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Motiva Enterprises (1406), Norco

Releases in 2011

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
136170

2011-12-22
Point Source(s):
GO-1 Elevated Flare (EPN 1-90); Ground flare (EPN 9-84)

Pollutant(s):
Propylene - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Equipment Failure

On 12/22/11, Shell's GO-1 Process Unit experienced a unit upset. This process upset led to flaring at the Motiva's West Operations Ground Flare (EPN 9-84). Shell Chemical operations identified the cause of the unit upset was from problems with the hydrogen purity from the Process Swing Absorption unit (PSA). Shell Chemical operations switched to refinery hydrogen and the unit was stabilized. The cause of the issues in the PSA unit is believed to be several valves that were not functioning correctly. On December 22, 2011 Shell's GO-1 Process Unit had an upset in the de-propanizer column. This incident led to flaring at the GO-1 Elevated Flare (EPN 1-90).
Repairs to these valves were made and the system was safely returned to normal conditions. The failure of Shell's GO-1 Process Unit's de-propanizer column caused flares to occur in both Shell Chemical Elevated Flare (EPN 1-90) and Motiva's West Operations Ground Flare (EPN 9-84).
135909

2011-12-14
Point Source(s):
Residual Cat Cracking Unit (RCCU)

Pollutant(s):
Catalyst - 0
Cause of Problem: Maintenance/Procedures

On 12/14/11 Motiva Enterprises' Residual Cat Cracking Unit (RCCU) inadvertently released catalyst material while performing maintenance work on a RCCU slide valve. The maintenance work was being performed as part of a maintenance plan, and the process unit was not operating at the time of the release. Data gathering to perform calculations and investigation are ongoing. Motiva said they would provide an update within 60 days are required but report shows no record of such update.
No Information Given.
135731

2011-12-02
Point Source(s):
vent knockout drum PV-134

Pollutant(s):
Sour Water - BRQ
Cause of Problem: Maintenance/Procedures

On 12/2/11 at 7:40 pm a resident of Norco, LA phoned the Motiva Norco Site Supervisor and communicated that a strong odor was coming from the site into the community. An immediate investigation by onsite personnel determined that the odor was from Motiva's Coker Unit. While depressuring the coke drum, PV-917, sour water in the vent knockout drum, PV-134, was pressured out into the atmosphere causing a strong odor. The refinery claims the odor dissipated by 9:00 pm. A follow-up call was made to the resident describing what was found. The resident stated that the smell was gone.
Initial report says that the odor was traced to the Coker unit and that the coker unit was operating normal, but that the wind was blowing toward the neighbor's house. Further investigation shows there was a release. Weather at the time of the incident was 58 degrees and clear. The winds were out of the East/Northeast at 3mph.
135470

2011-11-22
Point Source(s):
DEA overhead stripper column flange at sulfur plant S-3

Pollutant(s):
Sour Water - BRQ
Hydrogen Sulfide - BRQ
Cause of Problem: Seal or Gasket

On 11/22/11 at 3:30 pm, maintenance personnel were in the process of replacing carbon steel bolts with stainless steel on E-6402. After changing seven of the eight bolts on the flange, a leak developed from the flange. The material released was sour water containing sulfur dioxide, and appeared to be coming from a failed gasket. Leak was on the inlet fans of the DEA stripper at sulfur plant S-3
The maintenance personnel immediately stopped work due to the safety hazard presented by the leak . A plan was developed to safely complete the repair, which was carried out the following day on 11/23/11. Final calculations confirm that no reportable quantities were exceeded during this event.
135263

2011-11-15
Point Source(s):
inlet to DEA overhead fan E-6402 in sulfur plant S-3

Pollutant(s):
Hydrogen Sulfide - BRQ
Cause of Problem: Seal or Gasket

On 11/15/11 at 2:00 am while performing unit sensory rounds in Sulfur Plant S-3, a Motiva operator discovered a small leak along a flange at the inlet to DEA overhead fan E-6402. The material released was sour water contained hydrogen sulfide and could be observed "bubbling" along the top of the gasket and dripping down the piping. The operator immediately notified his supervision and the Site Supervisor was contacted. An Emergency Work Order was created and Pressure Equipment Inspectors and pipefitters were dispatched to determine the condition of the equipment and to conduct repairs. The bolts were tightened on the flange and the leak stopped. Operations personnel continued to monitor the flange and no further leakage was observed.
LDEQ conducted an onsite inspected the morning of 11/15/11. Offsite air monitoring along the perimeter of the facility showed no elevated levels of H2S in the air.
134787

2011-10-20
Point Source(s):
Sour Water Stripper Plant (SWS) #1

Pollutant(s):
Hydrogen Sulfide - BRQ
Cause of Problem: Piping or Tubing

On 10/20/11 at approximately 3:35pm a release of hydrogen sulfide occurred at Motiva's Sour Water Stripper Plant (SWS). The release was attributed to a leak that was concealed behind insulation of the 14" outlet piping downstream of the SWS #1 overhead fans.
Immediately upon discovery this system was shutdown and depressured to allow for inspections and repairs to be made. Additionally, the overhead piping at SWS #2 was function tested and put online where repairs were being made to the overhead piping at SWS #1.
134693

2011-10-15
Point Source(s):
level bridle at sulfur plant S-3

Pollutant(s):
Hydrogen Sulfide - BRQ
Cause of Problem: Piping or Tubing

On 10/15/11 at approximately 1:40 pm, a release of hydrogen sulfide occurred at Motiva's Sulfur Plant No. 3 (S-3) from a leaking level bridle. Immediately upon discovery, the leaking level bridle was isolated and the leak stopped. A maintenance work ticket was generated to fabricate a new spool piece to replace the leaking section of pipe on the level bridle. The new spool piece was then installed and the level bridle was put back in service with no issues.
The report says that immediately upon discovery the level bridle was isolated and the leak stopped, yet the duration shows the leak went on for more than 1 day.
134344

2011-10-06
Point Source(s):
Hydrocracker Flare (FE-301)

Pollutant(s):
Hydrogen - BRQ
Hydrogen Sulfide - BRQ
Cause of Problem: Process Upset

On 10/6/11 at 1:42 am, while preparing the unit for a planned shutdown, the 2nd stage reactors of Motiva's Hydrocracking (HCU) Unit experienced an unexpected sixty-degree temperature rise resulting in a unit trip. During the time of the event, HCU Operators were following unit shutdown procedures in preparation of an upcoming turnaround. The sudden increase in temperature on the reactor bed was caused when oil was swept out of the oil passes on furnace F-43 to the reactors. Per procedure, oil must be de-inventoried from the associated piping, the furnace outlet temperatures rose rapidly. Consequently the instrument protective function (IPF) on the reaction system was activated for high temperature, and tripped the process unit as per design. Immediately upon activation of the trip mechanism, the unit was secured and stabilized. Shortly after stabilization, HCU shutdown activities continued following all operational and safety procedures.
For some reason this report contains an incident report for a previous incident from 2010 with the incident ID:128080 from Marathon's Refinery.
134290

2011-09-29
Point Source(s):
Coker Flare FE-401

Pollutant(s):
Nitrogen Oxide - 64 pounds
Sulfur Dioxide - 8,325 pounds
Carbon Monoxide - 347 pounds
Particulate Matter - 12 pounds
1-Butene - 2 pounds
Benzene - 4 pounds
1,3-Butadiene - 0 pounds
Methane - 88 pounds
Ethane - 54 pounds
3-Methyl-1-Butene - 0 pounds
Cyclohexane - 3 pounds
cis-2-Butene - 1 pounds
Ethylene - 7 pounds
Isobutane - 2 pounds
Volatile Organic Compounds (VOCs) - 2 pounds
Isopentane - 1 pounds
n-Butane - 5 pounds
n-Pentane - 2 pounds
Propane - 6 pounds
Propylene - 16 pounds
trans-2-Butene - 1 pounds
Cause of Problem: Equipment Failure

While starting the Coker Jet Pump on 9/29/11 at 6:45pm, the electrical breaker at Motiva's Coking Unit tripped de-energizing the Motor Control Center. Consequently, the Coker Wet Gas Compressor tripped offline therefore resulting in unit flaring and operating in hot circulation mode. Hot circulation mode is an operating mode in which the unit recycles feed at high temperatures. This mode of operation lessens the amount of flaring in comparison to a complete unit shutdown. The initial inspection of the Jet Pump revealed that the auto-transformer serving as a soft start for this pump had failed causing the electrical breaker to trip open. Once repairs were completed, the Coker Unit was safely re-started and flaring stopped.
Immediately, Operations placed the furnace F-125 in hot steam standby and brought the Coker Unit into hot circulation mode to prevent additional flaring of non treated gas. Norco maintenance personnel were called out to troubleshoot the trip of the Coker Wet Gas Compressor and related equipment. The auto-transformer was removed from the circuit. Relay coordination was modified in order to protect the new circuit. After troubleshooting, maintenance personnel determined that operations could safely re-start the Coker Process Unit. During this time the Coker Wet Gas Compressor was restarted and flaring stopped. By 12/31/11 a study will be completed to determine whether the auto-transformer can be permanently removed from the system. After this study is completed, a strategy will be created to address the required changes. This action will be completed by 3/31/12. Calculations confirm that the reportable quantity for sulfur dioxide was exceeded as well as the permitted maximum pound per hour emission limits for carbon monoxide, nitrogen oxide, particulate matter, sulfur dioxide, VOC's, 1,3 butadiene, and benzene as a result of the release.
134190

2011-09-26
Point Source(s):
8-84 RCCU Elevated flare
GO-1 Elevated Flare

Pollutant(s):
Carbon Monoxide - 2,875 pounds
Nitric Oxide - 528 pounds
Particulate Matter - 99 pounds
Sulfur Dioxide - 91 pounds
Volatile Organic Compounds (VOCs) - 1,396 pounds
Carbon Monoxide - 4,910 pounds
Nitric Oxide - 902 pounds
Particulate Matter - 170 pounds
Sulfur Dioxide - 29,547 pounds
Volatile Organic Compounds (VOCs) - 1,329 pounds
Hexane - 123 pounds
Cause of Problem: Seal or Gasket

On 9/26/11, Motiva's RCCU Process Unit identified smoke exiting the insulation on the process unit's reactor stripper overhead piping, indicating a leak of hydrocarbon. Consequently, the RCCU process unit had to divert feed causing flaring to occur at the RCCU Flare (EPN 8-89). The process unit safely diverted feed and continued to maintain catalyst circulation in order to avoid additional flaring. All operational and safety procedures were following at this time. Immediately after stabilizing the unit, insulation was removed from the overhead piping to determine the source of the leak. the leak was identified as a set of flanges on the reactor stripper overhead piping. Attempts were made to re-torque the flanges and stop the leak. However, the re-torquing efforts were unsuccessful and a decision was made to fabricate and install a blade clamp to permanently stop the leak. As of 9/28/11, the blade clamp was installed and the leak on the overhead piping had stopped. The RCCU had been restarted following all operational and safety procedures and remained at steady operation. the RGHT had not been restarted at that time. On 9/26/11 Motiva Enterprises LLC RCCU unit was shut down to do some maintenance work. Flaring occurred at the GO-1 Elevated Flare (EPN 9-84) as a result of the restart of Motiva's RCCU Unit. Untreated dry gas from the RCCU is flared during the restart of the RCCU at the GO-1 Elevated flare before the dry gas can be introduced to GO-1 as a feed.
The RCCU diverted feed and continued to maintain catalyst circulation in order to avoid additional flaring and stabilize the unit. Operations worked to identify the source of the leak and made preparations for repair. The flanges associated with the leak source were re-torqued in an attempt to stop the leak. A box clamp was fabricated and installed to encapsulate and stop the leak. Maximum lb/hr limits were exceeded for sulfur dioxide and VOC's, because the incident release was spread out across close to 3 days no reportable quantities were exceeded. Two follow up letters were received.
134097

2011-09-21
Point Source(s):
8-84 RCCU Elevated flare

Pollutant(s):
Carbon Monoxide - 2,176 pounds
Nitric Oxide - 400 pounds
Particulate Matter - 75 pounds
Sulfur Dioxide - 12 pounds
Volatile Organic Compounds (VOCs) - 1,396 pounds
Cause of Problem: Equipment Failure

On 9/21/11, Motiva's SBA Feed Prep Process Unit experienced a block valve malfunction during a back flush of exchanger E-809D. A cooling water supply valve for this exchanger failed in the closed position causing the exchanger to leak for five minutes. Consequently, there was not adequate cooling water to the exchanger and the SBA process unit had to be shutdown and depressured to the RCCU Flare (EPN-8-84). The process unit was safely shutdown following all operational safety procedures. The elevated flaring associated with the shutdown activities stopped on 9/21/11 at 11:15pm. Repair work for the cooling water system was completed and the SBA Feed Prep Unit was successfully restarted on 9/21/11.
The feed to the SBA Unit was immediately diverted and the process unit was idled. Due to a lack of cooling water, the SBA unit was then depressured and the unit cooling water system was de-inventoried in order to make the necessary repairs. Motiva replaced the cooling water valves associated with the system in order to prevent a similar recurrence. The maximum lb/hr permit limits for sulfur dioxide and VOCs were exceeded during the unit shutdown and restart activities.
133984

2011-09-03
Point Source(s):
Storm Water Impoundment

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

On 9/3/11 the Norco area experienced heavy trains from Tropical Storm Lee. The site was initially able to contain the rainfall associated with this event and route it to the Refinery Wastewater Treatment System (RWTS) for treatment and subsequent discharge through LPDES Outfall 002. However, as the heavy rains continued, the RWTC (consisting of the Storm Water Impoundment Basin and Aeration Basic) reached maximum capacity levels and Motiva opened LPDES Outfall 006 and 0805 to prevent flooding of the refinery and damage to the SWIB for overtopping of the SWIB retaining levee. Outfall 006 serves as the bypass outfall for the RWTS and is used to prevent/reduce flooding of the refinery during extreme rainfall events. Outfall 006 discharges to Engineer's Canal and then to Lake Pontchartrain via a flood control structure through the St. Charles Parish Hurricane Protection Levee. Motiva's normal operating procedures call for the initiation of bypass operations when no capacity remains in the RWTS and a bypass is the only alternative to prevent flooding of the facility. All required sample collection and analysis required by LPDES Permit LA00035222 were conducted in conjunction with the opening of Outfall 006. Emergency bypass operations were stopped at 12 pm on 12/5/11. No permit limits were exceeded and visual inspection showed no signs of adverse water quality of the storm water discharge during this bypass. The facility was being properly operated and maintained at the time of the incident and all required notifications were made.
Rain water released to Outfall 006
133785

2011-09-02
Point Source(s):
Shell Chemical LP Utilities East Flare (EPN 3-84)

Pollutant(s):
Nitrogen Oxide - 22 pounds
Propylene - BRQ
Carbon Monoxide - 122 pounds
Particulate Matter - 4 pounds
Sulfur Dioxide - 7 pounds
Volatile Organic Compounds (VOCs) - 7 pounds
1,3-Butadiene - 0 pounds
Cause of Problem: Equipment Failure

Motiva Norco experienced a malfunction and shutdown of the RCCU refrigerant chiller compressor (K-7200) resulting in a flare at the Shell Chemical LP Utilities East Flare (EPN 3-84) releasing nitrogen oxide and propylene.
LDEQ provided, but there was no Refinery Report included in the file. Motiva states that "final calculations confirmed no reportable quantities or permit limits were exceeded as a result of the incident".
133571

2011-08-26
Point Source(s):
S-3 Tail Gas Incinerator (EPN 2-90)

Pollutant(s):
Sulfur Dioxide - 370 pounds
Cause of Problem: No Information Given

On August 26, 2011 at approximately 1005, a release of sulfur dioxide (SO2) occurred at Motiva's Sulfur Plant No. 3 (S-3) Tail Gas Incinerator (EPN 2-90). The event was triggered while unit operators were making moves to send acid gas from S2 to S3.
No information given.
133432

2011-08-23
Point Source(s):
Light Olefins Feed Tank

Pollutant(s):
Crude Oil - 84 gallons
Cause of Problem: Instrument Failure

A tank being de-invetoryed Light Olefins Feed (derivitive of crude oil) the product being sucked out using a on site vaccumm truck overfilled and an overflow isolated a leak when the gauge failed. Approximately 84 gallons of Light Olefins Feed(benzene/toluene) relaeased.
LDEQ provided but no Refinery Letter included. Motivca states that "the spill was contained and cleaned within secondary containment." Contained in a dike and a vacuum truck was already on site for the procedure.
133050

2011-08-05
Point Source(s):
Hydrocrakcer unit

Pollutant(s):
Benzene - 17 pounds
Toluene - 7 pounds
Carbon Monoxide - 25,826 pounds
Nitrogen Oxide - 5,746 pounds
Particulate Matter - 893 pounds
Sulfur Dioxide - 29 pounds
Volatile Organic Compounds (VOCs) - 12,755 pounds
Hexane - 52 pounds
Cause of Problem: Equipment Failure

The Hydrocracker unit shutdown due to an electrical failure of the motor on P-1940, the charge pump of the 2nd stage of the Hydrocracker Unit. EPN 4-84 and FE-301
Operations shutdown and secured the 1st and 2nd stages of the Hydrocracker. A temporary onsite replacement motor for P-1940 was used to restore power to the motor control center to support HCU restart.
132917

2011-08-05
Point Source(s):
GO-1 Process Unit to West Ops Ground Flare (EPN 9-84)

Pollutant(s):
Benzene - BRQ
Carbon Monoxide - BRQ
Nitrogen Oxide - BRQ
Sulfur Dioxide - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Process Upset

The GO-1 Process Unit experienced a unit upset due to the over-pressuring of a column. This process upset led to flaring at Motiva's West Operations Ground Flare.
There were no remedial actions listed in the report.
No LDEQ Number Available

2011-08-05
Point Source(s):
NIG

Pollutant(s):
Benzene - 13 pounds
Cause of Problem: Equipment Failure

The Hydrocracker Unit shut down due to an electrical failure of the motor on P-1940. the charge pump of the 2nd stage of the Hydrocracker Unit.
After final calculation, 12.7 pounds of benzene was released, and it is confirmed the the reportable quantity was exceeded. This incident will be referred to the Enforcement Division. LABB only has access to the LDEQ Field Interview Form.
132873

2011-08-03
Point Source(s):
Cat Cracker

Pollutant(s):
Butadiene - BRQ
Benzene - BRQ
Carbon Monoxide - BRQ
Hydrogen Sulfide - BRQ
Sulfur Dioxide - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Nitrogen Oxide - BRQ
Cause of Problem: Maintenance/Procedures

While restarting the cat cracker until, materials flared
No refinery letter.
132264

2011-07-08
Point Source(s):
9-84 (West Operations Ground Flare, FG-201)

Pollutant(s):
1,3-Butadiene - 140 pounds
Carbon Monoxide - 1,079 pounds
Nitrogen Oxide - 198 pounds
Particulate Matter - 37 pounds
Volatile Organic Compounds (VOCs) - 716 pounds
Benzene - 32 pounds
Toluene - 2 pounds
Hexane - 22 pounds
Cause of Problem: Process Upset

On July 8, 2011 Shell Chemical's GO-1 Process Unit experienced a unit upset due to issues with re-boilers. This process upset led to flaring at the Motiva's West Operations Ground Flare (EPN 9-84).
The Go-1 Process unit was safely returned to normal operating conditions. Corrective actions to prevent reoccurrence will be addressed in a separate letter from Shell Chemical.
130903

2011-04-28
Point Source(s):
Flare: EPN 3-84

Pollutant(s):
Butane - BRQ
Carbon Dioxide - BRQ
Ethane - BRQ
Ethylene - BRQ
Hydrogen - BRQ
Hydrogen Sulfide - BRQ
Isobutane - BRQ
Isopentane - BRQ
Methane - BRQ
Nitrogen - BRQ
Pentane - BRQ
Propane - BRQ
Propylene - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Process Upset

A leak occurred at HIC-84, along the downstream block valves, allowing nitrogen to enter the column causing a rapid pressure increase. The distilling unit upper crude column became overpressured, and PCV-195 opened the flare to relieve pressure in the column. EPN 3-84 Flare at Shell was used because the Motiva flare was upset and the pilot light was out. Original upset occurred at Motiva DU-5 Crude Unit with a notrogen leak into the Upper Crude Column.
The Shell report for the motiva release was dated May 5th, 2010 instead of 2011.
130906

2011-04-28
Point Source(s):
HCU Elevated Flare (EPN 4-84)

Pollutant(s):
Natural Gas - BRQ
Benzene - BRQ
Hydrogen Sulfide - BRQ
Carbon Monoxide - BRQ
Cause of Problem: Maintenance/Procedures

On April 28, 2011 at 0717, Motiva's Hydrogen Unit experienced a release to the atmosphere from a loss of pilot flame at HCU Elevated Flare (EPN 4-84). Prior to the release, Motiva's Hydrogen Unit was in the process of restarting the unit after a planned maintenance activity. As part of the unit re-start procedure, operators are required to purge process vessels with steam and nitrogen to the HCU flare header in order to remove any excess oxygen that may have been entrained in the process vessels and/or piping as a result of maintenance activities. Following an investigation of this incident, Motiva has determined that steam was introduced into the Hydrogen plant process too quickly, causing a spike in nitrogen to the HCU flare which extinguished the flare pilots for approximately 6 minutes.
Operations responded immediately to the pilot loss alarm by reducing the steam rate to the flare header and re-lighting the flare pilots. In order to prevent a similar incident in the future, a step will be added to the unit startup procedure to slowly increase the steam purge rate in 50lb increments and hold each rate constant for 30 minutes before increasing to the next flow rate.
130936

2011-04-15
Point Source(s):
FLare: FCCU
FLARE: TGTU-4

Pollutant(s):
Sulfur Dioxide - 500 pounds
Carbon Monoxide - 0
Cause of Problem: Equipment Failure

The incident began at Motiva's Convent Refinery on April 15, 2011 at approximately 16:22, when the refinery's Boiler No. 4 shutdown due to an internal tube failure. With the loss of the boiler, the refinery transitioned to steam curtailment and several units were forced to reduce charge rates. As units were being reduced, the excess fuel gas not being utilized was routed to the refinery flare gas system (specifically, Refinery Flares No. 1 and No. 2). The opacity limit was exceeded due to the lack of steam available in the refinery to affectively control the smoke while flaring the excess fuel gas. Also during the transition, the FCCU experienced an upset which caused hydrocarbon to under carry from the high pressure fuel gas knock out drum into the amine acid gas header. As the amine acid gas (and the entrained hydrocarbon carried under from the FCCU) was combusted in the TGTU-4 incinerator, the SO2 and opacity released through the stack was apparently above the permitted limits. The excess emissions ceased when the FCCU stabilized.
The excess emissions ceased when the FCCU stabilized. No additional information. NOLDEQ or SPOC letter included. Emergency Condition.
130330

2011-03-31
Point Source(s):
Coker Blowdown Vent

Pollutant(s):
Hydrogen Sulfide - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Carbon Monoxide - BRQ
1,3-Butadiene - BRQ
Cause of Problem: Process Upset

The facility reported the Coker unit was water quenching the coke material in Cooke Drum PV-918 and encountered a problem with an automated water quench sequence.
The facility took the problematic water quench sequence out of automatic mode and and manually closed off on the water control valve. Once the pressure was reduced to normal operation, the quench cycle was completed. The sequence has been adjusted, and additional orders have been given to the Coker operators so that this activity is consistent on each work shift.
130202

2011-03-26
Point Source(s):
Logistics Berth 2

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

Initially, leaking pipe unable to be contained until the leaking pipe was isolated. A small pinhole developed on the firewater piping at Logistics Berth 2 causing a leakage of firewater into the Mississippi River.
LDEQ and Follow-Up Report provided, but no Refinery Report included. Motiva states that they were unable to contain spill, but isolated the leaking piping to stop the leak. The Follow-Up report stated "Motiva Norco is permitted to release firewater to the Mississippi River from the Wharf". All required monitoring requirements for the permitted discharge were met and were within permit limits.
129958

2011-03-21
Point Source(s):
Motiva's Coking Unit

Pollutant(s):
Coke - BRQ
Cause of Problem: Process Upset

Release of coke dust to the atmosphere from de-coking activity at Motiva's Coker Unit while Motiva's Coker unit was in the process of drilling coke material out of Coke Drum PV-918 and encountered a 3lb pressure increase "hot spot" releasing coke dust to the atmosphere.
BRQ
129951

2011-03-17
Point Source(s):
Ball valve on Butadiene Storage Tank

Pollutant(s):
1,3-Butadiene - BRQ
Cause of Problem: Seal or Gasket

At 0635 on March 17, 2011 Motiva operations was notified that there was an odor of 1,3 butadiene coming from the Butadiene Propylene Storage (BPS) area. Upon investigating, operations found that the odor was coming from the sump at the south end of the BPS area. Operations observed condensation downstream of a 3/4" isolation gate valve on the dewatering piping in the vicinity. Additionally, a ball valve downstream of the 3/4" gate valve was found to be closed past the fully closed indication. Operations checked the temperature of the piping with a temperature gun and noted a 10 deg F difference across the 3/4" gate valve indicating a slight leak from the valve.
At 1011 on March 17, 2011, Motiva operations used a wrench to tighten the 3/4" gate. The ball valve was also moved back to the fully closed position and the bent stop on this valve was corrected. After completing these repairs, the temperature of the piping downstream of the gate valve increased and the condensation stopped indicating that the repair was successful and the leak stopped.
129842

2011-03-13
Point Source(s):
PC2023B Valve

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

During starting up process unit, pressure build and pressure swing at the Deisohexanizer column caused release of several chemicals via relief valve PC2023B and RV-1144.
Flare.
129817

2011-03-11
Point Source(s):
GO-1 Elevated Flare (EPN1-90)

Pollutant(s):
Carbon Monoxide - 40,228 pounds
Nitrogen Oxide - 7,393 pounds
Particulate Matter - 1,392 pounds
Sulfur Dioxide - 1,152 pounds
Volatile Organic Compounds (VOCs) - 21,785 pounds
1,3-Butadiene - 2,287 pounds
Benzene - 782 pounds
Hexane - 370 pounds
Toluene - 265 pounds
Cause of Problem: Equipment Failure

Faulty Positioner ina control valve caused high levels in a suction drum. This caused the PGC to shutdown. The control valve was tested and returned to service. On March 11, 2011, the Process Gas Compressor (PGC) shutdown due to a high level indication in the fourth stage suction drum. The PGC is designed to shutdown under this condition to protect the compressor. Flaring occurred at the GO-1 Elevated Flare (EPN1-90) as a result of the PGC shutdown. Additional flaring as a result of this upset also occurred at Motiva's West Operation Ground Flare and will be addressed in a separate letter.
The PGC was checked and secured by operations. Feed reductions to the unit were made to minimize flaring while repairs to the PGC were made. After investigating the system, a faulty positioner in a control valve was identified as the cause of the high level in the suction drum that led to the PGC shutdown. Maintenance personnel replaced the positioner and the control valve was tested and placed back in service. The PGC was safely returned to normal operating conditions. Once the GO-1 Process Unit was returned to normal operating conditions the flaring was stopped. An alarm point will be installed to give operations an indication that the control valve is not functioning properly and allow for maintenance inspection prior to failure.
129714

2011-03-06
Point Source(s):
Gasket (Exchanger E11B)

Pollutant(s):
Hydrogen - 2,750 pounds
Cause of Problem: Seal or Gasket

LDEQ states that a gasket leak occurred on an exchanger, releasing 550 lbs. of hydrogen gas per day.
BRQ. Leak was contained after five days. LDEQ included. No Refinery Letter.
129562

2011-03-01
Point Source(s):
Coker Flare (EPN 2-84)

Pollutant(s):
1,3-Butadiene - BRQ
Benzene - BRQ
Carbon Monoxide - BRQ
Nitrogen Oxide - BRQ
Sulfur Dioxide - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Equipment Failure

On March 1, 2011, at approximately 1003 hours, Motiva operations initiated a shutdown of the Coker process unit due to a bearing failure on the Coker Inner Stage Cooling Fans (B-2369 & B-2370). This shutdown resulted in flaring at the Coker Elevated Flare (EPN2-84). The unit was safely shut down in a controlled manner utilizing all operational and safety procedures. Additionally, dry gas vent samples were taken prior to shutting down the Coker Wet Gas Compressor (K-2178) to confirm that minimal emissions were sent to the Coker Flare (EPN2-84).
The unit was safely shut down in a controlled manner utilizing all operational and safety procedures. No additional information.
129239

2011-02-13
Point Source(s):
HCU relief valve (RV-1178)

Pollutant(s):
Hydrogen Sulfide - BRQ
Butadiene - BRQ
Benzene - BRQ
Flammable Gas - BRQ
Highly Reactive Volatile Organic Compounds (HRVOCs) - BRQ
Cause of Problem: Process Upset

Release caused by a loss of separation in the High Pressure Separator which caused a relief valve to release. HCU relief valve (RV-1178) relieved to atmosphere due to a loss of product separation in PV-816 (HCU High Pressure Seperator). Rectified Absorber Column (PV-822) pressure built and was relieved by opening to the atmosphere.
BRQ. Letter is predated by several months and appears to be a form. Data is accurate to the event and signed on the 17th of february.