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Motiva Enterprises, LLC, Norco
Releases of Sulfur Dioxide
| 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 | 3,991.0 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 | 17,766.0 pounds |
| 81720 2005-08-28 | General facility Refinery Wastewater Treatment System (RWTS), LPDES Outfall 006; Wastewater treatment facility | Cause: hurricane Katrine caused unanticipated bypasses of water Followup: Yes Notes: waiting for situation to stabilize and operations to return to normal | |
| 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 | 916.0 pounds |
| 80320 2005-07-06 | Coker, HCU, West Op Ground flares | Cause: power failures due to weather (Tropical Storm Cindy) caused various releases from Motiva sources; led to total loss of electrical instrument air compressors and the loss of several steam Boilers that caused the shutdown of the HCU and RCCU process units. A voltage sag caused the Coker processor to shut down which resulted in a flaring event Followup: No Notes: Motiva claims that this was not preventable because of the unforeseeable weather conditions. | 1,150.0 pounds |
| 78747 2005-05-03 | Hydrocracker, Coker, CR-1 and NHT units | Cause: loss of 100# instrument air due to the mistaken closing of the 100# instrument air block valve Followup: Yes Notes: Remedial actions involved shutting down the affected operating units; found that Sulfur Dioxide levels were exceeded from the HCU flare and Volatile Organic Compounds exceeded at the Coker Flare. The instrument air system is owned and operated by ShellChemical LP -- Norco Chemical Plant -- East Site personnel; Motiva has no operation control over the instrument air system. (This was the explanation for why the incident was not preventable.) | 296.0 pounds |
| 77795 2005-03-23 | hydrocracker unit, HCU Flare (EPN #4-84) | Cause: A gasket on compressor K 1929's seal Oil pot gauge glass was leaking, causing a loss of seal Oil level. Caused hydrocracker unit to trip out and require a shut down Followup: No Notes: follow up to verbal notification on 03 23 09; remedial actions: notified site supervisor and secured the unit per procedures to shut it down. Gauge glass was inspected and it was found that the Jerguson valves did not contain ball checks; the ball checks were replaced. | 66.0 pounds |
| 90191 2007-07-05 | Coker Flare (EPN# 2-84) | Cause: shut down and restart of Motiva's Sulfur Plant No. 3 Followup: Yes Notes: Under investigation | |
| 92470 2006-12-07 | West Ops Ground Flare (EPN# 9-84) | Cause: shut down and start up of GO-1 Process Unit to repair a leaking heat exchanger Followup: No Notes: Letter states that emissions were BRQ | |
| 92253 2006-11-25 | No information given | Cause: No information given Followup: No Notes: Under investigation | |
| 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. | 15.0 pounds |
| 91490 2006-10-18 | West Ops Ground Flare (EPN# 9-84) | Cause: unexpected shut down of a steam boiler Followup: No Notes: No remedial actions, the incident was not under the control of Motiva | 3.0 pounds |
| 06-BB012-3614 2006-10-05 | RCCU Flare (EPN 8-84) | Cause: release due to decontamination of equipment at the RCCU Followup: Yes Notes: Investigation ongoing | |
| 91094 2006-10-03 | West Ops Ground Flare (EPN# 9-84) | Cause: upset at GO-1 process unit Followup: No Notes: No remedial actions, the incident was not under the control of Motiva | 5.0 pounds |
| 91050 2006-10-02 | No information given | Cause: It was reported that a pump was leaking due to the fact that a pipe had been broken. It was the casue of this broken pipe that resulted in the several compounds being released Followup: Yes Notes: Root cause failure analysis underway. It was further stated that maintenance people were working to fix the broken pipe. Notes: according to the followup report provided it stated another report would be provided as soon as data analysis was complete. | |
| 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 | 1,173.0 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 | 1,132.0 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 | 69.0 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 | 4,418.0 pounds |
| 86806 2006-03-28 | Hydrocracker Unit | Cause: see notes Followup: Yes Notes: Power outage at Hydrocracker unit causes release | |
| 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: | 476.0 pounds |
| 100076 2007-10-06 | HCU flare | Cause: leaking relief valve sent sulfur dioxide to HCU (hydrocracker unit) flare
Duration of leak unclear--one portion of report indicates it may have been ongoing for 3 days, but start/end time says only 4min.
Report is for a leak of sulfur dioxide, but lists 0 lbs as amount released. No detailed description of event included. Followup: Yes Notes: no information given | |
| 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" | 73.9 pounds |
| 93653 2007-02-01 | Utilities East Flare EPN 3-84 | Cause: see notes Followup: Yes Notes: This is described as a preliminary written follow-up report. Cause cited is unexpected leak on DU-5 Waste Gas Compressor K-1876 | |
| 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. | 21,640.0 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. | 1,682.0 pounds |
| 115844 2009-06-20 | Coker Flare | Cause: There was an operational upset with the wet gas compressor at the Coker Fractionator that resulted in the opening of the unit's pressure control valve. The opening of this valve allowed emissions to be sent to the Coker Flare thus allow several compound to be released into the air. Followup: Yes Notes: after immediate response the problem was troubleshooted. In the end, the high level increase in the overhead accumulator of the Coke Incinerator was corrected and operations returned to normal conditions | |
| 115703 2009-06-16 | incinerator stack in sulfur plant | Cause: there was an air trip transmitter failure that caused the Sulfur-3 unit to trip online unexpectedly. Due to this online trip, a release of sulfur dioxide (SO2) into the air occurred from both the S-3 and S-2 tail gas incinerators . Followup: Yes Notes: The sulfur gas was diverted from the S-3 unit to the S-2 unit. The transmitter was repaired by maintenance so that the S-3 unit could become fully operational. it was noted that material went offsite as the sulfur material was released into the air | |
| 115263 2009-05-27 | Cat Cracker debutanizer column | Cause: States that there was a problem with the Cat Cracker Debutanizer column. Propylene, butylene, Benzene, SO2, and H2S were released...there was no cause listed as to how these chemicals were released Followup: No Notes: There were no remedial actions listed as to how the problem was corrected with the Cat Cracker and no mention as to how the release of these chemicals were stopped. Verbal report only, no letter from the refinery. | |
| 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. | 2,989.5 pounds |
| 127976 2010-12-03 | FLARE: S-2 & S-3 Sulfur units; Coker flare (FE-401), Shell Go-1 & OL-5 Flares FLARE:Shell Go-1 & OL-5 Flares | Cause: Motiva's S-2 and S-3 sulfur plants tripped offline while analyzer FI-3677 was being calibrated. During analyzer calibration, air flow was reduced, initiating shutdown of S-2. Acid gas was diverted through to S-3 and pushed into gas knock out drum resulting in shut down of S-3. Acid gas was routed to Coker Flare and Shell's Go-1 flare. Shared incident with SHELL CHEMICAL LP. Emissions included flaring from both facilities. Followup: Yes Notes: RQ. Sulfur plants were restarted, operating procedures for safely calibrating instruments will be developed and included in operations training program, training conducted for personnel. Calculations provided confirm that the reportable quantity for sulfur dioxide, carbon monoxide, nitrogen oxide and particulate matter was exceeded. | 28,215.0 pounds |
| 127866 2010-11-27 | FLARE: West Ops Ground Flare [EPN 9-84] | Cause: Refinery letter states that "Shell Chemical's GO-1 Process unit experienced an upset when the feed to the unit furnaces was unexpectantly shut off. This process led to flaring at the Motiva's West Operations Ground Flare." SHARED INCIDENT WITH SHELL CHEMICAL PLANT.
Separate report will be filed for Shell LP Norco Chemical Plant-East Site will be submitted. FLARE. Followup: Yes Notes: BRQ. Follow-up reports states that no reportable quantities or permit limits were exceeded. No Information Given regarding remedial actions. Refinery letter states that this information will be included in the Shell Chemical incident report. | |
| 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. | 855.6 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. | 24,842.3 pounds |
| 126309 2010-09-12 | FLARE: DU-5 Unit, waste gas compressor (k1883); East UE Flare (EPN 3-84) | Cause: incident involved a "process upset at Motiva's DU-5 Unit."release of hydrogen sulfide, Nitrogen Oxide, and Sulfur Dioxide. A waste gas compressor (K1883) tripped releasing the previously stated gases to flare. Shared flaring incident with SHELL CHEMICAL LP. Followup: No Notes: BRQ. Feed was reduced on DU-5 unit, instrument technician called in. False level reading that cased waste gas compressor to trip was determined to be caused by sediment build-up; sediment sampled to identify composition and cause. | |
| 125532 2010-08-09 | FLARE: HCU elevated flare (EPN 4-84) | Cause: The HCU elevated flare (EPN 4-84) released Benzene, nitrogen oxides, sulfur dioxide, toluene, and VOC due to a faulty regulator and an orifice tee which was incorrectly installed by the manufacturer and also a faulty nitrogen regulator supplying the system. SECONDARY CAUSE: noted as equipment failure. FLARE. Followup: No Notes: RQ. Refinery later states that reportable quantities were exceeded for benzene. Both the relief valve and the nitrogen regulator were removed from service and repaired. When repaired, they were reinstalled and returned to service. | |
| 124892 2010-07-16 | FLARE: Hydrocracker Unit - relief valve | Cause: Report states that a relief valve on the hydrocracker unit failed causing the release. Valve was found to be improperly assembled by the manufacturer... Followup: No Notes: BRQ. Report states that "the valve was repaired on site by Motiva technicians and put back in service. No reportable quantities were exceeded as a result of this release." | |
| 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." | 91.8 pounds |
| 124129 2010-06-11 | FLARE: DU-5 Unit Waste gas compessor (K-1883); Shell East Flare | Cause: Air release. Process upset on vacuum flasher [DU-5 Unit] caused waste gas compressor K-1883 to trip offline. LDEQ report states that cause of release is unknown at this time. Shared flaring incident with SHELL CHEMICAL LP. Followup: No Notes: BRQ. Reduced feed and troubleshooted issues related to loss of vacuum. Air monitoring was conducted and "all parameters were non-detectable." | |
| 123043 2010-04-25 | FLARE - HCU elevated flare | Cause: FLARE. FIRE. Power failure caused rapid shutdown of Hydrocracking Unit due to a valve failure. Moisture had accumulated causing corrosion on the wiring and connections. During troubleshooting, hydroprocessing exchanger E-1057 bottom head caught fire. Fire extinguished with water, no injuries. Followup: No Notes: BRQ. No RQs exceeded but did exceed max lb per hour permit limit for SO2. Process unit restarted and conditions returned to normal. Wiring, connector block, and seal repaired to prevent moisture from causing further corrosion. | |
| 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. | 35,210.0 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. | 241.0 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. | 8,325.1 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. | 91.2 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. | 29,547.2 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. | 11.9 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". | 6.9 pounds |
| 133571 2011-08-26 | S-3 Tail Gas Incinerator (EPN 2-90) | Cause: On August 26, 2011 at approximately 1005, a release of sulfur dioxide (SO2) occurred at Motiva's Sulfur Plant No. 3 (S-3) Tail Gas Incinerator (EPN 2-90). The event was triggered while unit operators were making moves to send acid gas from S2 to S3. Followup: No Notes: No information given. | 370.0 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. | 29.0 pounds |
| 132917 2011-08-05 | GO-1 Process Unit to West Ops Ground Flare (EPN 9-84) | Cause: The GO-1 Process Unit experienced a unit upset due to the over-pressuring of a column. This process upset led to flaring at Motiva's West Operations Ground Flare. Followup: No Notes: There were no remedial actions listed in the report. | |
| 132873 2011-08-03 | Cat Cracker | Cause: While restarting the cat cracker until, materials flared Followup: Notes: No refinery letter. | |
| 130936 2011-04-15 | FLare: FCCU FLARE: TGTU-4 | Cause: The incident began at Motiva's Convent Refinery on April 15, 2011 at approximately 16:22, when the refinery's Boiler No. 4 shutdown due to an internal tube failure. With the loss of the boiler, the refinery transitioned to steam curtailment and several units were forced to reduce charge rates. As units were being reduced, the excess fuel gas not being utilized was routed to the refinery flare gas system (specifically, Refinery Flares No. 1 and No. 2). The opacity limit was exceeded due to the lack of steam available in the refinery to affectively control the smoke while flaring the excess fuel gas. Also during the transition, the FCCU experienced an upset which caused hydrocarbon to under carry from the high pressure fuel gas knock out drum into the amine acid gas header. As the amine acid gas (and the entrained hydrocarbon carried under from the FCCU) was combusted in the TGTU-4 incinerator, the SO2 and opacity released through the stack was apparently above the permitted limits. The excess emissions ceased when the FCCU stabilized. Followup: No Notes: The excess emissions ceased when the FCCU stabilized. No additional information. NOLDEQ or SPOC letter included. Emergency Condition. | 500.0 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. | 1,152.1 pounds |
| 129562 2011-03-01 | Coker Flare (EPN 2-84) | Cause: On March 1, 2011, at approximately 1003 hours, Motiva operations initiated a shutdown of the Coker process unit due to a bearing failure on the Coker Inner Stage Cooling Fans (B-2369 & B-2370). This shutdown resulted in flaring at the Coker Elevated Flare (EPN2-84). The unit was safely shut down in a controlled manner utilizing all operational and safety procedures. Additionally, dry gas vent samples were taken prior to shutting down the Coker Wet Gas Compressor (K-2178) to confirm that minimal emissions were sent to the Coker Flare (EPN2-84). Followup: Yes Notes: The unit was safely shut down in a controlled manner utilizing all operational and safety procedures. No additional information. | |
| 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. |
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