132125 2011-06-29 | FLARE: C-50 Flare gas recovery compressor | Cause: On 6/29/11, Exxon Refinery experienced a compressor malfunction. Operations personnel at the #2 Light Ends Unit discovered a vapor release from the C-50 flare gas recovery compressor due to a missing jackbolt. This release lasted 10 minutes.
Additionally, RHLA-1 unit experienced a release from the channel box of exchanger E-700F. Emissions from this release are currently estimated to be 704 pounds per 24 hours. This release, however, is ongoing. Followup: No Notes: The compressor was isolated and depressurized to end the vapor release. Removing C-50 from service resulted in reduced flare gas recovery capacity, and flaring ensued. Evacuating C-50 of vapor also resulted in flaring. The spare compressor, C-40, was started once C-50 was secured to end the event. To end the vapor release, the compressor was isolated. To end the flaring, the spare compressor was started. Additionally, development and execution of a plan to repair the 2nd release is underway. Both of these release are above reportable quantity. | 1,428.0 pounds |
| 131867 2011-06-17 | No Information Given | Cause: Sulfur dioxide was released when hydrogen gas was flared. No further information given. Followup: No Notes: BRQ. Flaring only lasted 8 minutes. No further information was given. | 59.0 pounds |
| 131058 2011-05-05 | Coker unit | Cause: The coker unit lost a compressor resulting in a release of sulfur dioxide. Followup: Yes Notes: Electrician corrected the problem on site within 5 minutes. Follow-up Letter corrects the inaccurate incident date from the original incident report from the refinery. | |
| 130413 2011-04-03 | FLARE | Cause: LDEQ states that when bringing a unit online, flaring occurred. Followup: No Notes: BRQ. The unit was secured. | 153.0 pounds |
| 130240 2011-03-29 | Flare: Unspecified flare | Cause: The GLA-3X gas compressor shut down resulting in flaring. Followup: No Notes: The 2x compressor was started to stop flaring. | 382.0 pounds |
| 130070 2011-03-20 | FLARE: ICN unit/R-800 reactor | Cause: During unit start-up there was a system pressure relief via flare causing a release of sulfur dioxide. Followup: No Notes: This release was BRQ. No additional information given. | 2.0 pounds |
| 129962 2011-03-17 | FLARE: Power former unit | Cause: During start-up of power former unit, sulfur dioxide went to the flare to relieve pressure in the system. Followup: No Notes: This release was BRQ. Due to the low hydrogen sulfide content of the material flared, less than one pound of sulfur dioxide was emitted. Initial report included 500 pounds of sulfur dioxide. | 1.0 pounds |
| 129440 2011-02-24 | Sulfur Recovery Unit incinerators | Cause: On February 24th, 2011, at approximately 8:23 am, there was a Tail Gas Incineration event at the ExxonMobil Baton Rouge Refinery.
The Sulfur Recovery Unit (SRLA) was undergoing monthly equipment evaluation when material that is normally routed from SRLA to the Tail Gas Clean Up Unit (TGCU) instead bypassed TGCU and was directed to the SRLA incinerators. This resulted in approximately 476 pounds of sulfur dioxide emissions above the incinerator permit limit. The cause of this release was inadvertent human error.
Within the same twenty four hour period, the Powdered Catalyst Unit(PCLA) experienced seal leaks on furnace F-301. The furnace produces steam, and the steam production tubes exit the furnace convection section. Seals where the steam tubes exit the furnace were leaking, allowing flue gas containing sulfur dioxide to exit the furnace. The leaks released 30 pounds of sulfur dioxide to the atmosphere.
Together, these two releases emitted approximately 506 pounds of SO2.
There were no offsite impacts, injuries, or complaints as a result of this incident. Followup: Yes Notes: To end the release, SRLA tail gas was routed through the Tail Gas Clean Up Unit (TGCU). After further review, ExxonMobil determined that the leaks from the Powdered Catalyst Unit were successfully repaired prior to February 24, 2011. Approximately 476 pounds of sulfur dioxide were released on February 24 due to Tail Gas Incineration. No reportable quantities were exceeded. Total sum of two incidents in 24 hours was 506 lbs which is reportable quantity. | 506.0 pounds |
| 129066 2011-02-05 | FLARE: Unspecified flare | Cause: 2 units were shutdown and caused flaring. Two light end PCLAs. Sulfur Dioxide was released. Followup: No Notes: There is no information given regarding remedial actions. | 286.0 pounds |
| 128902 2011-01-28 | FLARE: #4 Unit | Cause: As the #4 unit was starting up, it had a unit swing. To relieve the pressure, flaring took place.
During the same 24 hours, the Powdered Catalyst Unit (PCLA) also underwent startup operations. Difficulties with compressor GLA-2X during startup resulted in additional flaring. As a result of this flaring, 1616 pounds of sulfur dioxide was released.
Combined, these two sources release 1,716 pounds of sulfur dioxide. However, in a follow-up letter dated March 21, 2011, ExxonMobil stated that 2,063 lbs of sulfur dioxide were released. Followup: Yes Notes: This release is RQ. To end the Light Ends Flaring, pressures on the 4 West Rerun and 4 West Splitter towers were reduced. To end the PCLA flaring, compressor GLA-2X was started. To prevent recurrence, procedures will be reviewed for the Light Ends area startups following unplanned downtimes. Additionally, startup procedures for the GLA-2X compressor will be reviewed. | 2,063.0 pounds |
| 128794 2011-01-20 | Tank 261: Pressure Valve Vent | Cause: Sulfur dioxide, flammable gas, and hydrogen sulfide at levels below reportable quantities were released due to a leak in the pressure valve vent on Tank 261. Followup: No Notes: BRQ. Vapor recovery was performed. Refinery letter states that no reportable quantities were exceeded and this is considered a courtesy notification." | |
| 128556 2011-01-10 | #1 East Debutanizer | Cause: There was a sulfur dioxide spike in the burner line that occurred on the #1 East debutanizer. An investigation is underway to determine the cause. Followup: No Notes: BRQ. LDEQ report states that the spike was believed to be greater than 500 lbs, over reportable quanity. In the refinery letter, Exxon Mobile states that only nine pounds of excess sulfur dioxide was released, which is BRQ. | 9.0 pounds |
| 128526 2011-01-07 | Flange | Cause: A flange leak occurred in the sulfur unit. Sulfur dioxide and hydrogen sulfide were released. Followup: No Notes: BRQ. After further evaluation, ExxonMobil determined that no reportable quantities were exceeded. Mechanical unit cranked down on the bolts to secure the leak. | 1.0 pounds |
| 128480 2011-01-02 | FLARE Coker unit & furnace F-301 of the Powdered Catalyst Unit (PCLA) | Cause: Two separate incidents occurred, both resulting in a release of sulfur dioxide.
Incident #1: According to the refinery letter, "a drum level instrument on the coker unit malfunctioned" falsely indicating that the drum level was high, sending coker overhead gas to the flare system. This was due to a contaminant in the air system.
Incident #2: Seal leaks on the F-301 furnace of the Powdered Catalyst Unit (PCLA) caused the release of SO2 to the atmosphere. Followup: No Notes: RQ: The first incident released 411 lbs of SO2 and the second released an additional 206 lbs for a combined 617 lbs of sulfur dioxide which exceeds the amount necessary for reportable quantities. Incident #1: To end the release, the drum level instrument was repaired, and the compressor was restarted. As the level instrument malfunctioned due to a contaminant in the instrument air system, filters in the system were replaced and the supply has been restored to prevent recurrence. Incident #2: No solution described in report. Waiting for audit to determine remedial actions. | 411.0 pounds |
| 128480 2011-01-02 | FLARE Coker unit & furnace F-301 of the Powdered Catalyst Unit (PCLA) | Cause: Two separate incidents occurred, both resulting in a release of sulfur dioxide.
Incident #1: According to the refinery letter, "a drum level instrument on the coker unit malfunctioned" falsely indicating that the drum level was high, sending coker overhead gas to the flare system. This was due to a contaminant in the air system.
Incident #2: Seal leaks on the F-301 furnace of the Powdered Catalyst Unit (PCLA) caused the release of SO2 to the atmosphere. Followup: No Notes: RQ: The first incident released 411 lbs of SO2 and the second released an additional 206 lbs for a combined 617 lbs of sulfur dioxide which exceeds the amount necessary for reportable quantities. Incident #1: To end the release, the drum level instrument was repaired, and the compressor was restarted. As the level instrument malfunctioned due to a contaminant in the instrument air system, filters in the system were replaced and the supply has been restored to prevent recurrence. Incident #2: No solution described in report. Waiting for audit to determine remedial actions. | 206.0 pounds |
| 145500 2012-12-21 | NIG | Cause: On December 21, 2012 at 11:38 am, the Coker C-551 compressor tripped due to a low oil pressure indication. While filling the exchanger with lube oil, the pressure dipped and caused the C-551 compressor to trip. The resulting compressor trip routed gas to the Refinery flare system where it was combusted. The compressor was restarted and flaring ceased at 12:31 PM. After further investigation, it was determined that a procedure existed, but was not followed by unit personnel while completed by this task. Followup: Yes Notes: The resulting compressor trip routed gas to the Refinery flare system where it combusted. The compressor was restarted and flaring ceased at 12:31PM. LDEQ conducted fence line monitoring with the result of no detection. ExxonMobil also conducted monitoring with the result of no detection. The reportable quantity of SO2 was exceeded as a result. Oil pressure was restored to operating range and the compressor was restarted. Refresher training has been conducted with unit personnel on the procedures for placing the lube oil exchanger back in service. | 3,694.0 pounds |
| 145413 2012-12-17 | piping going to the PCLA unit F-301 furnace | Cause: There is a gasket leak on a furnace. After further investigation, a crack was discovered in the piping going to the PCLA unit F-301 furnace is releasing 142 pounds per day of sulfur dioxide. After further evaluation, the facility determined that no RQs were exceeded (that determination was impossible at the time of this report because the relase was still ongoing).
According to the facility's verbal notification the materials released to the air did go offsite. Followup: No Notes: 142 pounds per day of SO2 is being released as a result of this event (at the time of this report there were 2 days of release). The total amount released from this event will be reported in the 60 day follow up notification. | 284.0 pounds |
| 143315 2012-09-21 | No information given | Cause: From the verbal report, states that there was a crack in the primary burner at the sulfur plant. Followup: No Notes: SPOC report states that H2S was being released, but details not clear if it exceeded the 100 lbs RQ, 500 lbs of SO2 was released, and that the material did go offsite. The highest air monitoring readings inside the facility were 11-20 ppm. | 67.0 pounds |
| 138624 2012-04-03 | FLARE: Flare #5 | Cause: The facility is unsure what caused the flare of SO2 at flare #5. Followup: No Notes: There is no information regarding remedial actions. Initially ExxonMobil Refinery reported approximately 500 lbs of sulfur dioxide being released in their verbal notification to the LDEQ, but in their 7 day letter they reported that less than one pound of sulfur dioxide was released. ExxonMobil Refinery did not monitor the air during this event. | 1.0 pounds |
| 137655 2012-03-03 | FLARE: Flares #19 and #17 | Cause: The RGCU C-30 compressor shut down which resulted in flares #19 (2 minutes) and Flare #17 (1 minute) burning. Followup: No Notes: The scene was secured at time of notification or by 1335 on 3/6/12. | 30.0 pounds |
| 137359 2012-02-18 | FLARE: Flare #7 | Cause: Excessive rainfall caused an electrical ground fault to occur with some of the compressor's control instrumentation causing the three compressors to shut down. excesses gases were released to the flares. Followup: No Notes: Air monitoring occurred and eventually two of the three compressors were brought back on-line and flaring ceased. There is no refinery Incident report and no SPOC report attached to this file. | 18,333.0 pounds |
| 136880 2012-02-01 | Flare #17 | Cause: The Alkylation Unit lost a cooling tower pump (P-451B), which resulted in the D-301 safety valve lifting and venting to flare #17 for 8 minutes. Followup: No Notes: ExxonMobil later determined that no reportable quantities were exceeded. | 23.0 pounds |
| 136547 2012-01-16 | FLARE: Flare #17 and #23 | Cause: The Feed Prep unit experienced an upset which resulted in flaring of SO2 from flares #17 and #23. Followup: No Notes: No information given regarding remedial actions taken. Initial notification of a release of an estimated 500 lbs of sulfur dioxide. | 94.0 pounds |
| 152732 2013-12-05 | HCLA Unit | Cause: On December 5, the Recycle Feed pump at the HCLA unit experienced an unplanned shut down, causing material to be released to the site's flare gas system and atmospheric safety valves to lift. The unplanned shutdown occurred while swapping the in-service pump with a spare pump for a preventable maintenance inspection. The Recycle Feed pump was immediately isolated and unit feed rate was safely and quickly decreased to minimize flaring and emissions to the atmosphere. This incident is under investigation to determine the exact root cause and to provide mitigating steps to prevent recurrence.
The reportable quantity for flammable vapor, VOC, hydrogen sulfide, sulfur dioxide, and benzene was exceeded as a result of this event.
Follow up report submitted 1/30/2014. Investigation of the accident indicated the failure occurred due to a reverse over speed event caused by a failed pump discharge check valve. Followup: Yes Notes: Immediately upon the pump shutdown, unit feed rate was safely and quickly decreased to minimize flaring and emissions to the atmosphere. Installed two new check valves on the common discharge line in this service to mitigate backward flow. | 947.0 pounds |
| 152611 2013-11-27 | Sulfur Complex | Cause: On November 27, the ExxonMobil Baton Rouge Refinery Sulfur Complex experienced an operational upset as a result of hydrocarbon carry over from the Sour Water Stripper #1 (SWS #1) in the feed to the SRLA unit. Since emissions in the tail gas routed to the vent increased, the tail gas was diverted from the vent to the incinerators to minimize overall environmental impact. Immediately upon the upset, feed to the Sulfur Complex was reduced by cutting unit production rates from other operating units within the Refinery. Air monitoring was conducted every four hours for the duration of the incident.
The SWS #1 is preceded by a coalescer that separates water from hydrocarbon. The hydrocarbon is drawn off the top of the drum and the water from the bottom of the drum is routed to the SWS #1 for further separation. The level instrument can be verified in the field by a site glass; however, the site glass was fouled, preventing the water/oil interface from being visible in the site glass.
The Reportable Quantity for Sulfur Dioxide was exceeded. Followup: Yes Notes: Tail gas was diverted to the incinerators to minimize environmental impact. Feed to the Sulfur Complex was reduced by cutting unit production other operating units within the Refinery. Confirmed level instrument operations on SWS #1 coalescer. ExxonMobil will replace SWS #1 coalescer site glasses with fouling resistant gauges. | 1,057.0 pounds |
| 151430 2013-10-07 | Flare | Cause: On October 7, 2013, the GLA-3X compressor at the PCLA unit experienced an unplanned shut down, causing material to be released to the site's flare gas system. The shutdown was caused by a loss of communication with the remote programmable logic controller during replacement of the human-machine interface panel. Unit feed rate was safely and quickly decreased to minimize flaring and emissions to the atmosphere. The compressor was re-started shortly thereafter with no operational issues. The reportable quantity for sulfur dioxide was exceeded as a result of this event. Followup: No Notes: Immediately upon the compressor shutdown, unit feed rate was safely and quickly decreased to minimize flaring and emissions to the atmosphere. Survey existing installation to identify other compressors with similar configurations and replace during next scheduled T/A. Develop training package for Operations and Maintenance teams on how to service human-machine interfaces. | 2,656.0 pounds |
| No LDEQ Reported 2013-05-23 | Tail Gas Clean-Up Unit combustor | Cause: This Tail Gas incident violates a 2005 Consent Decree with the U.S. Environmental Protection Agency. ExxonMobil Refinery has to comply with this consent decree and file special incident summary for any incident releasing a quantity greater than 500 pounds SO2.
On May 22, 2013 an operator at the Baton Rouge Refinery (BRRF) observed a leak on the Tail Gas Clean-Up Unit (TGCU) combustor. Areas with elevated skin temperature were found on the combustor with insulation on. The team determined that the combustor would have to be shutdown to safely remove the insulation and determine the necessary repairs. At approximately 4:15 am on May 23, the unit reached reduced rates and began bypassing the TGCU and exceeded 250 ppm sulfur dioxide.
All three Claus trains were bypassing the TGCU and being routed to the incinerators by about 7:30 am the next day. The insulation was removed and additional infrared scans were performed on the combustor to establish areas for repair/corrective action. Repairs included installation of a pressurized leak box and nitrogen purge box used to mitigate vessel skin temperature increases. The repairs were complete by 22:30 pm on May 24. At 0:40 AM on May 25, natural gas from Claus 400 began routing through the combustor to bring the tail gas unit up to operating temperature. All Claus tail gas was being routed through the TGCU by approximately 5:35 Am on May 25 and the 12 hour average on the incinerator SO2 CEMs dropped below 250 ppmv SO2 at 19:00 PM on May 25.
The combustor design specified a need for personal protection associated with the heat from the combustor outer surface. During the combustor installation in 1996, insulation was installed as a barrier for the vessel outer surface temperature. However, design and installation failed to follow a procedure which specified that insulation should not be utilized for refractory lined vessels. Based on review of vessel integrity failure mechanism, it is believed that the insulation restricted heat transfer across the vessel surface and created isolated areas of elevated temperature leading to metal fatigue.
The emission calculations for the Tail Gas Exceedance are as follows: The analyzer associated with the incinerator was reading maximum range, so ExxonMobil used the following calculation to estimate the quantity of sulfur dioxide released:
Tons of SO2 = Acid Gas Rate to sulfur plant * SO2 factor based on 2009 turnaround emissions.
Where the acid gas rate = mcf/event = 26.57 mcf.
SO2 factor based on data from 2009 turnaround = tons/mcf = 2.0.
Tons of SO2 = 26/57 * 2.0 tons SO2/mcf = 53.14 tons SO2. Followup: Notes: The refinery quickly began reducing rates and maintained reduced rates until the combustor was repaired. Additional ExxonMobil personnel worked to ensure inspections and corrective actions were completed as soon as possible. Contractors and mechanical personnel worked overtime to build and install the leak box. One corrective action that was completed at time of the facility report is the insulation was reoved from the combustor to alleviate metal fatigue mechanism. BRRF determined that the following corrective action is required: develop plan to identify and evaluate other similar refractory lined equipment within the complex for potential for metal fatigue mechanism. The corrective action is scheduled for completion by 3rd quarter of 2014. ExxonMobil will submit a final report within 30 days of the completion of all corrective actions. | 106,280.0 pounds |
| 149414 2013-05-22 | TGCU combuster (F-331) | Cause: On May 22, 2013 the Baton Rouge Refinery (BRRF) experienced an incident on the Tail Gas Clean-Up Unit (TGCU). The initial cause of the incident was due to a leak on the TGCU combustor (F-331).
ExxonMobil received a compliance order (AE-CN-13-00463) from LDEQ authorizing interim emission limitations for the incident response, repair, and recovery. All community monitoring conducted by ExxonMobil were consistently below detection with the exception of a single monitoring hour on May 23, 2013. LDEQ's Mobile Air Monitoring Laboratory results were consistently below any concentration representing health concerns. The U.S. EPA contractor monitoring was consistent with BRRF monitoring efforts and results throughout the incident respose. Followup: No Notes: Upon discovery, ExxonMobil reduced Sulfur Plant (SRLA) feed rates to facilitate the transition to the F-101/F/-201 incinerators. This resulted in approximately 24 tons/day of potential sulfur dioxide being released. All emissions from this event will be provided int he follow-up reports as required per AE-CN-13-00436 Section IV and V. On May 24, 3012 at 10:30 p.m. a mechanical enclosure was installed on the combustor. Additional follow-ups will be provided in the reports as required per the compliance order. LABB has been unable to locate the follow up report with release amounts as of December 18, 2013. | |
| 157225 2014-07-04 | GLA-1X Compressor at PCLA unit | Cause: On 7/4/2014 the GLA-1X compressor at the PCLA unit experiences an unplanned shut down, causing material to be released to the site's flare gas system. As a result of water entering a flow meter, the meter reading incorrectly held constant while the flow increased. This led to a rapid increase in the compressor distillate drum level and when the emergency high level was reached, the protective system tripped the compressor, leading the the flaring of sulfur dioxide. Followup: No Notes: Immediately upon compressor shut down, the flow meter was repaired and the compressor was restarted. Further actions to prevent recurrence are the implementation of an alarm notification to notify operations team of flow rate deviations and valve position. | 2,611.0 pounds |
| 155370 2014-04-20 | compressor | Cause: The C-50 compressor at RGCU unit shut down, unexpectedly, releasing material into the flare gas system.
This incident alone did not exceed any reportable quantity, however in conjunction with other ongoing releases, the reportable quantity for sulfur dioxide was exceeded. Followup: No Notes: Upon compressor shutdown, a secondary compressor was started. The incident is under investigation to determine the exact root cause and to provide mitigating steps to prevent recurrence. | 594.0 pounds |
| 153723 2014-02-07 | Cause: Flaring occurred at the ExxonMobil Baton Rouge Refinery (BRRF). Followup: No Notes: No reportable quantities were exceeded. | 189.0 pounds | |
| 153588 2014-01-28 | NIG | Cause: On January 28, 2014, flaring occurred at the refinery due to an unknown cause. Followup: No Notes: | 19.0 pounds |
| 153521 2014-01-27 | Cause: On January 27, 2014 at approximately 4:08 PM, the compressor GLA-3X at the PCLA (a fluid catalytic cracking unit) unit experienced an unplanned shutdown, causing material to be released to the site's flare gas system. Preliminary investigation results indicate the shutdown was caused by a higher than normal concentration of condensable distillate in a level instrument chamber as a result of inadequate steam tracing. The excess liquid bridged between the chamber wall and the radar rod, resulting in a false high level reading which tripped the compressor. The incident is under investigation to determine the exact root cause. Followup: No Notes: Upon compressor shutdown, the level instrument was bypassed to mitigate a repeat event. The incident is under investigation to determine the exact root cause and to provide mitigating steps to prevent recurrence. | 6,497.0 pounds | |
| 153297 2014-01-14 | No Information Given | Cause: ExxonMobil Refinery was doing testing and overpressured the system. The overpressure triggered a safety device to open resulting in a release of sulfur dioxide and benzene. Followup: No Notes: No information given. | 12.0 pounds |
| 153226 2014-01-09 | NIG | Cause: On January 9, 2014, a release of sulfur dioxide was reported. Followup: No Notes: The only document related to this accident that LABB has access to is a one-page refinery letter dated January 16, 2014. | 260.0 pounds |
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