LA Bucket Brigade : Refinery Accident Database

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Placid Refining (2366), Port Allen

Releases in 2011

LDEQ Accident Number Accident Date	Point Source/Release	Cause	Notes
136143 2011-12-23	Point Source(s): incinerator 2 at sulfur plant #3 Pollutant(s): Sulfur Dioxide - 4,168 pounds Carbon Dioxide - BRQ Nitrogen - BRQ Hydrogen - BRQ Hydrogen Sulfide - BRQ Vapor - BRQ Carbon Monoxide - BRQ Carbon Disulfide - BRQ Carbonyl Sulfide - BRQ	Cause of Problem: Equipment Design The #2 SRU tripped causing the air shutdown valve to close, forcing operations to shift the feed from the #2 SRU to the #3 SRU. The catalyst in the #2 TGTU became overloaded from the excess feed and breakthrough occurred causing sulfur to carryover to the #2 TGTU Quench Tower. The #2 TGTU Quench Tower became plugged with Sulfur and could not run at full capacity. The #2 TGTU had to be bypassed in order to clean the #2 TGTU Quench Tower. Reached RQ at 18:45 on the 23rd due to bypassing the #2 Tailgas unit. Normal was not reached until the 25th. The facility goes on to report that the shutdown was caused by a malfunction of a safety shutdown inherent to the technology of the design of the unit.	In an effort to reduce the quantity of sulfur dioxide emissions from this incident, the refinery reduced the charge rate to the FCCU, discontinued processing LCO through the Diesel Hydrotreater and put the Sour Water Gas to the #2 SRU. These steps allowed them to keep the #3 SRU at minimum feed rates while the Quench tower in the #2 TGTU (which served the #3 SRU) was being cleaned. The shutdowns on the #2 SRU were tested and found to be in good working order. If it is shutdowns again, their alternative will be to divert the feed to the #3 SRU or flare Acid Gas. Placid does not feel that design, operational, or maintenance changes are required because shutdowns are tested during every turnaround. They classify this incident as unusual and rare, therefore, it is not expected to have a significant probability of occurring again. The sulfur dioxide emission rate was greater than 20.0 pounds per hour continuously for three consecutive hours or more. Placid Refinery then pushed more pollution out of SRU #3. Sulfur component releases from SRU #3 production from the start of the incident on 12/23/11 to 12/25/11 were approximately 1,380 lbs.
136091 2011-12-22	Point Source(s): Sulfur plants #2 and #3 Pollutant(s): Sulfur Dioxide - 134 pounds Hydrogen Sulfide - 5 pounds	Cause of Problem: Process Upset Sulfur Plant No. 2 Shutdown causing the No. 1 Incinerator to exceed the CEMS 500 ppm sulfur dioxide span until all of the acid gas load was shifted to Sulfur Plant No. 3. The increased load cause the No. 2 Incinerator to exceed the CEMS 500 ppm sulfur dioxide span until Sulfur Plant No. 2 was restarted. Both of the incinerators are permitted sources.	Restarted Sulfur Plant No. 2.
135611 2011-11-30	Point Source(s): Flare Pollutant(s): Carbon Monoxide - 1 pounds Nitric Oxide - 1 pounds Particulate Matter 10 - 0 pounds Sulfur Dioxide - 0 pounds Volatile Organic Compounds (VOCs) - 0 pounds	Cause of Problem: Maintenance/Procedures Placid Refining Company operates a flare gas recovery unit that recovers routinely generated gases that would have been otherwise flared in Source ID 18-74. The recovery unit was shut down due to turnaround related unit cleaning activities sending high concentrations of nitrogen and steam into the flare system. This control device bypass was not approved via a variance.	Report states that no RQ's were exceeded. On the other hand, it also says that mass emission permit limits for the flare were exceeded. Placid has requested a GCXVII activity be added to their permit to cover monthly preventative maintenance on the system but this will only cover 5 hours per month. Operations will notify environmental department prior to shutting down system in the future so it can be addressed properly with the agency prior to activity. Report says to see an attached calculation with the name and quantity of released pollutants. Report shows no sign of such calculation.
No LDEQ Number Available 2011-11-29	Point Source(s): #1 Incinerator Pollutant(s): Sulfur Dioxide - 3,695 pounds	Cause of Problem: Maintenance/Procedures The Sulfur Plant was shut down during the turnaround to replace the catalyst, as it was no longer active. Residual sulfur must be removed from the reactor beds to prevent the beds from plugging or solidifying. If the reactor beds are not swept of the residual sulfur, it becomes more hazardous to remove the old catalyst. The refinery notes that, even if the catalyst was not being replaced, it is likely that the catalyst would have plugged if the sweeping procedure was not performed, and it would not be able to achieve proper flow through the Sulfur Plant during startup.	The refinery will contact a Sulfur Plant specialist to explore any other possible shutdown techniques for sweeping the catalyst that do not cause a TG incident.
133455 2011-08-23	Point Source(s): Flare Pollutant(s): Smoke - BRQ	Cause of Problem: Process Upset Reformer Compressor shutdown due to electric failure.	Process upset was routed to the flare for release control. Operations safely shutdown the reformer unit and switched downstream unit to pipeline hydrogen.
132689 2011-07-23	Point Source(s): FLARE: Tailgas treater unit Pollutant(s): Sulfur Dioxide - 3,696 pounds	Cause of Problem: Process Upset The tailgas treater unit from SRU2 was bypassed due to plugging in quench tower servicing #1TGTU.	They swept the catalyst bed with sweet gas and washed the quench tower with fresh water. "Malfunction was corrected" No offsite monitoring, no onsite monitoring, not able to determine if offsite was impacted but they note air dispersion.
132636 2011-07-22	Point Source(s): FLARE: FCC unit Pollutant(s): Methane - BRQ Ethane - BRQ Propane - BRQ Butane - BRQ Hydrogen Sulfide - BRQ	Cause of Problem: Process Upset The main air blower tripped in the FCC unit. Because the feed was pulled from the unit there was potential for a release.	They were bringing the unit back up and waiting for stabilization.
130687 2011-04-17	Point Source(s): No Information Given Pollutant(s): Naphtha - 0	Cause of Problem: Equipment Failure State police report states that an there was an equipment failure of an unknown cause. However, in an effort to isolate the leak that was discovered, a fire started. The leak was composed of naphtha and was burned into the air. FIRE.	The leak was isolated. Liquid was contained in a concrete curbed area. The liquid would drain to the sewer system to be processed and discharged. Placid Refining Fire Fighters were called to put out the fire. LDEQ report only. No Refinery Letter.
129480 2011-02-24	Point Source(s): Tank: VOC control device Pollutant(s): Volatile Organic Compounds (VOCs) - BRQ	Cause of Problem: Maintenance/Procedures LDEQ states that the VOC stream from tank emissions was rerouted from one control device to another control device. No net emissions change from what was permitted was reported. The listed control device in the air permit for the VOC stream was taken out of service for unscheduled maintenance. It is reported that the alternate control device efficiency is equal or greater than that required by the permit.	BRQ. No Information Given. LDEQ included. No Refinery Letter.
128541 2011-01-08	Point Source(s): Frac Water Tank Pollutant(s): Water or Wastewater - 18,735 gallons	Cause of Problem: Human Factors A water supply line to a water storage tank was not completely closed and the valve was not broken or in need of repair.	IPT will develop a written checklist detailing the shut down procedures for the water feed and treatment area. The shift supervisor reported that water samples were clear and had no free hydrocarbons. IPT reported recovering 18,735 gallons of potable water in total.