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ExxonMobil Refinery (2638), Baton Rouge

Releases of Highly Reactive Volatile Organic Compounds (HRVOCs)

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

E-568 reboiler
Cause: leak in the E-568 reboiler

Followup: No

Notes: the exchanger was blocked out and the leaking tubes will be plugged; report stated this was not preventable because the exchanger was replaced in 1st quarter of 2003, with the previous bundle in service for 20 years; this bundle has previously leaked once due to suspected mechanical damage during installati
111.0 pounds
No LDEQ Reported

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.
4.0 pounds
No LDEQ Reported

Cause: distillate pump blew a seal

Followup: No

Notes: shut down the pump and started up a spare
118.0 pounds
No LDEQ Reported

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
136.0 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.
9.0 pounds
No LDEQ Reported

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
163.0 pounds

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.
46.0 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
177.0 pounds

E-205 A/B exchanger bank on the Heavy Cat Naptha Unit
Cause: the E-205 A/B exchanger bank on the Heavy Cat Naptha Unit was leaking to Cooling Tower #27. The leak is believed to be from corrosion on the tube bundle.

Followup: No

Notes: This incident was not preventable because the inspection data for this bank of exchangers did not indicate that a failure was imminent. These bundles were tested in January 2005 and were found to have no leaks. Remedial Measures - the exchanger bundle will be inspected and repaired or replaced as appropriate. The reportable quantities for benzene, toluene, naphthalene, volatile organic compounds, xylene mixed isomers, and o-xylene were exceeded. It is possible that the reportable quantities forylene and p-xylene were also exceeded, but available stream specification data does not allow differentiation between the these two isomers
1,581.0 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
30.0 pounds

Cause: ExxonMobil has a flange leak on an exchanger.

Followup: No

Notes: Only data available to LABB on incident is SPOC report, no other reports found on EDMS.
100.0 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
5.0 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.
72.0 pounds

MTBE Unit Exchanger E-557
Cause: MTBE Unit Exchanger was discovered to leaking into the condensate system causing vapor to flash off. 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

Exchanger leak-leak on E15A
Cause: corrosion of tube bundle

Followup: No

Notes: Exchanger blocked and removed from service. Tube bundle will be inspected and repaired as appropriate.
159.0 pounds

Cause: loose bolt on flange

Followup: No

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


Cause: OIl was found on the piping insulation on the 1st stage suction line to the GLA-2X gas compressor at the PCLA-2. Two pinhole leaks had developed in the line due to corrosion.

Followup: No

Notes: Once the extent of the leaks was evaluated, a detailed plan was developed to safely shutdown the compressor and replace the leaking portion of the line. Unit rate were cut in order to perform this work, and several Refinery units were required to adjust rates in order to accommodate the downtime. Gas was completely diverted from the compressor ending the release.
205.0 pounds

Cause: Pressure instrument failed & resulted in flaring. FLARE.

Followup: No

Notes: BRQ. Below Reportable Quantities.

Fuel Gas line to KDLA unit
Cause: A pinhole leak was discovered on a 6 inch fuel gas line going to the KDLA unit.

Followup: Yes

Notes: An engineered clamp was installed over the leak. Area monitoring was conducted and all readings were below detection limits. Follow-up letter contained initial report with the addition of emission calculations for the event.
13.6 pounds

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.
167.8 pounds


Cause: Flaring occurred at the ExxonMobil Baton Rouge Refinery (BRRF).

Followup: No

Notes: No reportable quantities were exceeded.
0.5 pounds

Cause: On January 28, 2014, flaring occurred at the refinery due to an unknown cause.

Followup: No

0.1 pounds