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Motiva Enterprises (1406), Norco

LDEQ Accident Report

Accident #134097
State Police #11-05883
Accident Date2011-09-21
Report Date 2011-09-29
Follow-up Date 2011-11-03
Follow-up: Yes

Pollutants Released

Pollutant Duration Point Source Greenhouse Gas Criteria Pollutant Ozone forming chemical Amount of Release
Carbon Monoxide8d 8h 38m8-84 RCCU Elevated flareNOYESNO2,176.0 pounds
Nitric Oxide8d 8h 38m8-84 RCCU Elevated flareNOYESNO399.9 pounds
Particulate Matter8d 8h 38m8-84 RCCU Elevated flareNOYESNO75.3 pounds
Sulfur Dioxide8d 8h 38m8-84 RCCU Elevated flareNOYESNO11.9 pounds
Volatile Organic Compounds (VOCs)8d 8h 38m8-84 RCCU Elevated flareNONOYES1,395.9 pounds

Accident Classified As: Below Reportable Quantity (BRQ)

Cause of Problem: Equipment Failure

On 9/21/11, Motiva's SBA Feed Prep Process Unit experienced a block valve malfunction during a back flush of exchanger E-809D. A cooling water supply valve for this exchanger failed in the closed position causing the exchanger to leak for five minutes. Consequently, there was not adequate cooling water to the exchanger and the SBA process unit had to be shutdown and depressured to the RCCU Flare (EPN-8-84). The process unit was safely shutdown following all operational safety procedures. The elevated flaring associated with the shutdown activities stopped on 9/21/11 at 11:15pm. Repair work for the cooling water system was completed and the SBA Feed Prep Unit was successfully restarted on 9/21/11.

Discharge Preventable - No

This incident was not preventable by Motiva. The valve which failed was properly designed and is utilized on a routine basis. There were no indications which would have allowed Motiva to detect an imminent failure.

Notes/Remedial Actions

The feed to the SBA Unit was immediately diverted and the process unit was idled. Due to a lack of cooling water, the SBA unit was then depressured and the unit cooling water system was de-inventoried in order to make the necessary repairs. Motiva replaced the cooling water valves associated with the system in order to prevent a similar recurrence. The maximum lb/hr permit limits for sulfur dioxide and VOCs were exceeded during the unit shutdown and restart activities.