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Honeywell (289, 183605), Baton Rouge

Releases in 2011

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes

Point Source(s):
piping on No. 46 G-113 crude tank

Dichlorotetrafluoroethane - 341
1,1-Dichloro-2,2,2-Trifluorethane (G-123) - 1,343 pounds
Cause of Problem: Piping or Tubing

A leak was discovered from a section of piping located at the bottom of the No. 46 113 crude tank. Release was caused by a small hole that had developed on a flange of the storage tank.
Release was secured within 30 minutes by installing a clamp on the section of the piping.

Point Source(s):
relief valve-343

1,1-Dichloro-2,2,2-Trifluorethane (G-123) - BRQ
Cause of Problem: Equipment Failure

The G-1113 production unit experienced a pressure drop during a time when the unit was down and not operating. Pressure relief valve-343 was leaking.
Condenser relief valve was switched to the spare and the leak was isolated. At the onset of, and for the duration of the event, the unit was in a blocked in state with no feed additions. The relief valve has been sent off for testing to confirm the failure.

Point Source(s):
rail car loading

Zinc chloride - 1,563 pounds
Cause of Problem: Instrument Failure

The zinc chloride storage tank was receiving feed from the process unit prior to off-loading into a railcar when personnel observed zinc chloride overflowing from the storage tank's overflow pipe into the containment area. Storage overflowed due to malfunction in level indicator.
Feed to the storage tank was immediately terminated, and feed to the railcar was initiated stopping the overflow condition. An outside vacuum service was summoned to the plant, and the liquid inside the containment area was removed for disposal.

Point Source(s):
steam ports

Sulfuric Acid - BRQ
Cause of Problem: Other - See text

While loading a stainless steel tank truck with wash water, personnel observed liquid being released from the steam ports located on the underbody of the trailer,
The loading operation was immediately terminated. The site's emergency response team was summoned, and the area was secured and spill containment and clean-up was initiated.

Point Source(s):
relief valve

1,1-Dichloro-2,2,2-Trifluorethane (G-123) - BRQ
Cause of Problem: Equipment Failure

Relief valve from the organic recycle vaporizer was leaking. Release occurred what a relief valve on a vapor riser lifted releasing a small amount of chemical into the air. Leak lasted about 10 min.
The relief valve was immediately blocked in and removed for repair and the spare relief valve was placed into service.

Point Source(s):
tank car loading/unloading area

1,1-Dichloro-2,2,2-Trifluorethane (G-123) - 14,578 pounds
Cause of Problem: Seal or Gasket

Approximately 14578 lbs of Trichlorotrifluoroethane was released due to a gasket failure in the load/transfer hose while filling the tankcar.
The chemical was released onto the railroad tracks, cross ties, gravel and soil underneath the tank car. The product was initially contained by a large dyke of oil dry. MasterVac had been called to vacuum up the product. Gravel and soil had been dug up to about a foot, new soil had been added, and gravel was being placed back in the track bed. The new cross ties were being laid in place. The soil/gravel had been placed into a rolloff and the cross ties had been placed into another rolloff. The two roll offs were going to Waste Management. The liquid product that was recovered had been placed into a drum. The drum was to be sent for incineration.

Point Source(s):
Brine Hold Tank

1,1-Dichloro-2,2,2-Trifluorethane (G-123) - 10,814 pounds
Cause of Problem: Process Upset

Leak in the G-1113 unit at the brine jacket relief valve on the brine pump tank. At the time of the leak, the G1113 unit was shutdown and the brine system was in circulation mode causing the unit to lose cooling water. The loss of cooling water caused by the brine temperature to increase and pressure up the brine hold tank resulting in the pressure relief valve lifting.
G1113 unit was shutdown and the brine system was in circulation mode. Circulating pump was immediately shutdown to seat the relief valve. The liquid portion of the leak was contained in the sump and containment area with a 2069 gallon capacity. As a precaution, the diversion gate to stormwater outfall 003 was closed and water was diverted for on-site treatment. Honeywell has modified its operating procedures to shutdown the brine pumps in the event the unit is down for an extended period greater than 6 hours. Long term plans are to redesign the pressure safety valves to add an additional layer of protection to prevent release to atmosphere.