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Phillips 66 (2538), Lake Charles

Releases in 2009

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
No LDEQ Number Available

2009-12-01
Point Source(s):
outfall 034

Pollutant(s):
Oil - BRQ
Cause of Problem: No Information Given

Visible sheen from outfall 034 reported
oil was cleaned up
119713

2009-11-25
Point Source(s):
Y-3 cooling tower

Pollutant(s):
Butane - 475 pounds
Cause of Problem: No Information Given

VOC leak in Y-3 cooling tower. source of VOCs was from exchanger X-136 in the Alky unit.
No information given
No LDEQ Number Available

2009-11-03
Point Source(s):
#2 Crude unit

Pollutant(s):
Crude Oil - BRQ
Cause of Problem: Piping or Tubing

A piece of tubing ruptured in the #2 crude unit.
oil was cleaned up.
118896

2009-10-21
Point Source(s):
No information given

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

SO2 emissions were elevated due to units being shut down in preparation of a turnaround.
No information given
118820

2009-10-17
Point Source(s):
reactor vessel of the Alky unit

Pollutant(s):
Sulfuric Acid - 15 pounds
Cause of Problem: No Information Given

Sulfuric acid being used to clean the reactor vessel in the Alky unit overflowed into the surface sewage system.
No information given
118250

2009-09-28
Point Source(s):
GRP unit

Pollutant(s):
Benzene - 1 pounds
Hydrogen Sulfide - 11 pounds
Cause of Problem: Piping or Tubing

Exchanger leak in the GRP unit. The channel head was leaking due to a reduction in charge rates.
No information given.
117613

2009-08-31
Point Source(s):
sump for tanks T-120 and T-104

Pollutant(s):
Slop Oil - 63 gallons
Cause of Problem: Piping or Tubing

Outlet drain at the sump for tanks T-120 and T-104 was plugged with solids and overflowed.
Outlet line is being line moled and the sump is being cleaned.
117474

2009-08-24
Point Source(s):
exchanger X-16107

Pollutant(s):
Volatile Organic Compounds - 1,264 pounds
Cause of Problem: Piping or Tubing

#10 Reformer exchanger X-16107 leaked to cooling water system.
Unit was shutdown to pull bundle for repair.
117349

2009-08-18
Point Source(s):
Exchanger X-428

Pollutant(s):
Volatile Organic Compounds - 467 pounds
Cause of Problem: Piping or Tubing

Exchanger X-428 was leaking into the cooling water system.
The exchanger was removed from service.
117158

2009-08-08
Point Source(s):
frac tanks

Pollutant(s):
Oil - 42 gallons
Cause of Problem: Human Factors

While operator was transferring oily material from T-120 to frac Tanks, it appears that the tanks were inadvertently overfilled which resulted in both frac tanks to spill approximately 1 bbl into the secondary containment area around and under the frac tanks.
material was cleaned up.
No LDEQ Number Available

2009-07-29
Point Source(s):
A plastic bag

Pollutant(s):
Oil - 0 gallons
Cause of Problem: No Information Given

A visible sheen was reported on the water, source was a quart sized plastic bag in the water.
Bag was picked up and the sheen was cleaned up.
115518

2009-07-07
Point Source(s):
T-37

Pollutant(s):
Crude Oil - 10 gallons
Cause of Problem: Piping or Tubing

A line inside the T-37 dike wall failed and released approximately 10 gallons of reduced crude.
No information Given
No LDEQ Number Available

2009-07-07
Point Source(s):
outfall 034

Pollutant(s):
Oil - 1 gallons
Cause of Problem: Weather

A heavy rainfall event overflowed an oil sump into outfall 034.
Oil was cleaned up
116265

2009-07-05
Point Source(s):
West Flare

Pollutant(s):
Sulfur Dioxide - BRQ
Cause of Problem: Equipment Failure

A 2A fuse blew which caused the five control valves in the Hydro-cracker unit to fail closed. The safety system worked as designed, and dumped the reactor pressure to the flare.
No information given
116058

2009-06-27
Point Source(s):
sump

Pollutant(s):
Gas Oil - 100 gallons
Cause of Problem: Instrument Failure

Pump Failed to start and sump overfilled. Pump failure was caused by failure of level switch on T-74 sump pumps.
Pumps were started manually, and the spill was cleaned up
115990

2009-06-25
Point Source(s):
West Flare

Pollutant(s):
Sulfur Dioxide - 1,707 pounds
Cause of Problem: Equipment Failure

Wet gas compressor tripped on low lube oil pressure. Report makes note that lube oil pressure should be verified by operators prior to switching pumps to prevent unit shutdown.
Modify anti-surge controller pressure transmitter set-points to allow restart or alert operation that pressure is reading top of scale.
115992

2009-06-25
Point Source(s):
#10 reformer unit

Pollutant(s):
Gasoline - 25 gallons
Cause of Problem: Start Up, Shut Down

A leak began after the start up of exchanger X-16106 in the #10 reformer unit.
Operating rate of the unit was decreased to get pressure of the exchanger. The exchanger head was tightened and the leak stopped.
No LDEQ Number Available

2009-05-29
Point Source(s):
Unknown

Pollutant(s):
Oil - BRQ
Cause of Problem: No Information Given

A visible sheen was reported from outfall 004. No source has been identified.
oil was cleaned up by contractor
115150

2009-05-21
Point Source(s):
#4/5 Sulfur Recovery Unit

Pollutant(s):
Sulfur Dioxide - 354 pounds
Cause of Problem: Start Up, Shut Down

While starting up the unit after a turnaround, problems were encountered. An instrument use for operating the unit was not responding properly resulting in a unit upset.
No information given.
114646

2009-05-03
Point Source(s):
#64/65 SRU stack

Pollutant(s):
Sulfur Dioxide - 22 pounds
Cause of Problem: Start Up, Shut Down

In the process of shutting down the #64 sulfur train,a loss of steam to the amine regenerator occurred. This caused an increase of SO2 released from the #64/65 SRU stacks.
Exceeds RQ. No additional information given.
No LDEQ Number Available

2009-04-28
Point Source(s):
A bucket

Pollutant(s):
Oil - 2 gallons
Cause of Problem: No Information Given

A bucket containing five gallons of gasoline was found on mike cook road. The source of the bucket is unknown. Approximately 2 gallons were spilled.
bucket was picked up and oil cleaned up.
114192

2009-04-16
Point Source(s):
T-36 tank spillback line

Pollutant(s):
Diesel Fuel - 84 gallons
Cause of Problem: Piping or Tubing

The T-36 tank's spillback line was leaking in the dike wall.
Secured pipeline and ES&H performed cleanup operation with pads and vacuum truck. Line was taken out of service for repair/replacement and spillback rerouted.
113697

2009-03-26
Point Source(s):
3700 undergroudn piperack

Pollutant(s):
Oil (Sheen) - 0
Cause of Problem: Piping or Tubing

Leak from 3700 piperack underground. The insulation from #1 Fuel oil Dock Line underground had oil seeping out. An oil sheen was detected at outfall 006.
ES&H performed cleanup with vacuum trick. Pads were deployed under the pipe rack to contain spill, and everything was packed with clay earth in the dike. Area is monitored everyday and no more instances of oil on the ground. #1 Fuel Oil Dock line is out of service, and the underground piperack will be excavated for further investigation.
113432

2009-03-16
Point Source(s):
Outfall 006

Pollutant(s):
No Information Given - 0
Cause of Problem: Equipment Failure

Control valve malfunctioned which caused an overflow of the EQ sump in Area A and B.
Overflow led to a ditch which releases to Bayou Verdine via Outfall 006. Water had no visible oil present and had a pH of 7. Samples were taken according to NPDES parameters and will be reported accordingly.
113039

2009-03-16
Point Source(s):
#1 Fuel Dock Line and T-308 sump

Pollutant(s):
Diesel Fuel - 84 gallons
Cause of Problem: Weather

Heavy rain caused residual oil entrained in the soil from a leak in #1 Fuel Oil Dock Line to cause sheen released from Outfall 006. Additionally, T-308 sump overflowed with diesel onsite in Area D.
NOTE: The originally submitted document on Match 21, 2009 had the wrong HAZMAT number. This was later corrected by a follow-up letter on March 26, 2009. However, the LDEQ number was not corrected. The sheen and the oil were cleaned up using absorbent booms, pads, and vacuum trucks.
113039

2009-02-26
Point Source(s):
P-808

Pollutant(s):
Diesel Fuel - 84 gallons
Cause of Problem: Seal or Gasket

A seal on pump P-808 in Area A ruptured spilling oil into secondary containment.
The pump was switched and P-808 was blocked in and secured. After the pump was isolated, floor sweep was spread, and a cleanup crew was called out to clean up the oil.
112925

2009-02-23
Point Source(s):
#1/2 SRU

Pollutant(s):
Sulfur Dioxide and Sulfur Trioxide - 70 pounds
Cause of Problem: Start Up, Shut Down

A boiler had an emergency shutdown due to a steam imbalance across the site. Various units that depend on steam to operate had rates rapidly reduced, and a release from #1/2 Sulfur Recovery Unit(SRU) was caused.
No information given
112924

2009-02-21
Point Source(s):
Area A, B, and C heater stacks

Pollutant(s):
Sulfur Dioxide - 716 pounds
Cause of Problem: Process Upset

The skimming of hydrocarbons at the #3 Flash Drum led to a foaming upset of the regenerator and inefficient H2S removal from the amine utilized in the high pressure fuel gas (HPFG). This caused a #3 Amine Regeneration Unit (ARU) system upset that resulted in combustion of refinery fuel gas with high H2S in the HPFG system. Ultimately, this caused SO2 to be released from fired heater stacks in Areas A, B, and C.
NOTE: Follow-up occurred on 3/31/09. Exceeds RQ. Immediate action taken was to add anti-foam to get the system back to normal and cleaning up the amine. Firing rates of heaters reduced to decrease SO2 released. Planned remedial action include increase frequency of skimming the #3 Amine Flash Drum to prevent sending large amounts of hydrocarbon to the regenerator all at once.
112249

2009-01-23
Point Source(s):
Targa underground pipeline

Pollutant(s):
Kerosene - 420 gallons
Cause of Problem: Piping or Tubing

Third party operated (Targa), underground pipeline was found ruptured.
ES&H performed cleanup of the oil leak site, and Targa was notified immediately to begin repairing the ruptured pipeline. Targa later called in the incident and is linked to #112264.
113443

2009-01-17
Point Source(s):
camlock fitting of offloading rail car

Pollutant(s):
Sulfuric Acid - 153 gallons
Cause of Problem: Seal or Gasket

Bad gasket on camlock fitting. Spill occurred during offloading of a rail car.
Exceeds RQ. Stopped offloading of acid. The acid was spilled into secondary containment and a small amount spilling onto the ground as low pH water. Conoco Phillips will include a step to check for camlot fitting in the standard operating procedure.
111942

2009-01-12
Point Source(s):
exchanger X-430

Pollutant(s):
Volatile Organic Compounds - 1,780 pounds
Cause of Problem: Piping or Tubing

FCCU Vapor Recovery Unit exchanger X-430 developed a leak into the cooling water tower Y1/Y2 (EP-152).
Greater than RQ. X-430 was taken out of service. The exchanger bundle will be repaired, including replacement if needed.
111828

2009-01-07
Point Source(s):
North Flare

Pollutant(s):
Sulfur Dioxide - 0
Hydrogen Sulfide - 0
Volatile Organic Compounds (VOCs) - 0
Cause of Problem: Start Up, Shut Down

Net gas compressor in No. 10 reformer was shutdown due to high vibrations. The shut down caused high volumes of gas and liquids to the North Flare. This resulted in a surge of high pressure on the flare header line to the North Flare.
Immediately after the discharge, Conoco Phillips shut down Old Spanish Trail Roadway, and the North Flare was taken out of service. A Conoco personnel did a FLIR camera monitoring of the flare header line for VOC leakage. No leaks were found. LDEQ personnel were dispatched to the site later in the day after the discharge. They collected a summa canister air sample offsite and downwind of the North Flare. The canister did not detect any readings. Samples of ditch water was collected by Conoco Phillips on the north side of Old Spanish Trail on Sasol property. The water samples of SO2 was detected to be 0.7-4.0ppm, while H2S and VOCs levels were not detectable. During the collection, the inspectors described a pungent, sulfuric odor. CITIZEN COMPLAINT (T111853)- Ms. Debra Ramirez stated concern over the Conoco Phillips discharge. The LDEQ inspector's observations stated that the release was caused by a malfunction of the net gas compressor in the No. 10 reformer, which relieves to the North Flare. In an attempt to mitigate the release, operations began cutting charge rates to the units and diverting vent streams from the North Flare to the South Flare system.
111853

2009-01-07
Point Source(s):
North Flare

Pollutant(s):
Sulfur Dioxide - BRQ
Hydrogen Sulfide - BRQ
Volatile Organic Compounds - BRQ
Cause of Problem: Equipment Failure

A net gas compressor shut down due to high vibrations, this resulted in a high volume of material being sent to the north flare.
No information given