LA Bucket Brigade : Refinery Accident Database

Motiva Enterprises, LLC, Norco

Releases of Particulate Matter

LDEQ Incident Number Incident Date	Point Source(s)	Notes	Amount of Release
83649 2005-10-29	Unit Main Air Blower, RCCU Flare (EPN 8-84)	Cause: RCCU experienced instrument protective function shutdown activation of the unit's MAB just prior to the release. There was low Oil pressure detected and therefore the MAB shut down automatically. The RCCU is dependant on the MAB for functioning Followup: No Notes: remedial actions: all units were secured and steps were taken to minimize emissions, also attempting to implement some mechanical improvement	43.0 pounds
83068 2005-10-12	GO-1 DEA Treater Tower	Cause: flaring due to a process upset at the source, pressure excursions with no known cause at this ti Followup: Yes Notes: following up from verbal notification on 10 13 05; remedial actions: untreated dry gas sent to the refinery fuel gas system and flared; said that it is not yet known whether this was preventable because the cause is not yet known	53.0 pounds
81012 2005-08-04	RCCU Flare (EPN #8-84), West Operations Ground Flare (WOGF- EPN 9-84)	Cause: maintenance was turning a blind when contents from the line started spraying; flaring occurred following the event Followup: Yes Notes: Under further investigation; no flare smoking occurred during this incident; remedial measures: vacuum trucks were deployed to try to capture the Oil in the RCCU drainage system, additional adjustments made to minimize the forward flow into the main fractionator column while isolations were made to the slurry system	24.0 pounds
80785 2005-07-25	West Ops Ground Flare (EPN #9-84)	Cause: indicators of the status of operations were out of service for maintenance and inspection; production of off specification product led to flaring Followup: No Notes: called in by telephone on 07 25 by Shell Chemical. Remedial actions: Material was flared at the West Ops Ground flare. Motiva maintains they were not in control of the incident and that a follow up letter was sent by Shell Chemical	29.0 pounds
77688 2005-03-18	Ship Keystone Texas	Cause: see notes. Followup: No Notes: CITIZEN COMPLAINT - black oily particulate settles over Norco after the ship Keystone Texas leaves Motiva dock and puts out a large amount of smok
76671 2005-02-02	OL-5 Ground Flare, FG-101	Cause: level controller on the BD5 Solvent Column was not functioning properly Followup: No Notes: Report from Shell states that no RQ's were exceeded	7.0 pounds
91641 2006-10-25	West Ops Ground Flare (EPN# 9-84)	Cause: see notes Followup: No Notes: operational issues at Marathon caused them to send off-specification dry gas to Shell's GO-1 Process Unit. A portion of it was flared at Motiva.	8.0 pounds
90114 2006-08-20	West Ops Ground Flare (EPN# 9-84)	Cause: upset at GO-1 process unit. Unit experiences exchanger leak Followup: No Notes: No remedial actions, the incident was not under the control of Motiva	650.0 pounds
89273 2006-07-20	RCCU CO Heater (EPN# 2-91)	Cause: shutdown of residual catalytic cracking unit Followup: No Notes: Existing RCCU operating procedures regarding the re-set of the air to the CO annulus have been amended	0
88170 2006-05-26	GO-1 Process Unit ; West Ops Ground Flare (EPN 9-84)	Cause: pipe leak on line at the base of a process vessel Followup: No Notes: Measures adopted by Shell will be addresssed in a Shell letter	20.0 pounds
87231 2006-04-17	West Ops Ground Flare (EPN# 9-84)	Cause: upset at GO-1 process unit due to a power outage Followup: No Notes: No remedial actions, the incident was not under the control of Motiva	74.0 pounds
87197 2006-04-15	RCCU Flare (EPN 8-84) and GO-1 Elevated Flare (EPN 1-90)	Cause: unexpected shutdown of RCCU b/c of catalyst bridging in the unit's spent catalyst standpipe Followup: No Notes: Research modifications to the Reactor Stripper Vessel to improve stability of the catalyst flow in the Catalyst Standpipe; inspect the burp tube on the Catalyst standpipe; repair local flow indicators on the fluidization steam nozzles at the CS; developa hot stand-by procedure for quick acquisition to understand the unit's status in terms of being ready for a unit restart	216.0 pounds
85653 2006-02-06	RCCU Flare (EPN 8-84)	Cause: a blown tube causes the shut down of Boiler #8 resulting in a loss of steam pressure and slowing of the Wet Gas Compressor Followup: Yes Notes:	5.0 pounds
97746 2007-07-10	OL-5 flare	Cause: instrument problems at DHT (diesel hydrotreater) Process Unit caused a vent gas compressor to trip, resulted in flaring at OL-5 elevated flare amount released was above permit limit/reportable quantities Followup: Yes Notes: secured & shut down the unit "long-term plan to prevent reoccurrence [sic] is to install plug connectors on the unused pins of the DeltaV backplans"	0.4 pounds
109940 2008-10-08	RCCU unit CO heater	Cause: RCCU unit discovered several tube leaks in the CO heater, necessitating a controlled shutdown of the heater and RCCU and the diversion of all regenerator flue gas to the atmosphere and away from the flue gas scrubber to mitigate safety concern. Even went on over 5 days--RQs exceeded. No DEQ report in this file--follow-up only. Followup: No Notes: 76 tubes that were in poor condition replaced in the CO heater.	21,166.0 pounds
105124 2008-04-26	RCCU Elevated Flare (EPN 8-84)	Cause: see notes Followup: Yes Notes: Motiva says event is not preventable because it is caused by upset at Shell Chemical LP - East Site Utilities. Boiler 7 trips causing a swing in the steam header and a steam shortage across the site. The Wet Gas Compressor slowed considerably causing venting of the suction to the RCCU elevated flare.	5,269.0 pounds
128035 2010-12-08	FLARE: Coker WGC (K-2178), Coker Flare (EPN 2-84)	Cause: Refinery letter states that Motiva experienced a flaring release caused by an unexpected shutdown of the Coker Wet Gas compressor due to power loss. Power loss is attributed to fault in MCC breaker and 4160V buss. Followup: No Notes: RQ. Coker Unit shutdown and restarted when flaring stopped. Re-evaluated relay settings and adjusted as needed to reduce potential for future trips.	8.7 pounds
127553 2010-11-08	FLARE: DHT Unit; SHELL OL-5 Flare (EPN 6-84)	Cause: Motiva DHT vent gas compressor tripped due to high liquid level in compressor's overhead accumulator (PV-1987). DHT experienced a rapid increase in feed rate DU-5 unit. Shared flaring incident with SHELL CHEMICAL LP. Followup: Yes Notes: RQ. Letter includes emissions calculations information. Took immediate corrective actions to return unit to normal feed conditions and restarted DHT vent compressor when flaring stopped. DHT operators were given safety training.	4.8 pounds
126371 2010-09-14	FLARE: RCCU flare (FE-201); Shell GO-1 Flare (EPN 1-90)	Cause: RCCU unit tripped and shut-down. Spend catalyst slide valve was not functioning properly and shut-down occurred during troubleshooting of valve. Shared flaring incident with SHELL CHEMICAL LP [GO-1 Elevated Flare (EPN 1-90)]. Followup: No Notes: Initiated study to review current maintenance program. Slide valve failure was also identified as a site threat and entered into Motiva's threats database to be tracked.
124245 2010-06-16	FLARE: DHT Unit; OL-5 Flare (FE-101)	Cause: Power outage from inclement weather caused a compressor on Motiva's Diesel Hydrotreater Unit (DHT) to trip releasing sulfur dioxide from the OL-5 Flare at Shell Chemical. Shared flaring incident with SHELL CHEMICAL LP. Followup: No Notes: BRQ. Report states that incident was BRQ but permit limit for SO2 was exceeded. Entergy was called to make repairs and "operations took corrective actions to safely return unit to normal conditions and minimize flaring."	0.3 pounds
121815 2010-03-01	FLARE - Shell's GO-1 Elevated Flare (EPN 1-90)	Cause: LDEQ report states, "cat cracker tripped due to main air blower problems." Refinery letter states there was an unexpected shutdown of Motiva's RCCU Process Unit; had to flare dry gas being fed to Shell's GO-1 Process Unity to meet specifications to prevent further contamination to GO-1 and need for additional flaring. FLARE. Followup: No Notes: RQ. Reportable quantities exceeded. File includes letters from both Motiva and Shell Chemical. Motiva letter dated 3/8/2010 references submitting a follow-up within 60 day and Shell letter references "a separate letter from Motiva dated 4/28/10," but follow-up letter from Motiva is not included in file.	202.0 pounds
121003 2010-01-22	DU5 Unit	Cause: LDEQ field report states that incident involved a fire and heavy gas oil leak in the DU5 Unit. Resulted in shut down of DU5, SATS, and DIH units. FIRE. LDEQ report states that "facility failed to perform operating procedures to prevent or reduce air pollution as required by LAC 33:III:905 A. Followup: Yes Notes: RQ. Reportable quantity for particulate matter and CO were exceeded. LDEQ field report states that according to facility personnel perimeter air monitoring at time of fire was conducted and indicated no off-site impact. As of 1/23/10 approximately 12,000 gallons of skimmed material [oil & water] had been collected. FOLLOW-UP: Resulted in emergency condition. Fire was extinguished. Vacuum trucks and boom deployed to contain spill and firefighting fluid. Soil excavated and transported to landfill.	7,832.0 pounds
134290 2011-09-29	Coker Flare FE-401	Cause: While starting the Coker Jet Pump on 9/29/11 at 6:45pm, the electrical breaker at Motiva's Coking Unit tripped de-energizing the Motor Control Center. Consequently, the Coker Wet Gas Compressor tripped offline therefore resulting in unit flaring and operating in hot circulation mode. Hot circulation mode is an operating mode in which the unit recycles feed at high temperatures. This mode of operation lessens the amount of flaring in comparison to a complete unit shutdown. The initial inspection of the Jet Pump revealed that the auto-transformer serving as a soft start for this pump had failed causing the electrical breaker to trip open. Once repairs were completed, the Coker Unit was safely re-started and flaring stopped. Followup: No Notes: Immediately, Operations placed the furnace F-125 in hot steam standby and brought the Coker Unit into hot circulation mode to prevent additional flaring of non treated gas. Norco maintenance personnel were called out to troubleshoot the trip of the Coker Wet Gas Compressor and related equipment. The auto-transformer was removed from the circuit. Relay coordination was modified in order to protect the new circuit. After troubleshooting, maintenance personnel determined that operations could safely re-start the Coker Process Unit. During this time the Coker Wet Gas Compressor was restarted and flaring stopped. By 12/31/11 a study will be completed to determine whether the auto-transformer can be permanently removed from the system. After this study is completed, a strategy will be created to address the required changes. This action will be completed by 3/31/12. Calculations confirm that the reportable quantity for sulfur dioxide was exceeded as well as the permitted maximum pound per hour emission limits for carbon monoxide, nitrogen oxide, particulate matter, sulfur dioxide, VOC's, 1,3 butadiene, and benzene as a result of the release.	12.0 pounds
134190 2011-09-26	8-84 RCCU Elevated flare GO-1 Elevated Flare	Cause: On 9/26/11, Motiva's RCCU Process Unit identified smoke exiting the insulation on the process unit's reactor stripper overhead piping, indicating a leak of hydrocarbon. Consequently, the RCCU process unit had to divert feed causing flaring to occur at the RCCU Flare (EPN 8-89). The process unit safely diverted feed and continued to maintain catalyst circulation in order to avoid additional flaring. All operational and safety procedures were following at this time. Immediately after stabilizing the unit, insulation was removed from the overhead piping to determine the source of the leak. the leak was identified as a set of flanges on the reactor stripper overhead piping. Attempts were made to re-torque the flanges and stop the leak. However, the re-torquing efforts were unsuccessful and a decision was made to fabricate and install a blade clamp to permanently stop the leak. As of 9/28/11, the blade clamp was installed and the leak on the overhead piping had stopped. The RCCU had been restarted following all operational and safety procedures and remained at steady operation. the RGHT had not been restarted at that time. On 9/26/11 Motiva Enterprises LLC RCCU unit was shut down to do some maintenance work. Flaring occurred at the GO-1 Elevated Flare (EPN 9-84) as a result of the restart of Motiva's RCCU Unit. Untreated dry gas from the RCCU is flared during the restart of the RCCU at the GO-1 Elevated flare before the dry gas can be introduced to GO-1 as a feed. Followup: Yes Notes: The RCCU diverted feed and continued to maintain catalyst circulation in order to avoid additional flaring and stabilize the unit. Operations worked to identify the source of the leak and made preparations for repair. The flanges associated with the leak source were re-torqued in an attempt to stop the leak. A box clamp was fabricated and installed to encapsulate and stop the leak. Maximum lb/hr limits were exceeded for sulfur dioxide and VOC's, because the incident release was spread out across close to 3 days no reportable quantities were exceeded. Two follow up letters were received.	99.4 pounds
134190 2011-09-26	8-84 RCCU Elevated flare GO-1 Elevated Flare	Cause: On 9/26/11, Motiva's RCCU Process Unit identified smoke exiting the insulation on the process unit's reactor stripper overhead piping, indicating a leak of hydrocarbon. Consequently, the RCCU process unit had to divert feed causing flaring to occur at the RCCU Flare (EPN 8-89). The process unit safely diverted feed and continued to maintain catalyst circulation in order to avoid additional flaring. All operational and safety procedures were following at this time. Immediately after stabilizing the unit, insulation was removed from the overhead piping to determine the source of the leak. the leak was identified as a set of flanges on the reactor stripper overhead piping. Attempts were made to re-torque the flanges and stop the leak. However, the re-torquing efforts were unsuccessful and a decision was made to fabricate and install a blade clamp to permanently stop the leak. As of 9/28/11, the blade clamp was installed and the leak on the overhead piping had stopped. The RCCU had been restarted following all operational and safety procedures and remained at steady operation. the RGHT had not been restarted at that time. On 9/26/11 Motiva Enterprises LLC RCCU unit was shut down to do some maintenance work. Flaring occurred at the GO-1 Elevated Flare (EPN 9-84) as a result of the restart of Motiva's RCCU Unit. Untreated dry gas from the RCCU is flared during the restart of the RCCU at the GO-1 Elevated flare before the dry gas can be introduced to GO-1 as a feed. Followup: Yes Notes: The RCCU diverted feed and continued to maintain catalyst circulation in order to avoid additional flaring and stabilize the unit. Operations worked to identify the source of the leak and made preparations for repair. The flanges associated with the leak source were re-torqued in an attempt to stop the leak. A box clamp was fabricated and installed to encapsulate and stop the leak. Maximum lb/hr limits were exceeded for sulfur dioxide and VOC's, because the incident release was spread out across close to 3 days no reportable quantities were exceeded. Two follow up letters were received.	169.9 pounds
134097 2011-09-21	8-84 RCCU Elevated flare	Cause: 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. Followup: Yes Notes: 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.	75.3 pounds
133785 2011-09-02	Shell Chemical LP Utilities East Flare (EPN 3-84)	Cause: Motiva Norco experienced a malfunction and shutdown of the RCCU refrigerant chiller compressor (K-7200) resulting in a flare at the Shell Chemical LP Utilities East Flare (EPN 3-84) releasing nitrogen oxide and propylene. Followup: No Notes: LDEQ provided, but there was no Refinery Report included in the file. Motiva states that "final calculations confirmed no reportable quantities or permit limits were exceeded as a result of the incident".	4.2 pounds
133050 2011-08-05	Hydrocrakcer unit	Cause: The Hydrocracker unit shutdown due to an electrical failure of the motor on P-1940, the charge pump of the 2nd stage of the Hydrocracker Unit. EPN 4-84 and FE-301 Followup: Yes Notes: Operations shutdown and secured the 1st and 2nd stages of the Hydrocracker. A temporary onsite replacement motor for P-1940 was used to restore power to the motor control center to support HCU restart.	893.5 pounds
132264 2011-07-08	9-84 (West Operations Ground Flare, FG-201)	Cause: On July 8, 2011 Shell Chemical's GO-1 Process Unit experienced a unit upset due to issues with re-boilers. This process upset led to flaring at the Motiva's West Operations Ground Flare (EPN 9-84). Followup: No Notes: The Go-1 Process unit was safely returned to normal operating conditions. Corrective actions to prevent reoccurrence will be addressed in a separate letter from Shell Chemical.	37.3 pounds
129817 2011-03-11	GO-1 Elevated Flare (EPN1-90)	Cause: Faulty Positioner ina control valve caused high levels in a suction drum. This caused the PGC to shutdown. The control valve was tested and returned to service. On March 11, 2011, the Process Gas Compressor (PGC) shutdown due to a high level indication in the fourth stage suction drum. The PGC is designed to shutdown under this condition to protect the compressor. Flaring occurred at the GO-1 Elevated Flare (EPN1-90) as a result of the PGC shutdown. Additional flaring as a result of this upset also occurred at Motiva's West Operation Ground Flare and will be addressed in a separate letter. Followup: No Notes: The PGC was checked and secured by operations. Feed reductions to the unit were made to minimize flaring while repairs to the PGC were made. After investigating the system, a faulty positioner in a control valve was identified as the cause of the high level in the suction drum that led to the PGC shutdown. Maintenance personnel replaced the positioner and the control valve was tested and placed back in service. The PGC was safely returned to normal operating conditions. Once the GO-1 Process Unit was returned to normal operating conditions the flaring was stopped. An alarm point will be installed to give operations an indication that the control valve is not functioning properly and allow for maintenance inspection prior to failure.	1,391.7 pounds
139564 2012-05-08	Residual Catalytic Cracking Unit's elevated flare	Cause: The refinery's RCCU CO Heater was struck by lighting during a heavy rainstorm event, causing the CO Heater to shut down. Consequently, an Instrument Protective Function associated with the CO Heater's FD fans automatically tripped the system's main fuel gas burners to safely secure the heater, as per design. This incident also caused flaring at the Shell Chemical OL-5 Elevated Flare. Followup: Yes Notes: Operations worked to stabilize the RCCU process unit and assess the damages to the RCCU CO Heater resulting from the lightning strike.