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Phillips 66 (2538), Lake Charles

Releases in 2006

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
92372

2006-12-01
Point Source(s):
Area A- North Flare (EP64)

Pollutant(s):
Sulfur Dioxide - 2,074 pounds
Cause of Problem: Other

see notes. RV lifting in the #5 HDS & releasing to the flare. Overhead pressure controller froze up due to cold weather snap pressured up 5 HDS overhead & stripper
WEATHER. Put steam on pressure controller and bypassed process around overhead cooling water condenser to heat up 5 HDS overhead. Potentially add low temp alarm on overhead drum to adjust operation during cold weather
92036

2006-11-17
Point Source(s):
Sulfuric Acid Plant

Pollutant(s):
Sulfur Dioxide - 76 pounds
Sulfur Trioxide - 0
Cause of Problem: Instrument Failure

Acid strength analyzer failed
Letter states that emission was BRQ. No information given
91237

2006-10-09
Point Source(s):
Area A-North Flare (EP-64)

Pollutant(s):
Sulfur Dioxide - 861 pounds
Nitrogen Oxide - 3 pounds
Cause of Problem: Start Up, Shut Down

A relief valve on the stripper is the 6HDS lifted due to a process upset caused by a hydrogen compressor shutdown & consequent unit upset.
A management environmental review will develop a plan to identify leaking RVs and troubleshoot the flare system during relied events/upsets so that future releases do not exceed permit limits. HAZMAT#0606318
91101

2006-10-04
Point Source(s):
Area A- North Flare EP64

Pollutant(s):
Sulfur Dioxide - 3,026 pounds
Cause of Problem: Equipment Failure

RV leakage
Relief Valve is being changed to prevent further leakage to the flare. HAZMAT#0606201
90166

2006-08-21
Point Source(s):
Area A- North Flare (EP-64)

Pollutant(s):
Sulfur Dioxide - 1,721 pounds
Cause of Problem: Start Up, Shut Down

Compressor was shutdown due to an external trip. The cause of the trip is unknown and is currently being investigated to prevent future occurence
The cause of the trip will be identified using the RCFA process and the area will take action - using engineering controls if possible - to ensure that trip never happens again. HAZMAT#0605264
90047

2006-08-16
Point Source(s):
2624-V5 Emission Point FUG009

Pollutant(s):
Volatile Organic Compounds - 200 pounds
Cause of Problem: Piping or Tubing

Leak in underground piping venting to atmosphere
Pipe was isolated from the process and depressured in order to make necessary repairs. HAZMAT#
89157

2006-07-10
Point Source(s):
Area B - South Flare (EP-31)

Pollutant(s):
Sulfur Dioxide - 0 pounds
Cause of Problem: No Information Given

Low suction pressure on C-1430, south flare gas recovery compress
Installing low and low-low level alarm on caustic level to prevent future shutdown of the SFGR compressor. HAZMAT #
89035

2006-07-02
Point Source(s):
Area A - No. 1 Coker

Pollutant(s):
Hydrogen Sulfide - 53 pounds
Volatile Organic Compounds - 336 pounds
Cause of Problem: Human Factors

A six inch drain valve on a live coke drum was inadvertantly opened by operator.
Interlocks that failed to prevent this event is being looked at. Live drum indications and permissive controls from the board are planned. HAZMAT #
88915

2006-06-27
Point Source(s):
#1/2 Sulfur Recovery Unit (SRU)

Pollutant(s):
Sulfur Dioxide - 40 pounds
Cause of Problem: Instrument Failure

An instrumentation malfunction occurred which resulted in a unit upset.
No information given
88848

2006-06-24
Point Source(s):
Area B - South Flare (EP-31)

Pollutant(s):
Sulfur Dioxide - 1 pounds
Hydrogen Sulfide - 0 pounds
Cause of Problem: Maintenance/Procedures

Planned maintenance to reinstall RV on #1 Amine Regeneration Unit (ARU) required shutdown of the South Flare Gas Recovery system.
South Flare Gas Recovery Compressor was restarted following completion of work. HAZMAT #06-03981
88686

2006-06-17
Point Source(s):
None Reported
Pollutant(s):
Cause of Problem: No Information Given

No Information Given
Letter indicates all was BRQ. No further information given.
88648

2006-06-16
Point Source(s):
Area A - Other

Pollutant(s):
Sulfur Dioxide - 15 pounds
Cause of Problem: Maintenance/Procedures

SFGR Compressor was shutdown to perform relief valve work.
None needed since exceedance did not occur HAZMAT # 06-038
88547

2006-06-13
Point Source(s):
South Flare

Pollutant(s):
Sulfur Dioxide - 0 pounds
Cause of Problem: Start Up, Shut Down

Release caused by a Flare Gas Recovery shutdown, associated with Turnaround activitie
No information given
88503

2006-06-12
Point Source(s):
Area B - South Flare (EP-31)

Pollutant(s):
Hydrogen Sulfide - 1 pounds
Sulfur Dioxide - 46 pounds
Nitrogen Oxide - 0 pounds
Cause of Problem: Maintenance/Procedures

The South Flare Recovery Compressor was shutdown to perform relief valve inspection work.
Once inspection was complete, compressor was put back in service. HAZMAT#
88366

2006-06-06
Point Source(s):
Area B- South Flare (EP31)

Pollutant(s):
Sulfur Dioxide - 2,360 pounds
Hydrogen Sulfide - 47 pounds
Volatile Organic Compounds - 5,144 pounds
Nitrogen Oxide - 199 pounds
Cause of Problem: Other

see notes. Intermittent power surge due to malfunctions at the Entergy Power Company. Emissions resulted from power failure.
Power failure. Restarted and/or isolatedpertinant units to prevent further impact. HAZMAT#
88297

2006-06-04
Point Source(s):
Area A- North Flare (EP-64)

Pollutant(s):
Sulfur Dioxide - 0 pounds
Cause of Problem: Start Up, Shut Down

A refinery process unit (#7 HDS) was being depressured and steamed to the flare as part of a pre-turnaround shutdown procedure.
Letter from CP indicates that an instrument malfunctioned causing an incorrect reading that indicated an excessive release of SO2
87832

2006-05-15
Point Source(s):
None Reported
Pollutant(s):
Cause of Problem: Start Up, Shut Down

The South Flare Unit was shutdown to peform mechanical work on the SFGR Compressor. During this event emissions were release
No Information Given
87173

2006-04-16
Point Source(s):
Area A- South Flare (EP-31)

Pollutant(s):
Sulfur Dioxide - 50 pounds
Cause of Problem: Other

see notes.
SFGR tripped due to high O2 right after a #2 Coker blow down event. SFGR was started back 30 minutes after the incident. HAZMAT#
86847

2006-03-29
Point Source(s):
Excel -Sulfur Plant (EP-111)

Pollutant(s):
Sulfur Dioxide - 220 pounds
Cause of Problem: Other

see notes. Based on temperature trends & air demand analyzer readings, the SO2 was being formed in the 3rd converter bed of the Claus reactor. Excess O2 from the reaction furnace was reacting with sulfur on the catalyst creating SO2 and hea
Discuss learnings with operations. HAZMAT#
86572

2006-03-18
Point Source(s):
Area B- South Flare (EP31)

Pollutant(s):
Sulfur Dioxide - 0 pounds
Nitrogen Oxide - 0 pounds
Hydrogen Sulfide - 0 pounds
Cause of Problem: Maintenance/Procedures

Emissions occurred when the SFGR compressor system was shut down to install relief valves.
South Flare Caustic Scrubber was in service during this outage. HAZMAT#
86430

2006-03-13
Point Source(s):
Area B- South Flare (EP31)

Pollutant(s):
Sulfur Dioxide - BRQ
Cause of Problem: Maintenance/Procedures

-The SFGR compressor was shut down to facilitate the installation of the RV for W-10.
Once work completed, the SFGR compressor will be started up. In the future, STL's must plan around routine operations. HAZMA
86154

2006-03-02
Point Source(s):
Area C- North Flare (EP-64)

Pollutant(s):
Sulfur Dioxide - 1,120 pounds
Nitrogen Oxide - 13 pounds
Hydrogen Sulfide - 12 pounds
Volatile Organic Compounds - 67 pounds
Cause of Problem: Start Up, Shut Down

The No. # Crude Unit shut down for turnaround resulted in excess emissio
No Information given.
86076

2006-02-27
Point Source(s):
Area B -South Flare (EP31)

Pollutant(s):
Sulfur Dioxide - 55 pounds
Hydrogen Sulfide - 1 pounds
Nitrogen Oxide - 0 pounds
Cause of Problem: Maintenance/Procedures

South Flare Gas Recover compressor was shutdown to facilitate flare work on W-10.
Work is planned to minimize duration of compressor outage thus minimizing quantity of pollutants releases. HAZMAT #06-01195
85943

2006-02-24
Point Source(s):
Area B- South Flare (EP31)

Pollutant(s):
Sulfur Dioxide - 5,600 pounds
Hydrogen Sulfide - 61 pounds
Nitrogen Oxide - 1 pounds
Cause of Problem: Process Upset

Release caused by poor NaHS operation and south flare caustic scrubber startup not completed.
South Flare Caustic Scrubber is in full operation. HAZMAT # 06-01158
86019

2006-02-23
Point Source(s):
Area B- South Flare (EP31)

Pollutant(s):
Sulfur Dioxide - 0 pounds
Cause of Problem: Maintenance/Procedures

The suction pressure on the SFGR compressors dropped below the low-low suction pressure trip point and shutdown the compressor that was running. The suction pressure dropped due to commissioning activites or the South Flare caustic scrubber project.
Compressor restarted. Troubleshooting performed subsequent to the event reveled that the caustic scrubber level was not sufficient to hold enough backpressure or the recovery compressor suction. The level instrumentation will be revised to prevent reoccurence of this event. HAZMAT #06-01120
85927

2006-02-19
Point Source(s):
Area C- North Flare (EP-64)

Pollutant(s):
Sulfur Dioxide - 7,438 pounds
Cause of Problem: Other

see notes. Overpressure of W-1150 and W-1301, due to plugged offgas line, resulting in relief valves lifting to North Flar
WEATHER - near freezing ambient temperatures initiate chain of events that produce release.Reroute PB liquid from going through offgas line to prevent line freezing/hydrate formation.
85912

2006-02-17
Point Source(s):
Excel Paralubes' Boiler 76001 (EP109)

Pollutant(s):
Nitrogen Oxide - 226 pounds
Cause of Problem: Other

see notes. Flue gas damper closed during shutdown from loss of electricty on 2/15. After startup, the damper was not opene
Power Failure. Investigation and sharing of key learnings with operations will occur. HAZMAT #06-01023.
85804

2006-02-14
Point Source(s):
FCC Stack (EP-41)

Pollutant(s):
Carbon Monoxide - BRQ
Cause of Problem: Start Up, Shut Down

Exceedance of CO from the FCC Stack due to start-
The permit exceedance will be reported in the next quarterly New Source Performance Standard/Best Available Control Technology Report.
85778

2006-02-11
Point Source(s):
North Flare (EP-64)

Pollutant(s):
Sulfur Dioxide - 6,600 pounds
Hydrogen Sulfide - 3,400 pounds
Volatile Organic Compounds - 191 pounds
Sulfur Dioxide - 1,280 pounds
Hydrogen Sulfide - 640 pounds
Nitrogen Oxide - 68 pounds
Volatile Organic Compounds - 1,846 pounds
Cause of Problem: Other

see notes. A loss of electrical power occurred caused by failure of an Entergy own electrical transformer. The electrical power loss resulted in emergency shutdown of the majority of process units. Emergency shutdown instrumentation directed hydrocarbon gas streams to the refinery complex flares resulting in excess emissions of SO2, H2S, and NOx from the complex's North and South Flares. Additional flaring of gas streams resulted from the staggered process unit and various start up once electrical power was restore
POWER FAILURE. A root cause failure analysis is being conducted on this incident. Its results will be used to develop actions that will potentially preclude a recurrence.
85654

2006-02-06
Point Source(s):
North Flare (EP-64)

Pollutant(s):
Sulfur Dioxide - 1,820 pounds
Cause of Problem: Human Factors

Crude Tower pressure control valve, instrument air line was blocked in by a contractor. The control valve opened and the crude tower started depressing to the flare. The air line block valve was opened and the control valve closed of
Instrument air lined back up to valve to close off from flare.
85530

2006-02-02
Point Source(s):
Excel Paralubes' Boiler 76001 (EP109)

Pollutant(s):
Nitrogen Oxide - BRQ
Cause of Problem: Instrument Failure

HDC loss of containment occurred. Nox instrument indicated a release of Nox but futher investigation determined this did not occur. Instrument air was lost during HDC incident and fuel gas BTU analyzer used in Nox calcs failed. Also, Nox CEMS sample system plugged from plume blowing from the HDC to this boile
Instrument malfunction gave false reading indicating excess emissions. No remedial action taken.
85529

2006-02-01
Point Source(s):

Excel Paralubes SRU (EP-111)
Failed check valve
South Flare (EP-31)
West Flare (EP-110)

Pollutant(s):
Sulfur Dioxide - 140 pounds
Hydrogen Sulfide - 1,200 pounds
Sulfur Dioxide - 4,260 pounds
Hydrogen Sulfide - 900 pounds
Nitrogen Oxide - 154 pounds
Sulfur Dioxide - 27,600 pounds
Hydrogen Sulfide - 3,000 pounds
Nitrogen Oxide - 7 pounds
Sulfur Dioxide - 3,000 pounds
Hydrogen Sulfide - 2 pounds
Nitrogen Oxide - 68 pounds
Cause of Problem: Equipment Failure

Loss of containment occurred due to the structural failure of check valve on the discharge of Heater H-11001, which allowed a hydrocarbon release to the atmosphere. The hydrocarbons ignited causing significant damage to the process piping and insturmentation associated with the heater
root cause failure analysis is being conducted. Its results will be used to develop actions that will preclude a recurrence of this event.
85452

2006-01-28
Point Source(s):
High Pressure Fuel Gas Heater Stacks

Pollutant(s):
Sulfur Dioxide - 340 pounds
Cause of Problem: Piping or Tubing

Exchanger leak caused the H2S in the High Pressure Fuel Gas (HPFG) System to increase. This resulted in SO2 being released from all heater stacks on that system.
Investigating the root cause of the leak. Adjusted the pressure balance of the process as to not leak H2S into the Lean Amine System. Repair the heat exchangers at the next until shutdown.
85089

2006-01-11
Point Source(s):
None Reported
Pollutant(s):
Cause of Problem: No Information Given

No Information Given
No reportable limits for Opacity. Event will be reported on New Source Performance Standard/Best Available Control Technology (NSPS)Report.
84930

2006-01-04
Point Source(s):
South Flare, Compressor C-1430

Pollutant(s):
Sulfur Dioxide - 5,880 pounds
Cause of Problem: Equipment Failure

C-1430 had a release valve which was leaking in the reverse direction. This caused an increase in the flare gas to the South Flare header.
A DCS alarm to indicate run status of C-1430 is proposed.