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Motiva Enterprises (1406), Norco

Releases in 2012

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
145652

2012-12-30
Point Source(s):
Naphtha vapor return line DU-5 process unit

Pollutant(s):
1,3-Butadiene - BRQ
Benzene - BRQ
Cause of Problem: Piping or Tubing

On December 30, 2012 a leak was discovered in a naphtha vapor line in the DU-5 Process Unit. The leak was from a pinhole that developed in a weld on the line. The leak on a vapor control line resulted in the release of 1, 3 butadiene and benzene.
The vapor return line was immediately isolated and a nitrogen purge was established. Plans have been developed to complete repairs to the line before the line is safely returned to service. They initially reported over 10 lbs of both Butadiene and benzene being released. Motiva later reported that no reportable quantities were exceeded.
145641

2012-12-30
Point Source(s):


Pollutant(s):
Butene - BRQ
Nitrogen Oxide - BRQ
Cause of Problem: Process Upset

On December 30, 2012, Motiva's Residual Catalytic Cracking Unit (RCCU) experienced a process upset. The upset led to the opening of a pressure relief valve and flaring at the RCCU Flare.
The pressure transmitter that caused the problem last night has been repaired. Butene and Nitrogen Oxides are reported as being flared; quantities currently unknown. Motiva will release the quantities in their 60 day letter.
145521

2012-12-23
Point Source(s):
Finished butadiene line

Pollutant(s):
1,3-Butadiene - 51 pounds
Cause of Problem: Piping or Tubing

At 23:45 on December 23, 2012 a contractor reported a leak on the finished butadiene line. Maintenance removed the insulation from the line and a pin-hole leak was located.
Operations de-pressured the line to the flare and installed a temporary clamp to stop the leak. An engineered box was installed on Decembrer 26, 2012. There was an undetermined amount of 1,3 butadiene released reported in initial report. A follow up report written on February 21, 2013 indicates that the reportable quantity for 1, 3 butadiene was exceeded.
145159

2012-12-05
Point Source(s):
Spillway on northern side of SWIB

Pollutant(s):
Stormwater - BRQ
Cause of Problem: Weather

On December 5, 2012 the Norco area experienced extremely heavy rains from a slow moving thunderstorm. 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, the system storage capacity was reduced due to the amount of heavy rainfall that had occurred in such a short time frame; as the heavy rains continued, the RWTS (consisting of the Storm Water Impoundment Basin and Aeration Basin) reached maximum capacity levels. In accordance with the procedures outline in the LPDES permit application, Motiva opened the spillway, which is located on the northern side of SWIB, at 22:06 to prevent flooding of the refinery and damage to the SWIB from overtopping of the retaining 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. No mention of any pounds or gallons.
144566

2012-11-13
Point Source(s):
Olefins Flare (EPN 6-84)

Pollutant(s):
Carbon Monoxide - 11 pounds
Nitrogen Dioxide - 2 pounds
Particulate Matter - 0 pounds
Sulfur Dioxide - 150 pounds
Volatile Organic Compounds (VOCs) - 5 pounds
Cause of Problem: Process Upset

On November 13, 2012 at 08:45 hours, Motiva's Diesel Hydrotreater (DHT) flared vent gas to Shell Chemical's OL-5 elevated flare. This flaring was due to the DHT vent gas compressor (K-5337) tripping as a result of a high liquid level in the stripper's overhead accumulator (PV-1987) and in the compressor's interstage knock out pot (PV-1988). In addition, the DHT's recycle compressor (K5339) tripped due to high level in the recycle gas compressor knock out pot (PV-2028).
No remedial actions were given. The flaring occurred at Shell Chemical East, but was caused by a compressor tripping at Motiva Enterprises Norco Refinery's Diesel Hydrotreater (DHT) unit. No reportable quantities were exceeded; however the permitted limits for sulfur dioxide were exceeded as a result of this release. Only gives the total VOCs released in the Permitted Source Emissions table; no breakdown per chemical even though they stated some of the released VOCs in their written notification (ethane, hydrogen sulfide, isobutane, methane, n-butane, and propane). SPOC states that 6000-7000 lbs per hour were sent to the elevated flare, and with a 99% flare efficiency it only resulted in 32 lbs of hydrocarbons being released per hour.
144546

2012-11-09
Point Source(s):
Isolation valves on the Finished Butadiene pipeline from sphere S-416 to the Finished Butadiene metering skid

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

At 11:40 on November 9, 2012 Logistics operations was inventorying the Finished Butadiene pipeline from sphere S-416 to the Finished Butadiene metering skid. The operator noticed that the two isolation valves were leaking vapor from the upper portion of the valves. No liquid or ice formation occurred as a result of the leak.
The system was isolated and depressured. Nitrogen was introduced and the piping was decontaminated. The Butadiene leak stopped at 13:00 hours on November 9, 2012. The valves were rebuilt and re installed. The system was pressure tested then returned to full service on November 11, 2012. No mention of any pounds or gallons.
144121

2012-10-23
Point Source(s):
4" Butadiene line

Pollutant(s):
1,3-Butadiene - BRQ
Cause of Problem: Piping or Tubing

At 10:50 on October 23, 2012 during maintenance work to clean and paint a corroded area of the 4" Butadiene line, a contractor discovered an ice ball on the 4" butadiene line. The line was out of service and 95% depressurized for maintenance activities.
The area was cleared and the PEI inspector was called to investigate the leak. Upon investigation a pin hole in the pipe was discovered. At 13:30 there was no material detected exiting the pin hole. A clamp was installed and the leak officially stopped at 17:05. No mention of any pounds or gallons.
144106

2012-10-20
Point Source(s):
Valve packing on 10" Finished BD wharf/Tank Car loading line

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

At 04:35 on October 22, 2012 Motiva BPS Operators discovered the inlet block valve to RV-2960 iced over during his surveillance rounds. Motiva Site Supervisor was notified, the EST group was activated and the area was isolated. The 3/4" thermal RV protects a 10" Finished BD wharf/Tank Car loading line. The line was under 45 psig and not being used to load BD at this time. The source of the leak was the valve packing.
Once the line was depressured to 25 psig, the response team, under SCBA, used fire water to remove the ice and determine the exact source of the leak. The valve packing was tightened, and the leak was stopped at 07:22. No reportable quantities were exceeded. No mention of any pounds or gallons.
143782

2012-10-12
Point Source(s):
Six inch fuel gas line

Pollutant(s):
Isobutane - BRQ
Propane - BRQ
Cause of Problem: Corrosion

On October 12, 2012 at approximately 13:04 hours, a leak was discovered on a six inch fuel gas line located in a pipe rack near the CUS blend drum. The leak resulted in a release of Isobutane and Propane from the process gas piping. The leak was caused by internal corrosion.
Immediately upon discovery of the leak, Motiva operation responded by isolating the six inch fuel gas piping at both ends. Additionally, this section of piping was despressured and taken out of service to stop the leak. The line was then prepared for maintenance inspection. The leak was caused by internal corrosion, and x-ray results revealed pitting at the leak point. On October 16, 2012 Motiva installed an engineered box over the leak point to permanently repair the piping. No mention of any pounds or gallons.
143684

2012-10-09
Point Source(s):
Hose from the frac tank

Pollutant(s):
Benzene - 21 pounds
Ethylbenzene - 0 pounds
m-Xylene - 0 pounds
Isoprene - 0 pounds
p-Xylene - 0 pounds
Isopentane - 1 pounds
n-Pentane - 1 pounds
1-t-3-Pentadiene - 1 pounds
2-Methylpentane - 1 pounds
3-Methylpentane - 1 pounds
n-Hexane - 1 pounds
2-Methylhexane - 1 pounds
3-Methylhexane - 1 pounds
Toluene + 2,3,3-trimethylpentane - 2 pounds
Volatile Organic Compounds (VOCs) - 14 pounds
Cause of Problem: Human Factors

At 10:01 on October 9, 2012 Motiva Site Supervisor received a call of an odor around the SBA area. After responding to the issue, it was discovered that the odor was coming from the VAT sump. A contractor was in the process of removing material from one of the four frac tanks that were staged in preparation for Hurricane Issac to collect excess oil and water during the storm. During the storm material containing high benzene was mistakenly put into the frac tank. When the contractor disconnected the hose from the frac tank that was labeled oil and water, the material remaining in the hose spilled onto the pavement. The contractor attempted to wash the area, which in turn washed the material into the VAT collection sump.
Industrial Hygiene (IH) and ERT were contacted due to an odor in the area and high levels of benzene were detected. The area were secured and under fresh air, clean up efforts were immediately implemented. To prevent any further release of hydrocarbons, the VAT collection sump was immediately blocked in and the material was pumped into a frac tank. The VAT collection sump was water washed, pumped to a frac tank and cleaned. Air testing was performed and the benzene levels were below the limit. Liquids were recovered and returned to the frac tank. No soils were contaminated. Material that evaporated during the release and recovery operation was released to atmosphere and dispersed naturally. The following requirements were adopted to prevent reoccurence: A MSDS is required before any material can be removed by contractors; Procedures have been updated and include a tracking sheet for all loads. Motiva has no current knowledge of pollution migration as free product was contained to the VAT collection sump and recovered to a frac tank. Motiva exceeded the reportable quantity for benzene.
143044

2012-09-17
Point Source(s):
SWIB spillway

Pollutant(s):
Stormwater - BRQ
Cause of Problem: Weather

The unanticipated bypass of the Motiva wastewater treatment facility at the Storm Water Impoundment Basin (SWIB) spillway was caused by thunderstorms and associated heavy rainfall.
Norco experience extremely heavy rains from a slow moving thunderstorm. 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, the system storage capacity was reduced due to rainfall that had occurred on preceding days and as the heavy rains continued, the RWTS (consisting of the Storm Water Impoundment Basin and Aeration Basin) reached maximum capacity levels. Motiva opened the spillway, which is located on the northern side of the SWIB, to prevent flooding of the refinery and damage to the SWIB from overtopping of the retaining levee. The spillway discharges to Engineer's Canal and then to Lake Ponchartrain via a flood control structure through the St. Charles Paris Hurricane Protection Levee. Permit levels were not exceeded and a visual inspection showed no signs of adverse water quality of the storm water discharge during the bypass. No mention of any pounds or gallons.
142880

2012-09-08
Point Source(s):
Flange on 3" takeoff of the 10" Crude Booster line

Pollutant(s):
Crude Oil - 30 gallons
Cause of Problem: Seal or Gasket

The leak was a result of a small leak in a gasket in the flange of the crude booster line to the DU-5 Process Unit.
Motiva operations found a leaking flange on a 3" takeoff of the 10" Crude Booster line used to supply crude to DU-5 Operations Unit. The leak was identified after starting the crude pumps. Approximately 30 gallons of crude oil leaked to the ground. This amount is below reportable quantity. Immediately upon discovery, operations shutdown the crude pumps and isolated the 10" Crude Booster line. Repairs to the line and cleanup of the leaked crude have been completed. SPOC report states 1 bbl of crude oil released.
142652

2012-09-04
Point Source(s):
F-45 outlet piping

Pollutant(s):
Hydrogen - BRQ
Cause of Problem: Weather

Fire caused by a release of hydrogen to the atmosphere due to a rupture of the outlet piping of F-45, the Hydrogen Plant furnace. The failure of the outlet piping of F-45 was as a result of rapid quenching during Hurricane Isaac.
Operations immediately implemented an emergency shutdown in order to isolate the leak and contain the fire. The unit is down for repairs until a formal investigation can be completed to pinpoint the root cause of the piping failure. Motiva Enterprises, LLC-Norco Refinery states a preliminary follow-up report was submitted on September 12, 2012. LABB does not have access to this report at this time. No mention of any pounds or gallons.
142429

2012-08-28
Point Source(s):
multiple

Pollutant(s):
Butadiene - 1,791 pounds
Toluene - 1,208 pounds
Particulate Matter - 4,123 pounds
Carbon Monoxide - 119,185 pounds
Sulfur Dioxide - 33,102 pounds
Volatile Organic Compounds (VOCs) - 54,132 pounds
Hexane - 567 pounds
Benzene - 1,994 pounds
1,3-Butadiene - 1,136 pounds
Ethylbenzene - 154 pounds
Xylene - 615 pounds
Nitrogen Oxide - 21,873 pounds
Cause of Problem: Weather

Motiva Enterprises LLC, Norco Refinery is providing a preliminary report for a verbal notification on August 28, 2012 at 1854 hours of a release of 1,3 butadiene, benzene, carbon dioxide, ethylene, flammable gas, hexane, methane, nitrogen oxides, volatile organic compounds, propylene and sulfur dioxide from flaring and potential releases to atmosphere from the unexpected shutdown and restart of the site before and during inclement weather due to landfall of Hurricane Isaac. On August 28, 2012, Shell Chemical Norco Site operation was adversely affected by inclement weather due to the landfall of Hurricane Isaac. Several of Shell's Units were un-expectantly shutdown due to safety concerns associated with operating in the weather conditions brought on by the landfall of Hurricane Isaac. All materials were released lo the atmosphere from the associated flare's, and dispersed naturally.
Recovery and preparations for a safe re-start of the site is ongoing (Notification on September 4th). Data gathering to perform calculations and investigation are ongoing. Motiva will provide an update within 60 days as required by LAC 33:1 3925.A.3. The updates were each a word for word copy of the original written notification letter from Motiva. There were also duplicate letters printed on the Shell Chemical letterhead that contained all of the same details from the Motiva reports. At this time (May 22 2013) LDEQ is still processing the update that they claim will have final calculations from their investigation. February 20, 2013 is the most recent follow-up that LABB was able to find (Update May 2013 - we requested the final summary report from LDEQ and received this final report that was published April 25th, 2013). The final report lists completely different pollutants than the list that was being reported in prior written notifications. These inconsistencies are not addressed in the report. Final summary report from Shell chemical 4/25/2013: Shell Chemical operations look the necessary steps to safely shut units down and minimize emissions resulting from the weather associated with Hurricane Isaac. Operations assessed damages, made repairs to equipment and safely return process units to normal operating conditions. RCCU at Motiva Enterprises (from final summary letter dated april 25 2012) On August 29, 2012, Motiva's Residual Catalytic Cracking Unit (RCCU) initiated a shutdown of the process unit due to inclement weather associated with Hurricane Isaac making landfall. During this time, the RCCU experienced an unexpected loss of flare pilot indication at the RCCU Elevated Flare, and a loss of pilot indication on the RCCU CO Heater due to hurricane force winds. An inadvertent catalyst leak developed during this time on level indicator Ll1548. Subsequently, the pH control on the circulation water for the RCCU Flue Gas Scrubber was lost at this time. The reportable quantities for volatile organic compounds and particulate matter were exceeded during this time. Additional details on reportable quantity and permit limit exceedences are listed in the following tables of this report. (also from April 25th report) Shell Chemical Venting to Motiva West Operations Ground Flare On August 29, 2012, Shell Chemical's G0-1 Process Unit flared at Motiva's West Operations Ground Flare due to shutdown and startup activities due to adverse weather conditions associated with the landfall of Hurricane Isaac. Details of the flaring by Shell Chemical are addressed in a separate letter from Shell. A total of the VOCs is given, but report states certain VOCs (carbon dioxide, ethylene, flammable gas, methane, propylene) that do not have breakdown of individual amounts released anywhere. This event did not result in an emergency condition. There were no fatalities, injuries or road closures. Planning and review meetings were held, learning's will be executed in future weather related occurrences as appropriate.
142415

2012-08-28
Point Source(s):
Outfall 006

Pollutant(s):
Stormwater - BRQ
Cause of Problem: Weather

Bypass occurred at the SWIB at outfall 006 due to rainfall caused by Hurricane Isaac. The unanticipated bypass incident at the Storm Water Impoundment Basin spillway and permitted Outfall 006 was due to an upset condition and was cuased by thunderstorms and associated heavy rainfall from Hurricane Isaac.
An unknown amount of rainwater was bypassed. The facility reported that all samples were collected as required by their permit and visual inspections showed no signs of adverse water quality of the storm water discharge during the bypass event. Extremely heavy rains from Hurricane Isaac were experienced in the Norco area. Site was initially able to contain the rainfall associated with this event and route it to the Refinery Wastewater Treatment System for treatment and subsequent discharge. The system storage capacity was reduced due to rainfall and the heavy rains continuing, the RWTS reached maximum capacity levels. Motiva opened the spillway to prevent flooding of the refinery and damage to the SWIB from over-topping of the retaining levee. Heavy rainfall due to Hurricane Isaac continued requiring the opening of permitted outfall. The spill way serves as the protection structure for the SWIB and is used to prevent and reduce flooing of the refinery during extreme rainfall events. The spillway discharges to Engineer's Canal and then to Lake Pontchartrain via a flood control structure through the St. Charles Parish Hurricane Protection Levee. Although tests confirmed the discharged stormwater was within LPDES permit limits, there may be some pollution from process area stormwater going untreated directly to outfall canal. No mention of any pounds or gallons.
142166

2012-08-18
Point Source(s):
SWIB spillway

Pollutant(s):
Stormwater - BRQ
Cause of Problem: Weather

The facility opened the SWIB spillway to prevent flooding of the refinery due to extremely heavy rainfall. The unanticipated bypass of the Motiva wastewater treatment facility at the Storm Water Impoundment Basin (SWIB) spillway was due to an upset condition and was caused by thunderstorms and associated heavy rainfall. The Norco area experienced extremely heavy rains from a slow moving thunderstorm. The site was initially able to contain the rainfall associated with this event and routed it to the Refinery Wastewater Treatment System (RWTS) for treatment and subsequent discharge. However, the system storage capacity was reduced due to rainfall that had occurred on preceding days and as the heavy rains continued, the RWTS (consisting of the Storm Water Impoundment Basin and Aeration Basin) reached maximum capacity levels. In accordance to outlined procedures, Motiva opened the spillway, which is located on the northern side of SWIB, to prevent flooding of the refinery and damage to the SWIB from overtopping of the retaining levee.
The spillway serves as the protection structure for the SWIB and is used to prevent/reduce flooding of the refinery during extreme rainfall events. The spillway discharges to Engineer's Canal and then to Lake Ponchartrain 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. Emergency bypass operations were stopped on August 21, 2012. The facility was being properly operated and maintained at the time of the incident and all required notifications were made. No mention of any pounds or gallons.
141583

2012-07-27
Point Source(s):
Relief Valve at Residual Catalytic Cracking Unit

Pollutant(s):
1,3-Butadiene - BRQ
Benzene - BRQ
Flammable Gas - 2,189 pounds
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Equipment Failure

Motiva's Residual Catalytic Cracking Unit (RCCU) experienced a premature opening of a relief valve (RV) on the RCCU debutanizer column. The RCCU was operating under normal conditions at the time of the release, and operational data proves that the associated equipment did not reach the relief valve set point pressure to cause the RV to open. A contract pressure equipment company was called out to help identify any mechanical problems with the RV. Additionally, RCCU operations lowered the debutanizer column pressure 3psig aas a precautionary measure until troubleshooting efforts are completed. An update report was provided by Motiva on September 10, 2012.
A contract pressure equipment company was called out to help identify any mechanical problems with the RV. Additionally, RCCU operations lowered the debutanizer column pressure 3psig as a precautionary measure until troubleshooting efforts are completed. Upon investigation, the reportable quantity for flammable gas was exceeded in this release. 2189 pounds of flammable gas were were reported through the SPOC. The reportable quantity of flammable gas includes 1000 pounds. Refinery's attachment of listed pollutants released is too unfocused/fuzzy to read accurately.
140882

2012-06-28
Point Source(s):
Shell Chemical's GO-1 Elevated Flare and Motiva West Operations Ground Flare

Pollutant(s):
1,3-Butadiene - 4,190 pounds
Carbon Monoxide - 67,814 pounds
Hexane - 516 pounds
Nitrogen Oxide - 12,463 pounds
Toluene - 47 pounds
Volatile Organic Compounds (VOCs) - 40,000 pounds
Benzene - 727 pounds
Particulate Matter - 2,346 pounds
Cause of Problem: Equipment Failure

There was an unexpected loss of a boiler, causing a steam load shed, causing a unit shutdown, which caused the flaring. There was flaring at both Shell Chemical's 1-90 GO-1 Elevated Flare FE-602 and Motiva West Operations Ground Flare. The unexpected loss of the boiler was a due to a loss of lube oil on the forced draft fan and broken linkage of the trip and throttle valve.
Calculations and investigations confirm that the reportable quantity for 1,3-Butadiene was exceeded during release from the flare. Maximum permitted limits were exceeded for 1,3-Butadiene and Hexane from the West Ops Ground Flare. Ethylene, PAHs, and sulfur dioxide were listed in the written reports as being released but do not have the amounts released in the Permitted Source Emissions tables.
139564

2012-05-08
Point Source(s):
OL-5 Elevated Flare, FE-101 (EPN 6-84); OL-5 Ground Flare, FG-101 (EPN 7-84)
RCCU CO Heater and Flue Gas Scrubber (EPN 2-91)
RCCU CO Heater and Flue Gas Scrubber (EPN 2-91); OL-5 Elevated Flare, FE-101 (EPN 6-84); OL-5 Ground Flare, FG-101 (EPN 7-84)

Pollutant(s):
Toluene - 682 pounds
Ethylbenzene - 88 pounds
Benzene - 968 pounds
Butadiene - 1,033 pounds
Volatile Organic Compounds (VOCs) - 24,400 pounds
Sulfur Dioxide - 1,369 pounds
Particulate Matter - 2,169 pounds
Nitrogen Oxide - 12,443 pounds
Carbon Monoxide - 605,229 pounds
Xylene - 352 pounds
Hydrogen Sulfide - BRQ
Ethylene - BRQ
Hexane - BRQ
Propylene - BRQ
Catalyst Fines - BRQ
Cause of Problem: Weather

On May 8, 2012, the Motiva Enterprise's Residual Catalytic Cracking Unit (RCCU) was struck by lightning during a heavy rainstorm event resulting in an unforeseen shutdown of the RCCU CO Heater and Flue Gas Scrubber (EPN 2-91). Consequently, an Instrument Protective Function (IPF) associated with the CO Heater's force draft fans automatically tripped the system's main fuel gas burners to safely secure the heater as per design. Motiva operations then worked to stablize the RCCU process unit and assess the damages to the RCCU CO Heater resulting from the lightning strike. The causal analysis generated from the investigation of this incident revealed simultaneous alarms and IPF shutdowns for multiple pieces of equipment associated with the RCCU CO Heater during the time of the incident. A time stamp taken from the RCCU alarm summary noted that several pieces of equipment simultaneously shutdown at 5/8/2012 17:24:34. The pieces of equipment affected from this incident are listed below: CO Heater Forced Draft Fan Electric; CO Heater Forced Draft Fan Turbine; CO Heater Pilot Gas; RCCU Refrigeration Compressor Lube Oil; RCCU Main Air Blower Flow to Fluffing Rings; RCCU Cooling Water Pump Lube Oil Systems. The data proved that the signals initiating the multiple trips were not generated by the processes themselves, but by a non-process related influence. The investigation team determined that a bolt of lightning struck somewhere in close proximity of the junction boxes for the different pieces of equipment near the RCCU CO Heater. Consequently, this caused an inadvertent energy pulse to either stop current on the analog systems, or provide enough voltage to energize the trip signal and shutdown the equipment listed above. On May 8, 2012, Shell Chemical's OL-5 Process Unit experienced an unexpected shutdown of the OL-5 Process Gas Compressor (PGC) due to weather conditions which led to flaring at the OL-5 Elevated and Ground Flares. Weather conditions in the area caused issues in a Motiva Unit leading to a curtailment of the sites steam supply. As per site load shedding policies OL-5 was instructed to shut down the PGC which is a consumer of steam.
Motiva: The RCCU initiated a unit shutdown in a controlled manner following all operating and safety procedures in order to minimize excess emissions to the atmosphere. As part of the initial shutdown procedure, operating rates were reduced significantly leading up the unit showdown. Simultaneously, a maintenance work plan was developed and executed in a effort to re-establish normal operations of the RCCU CO Heater. At this time electrical inspectors were called in to visually inspect the associated junction boxes for this shutdown system. Additionally, enhanced monitoring of the shutdown system was performed to assure that no damage had occurred as a result of the lightning strike. Once the maintenance work was complete, the RCCU CO Heater was returned to service. Operations then worked to stabilize the CO Heater operations, and began to reverse the shutdown process following all operating and safety procedures. Motiva completed IPF checks to confirm that the instrument protective functions for this system are functioning as needed. Shell Chemical LP.-East: Furnaces in OL-5 were taken off feed after the PGC was shutdown to minimize flaring. The OL-5 process unit was secured until the steam supply was restored to normal conditions to allow for a safe restart of the PGC. In their original final report, Shell Chemical LP - East Site indicated that the permit level for benzene was exceeded; they sent a corrected final report on August 9, 2012 explaining that the permit level for benzene was not exceeded as indicated in the earlier report. As seen on first table Date/Time: 5/8/12 17:25 - 5/9/12 17:25 for section V.a. carbon monoxide was released about reportable quantities. In addition to carbon monoxide being above reportable quantity, benzene was as well although it was not reported as such. The reportable quantity for benzene is 10 lbs with the total amount of benzene being released from Shell Chemical LP - East Site being 967.9 lbs. The LDEQ sent out an emergency responder, Nicole Hardy, who took atmospheric samples from May 8, 2012 at 17:40 to 5/9/12 at 23:30 for a total of 1 day, 5 hours and 50 minutes; all of the samples came back as being below the Permissible Exposure Limits. Although they do not report the pollutant as exceeding reportable quantity - the facility released quantities that exceeded reportable quantities for benzene during the 2 days of this event. The initial verbal notification was made on May 8, 2012. There was an initial written notification (follow up report to verbal notification) made by both Shell chemical and Motiva on July 3, 2012. The first written notification was not made in a timely manner as per state regulations. Since the July 3rd report was their first written notification following the initial verbal notification, therefore they missed the 7 day deadline to make written notification (the deadline would have been May 15, 2013; it would be 48 days late as it was written 55 days after the accident). Another follow up report termed the "final release report" was made by both Shell chemical and Motiva on August 2, 2012. A final follow up report termed the "corrected final release report" was made by by Shell chemical on August 9, 2012 - there was no corrected final report made by Motiva.
138871

2012-04-16
Point Source(s):
Train Car

Pollutant(s):
1,3-Butadiene - BRQ
Cause of Problem: Other - See text

A tank that was carrying butadiene was derailed on the facility grounds. The refinery stated that the tank car remained upright throughout the event, and that only its front two wheels derailed. No spill or damage to the car occurred as a result of the event.
The refinery called Hulcher Services, Inc., to place the car back on the tracks. The railcar was successfully placed back onto the tracks after being derailed for 4 hours and 26 minutes.
138462

2012-04-02
Point Source(s):
Rubber boot in sewer line on Berth 1

Pollutant(s):
Sewage - 1 gallons
Cause of Problem: Piping or Tubing

Through a small hole in a rubber boot on the sewer line in Berth 1, sewer water was spilled to the Mississippi River. The released material did not go through the wastewater treatment facility. Normally, the sewer line is routed to the refinery wastewater treatment facilities and then to the Mississippi River via LPDES Outfall 002.
Operations isolated the sewer line, stopping the release. Maintenance replaced the rubber boot on the sewer line at Berth 1 with a new rubber boot.
138205

2012-03-23
Point Source(s):
Storm Water Impoundment Basin

Pollutant(s):
Wastewater - BRQ
Cause of Problem: Weather

A heavy rain event caused the system to become overburdened and water was bypassed to prevent flooding to the refinery.
There were no remedial actions taken. The release was part of normal operating procedures when no capacity remains in the RWTS and a bypass is the only alternative to prevent flooding of the facility.
138076

2012-03-18
Point Source(s):
Pressure vessel PV-122

Pollutant(s):
Benzene - BRQ
Toluene - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Human Factors

The pressure vessel PV-122 was inadvertently overfilled during refilling, and liquid was released from the vent on top of the pressure vessel.
All material released was contained within the concrete containment dike. Once the release was realized, flow to the vessel was isolated, the inlet valve on the pressure vessel was closed, and the area was secured. A pumper truck was staged at the pressure vessel to remove the hydrocarbons from the containment area. Once all liquid hydrocarbons had been removed from the containment area, the area was washed with water to a pumper truck to remove residual hydrocarbons.
137083

2012-02-09
Point Source(s):
RCCU

Pollutant(s):
Heavy Naphtha - BRQ
Benzene - BRQ
Flammable Liquid - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Equipment Failure

During normal operations, there was an unexpected opening of a relief valve (RV) on the RCCU Main Fractionator, causing a release from the Residual Catalytic Cracking Unit (RCCU). The Naphtha was released to the concrete below the unit.
Operations responded immediately to isolate the RV, and the release was stopped. The Naphtha was cleaned immediately. The main Fractionator column pressure remained steady prior to release. After the investigation was completed, the facility took precautionary measures and reinstalled the relief valve to prevent further occurrence.
136650

2012-01-20
Point Source(s):
An Alky six-inch pipeline on the north side of OP-1 process gas compressor

Pollutant(s):
Isobutane - BRQ
Propane - BRQ
Cause of Problem: Corrosion

The leak was caused by internal corrosion, and x-ray results revealed pitting at the leak point. 6 inch pipeline on northside of OP-1 process gas compressor PGC.
Upon discovery of the leak, the refinery isolated the six-inch fuel gas piping at both ends. The problematic section of piping was also depressured and taken out of service to stop the leak. The line was prepared for maintenance inspection, from which the cause--internal corrosion--was discovered. On January 27, 2012, the refinery installed an engineered box over the leak point to permanently repair the piping.
136422

2012-01-09
Point Source(s):
FLARE: HCU flare (EPN-4-84)

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

The HIC on the low pressure separator (PV-817) was opened to the HCU flare (EPN-4-84) because an atmospheric relief valve (RV-4297) on the rectified absorber column (PV-822) at the Hydrocracking Unit relieved prior to its set point. Hydrocracker Flaring
RV-4297 was isolated and repaired. Flaring stopped once the unit was stabilized.