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Phillips 66 (2418), Belle Chasse

Releases in 2007

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
101938

2007-12-28
Point Source(s):
Diesel Hydrotreater Unit

Pollutant(s):
Sulfur Dioxide - 241 pounds
Hydrogen Sulfide - 2 pounds
Cause of Problem: Piping or Tubing

A small fire occurred in the convection section of the Diesel Hydrotreater Unit 293 in one of the tubes. While in the process of isolating the H-1 Heater for inspection and repair of the tube, the tube completely failed resulting in a fire in the entire convection sectino of the heater.
The Refinery's Fire Brigade and Emergency Response Teams were activated and the fire was extinguished. No offsite impacts were noted during air monitoring.
101672

2007-12-13
Point Source(s):

412-A-FF

Pollutant(s):
Isobutane - 15,042 pounds
Isobutane - 0
Cause of Problem: Process Upset

The Pressure Safety Valve relieved to the atmosphere for approximately 15 minutes after being installed. THe PSV is designed to open enough as requeired to relieve in an overpressure situation. It has a set pressure for Tank 503 set to approx. 83 psig. During this event it was noted that pressure in Tank 503 remained at approx. 30 psig and the set pressure for the PSV was never reached. There is no explanation given for why this might have occurred.
The adjacent PSV 100 PSV 15B was placed into service as PSV 15A was blocked in and isolated to minimize the release.
100933

2007-11-09
Point Source(s):
301-D-3 FCC Regenerator Flue Gas Bypass Stack

Pollutant(s):
Carbon Monoxide - 21,192 pounds
Cause of Problem: Maintenance/Procedures

A portion of the process control system for the Fluidized Catalytic Cracking Unit was taken offline to perform software maintenance. At the time of reactivation, the control system malfunctioned causing the High Integrity Pressure Protection System to activate and shut down the FCC Unit via computer software control. During shutdown, the FCC regernator flue gas is diverted to the bypass stack.
The FCC Unit was brought into safe condition and to allow evaluation of the control system before re-commissioning the unit.
100855

2007-11-08
Point Source(s):
No Information Given

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

Spill of kerosene from a leaking pipe.
The kerosene fell onto paved area that drains to the WWTP. No product left facility property.
100489

2007-10-24
Point Source(s):
1792-FF

Pollutant(s):
Benzene - 56 pounds
Flammable Gas - 1,725 pounds
Cause of Problem: Process Upset

Compressor trip caused by a high level signal from its suction drum which caused a pressure safety valve release.
Refinery claims that preventative maintenance could not have prevented this accident.
100206

2007-10-16
Point Source(s):
292-FF, 308F-D-1 Low Pressure Flare

Pollutant(s):
Sulfur Dioxide - 673 pounds
Hydrocarbon - 399 pounds
Hydrogen Sulfide - 90 pounds
Nitrogen Oxide - 5 pounds
Cause of Problem: Piping or Tubing

Vapor leak coming from a tube at the exchanger. Unit 292 was depressurized and shut down which caused flaring.
Determined that preventative maintenance procedures could not prevent this accident.
99785

2007-09-27
Point Source(s):
308F-D1 Low Pressure Flare

Pollutant(s):
Sulfur Dioxide - 684 pounds
Hydrocarbon - 43 pounds
Hydrogen Sulfide - 7 pounds
Nitrogen Oxide - 5 pounds
Cause of Problem: Equipment Failure

The Delayed Coking Unit was in hot circulation and preparing for startup after unexpectedly losing its coke cutting water pumps and its compressor (891 K-1) tripped off line due to high liquid level in the compressor suction drum 891-V-12, unexpectedly carried over to V-15. The compressor's suction stream is automatically diverted to the Low Pressure Flare during an emergency shutdown.
Investigation to determine the cause of liquid carryover from the Delayed Coking Unit combination tower overhead drum. The refinery claims that there was no offsite impact.
99023

2007-08-29
Point Source(s):
308F-D-1 Low Pressure Flare, 308F-D-2 High Pressure Flare

Pollutant(s):
Sulfur Dioxide - 605 pounds
Hydrocarbon - 192 pounds
Nitrogen Oxide - 14 pounds
Hydrogen Sulfide - 6 pounds
Cause of Problem: Power Failure

98459

2007-08-07
Point Source(s):
Product Dock 1

Pollutant(s):
Flammable Gas - 346 pounds
Benzene - 2 pounds
Cause of Problem: Equipment Failure

During loading of gasoline onto the ship moored at the product dock. An odor prompted an investigation that found a leaking vacuum breaker valve on the marine vapor recover system leaking. LDEQ report states that the vacuum breaker malfunctioned and started leaking vapors.
Operator immediately shutdown the vessel loading and maintenance replaced the valve. Below reportable quantities.
97401

2007-06-26
Point Source(s):
308F-D-1 Low Pressure Flare

Pollutant(s):
Sulfur Dioxide - 1,136 pounds
Hydrogen Sulfide - 11 pounds
Cause of Problem: Equipment Failure

The Delyaed Coking Unit compressor 891 K-1 tripped offline due to high level in the suction drum, 891-V-15. Liquid from the DCU combination tower overhead drum, 891-V-12, carried over to V-15 due to plugged strainers on the V-12 on the water boot pumps and hydrocarbon pumps or some other flow restriction. The compressors suction stream is automatically diverted to the Low Pressure Flare during and emergency shutdown of the compressor.
Operators tried to mitigate the accident by cleaning the strainers and tried to draw liquid from V-15 to the flare drums. Attempts were unsuccessful and the K-1 compressor still tripped. Compressor was purged of liquid and restarted. ConocoPhillips claims "no offsite impact" from fenceline monitoring.
96572

2007-05-28
Point Source(s):
100-Pressure Safety Valve-5A

Pollutant(s):
Light Hydrocarbons - 792 pounds
Cause of Problem: Process Upset

Pressure relief valve(100-PSV-5A) on sphere T-205 relieved prematurely and unexpectedly, releasing Light Hydrocarbon Vapors (VOCs).
The valve was blocked and removed by maintenance for repair.
96562

2007-05-26
Point Source(s):
301 D 3 CO Bypass Stack

Pollutant(s):
Carbon Monoxide - 850,074 pounds
Cause of Problem: Equipment Failure

The actuator on the 301 HV 2 malfunctioned and would not respond to commands from the distributed control system board to open to allow CO gases to be routed to the boilers.
96490

2007-05-23
Point Source(s):
410-PSV-62
Carbon Monoxide Bypass Stack
Induction gas relief valve (APC-105), Low Pressure Flare, High Pressure Flare
Low Pressure Flare (308F-D-1), High Pressure Flare, 191 APC-105
Low Pressure Flare, High Pressure Flare, 191-PV-105
Low Pressure Flare, High Pressure Flare, SRU incinerator Stack, 191-PV-105, Heaters

Pollutant(s):
Carbon Monoxide - 996,323 pounds
Sulfur Dioxide - 42,788 pounds
Volatile Organic Compounds (VOCs) - 49,498 pounds
Hydrocarbon - 17,959 pounds
Hydrogen Sulfide - 474 pounds
Nitrogen Oxide - 138 pounds
Cause of Problem: Weather

During a rain storm the line from Entergy's substation tripped. The loss of power forced most of the refinery's process units to shutdown resulting in flaring. While shutting down the 191 crude unit the pressure controller relieved vapors and liquid hydrocarbons from a vent at the top of the Vacuum Tower. The hydrocarbons ignited and caused a fire at the top of the Vacuum Tower. With most of the process units down there was insufficient feed to keep the SRU tail gas treater online. The tail gas was routed to the SRU incinerator. When units were started up again they required more flaring for prepare for recommissioning.
Determined that although there are back up systems there are no ways to prepare for these types of power outages. Electrical department will preform preventative maintenance and replacement of components. 191-PV-105 pressure controller at the crude unit no longer vents to the atmosphere. Piping was installed that routes gases from this vent directly to the flare.
95882

2007-05-04
Point Source(s):
179 Thermal Hydrodealkylation Unit H1 Heater

Pollutant(s):
Toluene - 449 pounds
Cause of Problem: Weather

The outlet flanges located on the outside of the convection section of the 179 Thermal Hydrodealkylation Unit H1 Heater leaked toluene onto surrounding hot surfaces. The toluene ignited causing a small fire at the flanges. It is suspected that the heavy rainstorm may have caused the metal to contract creating the slight opening at the flange faces.
Fire was extinguished using fire water. Unit was shutdown and de-pressured.
94176

2007-02-23
Point Source(s):
Incinerator Stack

Pollutant(s):
Sulfur Dioxide - 493 pounds
Cause of Problem: Equipment Failure

The condensate boot on the Tail Gas Treater Unit reboiler malfunctioned resulting in a loss of temperature on the 591-V-33 Stripper. This caused excess emissions of SO2.
94074

2007-02-19
Point Source(s):
Unit 294

Pollutant(s):
Naphtha - 24,192 gallons
Benzene - 126 gallons
Cause of Problem: Equipment Failure

The pump shaft bering in the LOw Sulfur Gasoline Unit failed causing significant pump vibrations. The vibrations caused the nuts on the bolts of the suction and discharge of hte pump to back out. A small portion of release vaporized to atmosphere a portion was collected in the wastewater system and a portion condensed into the the ground adjacent to the unit.
Water deluge system was activated and motor operated valves were activated to secure the pump. The LSG unit was shut down.
94025

2007-02-07
Point Source(s):
FLARE - 308F-D-1 Low Pressure Flare

Pollutant(s):
Sulfur Dioxide - 647 pounds
Hydrogen Sulfide - 7 pounds
Nitrogen Dioxide - 8 pounds
Hydrocarbon - 80 pounds
Cause of Problem: Equipment Failure

A 34.5KV lightning arrestor failed near breaker W5305 (Carlisle #1 Line Bus, and an insulator failed on the disconnect switch on the other side of breaker W5305 (ConocoPhillips # 2 Line Bus). ConocoPhillips Alliance breakers W5305, W5301, W5304 tripped along with Carlisle W6922 breaker. All of these de-energized ConocoPhillips #2 Line to the plant leading to the Coker Compressor to trip off the line. The compressors suction stream was automatically diverted to the Low Pressure Flare (308F-D-1) during the emergency shutdown of the compressor.
Three arrestors on breaker W3505 were replaced, as well as a failed insulator. Preventive measures are in place, but incidents of this type could not be anticipated by the prevention measures. A further investigation to discover the root cause of the malfunctions is ongoing.
93785

2007-02-07
Point Source(s):
308-F-D-1 Low Pressure Flare

Pollutant(s):
Sulfur Dioxide - 647
Hydrogen Sulfide - 7
Nitrogen Dioxide - 8
Hydrocarbon - 80
Cause of Problem: Power Failure

A 34.5KV lightning arrestor failed at Entergy substation. An insulator also failed on the disconnect switch. The opening of these breakers caused the Coker Compressor to trip off line. The compressor's suction stems is automatically diverted tot he Low Pressure Flare.
Three arrestors and a failed insulator are being replaced.
93750

2007-02-06
Point Source(s):
412-A-FF

Pollutant(s):
Propane - 19,397
Cause of Problem: Maintenance/Procedures

The Propane Pilpeline Pump was secured, bled down and isolated for maintenance. Personnel then reported a leak on the suction flange. To isolate the leak a 300 foot section of 10' diameter piping had to be de-pressured by venting liquid propane in the section to the atmosphere. There is no access to the flare system in this area of the tank field.
A plan was developed and executed to safely de-pressure the line and install a blind to isolate the leak.