em [kW -O? MERAUX REFINERY MURPHY | 2220x100 ‘iL USA, INC. MERAUX LA 70075-0100 November 11, 2009 CERTIFIED: 7001 1140 0001 6091 2450 : sot L36KF Ree ee eee eee 342 Single Point of Contact. (SPC) th ne Offies of Environnental Compliance ye Attn: Emergency Response gr Dior Box 1312 Po Baton Rouge, LA 70821-4312 3s Re: UNAUTHORIZED DISCHARGE NOTIFICATION REPORT Murphy 011 USA, Ine. Meraux Refinery, Agency Inte: 2500 E. St. Bernard Huy, St. Bernard Parish, Meraux, ZA Title V Permit: 2500-00001-V5, SERC Incident #: 09-06146 Gentlemen, ‘The Murphy O11 USA, Inc. Meraux Refinery is hereby submitting a notification of an air upset incident involving a release of hydrocarbon vapors in excess of a reportable quantity. The incident is described as follows: #2 FCCU Reactor leak 10/15/09 ~ 10/17/09 1 certify, based on information and belief formed after reasonable inquiry, the statements and information in thie document are true, accurate, and complete. ‘G. Bourgeois Refinery Managor Murphy 011 USA, Inc. Mr. Mike Algero, LDEQ SE Regional Office, New Orleans, LA Mr. Ken Lanier, LA Office of Public Health, Baton Rouge, LA RECEIVED NOV 1 6 2009 DEQ Single Point of Contact MURPHY (500) arts144 USA AX (504) 270-5201EMERGENCY OCCURRENCE AND/OR AIR UPSET ‘NOTIFICATION FORM COMPANY NAME: Murphy 012 USA, Inc. PHYSICAL LOCATION: 2500 £. St. Bernard Hwy. P. 0. BOX: P.0. Box 100 CITY, STATE, 21P: Moraux, LA 70075 TELEPHONE NO. (304) 272-4341, DATE/TIME OF CALL: 11/6/09, 15:24 hes DEQ OFFICIAL CONTACTED: Lynette Ourso MURPHY OFFICIAL WHO MADE CALL: M. Dobbins APPLICABLE PERMIT INVOLVED? 2800-00001-v5, EMISSION PP. SOURCE(S) INVOLVED? Facility Fugitives APPLICABLE AIR QUALITY REGULATIONS INVOLVED? LAC 33:IIZ.927 UPSET DESCRIPTION, CAUSE, AND WHAT OFFSITE IMPACT RESULTED: On October 14-17, 2009 Murphy Oil USA, Meraux Refinery (MOUSA) experienced a rolease of hydrocarbons due to a leak in the #2 FCCU Reactor manway flange. While it is difficult to quantify the emissions precisely, MOUSA conservatively stimates total emissions at 44,000 pounds, including approximately 155 pounds of benzene omissions over the 74.5 hour period. On October 14, 2009 at approximately 10:30 hours, MOUSA personnel discovered a mall leak at the 84” upper manway in the #2 FCCU Reactor. As a safety Precaution, MOUSA applied steam to the leak to disperse the vapors. MOUSA also called out a maintenance vendor to make a first attempt to repair the leak by tightening the manway flange bolts. After the repair attempt failed on 10/15, and 3 the leak apparently worsened, MOUSA made arrangemonts with a specialty group to fabricate and install a clamp on the manway. The vendor arrived on 10/16 to measure the manway and assess the leak. On 10/17, as MOUSA awaited that repair, the leak worsened, so MOUSA shut down the FCCU as a safety precaution. The vendor installed the clasp on 10/18. ‘The apparent late notification can be attributed to the difficulty in assessing the leak and estimating emissions. This was a highly unusual incident which had not been specifically accounted for in our agency notification scenarios. MOUSA acknowledges that we should have provided notification on October 14 as a place arker until we were able to quantify the omissions. MOUSA received two citizen inquiries regarding the noise from applying steam to the leak as a safety precaution DATE/TIME RELEASE BEGAN AND TIME IT LASTED: ‘The leak was estimated to have lasted 74.5 hours, from approximately 09:00 hrs on 10/24/09 to 11:30 hrs on 10/17/09 when the unit was shut down. The clamp was inatalled on the morning of 10/18/09. SERC Incident #09-06146EMERGENCY OCCURRENCE AND/OR AIR UPSET NOTIFICATION FORM WHICH SPECIFIC POLLUTANTS WERE EMITTED AND HOW MUCH OF EACH COMPOUND WAS RELEASED? The episode resulted in hydrocarbon emissions estimated conservatively at 44,000 pounds, with up to 155 pounds of benzene. MOUSA ostimated the emissions via an orifice calculation using estimated dimensions of the flango crack and process conditions in the reactor (i.e. pressure, temperature, feedstock chemistry, etc.). Deponding on the actual size of the crack, emissions could have been between 10,000 and 44,000 pounds. WHAT OTHER AGENCIES WERE NOTIFIED? SERC and LEPC. IMMEDIATE CORRECTIVE ACTION TAKEN? MOUSA had a specialty vendor fabricate and install a clamp on the manway, after which the clamp was injected with a sealant. MOUSA rostarted the #2 FCCU without further incident. SPECIFIC ACTIONS TAKEN/PLANNED 70 PREVENT RECURRENCE? MOUSA plans to inspect and repair the manway during the planned maintenance turnaround in January, 2010. In the interim, MOUSA will monitor the manway closely for any signs of additional leakage. In order to provide tinely notification in the event of a similar episode in the future, MOUSA will update ite agency notification guidelines to incorporate the emissions calculations from thie incident WAS THE RELEASE PREVENTABLE? (if no, provide details): No. The leak was the result of a malfunction in the manway flange. There wore no injuries resulted from this incident. REGULATION NOTIFICATION REQUIREMENT (S) : x__ LAC 33:I21.927 (Upset/Emergency) LAC 33:1.3917 (RQ) LAC 33:11I.5107B (Air Toxics) sno _ flu Du ufos TITLE -_Sr._ Environmental Engineer SERC Incident #09-06146