Bin 4-28 -0F MERAUX REFINERY MURPHY |! &.0.20x:00 O1L usa, inc. MERAUX LA 70075-0100, ‘April 28, 2009 CERTIFIED: 7001 1140 0001 6091 2078 Department of Environmental Quality Qt 2? : ‘Single Point of Contact (SPOC) 9 g Office of Environmental Compliance () # S Attn: Emergency Response P.O. Box 4312 ty? Baton Rouge, LA 70821-4312 je Re: UNAUTHORIZED DISCHARGE NOTIFICATION REPOR Murphy Oil USA, inc. Meraux RefneryAgency Interest #1238 > 2500 E. St. Bernard Hwy, St. Bernard Parish, Meraux, LA Tile V Permit: 2500-00001-v4 ‘SERC Incident #: 09-00806 : Gentiemen, The Murphy Oil USA, Inc. Meraux Refinery is hereby submiting a 30-day follow up letter regarding an air Upset incident involving an SO2 release >RQ reported to SPOC. The indents GESERBed as follows Hydrocracker shutdown ‘2118109 ‘nour previous letters (February 20, 2009 and March 23, 2009), Murphy noted that a Root Cause Analysis was underway. Murphy completed the investigation and is providing details in this submittal. Should you have any questions, please contact Mr. Matthew Dobbins or Mr. Kent Veron at (504) 271-4141 | certify, based on information and belief formed after reasonable inquity, the statements and information in this document are true, accurate, and complete. ee eas Refinery Manager ‘Murphy Oil USA, Inc LGBimsd RECEIVED MAY 0 4 2009 co: Mr. Mike Algero, LDEQ SE Regional Office, New Orleans, LA Mr, Ken Lanier, LA Office of Public Health, Baton Rouge, LA Single P een MURPHY le Point of Contact (608 a71-avat USA® FAX (504) 278-5201 :EMERGENCY OCCURRENCE AND/OR AIR UPSET NOTIFICATION FORM (SERC Incident Number: 09-0806) COMPANY NAME: Murphy Oil USA, Inc. PHYSICAL LOCATION: 2500 E. St. Bernard Hwy, P.O. BOX: P.O, Box 100 CITY, STATE, ZIP: Meraux, LA 70075 ‘TELEPHONE NO: (504) 271-4141 DATE/TIME OF CALL: 02/18/09, 07:39 hrs DEQ OFFICIAL CONTACTED: Michael Hawking MURPHY OFFICIAL WHO MADE CALL: M. Dobbins APPLICABLE PERMIT INVOLVED? 2500-00001-V4 EMISSION PT. SOURCE(S) INVOLVED? Noth Flare (#20-72) APPLICABLE AIR QUALITY REGULATIONS INVOLVED? LAC 33:lIL927 UPSET DESCRIPTION, CAUSE, AND WHAT OFFSITE IMPACT RESULTED: ‘On February 18, 2009 at approximately 06:33 hrs, MOUSA experienced an automatic safety shutdown of the Hydrocracker Unit, resulting in a Reportable Quantity release of sulfur dioxide at the North Flare, The 100 pound per minute safety depressurization of the unit occurred from 06:37 hrs to 07:07 hrs, resulting in SOz ‘emissions estimated at 4,000 pounds. The RQ for SO, was exceeded at 06:41 hrs, While there was an elevated flame in the flare, no smoke was observed, as the vented material was mostly hydrogen. This level of emissions would not be expected to cause adverse offsite impact, and no allegations of impact were received from neighbors in the surrounding community ‘The Hydrocracker automatic shuldown was triggered by the unexpected and sudden shutdown of the Recycle Gas Compressor. An investigation into the compressor trip found that a Triconex Process Logic Controller (PLC) card malfunctioned due to a manufacturer defect. The card was one of several ina surge control system installed on the compressor during the Hydrocracker turnaround in September, 2008 to improve compressor reliability and to act as a long-term corrective action for a reportable event that occurred on May 29, 2007. DATE/TIME RELEASE BEGAN AND TIME IT LASTED: The episode occurred from approximately 02/18/09, 06:37 to 07:07 hrs, for a duration of 0.5 hours, WHICH SPECIFIC POLLUTANTS WERE EMITTED AND HOW MUCH OF EACH COMPOUND WAS RELEASED? ‘The episode resulted in estimated emissions of 4,000 pounds of Sulfur Dioxide.EMERGENCY OCCURRENCE AND/OR AIR UPSET NOTIFICATION FORM (SERC Incident Number: 09-00806) WHAT OTHER AGENCIES WERE NOTIFIED? SERC and LEPC. IMMEDIATE CORRECTIVE ACTION TAKEN? Murphy Oil followed its operating procedures to safely secure and re-start the Hydrocracker. ‘SPECIFIC ACTIONS TAKEN/PLANNED TO PREVENT RECURRENCE? ‘Triconex replaced all of the PLC cards in the surge control system with new models verified to have been corrected of the defect WAS THE RELEASE PREVENTABLE? (no, provide detai's) ‘No. The PLC maifunctioned due to a manufacturing defect beyond the control of Murphy. itwas subsequently discovered that the manufacturer provided a generic product alert notice, but the defect could only have been detected through intensive and repeated diagnostic testing using specialized equipment, and only ifthe card was in a degraded condition. REGULATION NOTIFICATION REQUIREMENT(S): {LAC 3311927 (UpsevEmergency) 46 33:13917 (RQ) = LAC 33:11,51078 (Air Toxics) sevarure__ [HUES Dy vate __ 4/28 /a TITLE Sr, Environmental Engineer