LA Bucket Brigade : Refinery Accident Database

About the Database

Marathon Ashland Petroleum (3165), Garyville

Releases in 2011

LDEQ Accident Number Accident Date	Point Source/Release	Cause	Notes
136157 2011-12-27	Point Source(s): 205 Coker Unit to Unit 259 North Ground Flare Pollutant(s): Nitrogen Oxide - 6 pounds Particulate Matter 10 - 1 pounds Carbon Monoxide - 7 pounds Sulfur Dioxide - 591 pounds Hydrocarbon - 56 pounds Highly Reactive Volatile Organic Compounds (HRVOCs) - 1 pounds Volatile Organic Compounds (VOCs) - 9 pounds	Cause of Problem: Process Upset The incident occurred when the facility was switching from the online drum to the blowdown drum. During the switch, the Wet Gas Compressor surge controller attempted to open the second stage spillback valve. The valve hesitated to open, causing a spillback to trip open. This caused the frac and blowdown to pressure up and the compressor to send the product to the flare until the operations pressure returned to normal. At the time of the written notification, the incident was still being investigated to determine the cause of the overpressure condition.	The unit pressure levels were automatically corrected by the wet gas compressor surge control system.
135746 2011-12-06	Point Source(s): HF Alkylation Unit Pollutant(s): Hydrofluoric Acid - 0 pounds Hydrochloric Acid - 0 pounds	Cause of Problem: Seal or Gasket According to Mr. Chris Delaney, Marathon Petroleum, an estimated 4oz of Hydrofloric Acid (HF) was released into the oily water sewer system during the planned demolition of a blind flange in a pipe leading from the HF Alkylation Unit. Pipe was isolated from all other sources, source of the acid secured, and disconnected prior to installation. The acid traveled through the oily water treatment unit where it was then diluted and treated. Mr. Delaney stated the release was reported to the Louisiana State Police as a courtesy notification because an employee was exposed to the acid and treated for skin irritations.	Employees were wearing Level B protective clothing. Employees removed protective clothing upon completion of installation. Calcium gluconate was administered at Marathon's medical facility onsite. Employee was escorted to River Parish Medical Facility for further observation. Suspected exposure occurred during removal of clothing.
134898 2011-10-26	Point Source(s): SWDI roll-off box Pollutant(s): No Information Given - BRQ	Cause of Problem: Under Investigation There was smoke coming from the SWDI roll-off box located north of the non-hazardous drum storage area.	The incident is under investigation. The refinery's shift emergency response team (SERT) put out the domestic trash fire. There were no known off-site impacts.
134862 2011-10-25	Point Source(s): C-can storage container in Contractor Village Pollutant(s): No Information Given - BRQ	Cause of Problem: Human Factors While welding brackets on the outside wall of the C-can storage container the interior wood shelving and floor began to smolder and caught fire. The C-can was located in the Contractor Village.	The refinery response team extinguished the fire and brief air monitoring was conducted.
134819 2011-10-22	Point Source(s): Includes U21, U43, U55, U212, and U243 Pollutant(s): Methane - 2,282 pounds Pentene - 283 pounds Hydrogen - 591 pounds Hydrogen Sulfide - 0 pounds Nitrogen - 89 pounds Sulfur Dioxide - 442 pounds Carbon Monoxide - 4,635 pounds Pentane - 176 pounds Isopentane - 332 pounds n-Butane - 1,366 pounds Isobutane - 425 pounds Propane - 2,018 pounds Ethane - 2,272 pounds cis-2-Butene - 61 pounds trans-2-Butene - 16 pounds 1-Butene - 106 pounds Propylene - 137 pounds Ethylene - 173 pounds Carbon Dioxide - 35 pounds Oxygen - 8 pounds Nitrogen Oxide - 850 pounds	Cause of Problem: Process Upset On 10/21/11 the Propane Shipping Pump, 63-1537-01, was shutdown due to vibration problems which limited propane throughout the refinery. Operations made moves to cut charge rates and lined up the propane to the fuel gas system. Intermittently flared from Units 21, 43, 55, 212, and 243. No known off site impacts. Incident investigation is being conducted to determined the why the incident occurred.	Opened 21P6431C, sweet fuel gas valve to flare to reduce pressure on fuel gas header and lower the level in 43-1202 (3:22am -4:09 am) bullet. Unit 63 shutdown propane shoppin pump, 63-1537-01, and U22 & U222 propane was routed to the bullet, 21HC6431 sweet fuel gas valve opened to the south flare from (8:21 am - 3:30pm). Fuel Gas Mix Drum 243-PC-0180B opened to flare due to Unit 205 sending excess propane to fuel gas header. Valve opened intermittently during this time from (11:15 am- 4:28pm) not opened above 10%. C3 propane from Domains 1 and 9 in refinery fuel gas causing high fuel gas pressure and 43PC5355 opened to flare three times (11:20am-11:30am), (11:53am-12:20pm), (12:45pm-1:05pm). Unit 55 Flare sweet refinery fuel gas from C3 propane in RFG Domain 1 and 9, 10/22/11 (11:28 am -3:55pm), 10/22/11 (7:42pm)- 10/23/11 (4:07am). An incident investigation will result in recommendation items designed to prevent the recurrence of this event. Values for carbon monoxide and nitrogen oxides do not match the sum of the daily reports. They are higher than the sum of the reportable values.
134363 2011-10-05	Point Source(s): Unit 15 Heavy Gas Oil Hydrotreater Pollutant(s): Light Cycle Oil - 3,112 gallons	Cause of Problem: Equipment Failure A 3/4 inch bleeder valve failed on the Reactor Charge Startup Bypass Line while process equipment was being cleaned with LCO. There was no known off-site impact. An incident investigation is being conducted to determine why the incident occurred. LCO was released to and contained to the concrete slab of the Unit.	The line was allowed to depressure to the flare until the pressure on the line was atmospheric. LCO was processed in the onsite Waste Water Treatment Plant. An incident investigation will result in recommendation items designed to prevent the recurrence of this event.
133997 2011-09-16	Point Source(s): Unit 259 North Ground Flare Pollutant(s): Propane - 685 pounds Propylene - 1,008 pounds Isobutane - 0 pounds Nitric Oxide - 177 pounds Carbon Monoxide - 149 pounds Particulate Matter 10 - 14 pounds Ethane - 0 pounds	Cause of Problem: Instrument Failure On 9/16/11, level transmitted 205-LC-2050 failed which resulted in the filling of the Unit 205 C3/C4 Overhead Drum. This caused a pressure increase in the C3/C4 Splitter that led to the opening of the relief valve, 205-PSV-7077. This valve is routed to the flare header and the North Ground Flare.	The unit vessel levels were manually adjusted to stop the over-pressure condition. The level transmitter, 205-LC-2050, was repaired. An incident investigation is ongoing. C3/C4 Splitter Overhead leaked for 20 min. Report says the leak lasted 10 min but the release lasted 20 min.
133637 2011-09-06	Point Source(s): North Flare Stack Pollutant(s): Propylene - 608 pounds Propane - 298 pounds	Cause of Problem: Equipment Failure On 9/2/11 the valve wheel broke on the propylene mix pump relief valve. The valve stem then failed on 9/6/11 allowing propylene from the loading rack to be sent to the north flare stack.	Valve was blocked in to stop propylene flow to the flare. An incident investigation will result in recommendation items designed to prevent the recurrence of this event. The 1 1/2" Bypass valve leaked for 6 days. NO LDEQ Report, no First follow-up report, and no SPOC Report.
132513 2011-07-16	Point Source(s): Unit 212 Platformer Unit Pollutant(s): Hydrogen - 231 pounds Methane - 0 pounds	Cause of Problem: Seal or Gasket A fire occurred on the outlet flange of the Reduction Gas Heater #2 in Unit 212. The fire was the result of hydrogen leaking from a flange which ignited due to high temperatures. The fire was extinguished at 1:15 and a small amount of hydrogen continue to leak until 3 am when the process was isolated.	The flange was isolated, the fire was extinguished, and the leak was stopped. An incident investigation will result in recommendation items designed to prevent the recurrence of this event.
132261 2011-07-07	Point Source(s): Unit 259 South Ground Flare (EQT 286) Pollutant(s): Volatile Organic Compounds (VOCs) - BRQ Hydrogen Sulfide - BRQ NOx - BRQ Sulfur Dioxide - BRQ Carbon Monoxide - BRQ	Cause of Problem: Process Upset A heat exchanger in the Hydrocracker Unit (Unit 215) began to leak as the unit was starting up and achieving normal operating conditions. Some material was depressured to the flare so that maintenance on the exchanger could be performed. An incident investigation is being conducted to determine why the incident occurred.	The equipment was allowed to depressure to the flare until repairs could be made. At the time of the police report, all had been secured. An incident investigation will result in recommendation items designed to prevent the recurrence of this event.
132152 2011-06-30	Point Source(s): Unit 59 North Flare Pollutant(s): Sulfur Dioxide - 1 pounds Propane - 18 pounds Ethane - 0 pounds Methane - 0 pounds Hydrogen - 0 pounds Nitrogen Oxide - 1 pounds Carbon Monoxide - 1 pounds Particulate Matter 10 - 0 pounds Hydrogen Sulfide - 0 pounds	Cause of Problem: Process Upset The pressure relief valve on the unit 232 rich amine flash drum failed. Material in the flash drum was depressured by flaring until the relief valve would have closed. Leaking release valve and sour water stripper. Material was sent to Unit 59 North Flare (EQT# 0162 and EIQ# 83-74)	The flash drum was allowed to depressure to the flare until the relief valve would have close and the valve could be repaired. an incident investigation will result in recommendation items designed to prevent the recurrence of this event.
131865 2011-06-16	Point Source(s): RGP truck Pollutant(s): Propane - 1 pounds Propylene - 2 pounds	Cause of Problem: Equipment Failure While unloading a truck full of Refinery Grade Propylene (RGP), the relief valve on the truck began leaking to the atmosphere. Water was sprayed on the truck to cool it and the relief valve reseated in 20 minutes. An incident investigation is being conducted to determine why the incident occurred.	The lines coming from the truck were immediately closed. The deluge (water) system was opened and water was sprayed on the truck to cool the truck until the relief valve closed. An incident investigation will result in recommendation items designed to prevent the recurrence of this event. Initial report mentions that problem could be weather related. Propylene is the HRVOC included in the numbers. Propane is the VOC in the report. Together, they constitute 3lbs of VOC or 2.1lbs of HRVOC separately.
131650 2011-06-04	Point Source(s): Unit 222 Plant feed line Pollutant(s): Compressed Flammable Gas - 1,314 pounds Hydrogen Sulfide - 12 pounds	Cause of Problem: Piping or Tubing LDEQ report states Unit 222 Gas Plant feed line developed leak. Caused was cracked pipe.	RQ. Cracked pipe was replaced. State Police report indicates that the compressed flammable gas contained butane, methane, and propane. LDEQ and SPOC report only. No refinery letter included.
129605 2011-03-02	Point Source(s): Drain Line Pollutant(s): Diesel Fuel - 12 gallons	Cause of Problem: Piping or Tubing Diesel was shown to be leaking from a 4 inch line.	The line was evaluated and pressured tested; the line shows no further signs of leakage. The area around the spillage was excavated. The contaminated soil was placed in a roll-off box for proper disposal. LDEQ included. No Refinery Letter.
129232 2011-02-12	Point Source(s): Block Valve on Unit 12 Platformer Unit (FUG 018) Pollutant(s): Compressed Flammable Gas - 217 pounds	Cause of Problem: Under Investigation The bonnet to a block valve developed a leak to release butane. Cause of the leak was unknown, possibly weather related. Refinery letter states that "all aspects of this incident are currently under investigation."	BRQ. Steam was applied to the leak, and the valve was clamped.
128864 2011-01-25	Point Source(s): FLARE: Unit 59 North Flare (EQT #0162 EIQ #81-74) Pollutant(s): Sulfur Dioxide - 207 pounds - 0	Cause of Problem: Under Investigation Refinery letter states that pressure on main fractionator unexpectedly increased, and pressure control valve to the flare opened to decrease the pressure. Sulfur dioxide was released to the air. Refinery letter states that "all aspects of this incident/upset are currently under investigation." FLARE.	BRQ. No Information Given. Refinery letter states that "all aspects of this incident/upset are currently under investigation."
128662 2011-01-18	Point Source(s): Unit 233 Sour Water Tank Pollutant(s): Highly Reactive Volatile Organic Compounds (HRVOCs) - 2,315 pounds Volatile Organic Compounds (VOCs) - 11,844 pounds	Cause of Problem: No Information Given DEQ/ADQ Emergency Occurrence Notification Form states that no root cause is known and is undergoing investigation. However, fuel gas was discovered to be venting through the Sour Water Tank in Unit 233, the sour water stripper.	A perimeter was established around the tank. Personnel were kept out of the cordoned-off area. When it was determined that a gas stream was lined up to the tank, the line was closed. Future recurrence of the event will be prevented after analyzing the root cause investigation.
No LDEQ Number Available 2011-01-13	Point Source(s): Line Pollutant(s): Oil - 55 gallons	Cause of Problem: Corrosion Refinery letter states that corrosion on a three inch line under the dock resulted in pinhole leaks. OFFSITE: Material leaked into the Mississippi River.	An air monitoring team was dispatched, and there were not offsite impacts detected. The line was blocked in immediately. Boom was deployed. The oil spill contractor, EHS, was called out. EHS set more boom and placed absorbent pads within it. A clamp was placed on the line. Line will be replaced and not used until replacement occurs.