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Shell Chemical East (26336), Norco

Releases in 2013

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
153013

2013-12-24
Point Source(s):
pressure relief valve

Pollutant(s):
Propylene - BRQ
Cause of Problem: Equipment Failure

On December 24th 2013, Shell Chemical's OL5 operations discovered a pressure relief valve opening to the OL5 flare system.
OL-5 operations began working to remove non condensables in an attempt to get the relief valve to close. To close the pressure relief valve and stop the flow to the flare system, operations reduced the pressure upstream of the pressure relief valve, returning the unit to safe, normal operating conditions.
152979

2013-12-22
Point Source(s):
pump in GO-1 process unit

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

On December 22, 2013, GO-1 discovered a pump leak in the process unit. A hole developed on the bypass line around the valve adjacent to the pump.
The pump was isolated to repair the bypass line. The spill was contained and the area was cleaned up.
152977

2013-12-21
Point Source(s):
OL-5 Ground (EPN 7-84) and Elevated (6-84) Flares
OL-5 Ground flare (EPN 7-84)

Pollutant(s):
Carbon Dioxide - 2,078 pounds
Nitrogen Dioxide - 382 pounds
Particulate Matter - 152 pounds
Volatile Organic Compounds (VOCs) - 1,284 pounds
Cause of Problem: Process Upset

On December 21, 2013, Shell Chemical's OL-5 operations discovered a pressure relief device opening to the OL-5 flare system.
To close the pressure relief valve and stop the flow to the flare system, operations reduced the pressure of the propylene refrigeration compressor system, returning the unit to safely normal operating conditions. To minimize additional unit upset conditions and impacts, Operations drained exchangers, reducing the pressure of the propylene refrigeration compressor system caused by excess material in the system. In addition, Operations restored the propylene refrigeration systems to its normal operating conditions by reversing actions taken to stabilize the unit during the unit upset. An evaluation of the operating conditions of the propylene refrigeration compressor system will be performed to identify improvements which can be made to prevent future re-occurrences. If an corrective actions are identified, they will be reported in the 2013 2nd Half Semiannual Report.
152921

2013-12-19
Point Source(s):
GO-1 Elevated Flare (EPN 1-90)

Pollutant(s):
1,3-Butadiene - 0
Benzene - 0
Carbon Monoxide - 0
Hexane - 0
Nitrogen Oxide - 0
Styrene - 0
Sulfur Dioxide - 0
Toluene - 0
Xylene - 0
Volatile Organic Compounds (VOCs) - 0
Particulate Matter - 0
Cause of Problem: Process Upset

On December 19, 2013, GO-1 had an unexpected process upset which resulted in flaring at the GO-1 Elevated Flare. The flaring was a result of a swing on the cold site of GO-1, which resulted in an upset at the propylene re-compressor. Ending date above is the reported anticipated end date, assuming troubleshooting efforts continue as planned.
Operations is currently stabilizing the unit and minimizing the flaring. Data gathering to perform calculations and investigation are ongoing. Shell will provide an update within 60 days.
152916

2013-12-18
Point Source(s):
OL-5 Ground (EPN 7-84) and Elevated (EPN 6-84)

Pollutant(s):
Carbon Monoxide - 50,885 pounds
Nitrogen Oxide - 9,352 pounds
Particulate Matter - 1,760 pounds
Volatile Organic Compounds (VOCs) - 25,922 pounds
1,3-Butadiene - 913 pounds
Benzene - 9 pounds
Cause of Problem: Maintenance/Procedures

On December 18, 2013, Shell Chemical's OL-5 Unit shut down to complete scheduled maintenance. While walking out the unit, a pressure equipment inspector found a section of piping that was experiencing corrosion under insulation. After further investigation, a plan was devised to shut down the unit in order to repair this thinned section of piping and prevent additional unit upset conditions. Flaring to OL-5 Ground Flare (EPN 7-84) and OL-5 Elevated Flare (EPN 6-84) resulted from a unit shutdown to complete planned maintenance on a section of piping downstream of the ethylene refrigerant compressor experiencing corrosion.
To minimize additional unit upset conditions and impacts, the OL5 unit was shutdown and the thin wall piping was repaired. A review of the corrosion under insulation will be performed to identify improvements which can be made to prevent future re-occurrences.
152800

2013-12-10
Point Source(s):
OL-5 Ground Flare (EPN 7-84) and Elevated Flare (EPN 6-84)

Pollutant(s):
Carbon Monoxide - 589 pounds
Nitrogen Oxide - 108 pounds
Volatile Organic Compounds (VOCs) - 248 pounds
Particulate Matter - 43 pounds
Cause of Problem: Process Upset

On December 10, 2013, OL-5 operations experienced high acetylene content in the process. The material was flared to prevent further upsets which may have resulted in an even greater amount of flaring. OL-5 made adjustments to return the acetylene content back to specification. The OL-5 converter hydrogen appears to have been slipping a small amount of flow through a closed control valve into the hydrogen line supplying the acetylene converters causing the off specification production.
OL-5 is making changes in process guidelines to prevent recurrence. Shell Chemical confirmed that no reportable quantities were exceeded, however the maximum lbs/hr limit was exceeded for particulate matter.
152612

2013-11-28
Point Source(s):
OL-5 Elevated Flare (EPN 6-84) & Ground Flare (7-84
OL-5 Elevated Flare (EPN 6-84) & Ground Flare (7-84)

Pollutant(s):
Sulfur Dioxide - 7 pounds
Carbon Monoxide - 2 pounds
Nitric Oxide - 0 pounds
Particulate Matter - 1 pounds
Volatile Organic Compounds (VOCs) - 0 pounds
Cause of Problem: Instrument Failure

On November 28, 2013, OL-5 operations experienced a false high flow reading on a flow controller that resulted in high pressure in the diethanolamine stripper overhead. The high pressure caused a backup pressure controller to open the OL-5 Elevated Flare and OL-5 Ground Flare.
Upon investigation, it was discovered that the false high flow was the result of the plugging of one of the two transmitter taps. OL-5 operations and maintenance personnel cleared a plug from the transmitter taps of the flow controller, and the flow reading returned to normal operating conditions. The OL-5 Process Unit was safely returned to normal operation conditions, and the flaring stopped. Follow up report states that "additional measures to prevent reoccurrence have not been identified".
152570

2013-11-24
Point Source(s):
level control valve
level control valve in the de-methanizer system

Pollutant(s):
Carbon Monoxide - BRQ
Ethylene - BRQ
Hydrogen - BRQ
Methane - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Equipment Failure

On November 24, 2013, Shell Chemical's OL-5 operations discovered a packing leak on a level control valve in the de-methanizer system of the OL-5 Process Unit.
Operations took immediate action to mitigate the leak and have repairs made to the valve.
152357

2013-11-13
Point Source(s):
GO-1 Elevated Flare (EPN 1-90)

Pollutant(s):
Carbon Monoxide - 1,992 pounds
NOx - 366 pounds
Volatile Organic Compounds (VOCs) - 768 pounds
Particulate Matter - 145 pounds
Cause of Problem: Process Upset

On November 13, 2013, GO-1 had an unexpected process upset which resulted in flaring at the GO-1 Elevated Flare. The flaring was a result of the GO-1 South Acetylene Converter going off specification due to contaminants in the hydrogen supply to the converter due to a valve misalignment at Motiva's S3 Sulfur Unit. The material was flared at the GO-1 Elevated Flare to prevent additional upsets in GO-1. Incident Investigation is ongoing. Shell will provide an update within 60 days. Report states that no reportable quantities were exceeded.
GO-1 operations took corrective actions to return the acetylene converters to normal operation. GO-1 added steam and hydrogen to both converters. A pressure control valve for import hydrogen was put in manual to correct variations in the flow to the converters. The PSA hydrogen was stopped to the converters as part of initial troubleshooting, but was later lined up after the valve misalignment was discovered and corrected. Once the acetylene converters were returned to normal operating conditions the flaring stopped. To prevent this incident from reoccurring, the operations specialist at S3 has updated piping and instrument drawings to clarify the location of the S3 hydrogen and nitrogen valves in the field. Also the operations specialist at S3 has car sealed close the hydrogen valve from S3 to GO1.
152132

2013-11-03
Point Source(s):
OL-5 Ground Flare (EPN 7-84) and OL-5 Elevated Flare (EPN 6-84)
OL-5 Ground Flare and Elevated Flare

Pollutant(s):
Carbon Monoxide - 5,713 pounds
NOx - 1,050 pounds
Volatile Organic Compounds (VOCs) - 4,426 pounds
Particulate Matter - 2,934 pounds
Cause of Problem: Process Upset

On November 3, 2013, OL-5 had an unexpected process upset which resulted in flaring at the OL-5 Ground Flare (EPN 7-84) and OL-5 Elevated Flare (EPN 6-84). The flaring resulted from OL-5 taking a stream into the unit from OP-1 which caused the Acetylene Converter to go off specification. The material was flared at the OL-5 Ground Flare and OL-5 Elevated Flare to prevent additional upsets in OL-5.
Once OL-5 Operations was aware that the acetylene content increased above specification in the outlet of the acetylene converters, OL-5 Operations followed normal procedure and diverted the acetylene converter effluent to the OL-5 flare system until the Acetylene converter effluent was back in specification. The material was flared to prevent additional upsets in the unit. OL-5 operations immediately stopped the OP-1 de-ethanizer tops flow into the unit and ethylene product flow to the pipeline. The ethylene splitter received some of the high acetylene process gas exiting the acetylene converters. The ethylene splitter overhead and the liquid in the ethylene splitter reflux drum were sent to the flare until the column was also back on specification. Once the ethylene product stream was back on specification, the ethylene product leaving the ethylene splitter was returned to the pipeline and the flaring stopped. Report states that all released materials were dispersed naturally in the atmosphere from the OL-5 Ground and OL-5 Elevated flare stacks. Currently, an investigation is occurring. The results from this investigation will be incorporated, where applicable, into the standard work processes at the OL-5 Unit to prevent recurrence. Shell Chemical confirmed that the reportable quantity for Highly Reactive Organic Compounds was exceeded. The maximum permitted limits were exceeded for carbon monoxide, nitrogen oxide, particulate matter, and volatile organic compounds.
152124

2013-11-02
Point Source(s):
GO-1 Elevated Flare (EPN 1-90)

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

On November 2, 2013, GO-1 had an unexpected process upset which resulted in flaring at the GO-1 Elevated Flare. The flaring resulted from GO-1 taking a stream into the unit from OP-1 which caused the Acetylene Converter to go off specification. The material was flared at the GO-1 Elevated flare to prevent additional upsets in GO-1. Following the investigation and calculations, Shell Chemical confirmed that no reportable quantities or Maximum Permitted Limits were exceeded.
151584

2013-10-11
Point Source(s):
OL-5 Ground and Elevated Flares

Pollutant(s):
Carbon Monoxide - 5,874 pounds
Nitrogen Oxide - 1,079 pounds
Volatile Organic Compounds (VOCs) - 3,115 pounds
Particulate Matter - 3,016 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs) - 1,460 pounds
Cause of Problem: Power Failure

On October 11, 2013, Shell Chemical's OL-5 Process Unit experienced an unexpected power failure which resulted in the shutdown of several pumps in the OL-5 Process Unit leading to a process upset and flaring at the OL-5 Ground Flare and OL-5 Elevated Flare. Several breakers in the main central control room were lost. The transformer that supplies power to these breakers tripped unexpectedly. This resulted in the shutdown of several pumps in the OL-5 Process Unit. Most of the pumps that shutdown had back-up spare pumps available and the spare pumps either automatically started or operations manually started them. The ethylene product pump did not have a back-up spare pump available. OL-5 was unable to send ethylene product to the downstream pipeline. This resulted in an inability to remove ethylene product from OL-5's C2 Splitter column and the pressure of the C2 Splitter increased. Elevated pressure in the C2 Splitter column was controlled by relieving to the OL-5 Ground Flare and OL-5 Elevated Flare.
To minimize impacts, spared pumps automatically started and operations started spare pumps manually that do not auto start. After securing and stabilizing the unit, OL-5 operations contacted electrical engineering and maintenance to repair the tripped transformer. On the evening of October 11, 2013, repairs to the transformer were completed, the transformer was placed back in service and flaring stopped. It has been determined that there are not any measures that could be taken to prevent the recurrence of this incident or a similar incident. Report states that all released materials were dispersed naturally in the atmosphere from the OL5 Ground and OL5 Elevated flare stacks. Shell Chemical confirmed that reportable quantity for Highly Reactive Organic Compounds (ethylene and propylene) was exceeded. The maximum permitted limits were exceeded for carbon monoxide, nitrogen oxide, particulate matter, and volatile organic compounds.
150876

2013-09-08
Point Source(s):
OL5 Elevated Flare (EPN 6-84) and Ground Flare (EPN 7-84)

Pollutant(s):
Carbon Monoxide - 8,094 pounds
NOx - 1,488 pounds
Volatile Organic Compounds (VOCs) - 3,775 pounds
Particulate Matter - 591 pounds
Highly Reactive Volatile Organic Compounds (HRVOCs) - 664 pounds
Cause of Problem: Equipment Failure

On the night of September 8, 2013, Shell Chemical's OL-5 Unit experienced plugging of their online recycle filter located on the bottom of the pyrolysis fractionator (pyrofrac). Once plugged, the level at the bottom of the pyrofrac increased resulting in the level of the quench drum to decrease. This resulted in diversion of feed from several furnaces at OL-5. While stabilizing the OL-5 process unit, operations personnel experienced an upset in the process streams that resulted in flaring at the OL-5 Elevated Flare and OL-5 ground flare.
To minimize impacts, OL-5 operations made various process adjustments, while taking the furnaces off line. These adjustments stabilized the unit and reduced, eventually eliminating, the flaring. These adjustments also prevented the unit from shutting down. To prevent future occurrences, additional filters will be installed to create a robust filtering system. Report states that all released materials were dispersed naturally in the atmosphere from the OL5 Ground and OL5 Elevated flare stacks. Initial report stated that no reportable quantities were exceeded. Following the investigation and calculations, Shell Chemical confirmed they exceeded the reportable quantity for highly reactive volatile organic compounds.
150789

2013-08-31
Point Source(s):
7-84 (OL-5 Ground Flare, 6-84 (OL-5 Elevated Flare, FE-101)

Pollutant(s):
Carbon Monoxide - 14,697 pounds
NOx - 2,701 pounds
Volatile Organic Compounds (VOCs) - 3,758 pounds
Particulate Matter - 1,073 pounds
Cause of Problem: Process Upset

On the morning of August 31, 2013, Shell Chemical's OL-5 Process Unit experienced a higher than normal level of carbon monoxide (CO) in the furnace feed. The additional unexpected CO in the feed came from Enterprise, a supplier of feed to OL-5, and as a result of recent decoking activities. The higher level of CO was initially consumed by the Product Hydrogen and Converter Hydrogen Methanators, however, this did not resolve the issue. Without taking action, continued high levels of CO would have led to the ethylene product going off specification which in turn would have led to substantial additional flaring. Therefore, as per normal operating procedures, OL-5 opearations began routing the high AC converter stream to the flare to lower the CO levels in the process in an effort to prevent a further, more severe, upset in the OL-5 Process Unit. Once the AC converter effluent was within specifications, it was routed back to normal operation.
To minimize impacts, OL-5 operations adjusted unit operations in order to consume the excess CO in the Product Hydrogen and Converter Methanators. Once the Product Hydrogen and Converter Hydrogen Methantators became overwhelmed, OL-5 operations immediately diverted the AC converter effluent to the OL-5 flare system. Operations then used a different source of hydrogen that did not contain elevated carbon monoxide. Once the AC converter effluent was within specifications OL-5 operations positioned the stream back to its normal routing, eliminating flaring. An investigation is occurring. The results will be incorporated, where applicable, into the standard work processes at the OL-5 unit to prevent recurrence. Shell Chemical confirmed that reportable quantities for carbon monoxide, nitrogen oxide, and High Volatile Organic Compounds were exceeded. In addition, the maximum permitted limits were exceeded for carbon monoxide, nitrogen oxide, particulate matter, and volatile organic compounds at the OL-5 elevated flare. Shell admitted that Carbon Monoxide exceeded RQ for August 31, but not Sept 1. Carbon Monoxide exceeded RQ on both dates. Similarly, VOCS exceeded RQ for both Aug 31 and Sept 1, but was only reported as exceeding for the first. VOCs are mislabeled as HRVOCs (highly reactive VOCs).
150009

2013-07-29
Point Source(s):


Pollutant(s):
Highly Reactive Volatile Organic Compounds - 250 pounds
1,3-Butadiene - BRQ
Benzene - BRQ
Hydrogen Sulfide - BRQ
Cause of Problem: Equipment Failure

On July 29, 2013, there was a release of 1,3 butadiene, benzene, and hydrogen sulfide due to a GO-1 process gas leak to the condensate system. While working with operations, personnel monitoring the fugitive emission components in the unit found the GO-1 caustic column feed pre-heater exchanger leaking process gas to the condensate system. Operations redirected the contaminated condensate to the flare system due to the condensate system flash drum venting to the atmosphere.
GO-1 operations took the necessary steps to minimize the release to the atmosphere. Operations personnel were able to complete a management of change to route the contaminated condensate to the flare. The leaking exchanger is scheduled for a metallurgy upgrade during the next GO-1 North turnaround. Upgrading the metallurgy should prevent any future leaks.
149751

2013-07-18
Point Source(s):
No Information Given

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

On July 18, operations personnel in Logistics discovered a temporary clamp on a 1,3 Butadiene line was leaking.
Immediately after discovery, maintenance began repairs. This incident is linked to a complaint regarding excessive flaring investigated by LDEQ. The follow up report states that no reportable quantities were exceeded, and no additional information was provided.
149323

2013-06-20
Point Source(s):
EPN 1-90 GO-1 Elevated Flare FE-602
GO-1 Elevated Flare

Pollutant(s):
Carbon Monoxide - 1,204 pounds
NOx - 221 pounds
Volatile Organic Compounds (VOCs) - 464 pounds
Particulate Matter - 618 pounds
Cause of Problem: Process Upset

On June 20, an upset in the Shell Chemical's GO-1 unit caused by the AC Converter high temperatures due to unforeseen low hydrogen purity from the Pressure Swing Absorber which was started up and placed in service following the GO-1 South turnaround. The unforeseen low hydrogen purity prompted operations to divert feed to the elevated flare to prevent an off specification incident with ethylene production. This resulted in flaring at the GO-1 Elevated Flare (EPN 1-90).
GO-1 operations took the necessary steps to minimize flaring, restart the PSA and safely return the unit to normal operating conditions. The PSA was isolated from the header and remained isolated until lab samples indicated on specification hydrogen. To prevent recurrence, operations will incorporate additional guidance and operational measures into the PSA start up procedures to proactively identify unforeseen low hydrogen purity. The procedure will be updated with steps to ensure on specification hydrogen prior to introducing into the header. Shell claims no reportable quantities were exceeded, but CO and NOx emissions exceed lb/hr permit limits.
148977

2013-06-01
Point Source(s):
OL-5 Exchange Unit E1970
WWTP system

Pollutant(s):
Benzene - BRQ
Naphthalene - BRQ
Polycyclic Aromatic Hydrocarbons - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Gas Oil - BRQ
Cause of Problem: Piping or Tubing

On June 1, a release of Benzene, Naphthalene, Polycyclic Aromatic Hydrocarbons, and Volatile Organic Compounds occurred. The release was due to an unexpected leak on an OL-5 process unit 20lb Steam Regenerator Exchanger. The Norco Site Supervisor was notified by a st. Charles DEP deputy of an odor detected along highway 61. The leaking steam condensate entrained with CLGO (cracked light gas oil) hydrocarbon entered the storm water drain and the refinery conveyance system.
At the time of the LDEQ verbal notification, in house monitoring levels of Benzene were 5.0 ppm. The material was removed from the storm water drains and conveyance systems and disposed of properly. Mr. White stated the product was being routed to an oily/water separator, thence to their WWTP system for treatment. They were "slabbing" the condensate as of approximately 1415 hours. Gas oil release is now ongoing and is going to effluent system and being picked up at their separator. The material was reported to have gone offsite - released to the air. Inside the facility air monitoring was between 6-10 ppm. There was no offsite protective action. The 24 hour update states the exchanger 1970 was taken off line which is what was leaking. Have contractors picking up the oil out of the F1 system.
148877

2013-05-23
Point Source(s):
West Operations Elevated Flare (EPN 5-84)

Pollutant(s):
Carbon Monoxide - 63 pounds
Nitrogen Oxide - 12 pounds
Particulate Matter - 5 pounds
Volatile Organic Compounds (VOCs) - 39 pounds
Cause of Problem: Process Upset

On May 23, an upset in the Shell Chemical's OP-1 process unit led to flaring at the West Operations Elevated Flare (EPN 5-84). The flaring was due to a high level in the Ethylene Refrigeration Compressor causing the compressor to shut down unexpectedly.
OP-1 operations took the necessary steps to minimize flaring, restart the compressor and safely return the unit to normal operation conditions. Operation's support will provide additional guidance and operational measures to be more effective in controlling levels and restoring normal operations after a compressor shutdown. States that no reportable quantities were exceeded, but the maximum permit limits for carbon monoxide, nitrogen oxide, particulate matter, and VOCs were exceeded.
148901

2013-05-16
Point Source(s):
West Ops Elevated Flare

Pollutant(s):
Carbon Monoxide - 36,792 pounds
Nitrogen Oxide - 6,762 pounds
Particulate Matter - 11,933 pounds
Volatile Organic Compounds (VOCs) - 11,114 pounds
1,3-Butadiene - 719 pounds
Benzene - 111 pounds
Methanol - 719 pounds
Toluene - 8 pounds
Hexane - 279 pounds
Cause of Problem: Process Upset

On May 17,a release of carbon monoxide, ethane, and methane occurred due to flaring from a GO-1 unit upset caused by a De-methanizer shutdown. Unit feed composition caused unanticipated low temperature issues leading to a unit shutdown.
GO-1 operations took the necessary steps to safely return the unit to normal operating conditions and minimize flaring. Procedures will be updated to provide guidance and operational measures to restore normal operations after a unit shutdown.
148703

2013-05-10
Point Source(s):
1-90 (GO-1 Elevated Flare, FE-602)
5-84 (West Ops Elevated Flare, FE-601)
8-84 RCCU Elevated Flare (FE-201)

Pollutant(s):
Carbon Monoxide - 8,987 pounds
NOx - 1,652 pounds
Particulate Matter - 311 pounds
Sulfur Dioxide - 646 pounds
Volatile Organic Compounds (VOCs) - 4,441 pounds
Carbon Monoxide - 32 pounds
NOx - 6 pounds
Particulate Matter - 1 pounds
Sulfur Dioxide - 157 pounds
Volatile Organic Compounds (VOCs) - 9 pounds
Hexane - 1 pounds
Carbon Monoxide - 1,816 pounds
NOx - 334 pounds
Particulate Matter - 63 pounds
Sulfur Dioxide - 10,547 pounds
Volatile Organic Compounds (VOCs) - 517 pounds
Butadiene - 7 pounds
Benzene - 1 pounds
Toluene - 0 pounds
Hexane - 45 pounds
Cause of Problem: Piping or Tubing

On May 10, Motiva's Residual Catalytic Cracking Unit (RCCU) discovered a catalyst leak in the unit's second cyclone dip leg. Operations responded immediately and worked to isolate this section of the unit. However, due to the location of the leak it was determined the line could not be isolated without diverting the RCCU process unit to hot circulation. The diverting process required flaring at the GO-1 Elevated flare (EPN 1-90) and West Ops Ground Flare (EPN 9-84). Additional flaring occurred at the Motiva RCCU Elevated Flare (EPN 8-84). Emissions from that flare should be addressed in a separate letter from Motiva. The reintroduction of Motiva's RCCU untreated dry gas resulted in the shell GO-1 unit flaring to the West Ops Elevated Flare.
Once system was secured, Motiva's maintenance personnel began repairs at the catalyst leak point. By May 12, the repairs on the system were completed and the system was returned to service. The diversion and reintroduction of RCCU Untreated Dry Gas caused the Shell GO-1 unit to flare to the GO-1 Elevated Flare (EPN 1-90) until unit specifications were met. This flaring exceeded reportable quantities.
No LDEQ Number Available

2013-05-06
Point Source(s):
Furnace piping

Pollutant(s):
Heavy Gas Oil - BRQ
Cause of Problem: Piping or Tubing

On May 6, an employee of the neighboring facility called and reported to Shell that an odor was identified in the area of the north east side of the site around the OL-5 unit area by the fence line roadway. Shell investigated and found a hole in a furnace piping going to the process water drain. Residual cracked heavy gas oil was found in the furnace piping.
Operations personnel pressured out residual oil with steam and odor was eliminated.
No LDEQ Number Available

2013-05-05
Point Source(s):
tank vent

Pollutant(s):
Benzene - BRQ
Cause of Problem: No Information Given

On May 5, at 1750 hours there was a benzene release at Shell Chemical East Site. Shell Chemical's GO-1 Process Unit identified a trace of benzene venting from a temporary tank used for de-inventorying the GO-1 unit to prepare for turnaround activities.
GO-1 operations notified Shell Emergency Services to provide monitoring of the temporary tank and surrounding area until conditions were safely returned to normal.
148252

2013-04-20
Point Source(s):
GO-1 Elevated Flare, FE-602

Pollutant(s):
Carbon Monoxide - BRQ
NOx - BRQ
Particulate Matter - BRQ
Sulfur Dioxide - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Hexane - BRQ
Cause of Problem: Maintenance/Procedures

On April 20, 2013, GO-1 operations restarted compressor K5741 after planned maintenance was executed. During the restart event, GO-1 flared dry gas at the GO-1 Elevated Flare (EPN 1-90) until the dry gas met specification to be used feed in the unit. The GO-1 flaring resulted in no reportable quantities exceeded but a permit limit exceedence of 46.32 lbs of Hexane.
The cause was a mechanical failure of the compressor check valve that required a dry gas compressor shutdown to repair. Once repairs were completed, dry gas must be flared until it meets specification to be used in the unit. An investigation determined the cause was the mechanical failure of the compressor check valve. This required a dry gas compressor shutdown to repair. Shell Chemical procedures require that the dry gas must be flared until it meets specification to be used in the unit.
148176

2013-04-19
Point Source(s):
OL-5 Elevated Flare, FE-101

Pollutant(s):
Carbon Monoxide - BRQ
NOx - BRQ
Particulate Matter - BRQ
Volatile Organic Compounds (VOCs) - BRQ
1,3-Butadiene - BRQ
Benzene - BRQ
Ethylbenzene - BRQ
Toluene - BRQ
Xylene - BRQ
Cause of Problem: Process Upset

On April 19, 2013 Shell Chemical's OL-5 Process Unit experienced an unexpected upset that led to flaring at the OL-5 Elevated Flare (EPN 6-84). The flaring was caused by high pressure on the process gas compressor (PGC) first stage suction drum. A pressure increase on the suction drum was due to the PGC slowing down as a result to the loss of vacuum on the compressor surface condenser. The surface condenser vacuum was lost due to a faulty level indication causing the loss of vacuum on surface condenser. The PGC upset also caused OL-5 cold-side to flare propylene off the outlet of the map converters because of a low flow shutdown of the converters.
OL-5 operations field verified the level int he PGC surface condenser and took corrective actions to safely return the unit to normal operating conditions and stop the flaring. OL-5 Maintenance repaired the PGC surface condenser level transmitter. Control systems adjusted the vacuum alarm setting for the PGC surface condenser to warn operators before the surface condenser vacuum is lost. Final calculations confirm that no reportable quantities were exceeded. The maximum permitted limits were exceeded for particulate matter, ethylbenzene, toluene, and xylene.
148040

2013-04-11
Point Source(s):
GO-1 Elevated Flare (EPN 1-90)

Pollutant(s):
Propylene - BRQ
Ethylene - BRQ
Carbon Monoxide - BRQ
Sulfur Dioxide - BRQ
Volatile Organic Compounds (VOCs) - BRQ
Cause of Problem: Maintenance/Procedures

On April 11, 2013 Shell Chemical's GO-1 Process Unit flared at the GO-1 Elevated Flare. The flaring was a result of a restart of the import dry gas from a supplier. GO-1 operations has to flare the import dry gas until it can be confirmed that it meets the specifications for feed to the GO-1 Process Unit.
Carbon monoxide, ethylene, propylene, sulfur dioxide, and volatile organic compounds were released from flaring at the GO-1 Elevated Flare (EPN 1-90). Investigation and calculations confirm that no reportable quantities or maximum permit limits were exceeded. No duration or additional information was provided.
145744

2013-01-07
Point Source(s):
GO-1 Elevated Flare (EPN 1-90)

Pollutant(s):
Ethylene - BRQ
Hydrogen Sulfide - BRQ
Propylene - BRQ
Sulfur Dioxide - BRQ
Cause of Problem: Process Upset

Shell Chemical's GO-1 Process Unit flared at the GO-1 Elevated Flare as a result of an unexpected unit upset in GO-1 caused by the receiving of off specification feed from a supplier.
GO-1 operations took the necessary steps to minimize flaring and safely return the units to normal operating conditions and the flaring stopped. No reportable quantities were exceeded.