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ExxonMobil Chemical Plant (286), Baton Rouge
Releases of Ethylene
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| 79514 2005-06-01 | flare seal drum | Cause: Release from a very small pinhole leak in a ten-inch header to a flare seal drum. Followup: Notes: Amount of pollutants released is unknown. Believe that the amount of release will not break the RQ but are unsure. | |
| 91198 2006-10-08 | Reactor | Cause: A reactor over-pressured and PSV lifted to air. Reactor was emptied to another vessel. Followup: No Notes: Intial report says it may have exceeded RQs. Amount of ethylene and isobutane released is unknown. | |
| 91100 2006-10-04 | Exchanger | Cause: Exchanger leak into the cooling tower and then the air. Followup: no Notes: Exchanger was removed from service. | |
| 89593 2006-07-28 | Compressor | Cause: Compressor tripped off. Followup: No Notes: It was diverted to secure and took it out of the flare. | 121.0 pounds |
| 100166 2007-10-12 | RLA-1 Process unit | Cause: Followup: No Notes: At time of report event was still ongoing. Potential RQ for Flammable vapor. Potential RQ for VOC. Potential for highly reactive VOC. Potential for RQ for the Ethylene for DEQ of 100 lbs. There was a fire, but they called the internal fire squad as a precaution. Amount of ethylene released is unknown. | |
| 94916 2007-03-27 | Flare | Cause: They had a failure on a control valve, causing a safety valve release to the flare. The failure was due to a system overpressure. Followup: Notes: The flaring has stopped. The control valve is being repaired. | 10.0 pounds |
| 110452 2008-10-29 | Charge gas compressor | Cause: Followup: No Notes: They had an upset on a charge gas compressor and had to flare. They shut off the valve to stop the flaring. LDEQ received Exxon's report on 11/7/08. The release to the flare occurred as a result of incorrect pressure set point of the flare relief valve on the compressor suction. It was lowered during a previous upset and inadvertently not changed to the normal operating conidtions. Deferred until next inspection. Initial report says 120 lbs of ethylene were released but later report says 104 lbs. RQs exceeded for ethylene. | 120.0 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. | 1,520.0 pounds |
| 109342 2008-09-19 | Ethylene Unit | Cause: Followup: No Notes: Planned flaring due to the start up of the ethylene unit. Report says no RQ exceedences from this incident occurred. | |
| 109283 2008-09-17 | EPLA West Unit | Cause: ExxonMobil is starting up the EPLA West Unit. Followup: No Notes: Says this is permitted activity. Exxon was starting up their EPLA West ethylene unit on 9.17/08. They said flaring may occur through midday 9/18/08. No other information given. | |
| 109283 2008-09-17 | EPLA West Unit | Cause: ExxonMobil is starting up the EPLA West Unit. Followup: No Notes: Says this is permitted activity. Exxon was starting up their EPLA West ethylene unit on 9.17/08. They said flaring may occur through midday 9/18/08. No other information given. | |
| 108841 2008-09-09 | RGR Unit | Cause: Followup: No Notes: RGR Unit start up. Believed that flaring would occur throughout the night. Due to hurricane Gustav the flaring during RGR start up was extensive and a variation was obtained. Report says no RQs exceeded from this flaring. | |
| 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. | 1,169.0 pounds |
| 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. | 662.0 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. | 662.0 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. | 1,267.0 pounds |
| 105623 2008-05-14 | Safety valve | Cause: Safety valve released into vent stacks causing a fire. Unknown what the chemical is. Followup: no Notes: The valve was blocked away from the vent stack at 625pm. | 880.0 pounds |
| 104042 2008-03-18 | Flare | Cause: They lost an analog output card on a control system Off spec. Gasses went tot flare. Control valves and their by pass cause the system to go off spec. This caused them to flare the materials. Followup: Notes: The release is ongoing until they can bring things back on line. Materials released will be tracked against 5 yr rolling average for the Sp. Condition. Amount of nitrogen oxide released is over 70 pounds. | 250.0 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. | |
| 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. | 100.0 pounds |
| 114279 2009-04-18 | WM101 | Cause: WM101 valve failure to WM 12 bottoms. Followup: No Notes: Over 100 lbs of ethylene released. The exact amount released is unknown. Report says no RQs were exceeded. | 100.0 pounds |
| 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. | 2,348.0 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. | 3,463.0 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. | 3,463.0 pounds |
| 112558 2009-02-06 | RGR Unit | Cause: ExxonMobil is flaring. It is a permitted activity. Followup: No Notes: Exxon Mobil is flaring. Gave a courtesy call. RGR unit was shut down for planned mechanical activity. It is permitted activity. Flaring should last through the day as they continue with shutdown activities. | |
| 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. | 304.0 pounds |
| 127927 2010-12-01 | monoethanolamine system (MEA) at the Refinery | Cause: The plant receives feed streams from the Baton Rouge Refinery. The Refinery experienced an upset of its MEA system on 11/30 (SPOC #10-06865). This incident caused elevated hydrogen sulfide content of some of the plant's feed streams, resulting in off-specification products. Followup: No Notes: These materials were required to be diverted to the flare system. The plant's unit operations were adjusted to minimize emissions and incident duration. The refinery's scrubbing tower T-585 was removed from service to stabilize the MEA system, allowing the plant's feed streams to return to normal hydrogen sulfide concentrations. Successful conclusion of the Refinery incident resolved the root cause of the Chemical Plant feed stream issues. Unit procedures will be evaluated for consideration of potential incidents and responses of off-specification feed streams. RQs for ethylene and nitrogen oxide were exceeded. | 7,346.0 pounds |
| 127493 2010-11-08 | insulated line | Cause: Intial report said that there was a small leak on an insulted line resulting in an unknown release of the listed chemicals. Followup: No Notes: After further investigation of the small leak, no reportable quantities were said to be exceeded. | |
| 126818 2010-10-02 | J fractionator | Cause: Pin hole leak in J fractionator. Followup: No Notes: Final reports say no reportable quantities were reached. | 100.0 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. | 1,052.0 pounds |
| 125403 2010-08-04 | flare | Cause: Over pressure resulted in flaring of ethylene. Relief valve opened to control pressure. Followup: Notes: Due to prompt incident response to mitigate the event duration, they have determined that no reportable quantities were exceeded. Over 100 pounds of ethylene was released. | 100.0 pounds |
| 121196 2010-02-01 | T104 | Cause: T104 Overpressured and caused emergency shut down. Followup: No Notes: Burning to a flare. | 30.0 pounds |
| 120825 2010-01-15 | No Information Given | Cause: The purpose of the flaring was to start the maintain ethylene unit. It was also to help the South area control center along with the North area control center. Followup: No Notes: The caller stated that the flaring may continue as long as 1/16/10. They said that the flaring should not exceed reportable quantities. Just SPOC report. No mention of what it stopped of whether or not it reached RQ. | |
| 120703 2010-01-10 | flare | Cause: Unknown cause for leak in the propylene line of the EPLA (Ethylene Purification Unit). The EPLA uses high pressure propylene for refrigeration. Followup: Yes Notes: Initial report was received on 1/19/10. Ethylene Purification Unit (EPLA) uses high pressure propylene for refrigeration. Leak in pipe started 1/9/10 but discovered 1/10/10 at 8:20 pm. Proper and safe disposition of high pressure propylene is flaring. EPLA unit was shut down and more flaring occurred. Flaring occurred. Ended 1/11/10 at 3:22 am. Subsequent start up also resulted in flaring which are covered under permit. This was not preventable as it was an unusual incident. Follow up report after invesitgation was received on 3/22/10. Following corrective actions were contemplated: Design and install a permanent repair for the line, Review vibration study, Increase HAWK camera utilization to detect leaks early, Implement flow alarms for early warning via Real Time Advisor computer system. Exxon Mobil personnel requested and met with the Enforcement Divsion to settle the penalty on this preventable release. | 716.0 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. | 47.0 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. | 7,951.0 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. | 15.0 pounds |
| 130645 2011-04-13 | RT-03 | Cause: The South Ethylene Purification Unit (EPLA-S) experienced operational difficulties from depropanizer tower RT-03. RT-03 experienced operational difficulties with its overhead condensers when a control valve failed, resulting in EPLA-S receiving unsteady feed rates and material molecular weights. Due to teh unsteady feed, material was routed from EPLA-S to the flare system and an atmospheric safety valve released material.
A control valve failed. Followup: No Notes: Material was routed from EPLA-S to the flare system. To end the release, rates at RT-03 and EPLA-S were reduced. The failed control valve has been isolated. It will be repaired prior to being returned to service. | 3,414.0 pounds |
| 130066 2011-03-19 | no information given | Cause: Flaring of ethylene and propylene due to routine plant start up. Followup: Notes: All emissions were permitted and no reportable quantities were exceeded. | |
| 130274 2011-03-19 | EPLA-S | Cause: Prior to March 19, 2011 the South Ethylene Purification Unit was isolated for mechanical work. On March 20, 2011, and exchanger developed a head leak during start up operations. On March 30, 2011, the Poly unit developed a leak from a ring join flange. Followup: No Notes: To end the release, the flange was isolated. To end the EPLA-S pot venting, the vents were directed to the flare system. To end the EPLA-S exchanger head leak, the head was tightened and teh equipment brought to normal operating temperatures. To end the Poly T-2 release, the flange was isolated. | 1,282.0 pounds |
| 145241 2012-12-11 | NIG Flare and safety valve | Cause: ExxonMobil Chemical Plant experience an unanticipated cooling tower water line leak resulting in a shutdown of the Refinery Gas Recovery unit (OLA-1X and EPLA-S) causing 13 pounds of sulfur dioxide, 122 pounds of ethylene, and 29 pounds of propylene to be released as result of flaring. The OLA-1X compressor MC-01 experienced an increased in pressure resulting in an atmospheric safety valve lifting for approximately 45 seconds, released 5,817 pounds of flammable vapos into the atmosphere, 5,506 of which were propylene. Followup: No Notes: Unit operating procedures for stabilizing EPLA-S during an unanticipated OLA-1X shutdown were implemented to reduce the environmental impact. Root cause is under investigation. The reportable quantities for ethylene and propylene were exceeded. | 122.0 pounds |
| 145240 2012-12-10 | Flare | Cause: On December 10, 2012 at 23:40, ExxonMobil Chemical had a planned and controlled flaring incident that will last for approximately 24 hours. The flaring occurred during a planned unit start-up. Followup: No Notes: This event was a controlled flaring event that occurred during a planned unit start-up. All emissions were permitted, no reportable quantities were exceeded. | |
| 145178 2012-12-05 | Hydraulic Valve on EPLA-W KC-01 | Cause: On December 5, 2012 at approximately 6:18 pm, while repairing an inlet valve on EPLA-W KC-01 compressor the hydraulic valve failed, resulting in flaring. After further investigation it was determined that the lube oil clarifier malfunctioned allowing cooling water to backflow into the lube oil system. Followup: Yes Notes: Immediately following the failure of the hydraulic valve, the feed rates to the compressor were reduced. The compressor remained at reduced feed rates until a planned shutdown occurred. To prevent recurrence of this event, the valve has been cleaned and thoroughly inspected. Additionally, the lube, seal, and control oil reservoir circuit has been drained and refilled. | 464.1 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. | 3,572.0 pounds |
| 144402 2012-11-02 | compressor MC-02 | Cause: On 11/2/12, compressor MC-02 discharge casing developed a leak. Followup: No Notes: Sealant was pumped into the casking to isolate the leak. After further evaluation, Exxon Chemical has determined that no RQs were exceeded. Approximately 211 pounds per day of flammable vapor, 32 pounds per day of ethylene, and 26 pounds per day of propylene were released as a result of this event. | |
| 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. | 60.0 pounds |
| 138392 2012-03-29 | flare | Cause: Controlled shut down; planned mechanical repairs...Flaring occurred during a planned unit shut down for mechanical repairs. Ethylene was released to the atmosphere. Followup: No Notes: The flaring lasted several hours, and all emissions were permitted and no RQs were exceeded. | pollutant was releas |
| 138109 2012-03-20 | flare | Cause: HC-01 cracker compressor tripped, and all of ECLA-W furnace effluent was routed to the flare system.
The lube oil accumulator was found to have a broken bladder. The root cause of the event was due to a loss of lube oil pressure to the compressor during a pump swap. Followup: No Notes: To end the release, the lube oil pressure was returned to appropriate levels and the compressor was restarted. The lube oil accumulator was found to have a broken bladder. This device is designed to dampen pressure swings when the lube oil pumps are swamped. The faulty lube oil accumulator bladder has been replaced. | 271.9 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. | 1,476.0 pounds |
| 151413 2013-10-05 | Ethylene Refrigeration Compressor | Cause: On October 5, 2013 at approximately 9:15 Am, the Ethylene Refrigeration compressor motor shut down, causing material to be released to the site's flare gas system.
Preliminary investigation indicates the electrical motor shut down due to momentary low voltage resulting from a bird landing on an electrical transformer and causing an electrical fault.
A detailed investigation is underway to confirm the root cause of the power trip and determine recommendations to prevent recurrence. Followup: No Notes: Feed was quickly and safely removed from furnaces upstream of the compressor to minimize the load on the flare system and emissions to the atmosphere. Air monitoring was conducted frequently on October 5, 2013 and all results were below the level of detection. A detailed investigation is underway to confirm the root cause of the power trip and determine recommendations to prevent recurrence. | 7,392.0 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. | 3,456.0 pounds |
| 150492 2013-08-20 | No Information Given | Cause: Planned unit shutdown and startup of compressor. Followup: No Notes: Intermittent flaring occurred during a planned unit shutdown and start-up. All emissions were permitted and no reportable quantities were exceeded. | |
| 150134 2013-08-05 | No Information Given | Cause: On August 5 at approximately 2:17 PM, the ECLA-W cracker compressor shut down due to an unplanned processor card failure in the compressor control circuit. Feed was immediately isolated from all furnaces serviced by the compressor to reduce flaring until the compressor was restarted. This incident is under investigation to determine which component(s) of the processor card failed. Followup: No Notes: Feed was isolated from all furnaces serviced by the compressor to reduce flaring until the compressor was restarted. This incident is under investigation to determine which component(s) of the processor card failed and to provide mitigating actions to prevent this incident from occurring in the future. | 213.0 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. | 26.0 pounds |
| 148929 2013-05-25 | KGF-01 | Cause: On May 26, 2013 smoke was discovered coming from the stack of the steam cracking furnace KGF-01 at SACC. Upon investigation of the smoking, flooding conditions on the furnace were discovered and immediately mitigated. After further evaluation, it was determined that the furnace began experiencing flooding conditions during routine operation on May 25, 2013 at 3:23 am. Furnace flooding occurs when there is more fuel gas inside of the furnace than can be completely combusted. The uncombusted fuel gas released resulted in RQ exceedences for ethylene and flammable vapor. An investigation is underway to determine the root cause.
An oxygen analyzer false reading caused the furnace to go into a flooded condition. Followup: Yes Notes: Upon discovery, the furnace flooding conditions were mitigated. An oxygen analyzer false reading caused the furnace to go into a flooded condition. Conflicting analyzer readings caused the unit operator to make adjustments that extended the event duration and increased the degree of flooding to the point of generating smoke in the stack. Immediately upon discovering smoke from the stack, the furnace operation was corrected. Improvements to furnace controls and operator training are being implemented to prevent recurrence. Final investigation results indicate that the furnace flooding conditions were a result of an oxygen analyzer false reading. The follow up letter dated August 29 indicates a false reading, but the document scanned into EDMS only included one document and no additional information. | 883.0 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. | 3,709.0 pounds | |
| 148693 2013-05-05 | No Information Given | Cause: On May 5 at approximately 4:20 AM, the ECLA-W unit HC-01 compressor tripped due to low lube oil pressure. The compressors' automatic trip system detected the low lube oil pressure and tripped the machine. The compressor valves on the suction side automatically opened to relieve pressure to the flare. Subsequently, a unit upset on the downstream unit, EPLA-W caused the atmospheric safety valve to lift, and briefly flare off-specification ethylene product. Followup: No Notes: Immediate remedial action was to reduce the feed rates to minimum and the furnacys were put in standby to further reduce flaring until the compressor was restarted. Improvements are being made to assist operators in detecting low lube oil pressure and refresher training will be conducted to improve controller response. | 333.0 pounds |
| 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. | 6.7 pounds |
| 146054 2013-01-15 | Cause: Release occurred due to failure of a control valve for a splitter tower in the Ethylene Purification Louisiana South Unit (EPLA). Followup: Notes: Valve was in the process of being repaired. Feed to the unit was cut to reduce material going to the flare while air monitoring was conducted around the perimeter of the facility. | 43.4 pounds | |
| 158266 2014-08-25 | No Information Given | Cause: Intermittent hydrocarbon flaring is expected to occur through the month of September 2014 due to planned unit shut-down and start-up. All emissions are permitted. Followup: No Notes: No Information Given | |
| 157233 2014-07-03 | Cause: No reportable quantities were exceeded. Approximately 70 pounds of ethylene were released as a result of this event. Followup: No Notes: There is no information given on the cause of the incident , where the incident occured nor the duration. | 70.0 pounds | |
| 157143 2014-06-30 | Flare Gas system | Cause: The NACC unit HCO1 compressor experienced a shut down due to low lube oil pressure; causing material to be released to the site's flare gas system. Hydrocarbon feed was safely removed from all furnaces and the compressor was restarted. Air monitoring was conducted on 6/30/14 and all results were below the level of detraction. An investigation is underway to determine the exact root cause of the low lube oil pressure and provide mitigating steps to prevent recurrence. Followup: No Notes: Hydrocarbon feed was safely removed from all furnaces and the compressor was restarted. As of 7/7/14 this incident is still under investigation to determine the exact root cause of the low lube oil pressure and to provide mitigating steps to prevent recurrence. | 292.0 pounds |
| 155152 2014-04-09 | Flare Stack | Cause: A possible release of ethylene, propylene, Butadiene, benzene, and VOCs from a flaring incident coming from flare stack. Had an electrical glitch lead to a unit upset that lead to a flaring. Followup: No Notes: Air monitoring of the fence line. Initial notification states that ethylene, propylene, 1,3, butadiene, benzene and VOCs were released. Refinery letter states that only ethylene was released. | 69.0 pounds |
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