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Phillips 66 (2418), Belle Chasse

Releases in 2009

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
119920

2009-12-08
Point Source(s):
308F-D-2 (High Pressure Flare)

Pollutant(s):
Hydrocarbon - 12,082 pounds
Hydrogen Sulfide - 2 pounds
Cause of Problem: Weather

The flame on 308F-D-2 (High-Pressure Flare) had extinguished due to wind and rain. Multiple attempts were made to relight the flame; including the use of the automatic igniter and hand held flare gun. The wind prevented these methods from working. A manual flare flame generator finally allowed for the flame to be reignited. During the flame out, 12,082 lbs of hydrocarbon and 2 lbs of Hydrogen Sulfide were released.
Operations immediately blocked in the steam controllers and orifices in the High Pressure Flame and added additional purchased fuel to the tip. The manual flame generator was finally used to reignite the High Pressure Flare. The additional purchased fuel gas was then blocked in and the steam controller were unblocked to provide smokeless flaring capabilities.
119864

2009-12-05
Point Source(s):

No information given

Pollutant(s):
Sulfur Dioxide - 241 pounds
- 0 pounds
- 0 pounds
- 0
- 0 pounds
Cause of Problem: Process Upset

The 592 Sulfur Recovery Unit (SRU) has 3 combustion air blowers. Usually, 2 are on line. On 12/5, one of the two operating blowers tripped due to a thermal overload. This drop in air discharge pressure activated the Low Combustion Air Pressure alarm which shutdown combustion in the SRU Reaction Furnace. This activated the Sour Water Stripper (SWS).
The refinery initiated "sulfur-shedding" procedures until SRU could be brought back online.
No LDEQ Number Available

2009-10-07
Point Source(s):
308F-D-1 (Low Pressure Flare)

Pollutant(s):
Sulfur Dioxide - 407 pounds
Cause of Problem: Start Up, Shut Down

"During the planned and controlled shut down of the Saturated Gas Unit's Compressor for an emergency maintenance repair, the Diesel Hydrotreater Overhead gases were re-routed to the FCC Unit's compressor. While routing the gases to the FCC compressor, increased pressure drop caused the Diesel Hyrdrotreater overhead pressure controller to open the Low Pressure Flair (308F-D-1). The overhead pressure was adjusted which subsequently stabilized operations resulting in the closing of the flare valve..."
After a root cause investigation, it was determined that the a corrective action should be implemented. The Diesel Hydrotreater's Overhead pressure "shall be increased prior to routing that streat to the FCC compressor. This step should minimize the chance of opening the flare valve in the overhead system and also overcome the pressure drop phenonenon experienced while routing the gases to the FCC compressor. Fence-line monitoring reported "no offsite impact."
117421

2009-08-21
Point Source(s):
410-PSV-061

Pollutant(s):
Methane/Ethane Mixture - 4,469 pounds
Cause of Problem: Human Factors

Electrical contractors were working inside the instrumentation building in the Crude Tankage area of the refinery. One of them bumped the on/off switch for the Uninterruptible Power Supply (UPS) which provides power to the controllers for both the Crude Oil Unit's charge pumps and the Refinery's purchased fuel gas system. Due to a loss of signal from the control system, when their power was turned off, bumped by an electrical contractor, both the Crude Oil Charge pump valves and purchased fuel gas valves when into their fail safe mode of "closed." This caused a sudden increase in pressure on the fuel gas system, causing a release.
Cover has been placed over the on/off switch.
117130

2009-08-07
Point Source(s):
no information given

Pollutant(s):
Carbon Monoxide - 826 pounds
Cause of Problem: Start Up, Shut Down

Following maintenance of the air blower train, a planned and controlled start up of the Fluidized Catalytic Cracking (FCC) Unit was begun on August 7th followed by the planned and controlled start up of the Alkylation Unit and Low Sulfur Gasoline Unit. All units started up as planned. However, following the start up of the FCC Unit in full-combustion mode, some feed quality issues caused a small amount (826lbs) of carbon monoxide to be emitted.
No offsite impact reported.
116589

2009-07-17
Point Source(s):
No Information Given

Pollutant(s):
Crude Oil - 77 pounds
Cause of Problem: Piping or Tubing

Lebeouf Bros. Towing, LLC. was transferring oil from the Conoco Refinery to the Gonsulin 104 Oil Barge and a leak developed in a transfer line which resulted in approximately 1 barrel of product being released onto the barge. *Report filed by ES&H Consulting Group (contracted by LeBouf Bros. Towing, LLC). ** This incident is NOT listed on the master list.
Upon discovery of the leak, the transfer operation was immediately terminated. All released product was contained on the oil barge. In site personnel initiated cleanup with absorbents, and an ES&H OSRO crew was dispatched to assist. After further investigation, the released quantity was determined to be 10 gallons. A large amount of rain water was present on the deck which was initially mistaken for product. No offsite impact reported.
116461

2009-07-14
Point Source(s):
308F-D-1 (Low Pressure Flare)

Pollutant(s):
Sulfur Dioxide - 2,522 pounds
Cause of Problem: Start Up, Shut Down

The FCC Regenerator Flue Gas Expander, 1291-K-1, tripped offline due to a mechanical failure causing an emergency shutdown of the FCC Unit. Flaring occurred from the Low Sulfur Gasoline (LSG) Unit 294 and the Diesel Hyrdrotreater Unit 292 due to the emergency shutdown of the FCC Unit. There was also a small fire on the Expander's lube oil and seal oil piping that occurred incidentally with the Expander mechanical failure, but was quickly extinguished with a fire extinguisher.
FCC Unit initiated emergency shutdown procedures.
116329

2009-07-09
Point Source(s):
410-PSV-061

Pollutant(s):
Methane/Ethane Mixture - 12,284 pounds
Cause of Problem: Process Upset

Pressure in the refinery instrument air supply system decreased unexpectedly which resulted in the loss of pressure control at the Enbridge purchased fuel gas control station (on the property of the refinery). This loss of pressure control caused the PSV (410-PSV-061) to lift until proper pressure within the instrument air system could be restored.
Immediately regained control of the plant fuel gas system manually. "No offsite impact was noted."
115847

2009-06-20
Point Source(s):
308F-D-1 (Low Pressure Flare)

Pollutant(s):
Sulfur Dioxide - 298 pounds
Cause of Problem: Start Up, Shut Down

Following various maintenance repairs at the Alkylation Unit, start-up procedures for the FCC Unit were initiated. The FCC Unit started up and some flaring at the Low Pressure flare (308F-D-1) occurred. There were some emissions of sulfur dioxide that occurred during the flaring event, but below RQ.
The Alkylation and Low Sulfur Gasoline Units were subsequently started up following the FCC Unit with no further flaring or venting noted. Community monitoring was performed throughout the start-up of all three refinery process unites with no offsite impact noted.
115614

2009-06-12
Point Source(s):
308F-D-1 (Low Pressure Flare); 308F-D-2 (High Pressure Flare)

Pollutant(s):
Sulfur Dioxide - 1,446 pounds
Cause of Problem: Instrument Failure

Approximately three hours following the installation of the level transmitter, operating conditions within the saturated gas unit began to show periodic spikes of liquid carryover into the inlet of the compressor (7991-K-1) by having periodic compressor speed slowdowns. The liquid carryover seems to have been attributed to the level transmitter malfunctioning both in response time and level indication. The next day, the Saturated Gas Unit Compressor unexpectedly shut down due to a high level alarm in the compressor's suction drums (7991-V-7 and V-8) which get their feed from the Absorber/Stripper column (V-2). Several process unites then flared due to inlet gases being routed to the FCC Compressor and subsequent upset conditions from suddenly swinging into a different compressor system. This eventually caused the FCC compressor to shut down. When the FCC Compressor shuts down in an emergency, it causes the entire Low Sulfur Gasoline Units (among other operations) to shutdown as well. *Could also be classified as start up/shut down.
Immediately tried to restart the Saturated Gas Unit's compressor as well as route the inlet gases to the FCC Compressor which began to also have de-stabilizing operating conditions. "No offsite impact noted throughout the event."
114566

2009-04-30
Point Source(s):
308F-D-1 (Low Pressure Flare)

Pollutant(s):
Sulfur Dioxide - 1,871 pounds
Hydrogen Sulfide - 19 pounds
Nitrogen Oxide - 5 pounds
Hydrocarbon - 52
Cause of Problem: Equipment Failure

On April 30, 2009 at approximately 2:40 AM, the Coker compressor unexpectedly tripped off-line. At approximately 2:41 AM the suction drum flare valve opened, which it is designed to do when the compressor experiences an unexpected complete shutdown. The suction stream is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown.
The compressor was started and brought online following review of alarm and trip logs.
114066

2009-04-08
Point Source(s):
308F-D-1 (Low Pressure Flare)
308F-D-1 (Low Pressure Flare); 191-PSV-009

Pollutant(s):
Sulfur Dioxide - 1,254 pounds
Nitrogen Oxide - 5 pounds
Hydrogen Sulfide - 13 pounds
Hydrocarbon - 49 pounds
Cause of Problem: Equipment Failure

The 891-K-1 Compressor tripped off-line due to a high liquid level inside the first stage suction drum (891-V-15). This was caused by high liquid levels in the fractionator tower's reflux drum (891-V-12) due to coke fines plugging the filters of the L-11 reflux pumps and L-13 Sour Water pumps at an unexpectedly rapid rate. The compressor's suction steam is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown of the compressor. Monitoring at the refinery permitter was performed and "there was no offsite impact."
The compressor was started and brought online as soon as proper levels could be established in the first stage suction drum. An investigation is in process to determine the cause of the high levels in the first stage suction drum (which caused the compressor to trip).
113974

2009-04-06
Point Source(s):
308F-D-1 (Low Pressure Flare); 191-PSV-009
Unit 191-PSV-009

Pollutant(s):
Sulfur Dioxide - 12,914 pounds
Hydrogen Sulfide - 130 pounds
Hydrocarbon - 505 pounds
Nitrogen Oxide - 53 pounds
Hydrocarbon - 58,184 pounds
Cause of Problem: Power Failure

A power failure occurred as a result of grid failure due to scheduled maintenance by Entergy. Entergy's method did not allow for ConocoPhillips to secure an alternative source while the main grid was down. The refinery thus had to initiate an emergency shutdown. As a result, the refinery had to employ the low pressure flare.
Entergy has proposed a three phase project that will build additional substations within the electrical power grid over the next five to eight years to improve its reliability. Entergy is currently seeking federal funding for this project.
113745

2009-03-27
Point Source(s):
308-WW Collection System-Refinery Drains, Manholes, Catch Basins, and Lift Stations

Pollutant(s):
Oil - 967 pounds
Cause of Problem: Weather

On March 27, within five hours, 10 inches of rain fell on the finery resulting in several feet of standing water accumulating at certain points of the refinery. After the rain subsided, it was discovered that hydrocarbon had begun to float on the standing water at certain points. Vacuum trucks were immediately mobilized to recover the oil floating in the water and portable emergency pumps were used to remove the standing water. Community air monitoring was conducted throughout the recovery phase and no offsite impacts were noted.
The refinery was divided into zones for effective oil reclamation. "Projects and plans are in place to improve the pumping capabilities of the refinery's drain system to prevent standing water in the refinery for prolonged periods of time."
113242

2009-03-08
Point Source(s):
308F-D-1 (Low Pressure Flare)

Pollutant(s):
Sulfur Dioxide - 627 pounds
Nitrogen Oxide - 5 pounds
Hydrogen Sulfide - 6 pounds
Hydrocarbon - 47 pounds
Cause of Problem: Equipment Failure

Problems with the Coker drum steam condensate operations caused inadequate heating of the"inactive Coke drum. To avoid shutting down the Coker Unit, Operations personnel switched Coker feed from teh "active" drum into the "inactive" drum that was much cooler than normal operating systems. The switch into a cooler coke drum reduced the flow to the 891-K-1 compressor and caused the "compressor kickback" control scheme to activate. This scheme caused the compressor kickback valve to open, sending additional flow to the compressor's suction drum (891-V-15). The pressure in the compressor suction drum increased to the point that the pressure control system opened the valve to the Low PRessure Flare (308F-D-1).
Coker unit operations and pressure were stabilized and the valve to the flare was closed.
113178

2009-03-05
Point Source(s):
308F-D-1 (Low Pressure Flare)

Pollutant(s):
Sulfur Dioxide - 1,481 pounds
Cause of Problem: Equipment Failure

The refinery experienced an unexpected trip in the Coker Compressor which resulted in an unexpected release of SO2. Approximately 1,480.5 lbs of S02 was released. The 891-K-1 Compressor tripped off-line due to a low seal oil liquid level inside Tank (891-V-23). This was due to a lack of pressure controller (PCV-152) causing sea oil to spill back into the main Seal Oil Tank (T-2B-X) and not holding enough pressure to keep the overhead seal oil tank properly filled. The compressor's suction sctream is automatically diverted to the Low Pressure Flair (308F-D-1) in an emergency shutdown.
The compressor was started and brought online as soon as proper Seal Oil level could be established in the Overhead Seal Oil Tank. "No offsite impact detected."
112738

2009-02-13
Point Source(s):
308F-D-1 (Low Pressure Flare); 1391-FF (1391-PSV-009); 301-D-3 (CO Bypass Vent)

Pollutant(s):
Carbon Monoxide - 15,764 pounds
Hydrocarbon - 16,742 pounds
Sulfur Dioxide - 161 pounds
Cause of Problem: Start Up, Shut Down

During the startup of the FCC Unit following a 36 day refinery maintenance turnaround outage, the unit unexpectedly transitioned to partial-burn combustion in the catalyst regenerator for less than an hour before the bypass vent was closed. Shortly after starting up the Reformer Unit during a test of newly installed burners in heater 1391-H-4, a high concentration of very light material (hydrogen and propane) caused the Depentanizer tower's overhead pressure to rise, resulting in the PSV-009 to relive for approximately 3 minutes. This reduced the pressure and the PSV re-sealed properly. While starting up the Coker Unit, light material in its feed stream from the Crude Unit also caused an unexpected increase in pressure in the suction drum of the compressor which caused the flare valve at the suction drum to open into the low pressure flare. Compressor suction drum pressure was stabilized as feed quality to the Coker Unit improved and the flare valve was closed.
Operations has developed for its operators responsive drills for rapidly occurring unstable conditions which will eventually help minimize impact of emissions to the environment.
112632

2009-02-10
Point Source(s):
No Information Given

Pollutant(s):
Carbon Black Feedstock - 84 pounds
Cause of Problem: Human Factors

ConocoPhillips reported a spill of 2 bbls of carbon black feed stock on the ground inside the Alliance Refinery. The spill occurred as the material was being transferred from a tank to a barge and flowed out of a high end bleeder valve, which was unintentionally left open. The material was able to be scraped of the ground for disposal.
The material was able to be scraped of the ground for disposal. Verbal report only. No report from the refinery.
111891

2009-01-08
Point Source(s):
308F-D-1 Low Pressure
308F-D-1 Low Pressure Flare

Pollutant(s):
Sulfur Dioxide - 9,757 pounds
Hydrogen Sulfide - 8 pounds
Hydrocarbon - 48 pounds
Cause of Problem: Start Up, Shut Down

A notification for the controlled shutdown of the entire plant was made on January 7, 2009. On January 8, the Sulfur Recovery Unit/Tail Gas Treater (SRU/TGT) was determined to have pluggage issue that precipitated the premature shutdown of the SRU/TGT. This led to flaring and SO2 emissions. The loss of the SRU/TGT required the initiation of a controlled shutdown of the remaining process units which contributed additional Sulfur Dioxide emissions.
An immediate shutdown was conducted of refinery process units. An investigation of the SRU upset is in progress and "will be reported in a subsequent letter."
111752

2009-01-02
Point Source(s):
FLARE

Pollutant(s):
No Information Given - BRQ
Cause of Problem: Maintenance/Procedures

ConocoPhillips notified LDEQ that the facility would be running at a reduced rate that would result in venting of the FCC Unit Regenerator and potential intermittent flaring.
RQ not exceeded. No offsite impact reported.
11752

2009-01-02
Point Source(s):
None Reported
Pollutant(s):
Cause of Problem: No Information Given

Reduced refinery operating rates resulted in venting of the FCC Unit Regenerator flue gas and "potential intermittent flaring."
No reportable quantities exceeded and no offsite impact noted.