Home Search Emissions Pollutants About the Database


ExxonMobil Chemical Plant (286), Baton Rouge

Releases of Propylene

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
80016

2005-06-22
line
Cause: A leak was discovered in the line used to transfer IPA tail gas, which is primarily liquid propane, to the Poly unit. The cause was determined to be localized internal corrosion.

Followup:

Notes: The leaking section of the line was blocked in and water spray was applied to the leak to help minimize the vapors. Line-up changes were made so that this section of line could be depressurized to the flare system. A section of pipe, approximately 30 feet long, has been replaced. Ultrasonic measurements of additional elbows, low points, and horizontal sections of the pipe were taken. No other potential areas of corrosion were detected.
180.0 pounds
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.
79338

2005-05-25
WBT 01 Tower
Cause: Small hole on WBT 01 Tower. This is an absorber tower which contains flammable gas. On examining the hole in the tower they shut it down.

Followup: No

Notes: Immediately feed was cut out of the tower, water spray was applied to the leak to help minimize the vapors, and the weep hole was plugged. The area surrounding the leak was ultrasonically tested and found to be of acceptable thickness. A more intense UT scan was performed over the entire vessel and confirmed to be of acceptable thickness. The leaking tell-tale hole was plugged per mechanical design standards. About 1/3 of the vessel is being sand-blasted and visually inspected to verify that there are not any unplugged tell-tale holes remaining.
511.0 pounds
77758

2005-03-22
flange
Cause: An assistant operator found a flange on a level instrument tap leaking at the top of a tower. Immediately the tower feed was shut off, and the operator began to controllably depressure the tower to the flare system so that the leak could be repaired.

Followup:

Notes: Immediately feed was cut out of the tower. It was depressured as quickly as possible so that the leak could be repaired. The flange gasket has been replaced. Per ExxonMobil Chemical's usual procedures, the next time the tower is scheduled to go on turnaround at the end of 2006, all the tower gaskets will be replaced.
117.2 pounds
92930

2006-12-28
#4 Mox Boiler
Cause: Their #4 Mox boiler has a mechanically operated valve that opens at high pressure. High pressure in the line caused it to open, but they do not know what caused the high pressure yet.

Followup:

Notes: It was determined that Ethane, Methane, and Propylene were the chemicals involved in the fire. They believe they exceeded the RQ for VOC's.
87695

2006-03-09
Exchanger
Methane relief valve on POX heat-up-gun header
Cause:

Followup: No

Notes: On 3/2706 they disocvered they had an on-going release of methane. A meter indicated the release started on 3/9/06. Methane was released at 3120 lbs/day. Methane was released at 3120 pounds per day.
217.0 pounds
93999

2007-02-16
Rich Stage Absorber Tower
Cause: While making routine rounds, an assistant operator on the Isopropyl Alcohol Unit discovered a leak on the sixth level of the Rich Stage Absorber Tower. The leak was caused by a failure of the thermowell assembly.

Followup:

Notes: Personnel immediately began to isolate and shut down the tower. Elevated fire monitors were activated which sprayed water on the release to minimize emissions to the air. Feed was blocked out of the tower, the liquid drained to other process equipment, and the tower was depressured to the gas recovery system. The failed thermowell assembly was replaced. The failed thermowell assemblly was sent to an outside lab for metallurgical analysis to determine the cause of the failure.
468.0 pounds
111125

2008-11-30

Tower CT01
Cause: They have a leak on the "bottoms line" on Tower CT01

Followup: No

Notes: Water was applied to wash down liquids. Incident caused by a leak on the "bottoms line" on Tower CT01. Unit was shut down. No quantities were exceeded. Material went off site and the air was not monitored.
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.
36.0 pounds
110418

2008-10-28
Line in the Isopropanol unit
Cause: Had a leak on a line in the isopropanol unit.

Followup: No

Notes: The line was being blocked in a depressurized. Exxon's report was received on 11/5/08. No RQ exceedence for this incident. Amount of propylene released is unknown.
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.
1,034.0 pounds
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.
109655

2008-09-01
Advanced Wastewater Treatment Unit
Flare
Storage Tank
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.
6,915.0 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.
451.0 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.
451.0 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.
862.0 pounds
106447

2008-06-16
compressor
flare
Cause: They have compressor trip. All the gas went to the flare. The unit is being depressured.

Followup: no

Notes: Event was ongoing.
700.0 pounds
106447

2008-06-16
compressor
flare
Cause: They have compressor trip. All the gas went to the flare. The unit is being depressured.

Followup: no

Notes: Event was ongoing.
106067

2008-06-02
Flare
Cause: Flaring propylene during unit start up.

Followup:

Notes: No RQ exceedance from event.
106066

2008-06-01
flare
Cause: Starting up an unit and depressurized to the flare.

Followup: No

Notes: No RQ exceedance from this flaring.
106068

2008-06-01
flange on exchanger
Cause: A flange leaked on an exchanger during start up operation of a unit.

Followup: No

Notes: No additional information given.
672.0 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.
1,295.0 pounds
115845

2009-06-20
WCT 01
Cause: Safety valve on WCT 01 failed and released to flare. Root cause for flaring was positional failure of the control valve resulting in a pressure surge to the tower WCT01. The safety valve did not properly seal after the lift and VOCs leaked to the flare.

Followup: No

Notes: Uncombusted propylene released through the flare.
171.0 pounds
115854

2009-06-20
WCT 01
Cause:

Followup: No

Notes: Release came out of the top of one of the flares. Caused by a safety valve failure on WCT 01. Just SPOC report.
171.0 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.
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.
3,470.0 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.
1,417.0 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.
1,417.0 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.
127749

2010-11-22
suction drum
Cause: there was a high level on a suction drum and it tripped the recycle compressors. The flaring event was due to start-up activities, and all emissions were permitted.

Followup: No

Notes: An unknown quantity of propylene was released. There was no unauthorized discharge.
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.
127137

2010-10-20
WSD 10 drum
Cause: Leak in the WSD 10 Drum

Followup: No

Notes: Initial report of a release of an unknown quantity of propylene due to a leak in the WSD 10 Drum. A written report from Exxon stated that no reportable quantities were exceeded.
126833

2010-10-03
compressor piping
Cause: The Ethylene Purification Unit was being surveyed using an optical imaging "HAWK" camera when a pinhole leak was detected coming from a pipe.

Followup: No

Notes: On 10/3/10 around 8:15 pm the plant experienced a propylene release. Because of the location of the release, scaffolding was required to allow access of the pipe. A clamp was installed on the pipe, which ended the release. A permanent repair was being evaluated. The release was due to unanticipated corrosion. RQs for propylene were exceeded.
278.0 pounds
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.
819.0 pounds
125934

2010-08-25
pump on P-541 discharge line
Cause: Leak on pump discharge line P-541.

Followup: No

Notes: No RQs were exceeded. At time of report Exxon was determining how to stop the leak.
125267

2010-07-29
pipe going to CT01
Cause: There is a small leak on tower CT-01.

Followup: No

Notes: Because of the location of the leak the unit was brought down to repair. Propylene was released. Written report says no RQs were exceeded.
124687

2010-07-08
Halobutyl Unit flare line
Cause: Crack in the line was discovered on a Halobutyl Unit Flare. It was a nonpreventable released caused by unanticipated corrosion.

Followup: No

Notes: Upon discovery, temporary clamps were installed to end the release and close the potential emission sources. A permanent repair plan is being developed. This incident was caused by unanticipated corrosion. Exceeded RQs.
329.0 pounds
124659

2010-07-07
Piping weld
Cause: There was a pinhole leak in a piping weld.

Followup: No

Notes: Isolated and evacuated. Propylene is the chemical on line.
124078

2010-06-10
flange
Cause: Propylene leak from a flange at the discharge end of the compressor. Attempts to fix the check valve flange resulted in the bolts being stripped and more release occured.

Followup: No

Notes: Propylene leak from a flange at the discharge end of compressor. Planned to put a clamp to stop the leak and monitor air quality. Exxon's report was received on 6/21/10 at CRO. Fugitive emission leak was deteced at the propylene refrigeration system during LDAR round. Attempts to fix the check valve flange resulted in the bolts being stripped and more release occurred. Effort to clamp the flange stopped the release. Exceeded RQ for propylene (an HRVOC). Report says this will be addressed during the next inspection.
1,260.0 pounds
123193

2010-05-03
Exchanger-18X
Cause: On 4/15/10 the Baton Rouge Complex sampled cooling tower #33 for MACT CC compliance using the El Paso cooling tower sample method, as required by refinery operations. Cooling tower #33 is located in the refinery and services both refinery and chemical plant units. The sample results from 4/15 showed more hydrocarbon than expected, so the tower was resampled on 4/16. These results also indicated a hydrocarbon leak.

Followup: No

Notes: The unit personnel began looking for the source under the premise that the release had to be repaired within 45 days, as required by MACT CC. On 4/3/10, the leaking exchanger (E-18X) was identified as the leak source. The exchanger is part of the Baton Rouge Chemical Plant so MACT CC provisions do not apply. Once the leaking exchanger was identified, the release calculations were updated based on the actual stream speciation. These updated calculations relevealed that the release was larger than orginially calculated using the EL Paso method and exceeded the reportable quantity for propylene. RQ for VOC was not exceeded. The exchanger bundle will be repaired before returning to service. Cooing tower MACT CC sampling procedures will also be updated for cooling towers that service both refinery and chemical plant units. Caused by an unforseen exchanger leak. Release of HRVOC during ozone reason, will take up upon next inspection.
7,258.0 pounds
122853

2010-04-17
propylene compressor
Cause: Trip of propylene compressor and gas is going to the flare.

Followup: No

Notes: Originally they thought it may be greater than 100 lbs but the actual reprted release was 9 lb, below RW. Prompt shut down resulted in the release being BRQ.
9.0 pounds
121196

2010-02-01
T104
Cause: T104 Overpressured and caused emergency shut down.

Followup: No

Notes: Burning to a flare.
100.0 pounds
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.
2,421,834.0 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.
14.0 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.
2,422.0 pounds
133562

2011-08-26
EPLA-S
Cause: Pinhole leak in a valve body at the Ethylene Purification Unit (EPLA-S).

Followup: No

Notes: The propylene is leaking at a rate of 80 pounds per hour. Approximately 34 pounds of propylene and propane were released.
34.0 pounds
132204

2011-07-03
West Ethylene Purification Unit (EPLA-W)
Cause: The propylene at this time experienced higher than normal methyl acatylene and propadiene concentrations, so it was required to be flared. The root cause was suspected to have been contaminated feed, since no equipment or operational issues had been identified at EPLA-W.

Followup:

Notes: Feed rates were reduced to minimize flaring and attempt to isolate a source of contamination until the feed quality improved. LDEQ Verbal report also mentions that they also released more than 1,000 pounds of Nitrogen Oxide to the air. This was not mentioned in the 7 day letter. Facility conducted air monitoring.
1,181.0 pounds
132165

2011-06-30

Cause: There was a pinhole leak in a pump.

Followup: No

Notes: Approximately 30lbs of propylene released to the atmosphere. All of the liquid released was captured in secondary containment.
30.0 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.
4,619.0 pounds
130238

2011-03-30
overhead piping of process tower
Cause: Leak on overhead piping of process tower.

Followup: No

Notes: Due to rapid response, this leak did not result in reportable quantities being exceeded.
4.0 pounds
130068

2011-03-20
exchanger head
Cause: Leak found on the head plant of an exchanger. Approximately 52lbs of propylene and 3lbs of propane.

Followup: No

Notes: Prompt incident response to mitigate the event duration, no reportable quantities were exceeded.
52.0 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.
2,218.0 pounds
129557

2011-03-01
No Information Given
Cause: Leak on a piece of piping caused a release of propylene.

Followup: No

Notes: Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded.
79.0 pounds
129081

2011-02-07
Tube on an exchanger
Cause: 85lbs of propylene and propane were released into the atmosphere in a 24hr period when there was a tube leak on an exchanger.

Followup: No

Notes: 85 pounds of propylene and propane were released.
85.0 pounds
145241

2012-12-11
Flare and safety valve
NIG
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.
5,535.0 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.
145185

2012-12-06
Flare
Cause: Unit upset required the release of propylene to the flare system.

Followup: No

Notes: Flaring was part of online operating adjustments in lieu of shut down.
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.
109.4 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.
1,423.0 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.
143828

2012-10-15
tube on the RLA3 Unit
Cause: on 10/15/12 at approximately 09:54, EMCP had a tube leak in the RLA3 unit. A clamp was put on the leak, but there was still a small leak around the clamp.

Followup: No

Notes: Air monitoring showed 2000 ppm at the site of the leak. A clamp was placed on the leak but there is still a small leak arounf the clamp. No RQs were exceeded, and approximately 5.8 lbs of propylene were released as a result of the event.
5.8 pounds
143727

2012-10-10
None given
Cause: No Relevant information is provided regarding the cause of this event. Approximately 20 pounds of propylene were released as a result of this event.

Followup: No

Notes: No information given. LABB only has the 7 day letter written notification - we have not found the initial notification made to SPOC or the LDEQ verbal report.
20.0 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.
1.8 pounds
140713

2012-06-21
MKC-02 propylene refrigeration compressor at the EPLA-W unit.
Cause: There was a leak on the clamp of the discharge piping from MKC-02 propylene refrigeration compressor at the EPLA-W unit. The root cause of the clamp leak was due to vibration of the piping. The followup letter states that "individually, this event did not exceed the reportable quantity for propylene, but in concurrence with Incident #12-01617 (EPLA-S cooling tower leak), the reportable quantity for propylene was exceed in a 24-hr period."

Followup: Yes

Notes: Upon discovery, the clamp was pumped with a sealant to reduce the leak rate. The clamp was pumped with sealant on 6/21/12 and 6/22/12, decreasing the leak rate each time. This process significantly reduced the leak around the clamp. Two engineered collared clamps were designed, fabricated, and installed on each end of the original clamp to isolate the remaining leak. ExxonMobil and the clamp vendor are continuing efforts to improve the clamp efficiency. Periodic monitoring was conducted during normal operational rounds. LABB's file includes the 60-day follow-up and the Discharge Notification Report, but no SPOC or LDEQ report. This incident exceeded RQs because it is linked to another emission event - LSP Incident #12-01617. Any additional follow-ups will be communicated through LSP incident # 12-04963
102.0 pounds
138107

2012-03-19
EPLA-S cooling tower
Cause: Release to EPLA-S cooling tower of 26.7 pounds o VOCs (of which 24.4 pounds were propylene).

Followup: No

Notes: No information given regarding remedial actions. Leak on EPLA-S cooling tower was tested to determine no RQs were exceeded.
24.4 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.
588.0 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.
2,028.0 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.
1,376.0 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.
150346

2013-08-12
EPLA-S unit
Cause: On August 12, a propylene leak above the reportable quantity was discovered on the ethylene unit (EPLA-S) and reported. Initial El Paso sampling indicated a leak rate of 730 lbs/day. Further refinement of the leak rate estimate indicates a current leak rate of 798 lbs/day. Investigation results indicate the exchanger had been in service for an extensive amount of time. However, the chiller is in a clean, non-corrosive service and there was no expectation that this equipment would have leaked. As discussed with LDEQ, the BRCP planned and safely executed a controlled shutdown of the EPLA-S unit.

Followup: Yes

Notes: ExxonMobil safely executed a controlled shutdown of the EPLA-S unit. To prevent recurrence, exchanger tubes were plugged as short term mitigation. The bundle will be replaced during the next scheduled unit maintenance interval. ExxonMobil was fined in 2011 for similar leaks in the ethylene unit as a part of a settlement agreement with LDEQ (Settlement Tracking No. SA-MM-13-0030).
5,985.0 pounds
149925

2013-07-25
No information given
Cause: On July 25, a release of propylene occurred.

Followup: No

Notes: Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded.
0.0 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.
11.0 pounds
148926

2013-05-29
No Information Given
Cause: ExxonMobil Chemical plant identified a hole in a pipe. The product was being released to the pavement and then evaporated to the air. The facility has determined that no reportable quantities were exceeded. The propylene released to soil and air - and was determined to have resulted in offsite impact although no air motioning was conducted by ExxonMobil. There was also an injury reported

Followup:

Notes: Prompt incident response was implemented to mitigate event duration, and it was determined that no reportable quantities were exceeded.
2.4 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.
1,477.0 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.
0.2 pounds
146061

2013-01-15

Cause: The Ethylene Purification Unit experienced an unanticipated atmospheric safety valve lifting prior to reaching its set point for approximately 26 minutes. Unanticipated safety valve was due to a broken O-ring causing material to be released into atmosphere.

Followup:

Notes: The safety valve was immediately blocked upon discovery. To return the unit to normal operating conditions, the DeEthanizer overhead and splitter bottoms were flared. To prevent recurrence, the preventative maintenance frequency of the atmospheric safety valve will be increased, and ExxonMobil engineers are evaluating potential upgraded material type for the O-ring.
35,590.0 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.
146024

2013-01-12
IPA Unit
Cause: While operators worked to repair a leak on the Isopropyl Alcohol Unit (IPA) by installing a spare extract pump, a flange on the downstream control valve station began leaking extract. As operators began troubleshooting the leak, the flange gasket failed, causing 2,844 pounds of extract to be released onto the concrete, of which approximately 203 pounds were propylene vapor.

Followup: No

Notes: The unit was immediately shut down to isolate the leak. The gasket was replaced and the flange bolts were tightened.
203.0 pounds
145808

2013-01-10

Cause: Compressor RLA-3 C-201 tripped, resulting in flaring.

Followup: No

Notes:
32.0 pounds
145693

2013-01-01
cooling tower water chiller UE-07
Cause: On January 3rd a propylene leak was discovered coming from cooling tower water chiller UE-07 to GFLA-3 cooling tower. On January 1st at approximately 3 PM, the Refinery Gas Recovery Unit noticed that the propylene refrigeration inventory was decreasing at an increased rate. Operations immediately began troubleshooting by utilizing the HAWK camera, testing unit safety valves, checking cooling tower gas detectors, and verifying all unit line-ups until the source of the leak was discovered. On January 3rd at 11:06 AM cooling tower water chiller UE-07 was isolated as part of this troubleshooting activity. The propylene inventory levels returned to the normal operating range by 1:00 PM, confirming the leak had been isolated. Inspection of the chiller, UE-07, is being expedited to determine the root cause of the leak. Based on the mechanical inspection results, repairs will be completed and ling-term mitigation plans developed.

Followup: No

Notes: Unknown product is a flammable vapor. An exchanger leaked to the cooling tower, which was blocked in and secured prior to discovering the leak. The site has been secured. Highly reactive volatile organic compounds were released. Material went offsite and air was monitored at the perimeter of the facility. The incident was classified as an unusual event. This facility exceeded the RQ of propylene by more than 64x the reportable quantity. Based on the mechanical inspection results, repairs will be completed and long-term mitigation plans developed. While SPOC was notified of the discharge on January 7th, the Unauthorized Discharge Notification Report, also known as the 7-day letter, was not submitted till January 10th, 2013. While the source of the problem was identified on January 3rd, the problem was recognized on January 1st, which means that the 7-day letter should have been submitted on January 8th, or seven days after the problem was initially recognized.
64,179.0 pounds
158713

2014-09-12
ICLA Unit
Cause: On Sept 12, 2014 the ICLA unit experiences a pinhole leak on a tower suction line as a result of internal corrosion.

Followup: No

Notes: Upon discovery, feed to the unit was isolated. To prevent recurrence, the refinery plans to increase the inspection frequency of this piping circuit and explore the feasibility of using an alloy piping option.
324.0 pounds
158593

2014-09-06
No Information Given
Cause: Discovered a propylene leak at one of the systems. Release of 6 pounds of propylene and 6.5 pounds of flammable vapor.

Followup: No

Notes: No Information Given other than prompt incident response to mitigate event duration. Initial state police hotline report states that a gas detection device was being used at the time of the leak.
6.0 pounds
156446

2014-06-02
No information given
Cause:

Followup: No

Notes: The report fails to provide an accurate description of the events that took place in regards to how the accident occurred, the duration and the location of the accident.
20.0
155154

2014-04-09
Exchanger
Cause: ExxonMobil Chemical Co had an exchanger leak with potential RQ exceedances for Propylene and HRVOCs. Due to prompt incident response to mitigate the event duration, no reportable quantities were exceeded. Approximately 0.06 lbs of propylene were released as a result of this event.

Followup: No

Notes: The reports also mention incident 14-01580 that occurred a day prior to this incident. According to initial reports, emissions from these two events exceeded the reportable quantities. The report fails to mention the amount released from incident 14-01580. There is also no mention of the end time for this accident. There is also no mention of what caused the exchanger leak.
0.1 pounds
155065

2014-04-07
No information given
Cause: This event is also associated with state police numbers 14-01528 and 14-01529. During a severe thunderstorm on 4/7/14, the Baton Rouge Chemical Plant (BRCP) experienced an electrical power interruption, resulting in unit upsets and temporary flaring (state police number 14-01528). A subsequent notification (state police number 14-01529) was made regarding releases from safety valves directly to the atmosphere. It has been confirmed that these safety valves relieved to the site's flare system and not directly to the atmosphere. A detailed investigation is underway to confirm root causes of the power trip and provide recommendations to prevent recurrence.

Followup: Yes

Notes: Upon restoration of power, impacted equipment was restarted and returned to normal operating conditions.
363.0 pounds
154160

2014-02-24
Isopropyl Alcohol Unit
Cause: On February 24, 2014, the Exxon-Mobil Baton Rouge Chemical Plant experienced a propylene leak on the isopropyl alcohol unit (IAU). Upon notification of an odor in the unit area, unit personnel discovered propylene leaking from a pinhole in a weld. The leak was immediately isolated and the unit was shut down to minimize environmental impact.

Followup: No

Notes: The leak was immediately isolated and the unit was shut down to minimize environmental impact.
10,931.0 pounds