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Phillips 66 (2418), Belle Chasse
Releases of Hydrogen Sulfide
| LDEQ Accident Number Accident Date |
Point Source(s) | Notes | Amount of Release |
| No LDEQ Reported 2005-07-29 | 308F-D-1 Low pressure flare | Cause: The liquid/gas pressure relay on transformer XFR 5CE at electrical substation 5C unexpectedly tripped breaker VCB 3CG. Followup: Yes Notes: Claimed preventative maintenance could have been used, but the failure was unforeseeable. The level of SO2 exceeded that of a reportable level. | 6.6 pounds |
| No LDEQ Reported 2005-07-25 | Low Pressure Flare | Cause: A contractor came into contact with the instrument air supply line for the FCC Unit's K-2A Supplemental compressor. This caused the lines to separate and for air to leak. Followup: No information given Notes: It was immediately repaired and they claimed to go over similar air supplies. | 3.0 pounds |
| No LDEQ Reported 2005-07-05 | FCC Unit #1291 | Cause: The FCC Unit #1291 system tripped off-line due to a false airflow alarm. Followup: No information given Notes: They claimed they restarted it and it is now safe and secure. | 2.0 pounds |
| No LDEQ Reported 2005-06-26 | Saturate Gas Unit (7991-PSV-18) | Cause: Pressure control valve BPC-244 malfunctioned gave a false signal of being open when actually in the closed position. This caused the pressure relief valve 7991-PSV-18 to lift for 5 minutes. Followup: Yes Notes: Assured they would operate this at a Òlow pressureÓ pending findings of the investigation. | 90.0 pounds |
| No LDEQ Reported 2005-05-10 | (308F-D-1) Low Pressure Flare; (308F-D-2) High Pressure Flare; (301-D-3) CO Bypass Stack; (591-D-21X) SRU Incinerator | Cause: Entergy experienced a ground fault and the backup supply failed to switch in a timely manner. Forced most process units to shutdown resulting in flaring and venting of CO. Two pressure valves relieved to the atmosphere. Followup: No Notes: With most of the process units down, there was isufficient feed to keep the SRU tail gas treater online. The tail gas from SRU 591 was routed directly to the SRU incinerator until other refinery process units restarted to provide sufficient feed to support stable TGT operation. There was some smoking form the flares. | 413.0 pounds |
| No LDEQ Reported 2005-02-28 | Saturated Gas plant 7991 -V-1 | Cause: The signal to the 7991-V-1 straight run Debutinizer Bottoms level controller stopped transmitting it's signal from the field of the distributed control system Followup: No information given Notes: After inspection a set of wires appeared to be frayed. They sent a group of employees to fix the frayed wires. | 565.8 pounds |
| 92941 2006-12-31 | Saturated Gas Plant 7991-V-2 | Cause: Failure of the Process Safety Valve Followup: No Notes: Could not have been predicted, preventative safety measures were in place already. | 3.0 pounds |
| No LDEQ Reported 2006-11-23 | 301-D-3 FCC Regenerator Flue Gas Bypass Stack; 308F-D-1 Low Pressure Flare; 308F-D-2 High Pressure Flare | Cause: The FCC process control system malfunctioned causing upset operating conditions at the FCC Unit. This malfunction caused an immediate and unecpected shutdown of the entire FCC Unit. Followup: yes Notes: According to the report: "Although preventative maintenance procedure exist, conditions of this type cannot be anticipated. An investigation is continuing to determine the root cause of this accident." | 7.0 pounds |
| No LDEQ Reported 2006-08-09 | 308F-D-1 Low Pressure Flare | Cause: During Coke Drum switch the actuator on isolation valve XV627 malfunctioned which in turn caused the compressor kickback valve to open. Followup: No Notes: Coker unit operations and pressures were stabilized and the valve to the flare was closed. | 34.0 pounds |
| No LDEQ Reported 2006-07-18 | 308F-D-2 High Pressure Flare | Cause: Low flare vapor traffic and a possible sudden release of high velocity steam may have snuffed out the HP flare flame at its tip. Followup: No Notes: Operations immediately blocked in the steam controllers and orifices to the High Pressure flare and added additional purchased fuel gas to the tip. The manual flame front generator was then reactivated to reignite the High Pressure Flare. The additional purchased gas was then blocked in and the steam controllers were ublocked to provide smokeless flaring capabilities. | 79.0 pounds |
| No LDEQ Reported 2006-06-07 | 308F-D-1 Low Pressure Flare | Cause: Coke fine particles clogged downstream of the valve causing liquid levels in V16 to increase. Followup: No Notes: It seems these coke particles had accumulated failry quickly near the valve due to the manner in which the outlet valve had been operating over the past several drum switch cycles. | 6.5 pounds |
| No LDEQ Reported 2006-06-06 | 308F-D-1 Low Pressure Flare | Cause: The level float column in the 1291 V 15 Sour Water Drum malfunctioned causing its level controller OLC 180 to open and caused a higher than normal rte of sour water and hydrocarban to inter the Sour Water Stripper Flash Drum v12. Followup: No Notes: The OLC 180 controller valve was manually closed and then re opened to establish a proper water level in the Sour Water Drum. | 2.0 pounds |
| No LDEQ Reported 2006-05-18 | 308F-D-1 Low Pressure Flare | Cause: The 891-K-1 compressor tripped off line due to a faultry level indicator on the high level alaerm in the compressor interstage drum. There was foreign material collecting and plugging the level bridle on V-16. Followup: No Notes: The liquid levels in the interstage drum were drained manually and the circuit breaker for the compressor was reset and the compressor put back on line. A periodic flush of the V16 level bridle with fresh water is the corrective action. | 10.9 pounds |
| No LDEQ Reported 2006-05-16 | 308F-D-1 Low Pressure Flare | Cause: Malfunction with the bus bar caused the main circuit breaker supplying power to the Crude Unit 191, Saturated Gas Unit 7991 and the WWTP to trip. The power interruption caused unit upsets at the Crude Unit and Hydrotreating Unit 292. Followup: No Notes: Immediately switched power source to an alternative feeder. | 34.4 pounds |
| No LDEQ Reported 2006-04-26 | 308F-D-1 Low Pressure Flare | Cause: Problems with the coke cutting system required a switch of drums which reduced the flow to the compressor and caused a compressor kickback valve to open to the flare. Followup: No Notes: Pressures were stabilized and the valve was closed. | 19.0 pounds |
| No LDEQ Reported 2006-04-19 | 293-PSV-4A | Cause: The 293-KN-1 compressor tripped due to a false high level alarm from the suction drum 293-V-5. The suction drum had had been drained by the unit operator but the local level alarm continued to show a high level signal to the compressor. Thie high level alarm indicator caused the compressor to trip unexpectedly. The compressor's turbine could not be reset immediately resulting in 293-PSV-4A lifting to the atmosphere for a short duration. Followup: yes Notes: None | 449.0 pounds |
| 101938 2007-12-28 | Diesel Hydrotreater Unit | Cause: A small fire occurred in the convection section of the Diesel Hydrotreater Unit 293 in one of the tubes. While in the process of isolating the H-1 Heater for inspection and repair of the tube, the tube completely failed resulting in a fire in the entire convection sectino of the heater. Followup: No Notes: The Refinery's Fire Brigade and Emergency Response Teams were activated and the fire was extinguished. No offsite impacts were noted during air monitoring. | 2.4 pounds |
| 100206 2007-10-16 | 292-FF, 308F-D-1 Low Pressure Flare | Cause: Vapor leak coming from a tube at the exchanger. Unit 292 was depressurized and shut down which caused flaring. Followup: Yes Notes: Determined that preventative maintenance procedures could not prevent this accident. | 90.0 pounds |
| 99785 2007-09-27 | 308F-D1 Low Pressure Flare | Cause: The Delayed Coking Unit was in hot circulation and preparing for startup after unexpectedly losing its coke cutting water pumps and its compressor (891 K-1) tripped off line due to high liquid level in the compressor suction drum 891-V-12, unexpectedly carried over to V-15. The compressor's suction stream is automatically diverted to the Low Pressure Flare during an emergency shutdown. Followup: Yes Notes: Investigation to determine the cause of liquid carryover from the Delayed Coking Unit combination tower overhead drum. The refinery claims that there was no offsite impact. | 6.9 pounds |
| 99023 2007-08-29 | 308F-D-1 Low Pressure Flare, 308F-D-2 High Pressure Flare | Cause: Followup: Yes Notes: | 6.0 pounds |
| 97401 2007-06-26 | 308F-D-1 Low Pressure Flare | Cause: The Delyaed Coking Unit compressor 891 K-1 tripped offline due to high level in the suction drum, 891-V-15. Liquid from the DCU combination tower overhead drum, 891-V-12, carried over to V-15 due to plugged strainers on the V-12 on the water boot pumps and hydrocarbon pumps or some other flow restriction. The compressors suction stream is automatically diverted to the Low Pressure Flare during and emergency shutdown of the compressor. Followup: Yes Notes: Operators tried to mitigate the accident by cleaning the strainers and tried to draw liquid from V-15 to the flare drums. Attempts were unsuccessful and the K-1 compressor still tripped. Compressor was purged of liquid and restarted. ConocoPhillips claims "no offsite impact" from fenceline monitoring. | 11.0 pounds |
| 96490 2007-05-23 | Carbon Monoxide Bypass Stack Low Pressure Flare, High Pressure Flare, SRU incinerator Stack, 191-PV-105, Heaters 410-PSV-62 Induction gas relief valve (APC-105), Low Pressure Flare, High Pressure Flare Low Pressure Flare (308F-D-1), High Pressure Flare, 191 APC-105 Low Pressure Flare, High Pressure Flare, 191-PV-105 | Cause: During a rain storm the line from Entergy's substation tripped. The loss of power forced most of the refinery's process units to shutdown resulting in flaring. While shutting down the 191 crude unit the pressure controller relieved vapors and liquid hydrocarbons from a vent at the top of the Vacuum Tower. The hydrocarbons ignited and caused a fire at the top of the Vacuum Tower. With most of the process units down there was insufficient feed to keep the SRU tail gas treater online. The tail gas was routed to the SRU incinerator. When units were started up again they required more flaring for prepare for recommissioning. Followup: No Notes: Determined that although there are back up systems there are no ways to prepare for these types of power outages. Electrical department will preform preventative maintenance and replacement of components. 191-PV-105 pressure controller at the crude unit no longer vents to the atmosphere. Piping was installed that routes gases from this vent directly to the flare. | 474.0 pounds |
| 93785 2007-02-07 | 308-F-D-1 Low Pressure Flare | Cause: A 34.5KV lightning arrestor failed at Entergy substation. An insulator also failed on the disconnect switch. The opening of these breakers caused the Coker Compressor to trip off line. The compressor's suction stems is automatically diverted tot he Low Pressure Flare. Followup: No Notes: Three arrestors and a failed insulator are being replaced. | 6.5 |
| 94025 2007-02-07 | FLARE - 308F-D-1 Low Pressure Flare | Cause: A 34.5KV lightning arrestor failed near breaker W5305 (Carlisle #1 Line Bus, and an insulator failed on the disconnect switch on the other side of breaker W5305 (ConocoPhillips # 2 Line Bus). ConocoPhillips Alliance breakers W5305, W5301, W5304 tripped along with Carlisle W6922 breaker. All of these de-energized ConocoPhillips #2 Line to the plant leading to the Coker Compressor to trip off the line. The compressors suction stream was automatically diverted to the Low Pressure Flare (308F-D-1) during the emergency shutdown of the compressor. Followup: No Notes: Three arrestors on breaker W3505 were replaced, as well as a failed insulator. Preventive measures are in place, but incidents of this type could not be anticipated by the prevention measures. A further investigation to discover the root cause of the malfunctions is ongoing. | 6.5 pounds |
| 110898 2008-11-19 | 308F-D-1 (Low Pressure Flare); 308F-D-2 (High Pressure Flare); 191-FF (191-PSV-009A); 191-FF (191-PSV-011) | Cause: On 11/19/09, the refinery "experienced an unexpected internal electrical power phase to ground fault." This fault caused a power interruption from internal Substation 5D to the Crude Unit 191 and resulted in the loss of most of the Crude Unit's pumps and several fin fans causing a major unit upset and emergency shutdown. These upset operations subsequently caused the Atmospheric Tower's pressure relief valve (191-PSV-009A) to open to protect the upper section of the Atmospheric Tower.
An attempt to circulate the liquid inventory in the Vacuum Tower (VT) back to the Crude Tanks caused as unexpected high liquid level and the VT pressure relief valve (191-PSV-011) opened up to protect the upper section of the VT. This relief valve relieved vapors, liquid hydrocarbons, and crude oil from a vent at the top of the VT.
The loss of the Crude Unit forced most of the refinery's process units to shutdown resulting in intermittent flaring.
Following the shutdown and the re-establishment of power to substation 5D, the process of restarting several refinery units was initiated. The Coker Unit's Compressor (891-K-1) motor amp limit controller (PJC-404) unexpectedly opened the flare valve (PPC-998) due to a very high motor amperage surge at its initial start.
Flares smoked intermittently throughout shutdown and startup events. Fenceline monitoring indicated "no offsite impact."
Fenceline monitoring Followup: No Notes: Immediate: Units were shut down until electrical supply was repaired. After a formal investigation, the cause of the incident was determined to be a loose connection between the bus and runback rod that put enough electrical load on the connecting bolt to melt it thus creating the ground fault. Connecting bolts are now inspected and replaced as necessary, COP electricians are being further trained, and a QC checklist and testing procedures to verify proper electrical connections have been implemented. Discharge classified as "Extremely Hazardous Substance" Regulated by OSHA HazCom | 5.0 pounds |
| No LDEQ Reported 2008-06-03 | Fluid Catalytic Cracker (FCC) Unit, 308-D-1 Low Pressure FLARE, 308F-D-2 High Pressure FLARE, 301-D-3 CO Bypass Stack | Cause: Followup: Yes Notes: FCC shut down to repair a crack. During repairs, a broken valve was discovered and also repaired (#106247). Emissions released during startup of FCC and below reportable quantities. Investigation into procedures to prevent flarting during shutdown/startup | 8.6 pounds |
| No LDEQ Reported 2008-05-17 | FLARE-PSV-84 relief valve on Reactor (491-V-49) | Cause: Valve failure cause by a power surge from lightening. Followup: Yes Notes: Incident due to a valve failure caused by a power surge from lightning. Motor control and trim on valve fixed. | 3.0 pounds |
| No LDEQ Reported 2008-01-25 | Diesel Hydrotreater Unit 293 | Cause: Start Up, Shut Down --Unit 239 restarted after repairs completed on failed tubes Followup: No Notes: Community monitoring during a planned emission. Incident considered a courtesy notification for potential flaring. | |
| 119920 2009-12-08 | 308F-D-2 (High Pressure Flare) | Cause: The flame on 308F-D-2 (High-Pressure Flare) had extinguished due to wind and rain. Multiple attempts were made to relight the flame; including the use of the automatic igniter and hand held flare gun. The wind prevented these methods from working. A manual flare flame generator finally allowed for the flame to be reignited.
During the flame out, 12,082 lbs of hydrocarbon and 2 lbs of Hydrogen Sulfide were released. Followup: No Notes: Operations immediately blocked in the steam controllers and orifices in the High Pressure Flame and added additional purchased fuel to the tip. The manual flame generator was finally used to reignite the High Pressure Flare. The additional purchased fuel gas was then blocked in and the steam controller were unblocked to provide smokeless flaring capabilities. | 2.0 pounds |
| 114566 2009-04-30 | 308F-D-1 (Low Pressure Flare) | Cause: On April 30, 2009 at approximately 2:40 AM, the Coker compressor unexpectedly tripped off-line. At approximately 2:41 AM the suction drum flare valve opened, which it is designed to do when the compressor experiences an unexpected complete shutdown. The suction stream is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown. Followup: No Notes: The compressor was started and brought online following review of alarm and trip logs. | 18.9 pounds |
| 114066 2009-04-08 | 308F-D-1 (Low Pressure Flare) 308F-D-1 (Low Pressure Flare); 191-PSV-009 | Cause: The 891-K-1 Compressor tripped off-line due to a high liquid level inside the first stage suction drum (891-V-15). This was caused by high liquid levels in the fractionator tower's reflux drum (891-V-12) due to coke fines plugging the filters of the L-11 reflux pumps and L-13 Sour Water pumps at an unexpectedly rapid rate.
The compressor's suction steam is automatically diverted to the Low Pressure Flare (308F-D-1) during an emergency shutdown of the compressor. Monitoring at the refinery permitter was performed and "there was no offsite impact." Followup: No Notes: The compressor was started and brought online as soon as proper levels could be established in the first stage suction drum. An investigation is in process to determine the cause of the high levels in the first stage suction drum (which caused the compressor to trip). | 13.0 pounds |
| 113974 2009-04-06 | 308F-D-1 (Low Pressure Flare); 191-PSV-009 Unit 191-PSV-009 | Cause: A power failure occurred as a result of grid failure due to scheduled maintenance by Entergy. Entergy's method did not allow for ConocoPhillips to secure an alternative source while the main grid was down. The refinery thus had to initiate an emergency shutdown. As a result, the refinery had to employ the low pressure flare. Followup: No Notes: Entergy has proposed a three phase project that will build additional substations within the electrical power grid over the next five to eight years to improve its reliability. Entergy is currently seeking federal funding for this project. | 130.0 pounds |
| 113242 2009-03-08 | 308F-D-1 (Low Pressure Flare) | Cause: Problems with the Coker drum steam condensate operations caused inadequate heating of the"inactive
Coke drum. To avoid shutting down the Coker Unit, Operations personnel switched Coker feed from teh "active" drum into the "inactive" drum that was much cooler than normal operating systems.
The switch into a cooler coke drum reduced the flow to the 891-K-1 compressor and caused the "compressor kickback" control scheme to activate. This scheme caused the compressor kickback valve to open, sending additional flow to the compressor's suction drum (891-V-15). The pressure in the compressor suction drum increased to the point that the pressure control system opened the valve to the Low PRessure Flare (308F-D-1). Followup: No Notes: Coker unit operations and pressure were stabilized and the valve to the flare was closed. | 6.0 pounds |
| 111891 2009-01-08 | 308F-D-1 Low Pressure Flare 308F-D-1 Low Pressure | Cause: A notification for the controlled shutdown of the entire plant was made on January 7, 2009. On January 8, the Sulfur Recovery Unit/Tail Gas Treater (SRU/TGT) was determined to have pluggage issue that precipitated the premature shutdown of the SRU/TGT. This led to flaring and SO2 emissions. The loss of the SRU/TGT required the initiation of a controlled shutdown of the remaining process units which contributed additional Sulfur Dioxide emissions. Followup: No Notes: An immediate shutdown was conducted of refinery process units. An investigation of the SRU upset is in progress and "will be reported in a subsequent letter." | 7.9 pounds |
| 126678 2010-09-24 | 308F-D-1 (low pressure flare) and various process heaters | Cause: During maintenance activities, "amine stripper vessel experienced unexpected level swings" and "SRU (sulfur recovery unit) waste heat boiler unexpectedly tripped offline due to its flame scanner no longer detecting a flame at the burner. Several attempts that were made to re-light the burner were unsuccessful due to igniter malfunction" -- had to flare excess. Followup: No Notes: "Routed acid gas feed stream to the LP flare and immediately implemented the sulfur shedding plan...root cause investigation has been initiated." Detailed refinery letter only in this file. No LDEQ Report. | 76.0 pounds |
| 123185 2010-05-02 | Cooling water exchanger & Coker compressor (891-K-1), Low-pressure flare (308F-D-1) | Cause: Report states that the release occurred as a result of a breaker trip in the Coker Compressor. Which seems to have originated within the compressor's motor. Followup: Yes Notes: RQ. Reportable quantity for sulfur dioxide was exceeded. LDEQ report states that "The facility will be referred to the Circuit Rider Review process for failure to submit an updated notification within 60 days of the initial 7 day letter as required by LAC 33:I.3925.A.3." An investigation is in process to determine the cause of the electrical breaker trip after which, corrective actions will be implemented. | 82.6 pounds |
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