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ExxonMobil Chemical Plant (286), Baton Rouge
Releases of Benzene
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 77893 2005-03-30 | steam trap | Cause: ExxonMobil had a steam trap on a line that goes into a furnace. Gas oil from the furnace backed into the line and went into the trap. The gas oil, which contained benzene, then went into ExxonMobil. Unknown at this time what caused the material to back through. Steam flow may have been cut off. Followup: Notes: Amount of benzene released is over 10 pounds. Exact amount released is unknown. | 10.0 pounds |
| 91788 2006-10-31 | Pump seal | Cause: A pump seal is leaking. Followup: Notes: They put water spray on to keep it confined to the area. Amount of benzene released is unknown. | |
| 87811 2006-05-12 | Product line from Isopropyl alcohol unit | Cause: A product line from the isopropyl alcohol unit in the chemical plant was leaking. Vapors were being released to the atmosphere. Followup: No Notes: ExxonMobil located the leak. They were trying to determine what options they had to stop the leak. Amount of chemicals released is unknown. | |
| 85116 2006-01-12 | Pump seal on processing unit | Cause: While making rounds on the unit, Aromatics operations personnel discovered a pump seal leaking to concrete containment and to the sewer. Followup: No Notes: Operations shut down the pump and blocked it away from the process stopping the leak. The pump seal will be replaced. | 18.0 pounds |
| 99883 2007-10-01 | safety valves | Cause: On October 1, 2007 at approximately 2:48 PM, the LOLA T-1 tower overpressured resulting in a hydrocarbon release to the atmosphere through three of the four safety valves on the overhead of the tower. The overpressure was caused by a faulty pressure reading on the tower pressure control system.
The T-1 overhead pressure instrument had been reading erratically prior to the incident and was being evaluated. During this time, the overhead pressure control valve was operated in manual to maintain a specified tower pressure. Pressure began to increase in the tower, and firing of the tower's reboiler furnace, F-402, was automatically shutdown when the pressure reached 35 psig. Furnace firing was restarted and pressue continued to rise, reaching 38.55 psig, even though the controller was using the pressure control valve in an attempt to lower tower pressure. After control was reestablished, it was determined that three of the four tower safety valves had relieved. Followup: No Notes: The pressure control valve on the T-1 overhead circuit was fully opened to relieve the pressure in the tower. The pressure instrument is being evaluated by instrument technicians, but at the time of the report, no cause for the erratic behavior was found. An investigation is ongoing and the appropriate follow up actions will be completed to prevent recurrence. | 134.0 pounds |
| 98264 2007-07-31 | compressor | Cause: A compressor tripped resulting in the emission of the gases to the air. Followup: No Notes: They have restarted the compressor. | 20.0 pounds |
| 93497 2007-01-25 | Tower 101 | Cause: Release was from the safety on Tower T101. It blew to drum D 106. That drum has a water seal on it that broke causing the vapors to release. Followup: No Notes: Exxon called SPOC to inform that they reached RQ for Benzene and Toluene was in the stream. Based on their data, they had no approached the flammable vapor RQ of 1000 lbs. The immediate area by the release had been evacuted internally. Caller stated at 4:39 pm an announcement of All Clear for evacuation and shelter in place was made. Air monitoring had started inside and was working towards perimeter. Airmatics is the name of the porcess unit. Just SPOC report. | 160.0 pounds |
| 110988 2008-11-22 | pump seal | Cause: Pump seal failed causing a release of Benzene to concrete inside of containment area. Followup: No Notes: Pump seal failed causing a release of benzene to concrete inside of containment area. Pump was shut down and benzene was washed out. Report says no RQs were exceeded but 10 b is the RQ for benzene. | 10.0 pounds |
| 110384 2008-10-26 | Ethylene Purification Unit | Cause: Followup: No Notes: Exxon believes that RQs were exceeded for all products released. Due to equipment failure, there was an unplanned shutdown of the Ethylene purificaInitial report says that they may exceed for RQs for Ethylene, propylene, nitrogen oxide, and opacity. Exxon's report was received on 11/5/08, and it said that no RQ exceedences occurred. The activity associated with this is covered under the Sp. Condition 2 of the operating Titile V permit for the Main train unit. | 329.0 pounds |
| 109484 2008-09-23 | Storage tank | Cause: The cause of the release was pressure in the feed tanks at the Waste water improvement unit. Followup: No Notes: A storage tank vented for 16 m. The cause of the release was pressure in the feed tanks at the waste water improvement (WILA) unit exceeded the vacuum vent setting for 14 m. The light material entered the flare knock out drum at the Olefins unit through a safety valve bypass which was left open inadvertently during the start up after Gustav. Manual error is the root cause. LDEQ said they would take this up at the next inspection. Exxon's written report was received on 10/6/08. | 548.0 pounds |
| 109408 2008-09-20 | Benzene fractionator reflux pump P-160B at the aromatics unit | Cause: P-160B caught fire due to thrust bearing failure. The cause of the pump failure is unknown. Followup: No Notes: A pump fire occurred in the aromatics plant. The benzene fractionator reflux pump caught fire due to thrust beating failure. Blocked the upstream valve and fire was put out. The cause of the pump failure was not known. The pump was repaired and put back into service. RQ for benzene exceeded. | 19.0 pounds |
| 109311 2008-09-17 | Storage tank #8 in WILA Tank 8 Tank 9 | Cause: Followup: No Notes: Storage tank 8 in WILA vented from unit upset. Pressure vacuum setting on feed tanks in the WILA unit exceeded for 10 min and released the listed chemicals. Several units that feed into WILA were on start up mode after hurricane Gustav. Communication between units if being reinforced. | 40.0 pounds |
| 109311 2008-09-17 | Storage tank #8 in WILA Tank 8 Tank 9 | Cause: Followup: No Notes: Storage tank 8 in WILA vented from unit upset. Pressure vacuum setting on feed tanks in the WILA unit exceeded for 10 min and released the listed chemicals. Several units that feed into WILA were on start up mode after hurricane Gustav. Communication between units if being reinforced. | |
| 109655 2008-09-01 | Flare Storage Tank Advanced Wastewater Treatment Unit | Cause: BRCP Flaring During Shutdown: On September 1, the Baton Rouge Chemical Plant began to safely shutdown operations due to power failures associated with Hurricane Gustav. During shutdown, excess gases were vented to the flare system in order to reduce emissions to the atmosphere.
Baton Rouge Turbine Generator NOx steam trip: ExxonMobil experienced difficulty providing NOx suppression steam for our BRTG. Condensate is required to desuperheat the NOx suppression steam prior to using it in the BRTG. The normal condensate supply from operating units to provide desuperheater water is unavailable as these units are down. Temporary demin trailers were used to help provide an interim source of condensate to mitigate the loss of NOx suppression steam, but were unable to continuously supply the condensate for NOx steam to BRTG.
Nitrogen blanketing for tanks on vapor recovery: The lack of nitrogen availability has also created a temporary loss of nitrogen blanketing for storage tanks on vapor recovery. Loss of nitrogen blanketing means that air will be pulled into the tank which is unacceptable from a hazard risk standpoint. The tanks without nitrogen blanketing must be blocked away from vapor recovery because it is unsafe to vent oxygen to a fuel gas or flare gas system due to the potential of creating an explosive mixture. Exxon shut down the vapor recovery controls when the site lost nitrogen. Once nitrogen is restored, Exxon will restart vapor recovery systems. Once normal operations are resumed, Exxon will report total excess emissions and duration of vapor recovery outages for affected tanks.
Two hatches found open: Two tank hatches were found open after the hurricane was over. These tank hatches were blown open when wind speeds were highest (>90 mph) during the hurricane. Tank hatches must remain closed to prevent emissions; as such, these incidents are considered bypassing of a control device. The estimated emissions from these open tank hatches are below RQ amounts.
AWT overflow to Monte Sano Bayou: The separator at the Advanced Wastewater Treatment unit overflowed to the Monte Sano Bayou. The incident occurred when the pumps lost power and could not pump down the level in the separator. Approximately 1300 gallons of untreated wastewater was discharged in to the bayou. Power to the pumps was restored and the level in the separator was pumped down to stop the overflow to the bayou. The composition of the discharged wastewater is unknown at this time due to a disruption in laboratory samples as a result of the hurricane. Followup: Yes Notes: BRCP was shutdown due to hurricane Gustav. | 88.0 pounds |
| 109677 2008-09-01 | Weather | Cause: As a result of Hurricane Gustav the Baton Rouge Resins Finishing Plant (BRFP) experienced significant facility damage and power interruptions that required operations to safely shutdown. Hurricane Gustav is clearly considered an "act of god."
The Baton Rouge Resin Finishing Plant only had generators for electrical power to maintain a small number of instruments and critical pumps. There was no power available for the compressors that collect vent gases from storage tanks and route them to the site's flare. The seal leg on the flare seal drum prevented the relatively small breathing losses from reaching the flare for combustion. The flare pilots were extinguished during the storm but we have established the ability to relight it. However due to natural gas supply availability and the inability to route the vent streams to the flare tip we elected to allow the flare pilots to remain unlit until we restored power to the vapor recovery compressors. Power was restored to BRFP at 230 pm on 9/6/08 and the flare pilots were relit. All tanks that were venting to the atmosphere were routed to the flare. Followup: No Notes: BRFP was safely and systematically shutdown due to hurricane Gustav. Learning from this event will be incorporated into future hurricane preparations. BRFP was unable to complete some of the timing obligations due to Hurricane Gustav. It has prevented from meeting all the timing obligations of the required September monitoring. At the time the primary focus of mechanical resources was on storm related repairs to enable safe startup of unit operations. The plant was to accomplish the LDAR monitoring within the next 60 days. In addition, the availability of parts is also a difficult logistics problem so the focus was on their resources toward startup. BRFP was safely and systematically shutdown due to Hurricane Gustav. Learnings from this event will be incorporated into future hurricane preparations. . | 23.0 pounds |
| 109655 2008-09-01 | Flare Storage Tank Advanced Wastewater Treatment Unit | Cause: BRCP Flaring During Shutdown: On September 1, the Baton Rouge Chemical Plant began to safely shutdown operations due to power failures associated with Hurricane Gustav. During shutdown, excess gases were vented to the flare system in order to reduce emissions to the atmosphere.
Baton Rouge Turbine Generator NOx steam trip: ExxonMobil experienced difficulty providing NOx suppression steam for our BRTG. Condensate is required to desuperheat the NOx suppression steam prior to using it in the BRTG. The normal condensate supply from operating units to provide desuperheater water is unavailable as these units are down. Temporary demin trailers were used to help provide an interim source of condensate to mitigate the loss of NOx suppression steam, but were unable to continuously supply the condensate for NOx steam to BRTG.
Nitrogen blanketing for tanks on vapor recovery: The lack of nitrogen availability has also created a temporary loss of nitrogen blanketing for storage tanks on vapor recovery. Loss of nitrogen blanketing means that air will be pulled into the tank which is unacceptable from a hazard risk standpoint. The tanks without nitrogen blanketing must be blocked away from vapor recovery because it is unsafe to vent oxygen to a fuel gas or flare gas system due to the potential of creating an explosive mixture. Exxon shut down the vapor recovery controls when the site lost nitrogen. Once nitrogen is restored, Exxon will restart vapor recovery systems. Once normal operations are resumed, Exxon will report total excess emissions and duration of vapor recovery outages for affected tanks.
Two hatches found open: Two tank hatches were found open after the hurricane was over. These tank hatches were blown open when wind speeds were highest (>90 mph) during the hurricane. Tank hatches must remain closed to prevent emissions; as such, these incidents are considered bypassing of a control device. The estimated emissions from these open tank hatches are below RQ amounts.
AWT overflow to Monte Sano Bayou: The separator at the Advanced Wastewater Treatment unit overflowed to the Monte Sano Bayou. The incident occurred when the pumps lost power and could not pump down the level in the separator. Approximately 1300 gallons of untreated wastewater was discharged in to the bayou. Power to the pumps was restored and the level in the separator was pumped down to stop the overflow to the bayou. The composition of the discharged wastewater is unknown at this time due to a disruption in laboratory samples as a result of the hurricane. Followup: Yes Notes: BRCP was shutdown due to hurricane Gustav. | 166.0 pounds |
| 107618 2008-07-30 | Heat exchanger LE-01 at OLA-2X No information given. | Cause: Leakage occurred from a heat exchanger LE-01 at OLA-2X to the cooling water tower GFLA-1. Followup: No Notes: Release rates: benzene (14.4 lb/day), toluene (15.02 lb/day), napthalene (6.3 lb/day). CRO received report on 8/11/08. There were 22 daily RQ exceedances during 7/9/08 at 9 AM and 7/31/08 at 12:30 PM. Leakage from heat exchanger LE-01 at OLA 2-X to the cooling water tower GFLA-1 which is subject to monitoring program under Ethylene MACT. The leaking exchanger was blocked in to stop the leak. Leaking tubes were tp be repaired. The facility argued that the actual discovery of the leak was 7/22/08 when the sample analysis indicated a leak. They will be referred to enforcement for further action. Release quantities listed are an estimate using the rates given multiplied by 22 days. | 316.8 pounds |
| 107618 2008-07-30 | Heat exchanger LE-01 at OLA-2X No information given. | Cause: Leakage occurred from a heat exchanger LE-01 at OLA-2X to the cooling water tower GFLA-1. Followup: No Notes: Release rates: benzene (14.4 lb/day), toluene (15.02 lb/day), napthalene (6.3 lb/day). CRO received report on 8/11/08. There were 22 daily RQ exceedances during 7/9/08 at 9 AM and 7/31/08 at 12:30 PM. Leakage from heat exchanger LE-01 at OLA 2-X to the cooling water tower GFLA-1 which is subject to monitoring program under Ethylene MACT. The leaking exchanger was blocked in to stop the leak. Leaking tubes were tp be repaired. The facility argued that the actual discovery of the leak was 7/22/08 when the sample analysis indicated a leak. They will be referred to enforcement for further action. Release quantities listed are an estimate using the rates given multiplied by 22 days. | |
| 107433 2008-07-22 | H furnace | Cause: Three events occurred within 24 hours of one another at the ExxonMobil Baton Rouge Chemical Plant. Two are reported in this report (LDEQ #107433), the other is reported separately (LDEQ #107421). In this incident (107433), a furnace tube leaked into convection section of H-furnace and caught fire. The tube leak occurred as a result of the incident described in report #107421.
At approximately 5:56 PM on July 21, 2008, the charge gas compressor at the Olefins unit shut down when several processing cards in the gas turbine control system failed. When the compressor shut down, four furnaces automatically shut down and the gas in the furnaces was evacuated to the flare system. One of the remaining three furnaces was subsequently shut down while the remaining two furnaces continued to operated at 50% rates in order to maintain stable unit operations, which resulted in additional flaring for the duration of the event. The high rate of gas to the flare system resulted in the #25 flare smoking for 2 hours and 17 minutes.
When the Olefins unit shut down, steam was introduced into the furnaces to displace the hydrocarbon feed to reduce flaring emissions. At 12:20 PM on July 22, 2008, while the H furnace was in the process of starting up, a leak was discovered in the convection section of the furnace. To stop the leak, water was introduced into the leaking pass of the furnace to displace the hydrocarbon feed. It is believed that the leak developed when steam was introduced into the furnace.
Tube leaked into convection section of H-furnace and caught fire. Followup: Yes Notes: This incident is the result of the incident #107421 (see comments under that incident). Immediately after the incident began, five of the seven furnaces at the Olefins unit were shut down. Excess gas was sent to flare system. Water was introduced into the leaking furnace pass to displace the feed and prevent uncombusted hydrocarbons from leaking into the atmosphere. Concerning subsequent preventative actions, the failed processing cards were replaced. The H furnace was taken out of service to be inspected for leak location and repairs will be completed as necessary. Used water in the tube to eliminate the burning material. Flammable gass consisted of mainly Butane. | 143.0 |
| 107422 2008-07-22 | Tanks # 8 and 9 Hydrocarbon recovery system, tanks 8 and 9 Hydrocarbon recovery system, tanks 8 and 10 Hydrocarbon recovery system, tanks 8 and 11 | Cause: Pressure vacuum vent for hydrocarbon recovery on storage tanks #8 and 9 exceeded for one minute. During transfer of material to storage tanks the pressure exceeded the pressure vacuum setting and VOC's were released. Followup: No Notes: Pressure vacuum vent for hydrocarbon recovery on storage tanks 8 and 9 exceeded for 1 m. Two other events occurred within 24 hours of this event and will be addressed seperately. During transfer of material to storage tanks 8 and 9 at the WILA (wastewater improvement unit) the pressure exceeded the pressure vacuum setting and VOCs were released. The operations personnel immediately stopped pumping the material until the overpressure situation was resolved. They were investigating the source of volatile material in the WW. RQ exceeded for benzene and 1,3-butadiene. | |
| 107422 2008-07-22 | Tanks # 8 and 9 Hydrocarbon recovery system, tanks 8 and 9 Hydrocarbon recovery system, tanks 8 and 10 Hydrocarbon recovery system, tanks 8 and 11 | Cause: Pressure vacuum vent for hydrocarbon recovery on storage tanks #8 and 9 exceeded for one minute. During transfer of material to storage tanks the pressure exceeded the pressure vacuum setting and VOC's were released. Followup: No Notes: Pressure vacuum vent for hydrocarbon recovery on storage tanks 8 and 9 exceeded for 1 m. Two other events occurred within 24 hours of this event and will be addressed seperately. During transfer of material to storage tanks 8 and 9 at the WILA (wastewater improvement unit) the pressure exceeded the pressure vacuum setting and VOCs were released. The operations personnel immediately stopped pumping the material until the overpressure situation was resolved. They were investigating the source of volatile material in the WW. RQ exceeded for benzene and 1,3-butadiene. | 23.0 pounds |
| 107421 2008-07-21 | Flare #25 | Cause: Due to an unknown cause, the compressor in the SACC unit failed and reduced the pressure on the system by flaring. The charge gas compressor in the Olefins unit shut down when several processing cards in the gas turbine control system failed. Four of the seven furnaces shut down immediately and gas from them were evacuated to the flare. The high rate flow caused #25 flare to smoke. The H furnace was starting up a leak developed in the convection section and uncombusted VOCs were released to air. It was believed a pinhole leak developed during steaming of furnace. Followup: Notes: The failed cards were replaced and the unit began operation. There was a complaint about black smoke that was coming from flare for about an hour, and ongoing flare. Steam was introduced into the furnaces to displace VOCs to reduce flaring emissions. The failed cards were replaced and the unit began operation. The flaring during start up were permitted emissions. | 167.0 pounds |
| 106838 2008-06-29 | Tanks 8 and 9 | Cause: The pressure feed tanks at the Waste water improvement unit exceeded vacuum setting and released hydrocarbon vapors to relieve the pressure. The cause is the material from the olefins unit flare knock out drum. Followup: Notes: It was unexpected that this material will impact the WWIU. | 123.0 pounds |
| 106776 2008-06-27 | control system on gas driven turbine driver | Cause: On 6/27/08 the charge gas compressor at the Olefins Unit shut down due to a control system failure of the gas driven turbine driver. Five furnaces automatically shut down and gas was routed to the f Followup: no Notes: First they cooled dow the furnace to shut down the unit. Repairs were made to the control system and restarted. Flaring occurred during startup. | 274.0 pounds |
| 105555 2008-05-13 | tower | Cause: On a tower control valve station the bypass valve packing blew out. Followup: no Notes: Tower was shut down to take pressure off and secure it. Replaced bypass valve. | 50.2 pounds |
| 105242 2008-04-30 | de-coke drum | Cause: They are investigating the root cause of the incident. A furnace at SACC unit was being returned to service. Hydrocarbon gases got into the de-coke drum and vented to the atmosphere. Followup: No Notes: No additional information given. | |
| 105211 2008-04-29 | line leak at flange | Cause: They had a line that has leaked at a flange and is causing the release. They are isolating the line to stop the leak. Followup: no Notes: Benzene was released at .67 lbs/hr. Butadiene was released at .11 lbs/hr. Hydrocarbon gas was released at 18.77 lbs/hr. Styrene Monomer was released at 50.41 lbs/hr. Ethylbenzene was released at 30.16 lbs/hr. Toluene was released at 120.66 lbs/hr. | |
| 104714 2008-04-12 | compressor | Cause: Fire developed on a compressor C-500 B associated with the Aromatics Unit. Cause of the fire was mechanical failure of the compressor which controls the vapors from storage tanks in the Aromatics Unit. Followup: Notes: As a result of the compressor shut down, the fire vapors from the tanks went to the air. Vacuum jets were turned on to control these tanks emissions. Concentrations of 7 ppm of Benzene were detected 10 ft downwind from the compressor after the fire was out. Hot zone was established as called for. Hydrocarbons were blocked off from the compressor to prevent further ignition. | 41.4 pounds |
| 120220 2009-12-16 | Vapor Recovery system | Cause: Vapor recovery system failed causing the tank to vent. Followup: No Notes: Vapor recovery system failed causing the tank to vent. The release was secured. Exceeded 10 lb reportable quantity. | 11.3 pounds |
| 120018 2009-12-09 | SACC unit LTO1 | Cause: A leak developed in a fifty four inch overhead pipe at the SACC Unit LT01. Followup: No Notes: There is approximately 5 lbs per square inch (psi) or pressure on the pipe. The insulation of the pipe was removed to identify the source. Pictures included of the plug of the pipeline due to the hole and a view of the repaired line. On the incident report form it says that the initial report said that RQs might be exceeded, but that none were exceeded. | |
| 119881 2009-12-05 | Vapor recovery compressor | Cause: Vapor recovery compressor shut down due to mechanical failure. Followup: No Notes: Vapor recovery compressor shutdown due to mechanical failure. Back up system was up. In the aromatics unit. | 10.3 pounds |
| 119584 2009-11-18 | Storage tank | Cause: Pressure vapor vent release on storage tank. Followup: No Notes: Greater than 1000 lbs of flammable vapor were released, calculations are estimates. The incident was caused by a pressure vapor vent release pressure on the storage tank. They stopped the system completely. It is cleared up now and back in service. | 55.0 pounds |
| 119046 2009-10-27 | No Information Given | Cause: Spill occurred when operator drained material to a green sewer preparing equipment for maintenance. Followup: No Notes: 10 gal of 80% benzene was discharged into a green sewer line leading to the in plant sewer system due to an operator error. Release occurred for approximately 10 min. SPOC report says that the operator was preparing equipment for mechanical work. SPOC report also says that the release was 74 lbs (about RQs). | |
| 118428 2009-10-02 | B furnace | Cause: Tube leak in "B" furnace. Shutting the unit down to check the furnace and root cause of the leak. Followup: No Notes: Incident caused by a tube leak in B furnace, cause is under investigation. They took it down and entered it to check. They shut the system down. They promised a call back with a close out time and whether or not RQs were exceeded. No note of call back. | 10.0 pounds |
| 118173 2009-09-23 | B furnace | Cause: Tube rupture in B furnace. Followup: No Notes: Tube taken out of service. Report says there was a potential for benzene and VOC emissions. LDEQ received the written report from Exxon but did not include it in this report, but stated that no RQs were exceeded. | |
| 116431 2009-07-14 | E206 Exchanger in the Aromatics Unit | Cause: Leak coming from the cooling tower. While backwashing the heat exchangers in the BHELA unit a hydrocarbon sheen was observed in the wash water indicating a leaking heat exchanger. The reason was internal corrosion and could not be anticipated. Followup: No Notes: Exchanger tubes will be repairs and replaced before putting back into service. Benzene release exceeded reportable quantities. | 30.0 pounds |
| 115611 2009-06-12 | pipe | Cause: Pinhole leak in a pipe. Followup: No Notes: There was a pinhole leak in a pipe. They were working to repair it. Said they would call with an update. | 10.0 pounds |
| 115416 2009-06-03 | No Information Given | Cause: E-201 exchanger had leak. Estimated releases were >10lbs of Benzene and >100lbs of Hydrogen sulfide Followup: No Notes: Just the written letter. It says that after further evaluation, it was determined that no RQs were exceeded. | |
| 114564 2009-04-29 | Drain valves on flare gas compressor | Cause: Drain valves were left open on their flare gas compressor. Followup: No Notes: Drain valves have been blocked in. No RQs were exceeded. | |
| 113980 2009-04-06 | RTO unit | Cause: RTO unit atmospheric safety and associated flaring caused by loss of an electronic card and computer failure. Failure of a computer control card resulted in several control valves to fail in the closed position and the atmospheric safety valve then lifted to the flare. Followup: No Notes: The card was replaced with a spare and the unit operations were reduced to minimize released. | 10.0 pounds |
| 113906 2009-04-02 | Storage tank in foam chamber | Cause: On going release from a storage tank through a foam chamber. Followup: No Notes: Late report, below RQ for benzene. No RQs were exceeded. No details mentioned of what caused the leak. | |
| 113772 2009-03-29 | E506B exchanger Exchanger 506B | Cause: In the Aromatics Unit during the preparation of an overhead condensor for mechanical work. Prior to the leak, steam was introduced to the exchanger to free the exchanger of hydrocarbon. When steam was introduced, the channel box gasket failed. Followup: No Notes: A gasket leak occurred on exchanger E 506 B. Most of the release went to the sewer and some may have evaportated into the air. Gasket was isolated and secured. During the preparation of an overhead condenser for mechanical work stem was introduced to the exchanger per procedure to free the BOCs but the gasket failed and released hydrocarbon on to the concrete pad. It was 60% benzene and all had evaporated. Estimated 44 lbs of total release (over RQ). Non preventable release. | 44.0 pounds |
| 113506 2009-03-19 | Under investigation | Cause: Followup: Notes: According to the Plant's Shift Supervisor, a trace amount of Benzene was detected in the facility sewer system. Investigation to find the source was conducted and Benzene will be processed through the facility's on site sewer system. No offsite impact was observed and no reportable quantities were exceeded. No further actions was taken by LDEQ. Exxon's report was received on 3/31/09 saying the release did not exceed RQ. Report says that this is not a reportable incident. Air monitoring at the time indicated 7 PPM inside the unit. | |
| 113475 2009-03-18 | control valve of HCE compressor WILA tanks #8 and 9 | Cause: The release was caused by the failure of a control valve downstream of the HCE compressor. The control valve downstream of the HCE compressor failed to close which caused the HCE compressor to trip off. Followup: Notes: Since there was no outlet for the vapor in the HCE system, the pressure built in the tanks until the pressure vents lifted, released hydrocarbon to the atmosphere. The back up hydrocarbon emissions control system which uses vacuum jets to recover the excess vapors was comissioned. Proper operation of the vacuum jets was confirmed shortly thereafter. The control valve and instrumentation will be repaired and inspected before being returned to servvice. | 69.0 pounds |
| 113260 2009-03-09 | WILA tanks #8 and 9 | Cause: The release was caused by the pumping of low flash material into WILA Tanks 8 and 9. The material evolved a greater amount of vapor than the tank's vapor recovery system could manage. The evolution of the vapor caused the pressure in the tanks to exceed that of the pressure vent set point. Followup: No Notes: Introduction of low flash point material into these tanks was immediately halted. They could not expect the flash material to evolve too much vapors. Tanks could not handle the vapors and valve lifted. Operators will be trained to communicate better to prevent the overpressure happening again. RQs exceeded for benzene. Total release of hydrocarbons is 600 pounds. | 15.0 pounds |
| 112825 2009-02-17 | EPLA-W Compressor, flares #10, 25, and 26 Flares #10, 25, and 26 | Cause: A fire resulted in a compressor shut down and material being flared from 10:30 pm - 11 pm. Around 10:30 pm the charge gas compressor (EPLA-W compressor) for the Olefins Maintrain furnaces tripped due to failed overspeed wiring. This occurred because of a small leak of lube oil from the steam driver which caught fire. This fire was small but close to the wiring which malfunctioned. Followup: No Notes: This incident is linked to incident #112824. The effluent gases were diverted to flares before the compressor could be repaired. Start up began around 8:45 pm on 2/18/09. Flaring during shut down through start up resulted in exceedances of RQs for ethylene, propylene, butadiene, nitric oxide, and sulfur dioxide. Also they had three compliance excursions from smoking of flares #10, #25, and #26. This was a non preventable incident from a malfunction. They are looking into preventing lube oil leaking and collecting near compressor wiring. | 339.0 pounds |
| 112824 2009-02-17 | stripper tower EPLA-W compressor | Cause: The EPLA-West compressor trip also caused the liquid to be sent to the hydrogen compressor at the benzene hydrotreater unit (BHLA). This led to the trip of the hydrogen compressor and shut down of the BHLA unit. This unexpected shut down caused the overpressure of the stripper tower above the PSV setting Followup: No Notes: This incident is linked to incident #112825, which is when the safety valve on the tower blew. The benzene release to air was above RQ limit. | 339.0 pounds |
| 112630 2009-02-09 | corroded line that ties into bleeder valve | Cause: Corroded line that ties into a bleeder valve started leaking Followup: No Notes: The line was isolated. Cleaned up with absorbent pads. Also clean up crew was en route to clean up the soil in containment area. | 10.0 pounds |
| 128380 2010-12-29 | knockout drum KD-05 on Ethylene Clarification unit | Cause: A knockout drum KD-05 on the Ethylene Clarification unit was experiencing high liquid levels. This increase in material in the quench water drum resulted in a disruption of quench water flow and led to increasing unit temperatures. Compressor HC-01 then tripped due to high temperature which caused unit material to be routed to the flare system, by design, until the compressor could be restarted. Followup: No Notes: To reduce the liquid levels quickly, operations personnel opened a bypass valve and routed material to a downstream quench water drum, HD-02. The RQs for ethylene, benzene, and 1-3 butadiene were exceeded. There was a light precipitation at the time of the event. This incident and responses to potential future incidents will be reviewed with operations personnel. | 16.0 pounds |
| 128350 2010-12-27 | MVTK 08 & 09 pressure vacuum vent | Cause: Tank pressure increased and the vent opened to relieve the pressure and then closed back up. Followup: No Notes: No RQs were exceeded due to prompt incident response. | |
| 128125 2010-12-12 | Seal on vapor recovery system | Cause: A seal malfunction corrected itself. Followup: No Notes: A potential maximum of 10 pounds of Benzene could have been released but the calculations had not been completed by the time of the call. Incident initiated and comments added during file review after inspection of Exxon Refinery on 8/31/11. This incident occurred at the Exxon Chemical plant. According to a written notificated faxed from Exxon Corp, there was promt incident response to mitigate the event durations, they have determined that no RQS were exceeded. The NRC notification regarding this event was made greater than 1 hour after incident discovery due to telephone difficulties. | |
| 128038 2010-12-08 | Cause: A compressor tripped offline at the Benzene Hydro-Finer and caused the automatic shut down procedure to be activated. Followup: No Notes: The release resulted in a temporary localized shelter in place. | ||
| 126818 2010-10-02 | J fractionator | Cause: Pin hole leak in J fractionator. Followup: No Notes: Final reports say no reportable quantities were reached. | 10.0 pounds |
| 126265 2010-09-10 | battery charger on Mark Ve control system | Cause: Preliminary investigation findings for the event indicated a battery charger malfunctioned on the Mark Ve control system, causing a power disruption in the Olefins area. The olefin area's primary fractionator overhead compressor tripped as a result of the power disruption, and the primary fractionator overhead was routed to the flare system per design. Followup: No Notes: Beginning at 10:20 am on 9/10/10 the plant experienced flaring. By 3:45 rates for all other olefins equipment were reduced, and flaring was minimized. Subsequent flaring from recovery and startup activities were authorized under Part 70 permit emissions limit. Unit rates were minimized to reduce flaring. Control system batteries were replaced and restart of the compressor was expedited to end the flaring. All batteries in this control system were replaced. This event is under investigation, with the aid of equipment manufacturers, to determine the root cause of the battery charger malfunction. All chemicals involved exceeded RQs. | 209.0 pounds |
| 124022 2010-06-08 | Sapple tubing on furnace | Cause: Leak on sapple tubing on one of furnaces. Followup: No Notes: Leak on sapple tubing on one of the furnaces. Residue was being disposed of and resured. Incident reviewed by Regenia "Faye" Taylor during inspection in June 2011, stated that it was below RQ. Incident closed. Just LDEQ report no SPOC or Exxon letter. | |
| 122560 2010-04-05 | Pressure relief valve | Cause: Pressure relief valve on a storage tank malfunctioned. Followup: Notes: The natural gas was blocked to the tank and reduced emissions by drafting the tank. Due to tank level management and prompt vent repair, Exxon said no reportable quantities were exceeded. | |
| 121682 2010-02-22 | pipe | Cause: Piping began leaking. Followup: No Notes: The product went to their seqer system. The unit was shut down and hey began to flush the system and repair the leak. The report says that no RQs were exceeded, but 10.5 lbs is above RQ. | 10.5 pounds |
| 121525 2010-02-17 | filter | Cause: Followup: No Notes: An individual was preparing to change a filter. For some reason a steam of steam, water and benzene was released. All stream was blocked in. The area is isolated and they are beginning to clean up. They said they may call back with the amount of the release. | |
| 121525 2010-02-17 | filter | Cause: Followup: No Notes: An individual was preparing to change a filter. For some reason a steam of steam, water and benzene was released. All stream was blocked in. The area is isolated and they are beginning to clean up. They said they may call back with the amount of the release. | |
| 121122 2010-01-29 | Blowdown drum D-106 | Cause: Earlier that morning, a TCD box, which contains computer hardware for controlling unit operations, had gone into "reset: mode and could not be restarted. Followup: No Notes: The box was shut down and the processor card replaced. An output card failed upon attempted restart of the box, which resulted in a steam drum safety valve lifting. Steam was sent to the Aromatic unit's blowndown drum, D-106, which has an atmospheric seal. The resultant pressure increase in D-106 caused brief venting of steam through the atmospheric seal leg. A small quantity of benzene was entrained with the steam as it vented to the atmosphere, resulting in an excess of the 10 lb reportable quantity threshold. The output card was replaced and the TCD box returned to full control. An investigation is underway to determine the root cause and prevent recurrence. This incident was not preventable because it was caused by unforseen computer hardware failure. | 31.0 pounds |
| 120682 2010-01-10 | HCE vacuum jet | Cause: The HCE vacuum jet went positive. Followup: No Notes: No additional information. | 31.0 pounds |
| 120636 2010-01-09 | No Information Given | Cause: Instrument malfunction. Followup: No Notes: Instrument malfunction. May not be a real release due to freezing conditions, but weather at the time of the event was 20 degrees Fahrenheit. | 10.0 pounds |
| 135834 2011-12-09 | Flange | Cause: Ground level flange leake. Air monitoring in the area showed readings which required isolation of the area. Perimeter monitoring showed no detect. Followup: No Notes: Plant workers tightened the flange. Mr. Ernesto Johnson stated that the fresh air breathing trailer was going to be utilized for the plant workers to tighten the flange. Inconsistency in the reported quantity released - there was no written notification from the facility to clarify the quantity - the original SPOC verbal notification stated the benzene was being released at about 12 lbs per hour (which would be closer to 24lbs total quantity) but the report stated 6 lbs was the total. | 6.0 pounds |
| 135246 2011-11-11 | KD-14 charge gas drier bypass line | Cause: A line leak was discovered on the KD-14 charge gas dier bypass line. 107 lbs of charge gas was released as a result of a line leak on the KD-14 charge gas drier bypass line. Followup: No Notes: Area monitoring was conducted and monitoring results repeatedly indicated low levels of hydrocarbon present at the leak site but at concentrations below the limit of detection at the BRCP fence line. A clamp has been placed on the line to isolate the leak. Prior to the permanent clamp being installed, a temporary clamp was installed on the line. Area monitoring was conducted. A permanent clamp was installed on the line on November 11. | 1.0 pounds |
| 135181 2011-11-09 | compressor KC-01 | Cause: A combination release occurred due to a cracked pipe in the thermo well of the ethylene production unit. Followup: Yes Notes: An engineered clamp is being fabricated and will be installed to isolate the leak. Estimated 72 hours to install clamp and secure leak. Individually this event did not exceed the RQ for HRVOC, but in combination with another incident (#11-07037) the RQ for HRVOC was exceeded on Friday, November 11. Approximately 122 pounds of HRVOC's were released. On November 11, 2011 at approximately 13:51 Derek Reese stated the ongoing release subsided to 4.25 lbs/hr and was now below RQ. (still ongoing on report date 11/16/11) Area monitoring and LDEQ monitoring on the fenceline (including grab sample) did not detect anything. LDEQ did pick up .25ppb of Benzene. A total of 108 pounds per day of charge gas is being released as a result of this event. Cumulative emissions which include the total emissions from the incident and complete response, will be included in the follow-up report. | 138.0 pounds |
| 135114 2011-11-07 | Aromatics unit | Cause: Loose water seal on a flare blowdown drum BD-106 of the Aromatics unit caused a Benzene release. Followup: No Notes: No information given. Four people were sent to Medical as a standard for being in the area. All four were asymptomatic. | 4.6 pounds |
| 135136 2011-11-05 | Control valve | Cause: Control valve malfunctioned releasing several materials into the air. Released to the flare after control valve malfunctioned. Followup: No Notes: No reportable quantities were exceeded. | 1.0 pounds |
| 133598 2011-09-01 | vent tanks 8 & 9 | Cause: Pressure vacuum vent on a tank released to atmosphere. Followup: No Notes: The release was located at Tanks 8 & 9. Approximately 649 pounds of total vapor were released. | 3.0 pounds |
| No LDEQ Reported 2011-08-11 | tankfield piping | Cause: Tnk 784 was determined to not have any unauthorized release of benzene. Tankfield and piping was determined to have a minor release, allowing less than one pound of benzene to reach the environment. Followup: No Notes: No reportable quantities were exceeded. Less than one pound of benzene was released. | |
| 132803 2011-07-29 | a pipe system | Cause: Release of 10lbs of Benzene came from small leak in piping system. Followup: No Notes: Material leaked onto the concrete and into a drain that is contained within the facility. Only verbal report in the file, no written 7 day letter by the facility. | 10.0 pounds |
| 130412 2011-04-03 | vapor recovery unit | Cause: Aromatics intermittent short duration vapor recovery unit compressor tripped. Followup: No Notes: Steam jets were used to secure the incident. | 10.0 pounds |
| 129620 2011-03-02 | BD-106 | Cause: Approximately 15 pounds of benzene was released due to an overpressured seal (BD-106) following a power flip at Louisiana Station. Followup: No Notes: Initial report dated 3/2/2011 reported of a release of approximately 15 pounds of benzene. Subsequently, written notification dated 3/3/2011 claims no reportable quantities were exceed. No material was released from blow down drum BD-106, as the drum maintained positive seal pressure throughout the event. | 15.0 pounds |
| 129439 2011-02-24 | PSV valve | Cause: PSV valve released gas into the air when two drums were switched and had a momentary over pressure.
Approximately 3 lbs of benzene were released. Followup: No Notes: Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded. | 3.0 pounds |
| 128886 2011-01-27 | Clamp on Aromatics Unit | Cause: Followup: No Notes: Initial report says there was more than 10 lbs of benzene released when a clamp on a drum maniford on the aromatics unit began leaking. The unit personnel discovered the leak during normal rounds. They collected the material into a 3'x3' catch plan and recovered the spilt material with an onsite vacuum truck. Industrial Hygiene conducted air monitoring during the event and no offsite impacts were noted. Approximately 1/2 gallon of material was released and 2 lbs of benzene were released to air. | 2.0 pounds |
| 145083 2012-12-01 | pipeline | Cause: A small pinhole leak in a pipeline caused a release of benzene. Followup: Notes: Approximately 0.5 pounds of benzene were released during this event. The facility placed absorbent pads and plastic around the pipeline and on the ground. A scaffolding area had to be constructed in order to perform a corrosive inspection. The pipe was repaired on 12/02/2012. | 0.5 pounds |
| 144539 2012-11-09 | Flare gas system | Cause: A failure of the fuel gas control valve servomechanism actuator failed due to particulate matter in the hydraulic system, causing OLA-2X gas turbine to trip and material to be released to the Site's flare gas system. Followup: Yes Notes: Feed was removed from five of seven furnaces and the remaining two furnaces were operating at minimal rates in order to reduce the load on the flare system and emissions to the atmosphere. The hydraulic oil filters and servos were replaced upon discovery of the foulant. The hydraulic oil system was drained, cleaned, and charged with fresh oil in December 2012 to remove a suspected contaminate and particulates. ExxonMobil is conducting additional laboratory analysis of the lube oil at our lubes and specialities lab to determine if additional steps are needed to help prevent recurrence. In addition, improved filtration has been installed. A citizen complaint was recorded and given LDEQ incident number 144543. The complaint cites "Exxon release causing terrible odors, making the caller sick." The LDEQ report references this report, incident 144539 for information on the release. The reportable quantities for VOC, benzene, ethylene, propylene, isoprene, 1,3-butadiene, sulfur dioxide, and nitrogen oxide were exceeded as a result of this event. | 819.0 pounds |
| 142193 2012-08-18 | transfer line from "D" furnance to EPLA-W | Cause: On August 18, 2012 at 20:27, a leak was discovered on a transfer line from "D" furnance to the "light end unit" EPLA-W. Followup: No Notes: The line was isolated and secured. | 1.6 pounds |
| 141729 2012-08-01 | pump UKPU-100B | Cause: Pump UKPU-100B was discovered leaking flare condensate Followup: No Notes: Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded. Less than one pound of 1,3-butadiene, benzene, and toluene were released. | 1.0 pounds |
| 141699 2012-08-01 | Pump UFPU-150 | Cause: On August 1, 2012 pump UFPU-150 was discovered leaking flare condensate to the concrete. Followup: No Notes: Due to the prompt incident response to mitigate the event duration, no reportable quantities were exceeded. | 3.3 pounds |
| 140470 2012-06-14 | Tank 21 and Rain Basin 1 | Cause: A failed bleeder plug was found at Tank 801 in the BRCP's Aromatics Tankfield. Approximately 411 barrels of steam cracked naptha reached the sewer system via this bleeder. All material was retained in waste water treatment facility. While the naphtha was being pumped to tanks #778, #26, #22 and #21, a rain event occurred, which overwhelmed the facility's ability to pump the liquid to the tanks. Therefore, the material was diverted to the Rain Basin I surface impoundment. Of the water pumped into the basin, there were 1,712 lbs of benzene and 419 lbs of toluene. Followup: Yes Notes: The water was to be pumped to the waste water treatment plant for treatment before being discharged to outfall 001. Firefighting foam was placed on top to reduce volatilized chemicals. Half the materials spilled were recovered. All values are based on the vaporized material and represents a very small amount of loss. The material is being pumped and moved to onsite storage to facilitate recovery and treatment of the material. All recovered liquid material is being placed in tanks 778, 21, 22, and 26, all of which are properly configured and permitted to store this material. On June 14, 2012, the site began the process of understanding the constituents of the steam cracked naptha that may have been released to the air by performing material balance calculations. During the first 24-48 hours of the incident response, the intial assumptions were that a majority of the material was being contained with minimal evaporative losses. Emissions reporting was based on the initial vaporization of material from the leak duration. Sample of the stored and liquid material were collected from multiple areas and storage facilities to help develop a more definitive material balance of the total steam cracked naptha released. As a precaution, at 1230pm on Jun 14, 2012, approximately 400 employees and contractors in the impacted areas of the complex were tested for potential exposure. ExxonMobil believes that none of these individuals will have any adverse impacts. The site conducted regular monitoring at the fence line every four hours and in three unit areas on an hourly basis during the incident response activites. All fence line readings remain below detection. ExxonMobil Industrial Hygiene personel continue to conduct air monitoring and are verifying safe conditions for areas were personnel are working. Fenceline monitoring will be conducted until the steam cracked naptha material in tank 21 and RB-1 have been treated through the Refinery Wastewater Treatment facilities. Firefighting foam was added to the sewer system every 1-2 hours to minimize the amount of evaporative losses. This foam did not impact wastewater treatment operations or capabilities in the quantities utilized during this incident. | 31,022.0 pounds |
| 140095 2012-05-28 | Tank 784 Socks | Cause: Due to the degradation of the socks of the storage tank over time, there was a release of benzene.Tank 784 socks leaked 0.75 lb/hr of benzene. OSHA requires a Highly Hazardous Entry permit to go to the top of the tank and fix the problem. Followup: No Notes: On 5/29/12/ at approximately 17:00 hours, the socks on the benzene tank were replaced and the release was secured. In the initial report on 5/28/12, the refinery stated that it expected reportable quantity for benzene to be exceeded. However, in the follow-up letter on 5/31/12, the refinery stated that no reportable quantities were exceeded. | |
| 136458 2012-01-11 | KND-72 seal oil drum | Cause: A leaking union was discovered on KND-72 seal oil drum. Followup: Notes: They have determined that no reportable quantities were exceeded. | 2.7 pounds |
| 152616 2013-11-28 | NIG | Cause: A release of butadiene and benzene from the ExxonMobil Baton Rouge Chemical Plant on November 28, 2013. Followup: No Notes: Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded. | 1.0 pounds |
| 152527 2013-11-20 | OLA-2X gas compressor | Cause: On November 20, 2013 at approximately 2 PM, the OLA-2X gas compressor tripped due to high vibrations; causing material to be released to the site's flare gas system. Follow-up investigation results indicate that the drain line for the compressor coupling guard became plugged with an extensive amount of coke, allowing oil to build up and degrade the inside of the coupling guard. Over time, the oil degradation impinged on the coupling, causing the high vibrations.
The Reportable Quantities for ethylene, propylene, butadiene, isoprene, benzene, nitrogen oxide, and sulfur dioxide was exceeded as a result of this event. Followup: Yes Notes: Immediately after the trip, unit shutdown procedures were executed and feed was safely removed from the unit. Air monitoring was conducted on November 20 and November 21 and all results were below the level of detection. Insulated the coupling guard drain line. Will evaluate installing a manometer on the coupling guard to attempt to measure air flow in the coupling guards and establish a monitoring program to determine if coke is accumulating in the coupling guards. Note: the initial report claims that plugged drain lines are not able to be detected or repaired, so the incident was not preventable. However, the follow-up report claims that air monitoring might detect coke accumulation and allow prevention. | 338.0 pounds |
| 151342 2013-09-29 | OLA-2X Gas Turbine | Cause: On September 29 at approximately 11:20 PM, the OLA-2X gas turbine tripped causing material to be released to the site's flare gas system. The shutdown was caused by a loss of flame in the gas turbine. Initial findings indicate that a change in power augmentation steam quality caused the loss of flame.
An investigation is underway to determine the root cause of the change in steam quality. Followup: No Notes: Feed was safely removed from five of the seven furnaces to minimize the load on the flare system and emissions to the atmosphere. The remaining two furnaces were operated at minimal rates to minimize start-up emissions. Air monitoring was conducted on September 30, 2013 and all results were below the level of detection. This incident is under investigation to determine the root cause of the change in steam quality. Short term mitigation steps have been implemented to ensure consistent steam delivery to the gas turbine. | 792.0 pounds |
| 150818 2013-09-04 | Tank #8 | Cause: On September 4, tank #8 went above the pressure threshold resulting in a release of benzene and butadiene vapors. Followup: No Notes: Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded. | 8.0 pounds |
| 149640 2013-07-11 | No Information Given | Cause: On July 11, 2013, there was a release of butadiene and benzene that occurred at the ExxonMobil Baton Rouge Chemical Plant. Due to prompt incident response to mitigate the event duration, there were no reportable quantities exceeded. Followup: No Notes: No information was provided in the refinery letter regarding point source or duration of the incident. | 5.0 pounds |
| 149351 2013-06-25 | WILA unit | Cause: ON June 25, 2013, the Baton Rouge Chemical Plant WILA unit experienced a series of intermittent PV vent liftings on TK 8 & 9. This event was due to level instrument malfunction on a water/butadiene separation drum during startup of the BELA-5 unit caustic scrubber system. As a result, butadiene was sent to the WILA unit. The butadiene vaporized in TK 8 & 9 causing elevated pressures, resulting in the PV vent liftings. The source of butadiene was immediately stopped and the WILA feed line was purged of butadiene to the flare system. Approximately 33 pounds of benzene and 2100 pounds of 1,3-butadiene were released as a result of the event. Followup: No Notes: The source of butadiene was stopped and the WILA feed line was purged of butadiene to the flare system. Repaired level instrument/control valve. Repaired site glass to restore visibility and enable confirmation of level instrument reading. Conducted refresher training for the process organization on improved alarm response to low level readings. | 33.0 pounds |
| 150018 2013-06-17 | Waste Water Treatment Unit | Cause: On July 29, 2013 at approximately 6:33 pm, predictive modeling showed increased benzene emissions from the Baton Rouge Chemical Plant Waster Water Treatment unit (AWT). Prior to being sent to AWT for final treatment before discharge, steam cracking furnace water effluent is stripped to recover benzene. The steam stripping distillation tower experienced abnormal operations in June as a result of internal fouling. This resulted in tower temperatures lower than the minimum temperature required to efficiently remove benzene.
During this period of abnormal operations, benzene levels were higher than normal but these elevated benzene levels were not detected until routine compliance samples caught at AWT were analyzed at a third party laboratory in July. Therefore, the results of these samples were not available until after tower operations were stabilized.
Initial notification indicates the release lasted for approximately 7 days. Initial notification occurred 7/29/13, incident started more than a month before, 6/17/2013.
A field inspection was conducted by LDEQ Inspection Division on 8/9/13 in response to this event. Followup: Yes Notes: The incident was detected upon third party sample analysis of scheduled monthly environmental samples taken to track compliance with the AWT Title V permit. While the BRCP permit requires annual modeling and sampling, the site voluntarily models samples on a more frequent, monthly basis to provide a back-up monitoring program. The sample results were not available until after appropriate measures has been taken to stabilize lower operations. Stable operations were validated by samples taken on July 1, 2013 which were within historical values. The tower has been taken out of service, cleaned, and returned to service. Alarms for critical operating parameters are being updated to ensure effective benzene stripping. The sampling protocol has been modified such that ExxonMobil will receive VOC concentration within 48 hours of arrival at the third party laboratory. | 6,577.0 pounds |
| 149002 2013-06-04 | Valve | Cause: Release of materials to air due to malfunctioning valve. Followup: No Notes: Necessary repairs were made. No additional information was provided in addition to the amounts released and duration. | 3.0 pounds |
| 148922 2013-05-27 | Tank #784 | Cause: On May 27, a benzene leak was detected by infrared camera coming from tank #784. Followup: No Notes: No specific remedial actions given. There was an attempt to minimize vapors coming from the tank. All air monitoring results were below detectable limits, and an infrared camera inspection of the tank showed no damage. Initially 10 pounds of benzene released was detected by infrared camera and no VOCs were detected. | 1.0 pounds |
| 148832 2013-05-21 | Cause: On May 21, the Baton Rouge Chemical Plant experienced a turbine trip at the OLA-2X unit. The material released was sent to the site flare gas system. After further investigation, it was determined that this event was due to the failure of the fuel gas control valve servomechanism actuator. The servomechanism actuator failed due to particulate matter build up in the hydraulic oil system. Followup: No Notes: Immediate remedial action was to reduce unit feed rates to help minimize emissions. The hydraulic oil filters and servomechanism actuators were replaced prior to restarting the machine. | 850.0 pounds | |
| 147267 2013-03-01 | N/A | Cause: Personnel working on an excavation project when an odor was detected. Initial air monitoring was conducted in the area with a Drager CMS using 0.2-10 ppm chip. Initial results indicated a benzene concentration greater than 10 ppm. Additional air monitoring was conducted and results indicated measurements greater than 250 ppm benzene. The site was immediately evacuated and barricaded to prevent personnel re-entry to the area. All readings conducted by the onsite Industrial Hygienist were below the detectable limits of the monitoring equipment.
There is potential for the reportable quantity for the characteristic hazardous waste D018 to be exceeded depending upon final sample results.
In the 60 day follow-up, no cause of problem was stated. The Baton Rouge Chemical Plant conducted soil sampling, and all results were below the detection limit. There were no reportable quantities exceeded as a result of this event. Followup: Yes Notes: As a precaution, 27 employees and contractors in the area were tested for potential benzene exposure. Test results were satisfactory and and demonstrated no effects on these individuals. All potentially contaminated soil has been segregated. Until further information is available ExxonMobile is treating this material as hazardous waste pending final sample results. Immediately upon discovery, the excavation site was evacuated and all personnel working in the area was tested for potential benzene exposure. Routine testing and respiratory protection steps were implemented. The Baton Rouge Chemical Plant conducted soil sampling, and all results were below the detection limit. The soil sampling included the excavated dirt piles, all soil previously place in bins and the areas not yet excavated in the vicinity of the project site. | |
| 146614 2013-02-10 | convention tube on C furnace | Cause: On February 10, 2013, a release of uncombusted ethylene (6.7 pounds), propylene (0.2 pounds), butadiene (0.2 pounds), butadiene (0.2 pounds), benzene (0.2 pounds), and other gases in smaller amounts (hydrogen, methane, and ethane). The incident began at 1000 hours and ended at 1045 hours. The release was caused due to a leaking tube in a steam cracking furnace (furnace C), which caused feed to enter the furnace. It was stated that most of the gases combusted inside the furnace. Some did not combust inside. The feed was stopped and the leaking tube later filled with water to prevent feed from entering that tube. Followup: No Notes: The leaking tube was filled with water to prevent feed from entering tube. The tube was reported to stay in this condiction until a more feasible time to replace or repair the tube and would not affect the operation of the furnace. | 0.2 pounds |
| 158676 2014-09-11 | pressure vent on NSHAP | Cause: Pressure Vent failed on the NSHAP. Event emitted approximately 4lbs benzene, 3lbs 1-3-butadiene, and 7 lbs of VOC's. Followup: No Notes: No Information Given. Due to prompt incident response the mitigate the event duration, no RQ's were exceeded. | 4.0 pounds |
| 157394 2014-07-14 | No information given | Cause: No reportable quantities were exceeded. Approximately 0.66 pounds of benzene were release as a result of this event. Followup: No Notes: There was no information given on the duration, the point source or the location of the incident. | 0.7 pounds |
| 153625 2014-01-30 | benzene storage tank | Cause: On January 30, 2014, a flange leaked on a benzene storage tank due to the freezing weather.
Some of the leaked benzene went into a sewer drain that leads to the facility's waste water treatment. Followup: No Notes: The leaking flange was secured. | 2.0 pounds |
| 153184 2014-01-07 | outlet emergency isolation valve | Cause: On January 7, 2014 at approximately 11:15 AM, a vapor leak was discovered on the outlet Emergency Isolation Valve (EIV) flange of a Finishing Clay Bed Treater, releasing benzene to the air.
The release was isolated via a vacuum hose and the emissions routed through a carbon-bed scrubber to reduce the release rate of benzene.
A detailed incident investigation is being conducted to determine the root cause and to provide mitigating steps to prevent reoccurrence. Followup: Yes Notes: The area was immediately barricaded and attempts were made to isolate the leak. The site conducted regular monitoring at the fence line and unit area for benzene. All fence line monitoring remained below detectable limits. This incident is still under investigation. Refinery letter dated March 7, 2014 states details of investigation will be provided in a 120-day follow up notification. | 101.0 pounds |
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