Major Accidents at Chemical/Refinery Plants
| Date Accident Occurred | Accident Description | Onsite Impact | Offsite Impact |
|---|---|---|---|
| Corteva Agriscience – Pittsburg Operations Sep. 3, 2024 |
During routine inspection, a chlorine rail car was found with a small leak while stored on a rail spur | No injuries reported | No offsite complaints or reported community impact |
|
PBF - Martinez Refining Company
Dec. 15, 2023 |
Loss of primary facility steam led to plant wide upsets in various units, causing flaring during stabilization of units and shutdown activities | No injuries reported | Strong odors were detected in the community adjacent to the facility |
| Martinez Renewable Fuels (formerly Marathon Refinery) Nov. 19, 2023 |
During the startup of the F-20 recycle furnace in the 2 HDO Unit, a furnace tube rupture released renewable diesel directly into the furnace which ignited | The fire damaged the furnace and neighboring equipment, and engulfed an operator who was working on the furnace at the time causing third-degree burns over 80% of their body | No offsite impacts were reported besides seeing flames |
|
PBF - Martinez Refining Company Nov. 24-25, 2022 |
20-24 tons of catalyst released from Fluid Catalytic Cracking Unit |
No injuries reported |
Visible dust impacting Martinez and surrounding communities |
|
Chevron Richmond Refinery |
Approx 800 gallon spill of diesel like material to bay | No injuries reported | Sheen observed on water near Chevron Richmond Refinery |
| Shell Martinez Refinery July 6, 2018 RCA Report - 7/16/18 |
Two separate events this day. 1) 1:00am Drop in pressure of refinery instrument air resulted in flaring and extinguishing of LOP flare pilots 2) 2:20am Small lube oil fire in Hydrocracker Unit forced shutdown of unit. At 3:20am, Hydrocracker depressured | Small fire resulted in unit shutdown that sent material to LOP Flare and flare pilots were unlit | HAZMAT personnel in field report slight to no odors in area. Only one field detection of H2S was 0.001 ppm at Shell Ave and Marina Vista. |
| Shell Martinez Refinery December 19, 2016 30 Day Report - 12/19/16 |
At approximately 13:15, on December 19, 2016, one of the refinery's three main electrical substations main breakers tripped during maintenance / troubleshooting of the subsystem causing loss of power to two 12kV distribution substations. This resulted in a loss of power to multiple units in LOP, OPCEN, Utilities and Logistics Vine Hill area. The multiple unit shutdown caused excessive flaring at the LOP and Flexicoker flares. | Multiple units tripped offline and depressured to LOP and Flexicoker flares. No injuries or equipment damage was reported. | Multiple odor and noise complaints were raised by the nearby community. No injuries were reported. |
| Tesoro Golden Eagle Refinery December 15, 2015 RCA Report - 12/15/15 |
The 6 Boiler unit, which provides 600 psig steam, tripped offline due to a loss of fuel gas. Loss of 600 psig steam caused the FCCU to trip offline and a rise in pressure in the flare knock out pot caused the flare gas recovery compressors to trip offline. This resulted in flaring from three flares which also generated smoke due to the loss of steam to the flares. A CWS level I was sent at approximately 11:59. A CWS level 2 was sent out at 12:19 hours due to smoking and potential offsite impact. One flare compressor was restarted at 12:50 hours and all flaring stopped as of 12:51 hours. | No injuries were reported on or off site | no odors were found in surrounding neighborhoods, slight odor detected in area around Highway 4 and 680 intersection. SO2 released exceeded RQ |
| Phillips-66 August 2, 2015 30 Day Report - 8/2/15 |
At approximately 15:05 PM on August 2, 2015, there was a fire on the top deck of the Coker unit. A 200-gallon Antifoam Day Tank located on top of the coke deck was overfilled resulted in the kerosene based solution to spill onto an ignition source, hot piping. The majority of the fire had burned out within 10 minutes of ignition, with residual light smoldering occurring for an additional 45 minutes. The fire did not involve any process materials, only the antifoam solution and other work materials (tables, carts, etc.) impacted by the flames. | Some equipment (small piping, site glass, displacement pumps, work carts) damaged by fire. No injuries. | Small amount of smoke potentially drifted offsite. CCHMP IR responders tested surrounding area for organics (benzene, volatiles), H2S, CO, and found all non-detect. |
| Dow Chemical Co March 27, 2015 30 Day Report - 3/27/15 Final Report - 3/27/15 |
At 2:50am, the Dowicil plant had an overpressurization of a reactor/drier resulting in three rupture disks (6", 24", 24") opening releasing methylene chloride and related Dowicil decomposition products to the atmosphere. Dowicil is used as an antimicrobial in various products (pharmaceuticals, paints, latex…). A visible plume was generated that lasted several minutes. Winds were 1 mph from the West. Temperature was 61F. The incident was called a Level 2. | A Large amount of material from the reactor/drier settled on Dow property over a 300 yard area immediately West of the Dowicil process. Odors were detected onsite. No injuries were reported. Dow estimated that 2,200 pounds of methylene chloride were released, approximately 2,200 pounds of various solid materials Dowicil decomposed into, ~68 pounds of methyl chloride, ~59 pounds of trimethylamine, ~88 pounds of flammable liquid (pyrimidine), and ~129 pounds of flammable solid (5-methyl pyrimidine). Total of 4,750 pounds of material were released. | CCHMP Hazmat team arrived to the site and performed downwind monitoring and found no evidence of offsite impact. No offsite odors or complaints were received by the public. |
| Shell Martinez Refinery August 14, 2012 30 Day Report - 8/14/12 Final Report - 8/14/12 |
A PRV on a distillation column in the Flexicoker failed open at 1230 hours. A Level 1 was issued through the CWS at 1241 hours. A level 2 was issued at 1334 hours as a result of flaring activity. The PRV was isolated at 1425 hours. Flaring took place as the column was depressured and the flare had intermittent black smoke. | No injuries or equipment damage were reported | Odors of mercaptans and H2S were detected in Martinez, Concord, Bay Point, Pittsburg, Antioch and Clayton. A number of complaints were received from the community. Flaring had intermittant black smoke and loud rumbling noises. The following materials were estimated as released: 7700 lbs hydrocarbon, 6 lbs mercaptans, 24 lbs H2S, 17 lbs SO2. |
| Shell Martinez Refinery August 13, 2012 30 Day Report - 8/13/12 Final Report - 8/13/12 |
A compressor in the first stage of the Hydrocracker tripped off-line due to an external lube oil fire at 1400 hours. The fire was put out by onsite personnel within 15 minutes. Flaring was performed as the 1st stage was brought down. CCHMP was notified of the event through the CWS by 1408 hours. | A small fire resulted in slight damage to ancillary tubing and electrical lines. | The fire sent a visible black cloud up into the air that drifted south down Pacheco Blvd as far as CCHMP's offices. The Shell community sampling team detected no H2S or benzene. The refinery estimated that approximately 580 pounds of SO2 was released thro |
| Chevron August 6, 2012 30 Day Report - 8/6/12 Public Meeting Final Report - 8/6/12 |
# 4 Crude Unit Fire. An 8" line from the atmospheric distillation column with hot diesel like material leaked and caught fire. | 5 Chevron emergency responders were treated for minor burns, and received first aid. | More than 15,000 people sought medical attention. |
| Phillips 66 June 15, 2012 72 Hour Report Supplemental Information Report |
A sour water tank (T-294) was over pressured resulting in a split in the top seam of the fixed roof tank. Vapors left the tank through the opening until it could be sealed. Chemicals involved included H2S, other sulfur compounds, natural gas, light hydrocarbons, nitrogen. Since the seam of the tank was ruptured, the repairs took some time to complete. The event started at 7:10am on 6/15/12 and continued as a Level 2 until approximately 12:05am on 6/17/12 when it was down graded to a Level 1. The event was determined to be a Level 0 at around 8:30am on 6/17/12 and then closed. During this time, various actions were performed to empty the tank, inert the tank with nitrogen to minimize flammable hazards, connect odor abatement equipment to control vapors, and to patch the tank. |
Atmospheric tank T-294 was overpressured resulting in a rupture along approximately 20 feet of the top seam of the roof. The rupture allowed vapors from the tank to exit into the surrounding area. H2S was one of the chemicals detected onsite although many other sulfur compounds were present. Operations were modified to remove the tank from active service. Various actions and repairs were made to the vessel. After approximately 36 hours temporary patches were positioned over the ruptured seam using heavy plastic tarping, gorrilla tape, and magnets. Eventually the tank was re-connected to the odor abatement system. |
Strong sulfur odors were detected by Hazmat IR personnel on Friday in areas from I-80 and the surrounding communities. The highest readings were approximately 1 ppm (as H2S) on I-80, which is a few hundred feet from the storage tank. Readings from 5-20 ppb (as H2S) were detected by Hazmat IR personnel around the town of Crockett on 6/15/12. On 6/16/12 concentrations from 1-5 ppb (as H2S) were found in Rodeo, Hercules, and Crockett. Numerous calls and complaints were received at Hazmat throughout the weekend regarding the odor (from skunk to rotten eggs to natural gas type odors). |
| Tesoro Golden Eagle Refinery December 9, 2010 RCA Report - 12/9/10 |
Partial Power outage due to damage at substation led to excess flaring and some unit shut down. CWS 2 activated at 10:31. CCHMP monitored the surrounding area and no hazardous substance was detected. Incident downgraded to CWS 0 at 13:18. | Plant-wide partial power due to fire and later explosion at Switching Station #7. | Significant flaring due to loss of power to mulitple units. |
| Tesoro Golden Eagle Refinery November 10, 2010 RCA Report - 11/10/10 |
Power outage from 3rd party power and steam supplier led to excess flaring and refinery-wide shutdown, very dark smoky plume. At 16:14, CWS 2 and at 16:45 upgraded to CWS 3. CCHMP monitored the surrounding area and took air samples. No hazardous substance was detected. | Complete refinery shutdown, and a grass fire around the flare. | Visible smoke and reports of burnt grass smell in N. Concord. |
| ConocoPhillips October 22, 2010 Incident Investigation Report Public Comments |
Third party (Air Liquide) hydrogen plant tripped resulting in elevated pressure in the Refinery's fuel gas system, and decreases in available hydrogen and steam to the Refinery. One turbine at the Refinery power plant immediately tripped further reducing available steam. Excess flaring (Level 1) resulted from Refinery units powering down due to less available hydrogen and steam and the fuel gas system imbalance. Approximately 3 hours into the incident (~2:20 pm), the remaining two turbines at the power plant tripped offline. Without a sufficient amount of steam to the flare, visible smoke was generated (Level 2). Refinery had to significantly slow down/shut down some operations. Refinery had a smoky flare until about 7pm. | Overpressured fuel gas system resulted in flaring. Loss of steam and hydrogen resulted in a slow down of some units. Power plant turbined tripped off resulted in smokey flare and further slow down of select operations. No equipment damage was reported. | The BAAQMD received a number of complaints of visible smoke and odor in the area. No contaminants were found in community air samples taken by Refinery personnel. No activity was seen on the Refinery's fenceline monitor. |
| Tesoro Golden Eagle Refinery October 10, 2010 |
At 12:20, fire on Tank 650 (foul water), contractor was replacing seal. Tank has a 3' diesel to layer for odor control. One Contractor treated for smake inhalation, released same day. No odor reported. All clear at 16:10. | Emergency Operation Center was activated. No reportable quantities of hazardous compounds were exceeded. | visible smoke plume, but air monitoring by Tesoro industrial hygiene yielded non-detect levels. |
| Reactions Products May 5, 2008 |
A brass valve was removed from a bottom of a storage tank partially filled with toluene. The removal looked ot be a theft of the valve over a weekend when no one was at the facility. Over 3,000 gallons of toluene was released. The spill went offsite into a ditch that run through the wetlands between Parchester Village and the Bay. The release was found on Monday morning and the US Coast Guard responded and requested that a shelter-in-place be called. The Parchester siren was sounded and information went out over the media to notify the residents of the shelter-in-place.When Health Services Hazardous Materials Response Team arrived onsite and took measurements of the amount of toluene in the air, the shelter-in-place was lifted. Health Hazardous Materials Programs is classifying this incident as a Community Warning System Level II and a Major Chemical Accident or Release Severity Level II, because if the toluene ignited the damage and consequences of the incident would be major. | The loss of over 3,000 gallons of toluene. | Toluene went offsite into the wetlands. The toluene was in a ditch that runs along the border of Parchester Village. Toluene odors were noticeable in the Parchester Village. Siren was sounded and the residents of Parchester Village were requested to shelter-in-place. |
| Calpine Los Moedanos Energy Center May 24, 2007 |
While overseeing the unloading of a bulk delivery of corrosion inhibitor, approximately 300 gallons of Nalco Trasar 3DT177 (phosphoric acid) was inadvertently unloaded into a storage tank containing about 378 gallons of 12.5% Sodium Hypochlorite solution. The chemical reaction of the two products resulted in a chlorine gas release in which the Field Operator and two other plant employees were exposed to. The three employees were transported via ambulance to the Mt. Diablo Medical Center for observation. Time of injury was reported to be 8:30 a.m. | The incident resulted in a chlorine gas release in which the Field Operator and two other plant employees were exposed to. The three plant employees inhaled chlorine gas resulting in throat irritation and minor chest pains. Three plant employees transported to Mt. Diablo Medical Center for observation. Symptoms identified as moderate throat irritation for all three employees and one of the employees complained of tightness in the chest. The emergency response team (consisting of local fire, police, paramedics, and the County HAZMAT team) isolated plant entry and perimeter access, removed non-essential personnel off-site, and notified neighboring plants. The facility flushed the neutralized contaminated tank contents to the cooling tower and ventilated affected building. | Shelter-in-place was declared for the area north of the Los Medanos Energy Center for about an hour. No offsite complaints were received. CCHS Hazardous Materials Response Team conducted air monitoring outside of the affected building with the highest level of chlorine at 0.15 ppm. Air sampling conducted at various locations of the plant perimeter indicated non-detect. |
| ConocoPhillips March 18, 2007 |
Sulphur plant shutdown due to electrical failure. XS sulfur to flare. | Haze in flare plume. | No complaints were received from the community. |
| Chevron Richmond Refinery January 15, 2007 |
"At 5:33 Chevron upgrades incident to Level 3 and sent message that there was a fire at the #4 Crude unit. Initial notification was 5:23 for a Level 2. Operators were in the process of shutting down the plant in preparation for scheduled maintenance. -Information About the Chevron January 15 Fire |
Fire near Vacuum column bottoms pump. One employee was treated for minor burns and released to return to work on the same day. Another employee received on-site treatment for minor skin irritation. | Sirens were sounded and TENS Zone 3 & 4 was activated. Unknown amount of hydrocarbons was combusted, resulting in a release of sulfur dioxide. Air monitoring did not indicate adverse air quality impacts. |
| General Chemical - Richmond June 23, 2006 |
The main turbine tripped and the shutdown interlock on the combustion air blower did not work correctly, so the blower pressured up the upstream side of the system which is normally under a vacuum. | The plant shut down. | Four Chevron employees were exposed. No other public appears to be affected. Wind at the time of the release was blowing towards Chevron. |
| ConocoPhillips May 1, 2006 |
Cogeneration Turbine "C" trippped off. The electrical systems powered from the generator lost power resulting in the shutdown of some units including the wet gas recovery compressor which is believed to have resulted in liquid to the flare system which caused the flare gas recovery compressor to shutdown which resulted in the flaring event. The steam system slumped due to the loss of the "C" turbine which resulted in lower that desired steam to the flare tip resulting in some incomplete combustion or a "smokey" flare. | Some units shutdown | Smokey Flare for about 10 to 15 minutes |
| Shell Oil Products U.S Martinez Refinery March 26, 2006 |
At 4:15pm, on Sunday 3/26/06, Shell Martinez Refinery reported via the Community Warning System a release of sulfur dioxide gas from the stack of Sulfur Recovery Plant #3 (SRU#3). Community Warning System sirens were sounded. Shell identified the release as a Shelter-in-Place because a visible plume was seen drifting across Shell Avenue and facility personnel at the time believed the plume could pose a health hazard. . TENS zones 3 and 2 were activated.Visible pluming stopped within 15 minutes. Shell Avenue was closed for 25 minutes. Shell downgraded the event to a CWS Level 0 within 40 minutes after the event started. | Shutdown SRU#3 briefly to assess for damage, found none, then returned to normal operation. Refinery officials did not report any injuries associated with this event. Refinery officials did not report any visible external damage to equipment. There may have been elevated temperatures in one of the catalyst beds that resulted in producing sulfur dioxide gas. CCHS Hazardous Materials did not receive word of any injuries or offsite impacts associated with this release. | Visible plume released from SRU#3 stack. Level 3 called with sirens and TENS activated. Pluming stopped in 15 minutes. Following the notification, Hazardous Materials Program staff responded to the incident within ten minutes by assessing the area around the refinery. Hand held monitoring equipment did not detect any sulfur dioxide or hydrogen sulfide. A slight sulfur dioxide odor was detected at Shell Avenue and Marina Vista. Feed to the process was shut off which quickly stopped the visible pluming. |
| Tesoro Golden Eagle Refinery March 24, 2006 |
Fire at #2 HDS at the F-20 furnace outlet piping at 15:38 hrs. Operations personnel shut down unit and activatd fire monitors on the unit. | Flange failure led to fire and unit shut down | No community complaints were received by BAAQMD |
| Shell Oil Products U.S Martinez Refinery November 8, 2005 |
At the FCC Unit, a 1 to 2 foot diameter slurry filter was taken off line to clean the filter. While the maintenance team was in the process of placing the/a clean filter back in the filter unit or housing, they noticed a small leak through the block valve, which quickly became big, and one person was not able to vacate fast enough, the material jet was approximately 200 feet in the air. The event started on 11/8/05 at about 8:24 pm. It was downgraded to a level 0 at about 2:54 am on 11/9/05. The event took so long to get under control because the liquid was hot, about 700F at 80 psig. 150 barrels of material was released and comprised of cat cracked slurry oil (heavy, dark oil) and lighter flushing oil (diesel type). Slurry oil comprised about 1% of total material. | One contractor was sent to San Pablo Medical Center with 1st, 2nd, and 3rd degree burns on head on arm. No fire occurred. Some flaring occurred, Oil and catalyst slurry spray residue coated neighboring equipment and took days to clean up. | Oil/catalyst slurry mist coated vehicles and pavement southwest of the refinery. No offsite injuries reported. Approximately 150 gallons of total material was estimated to travel offsite. No hydrocarbon or H2S was observed in facility air samples. Some flaring occurred and resulted in estimates of 62.6 lbs SO2 and 0.9 lbs Nox from the flare system. Oil droplets were observed on cars and pavement southwest of the refinery.Approximately 3000 insurance claims from community members have been filed as of the 30-day report. |
| Tesoro Golden Eagle Refinery October 26, 2005 |
Partial power outage at the refinery around midnight and early morning hours, resulted in upset and flaring at the Chem Plant. | Power outage lead to ammonia recovery unit shutdown to reduce acid gas load to sulfur plant. | A plume from chemical plant stack was visible from off-site and potentially contained Sulfur Dioxide. Odor patrol from Tesoro was in the Clyde area and reported no odor impact. Ground Level Monitors did not detect any sulfur dioxide or hydrogen sulfide. |
| Tesoro Golden Eagle Refinery August 24, 2005 |
Lube oil fire from mini blower near the main blower at FCCU. | 3665 pounds of lube oil est. to be combusted in the fire. No injuries. | Heavy smoke, one odor complaint from Bay Point. |
| General Chemical-Richmond July 26, 2005 |
A flow meter on a feed to the oleum stripper in the CP Plant developed a leak. The facility estimates that between 2 and 18 pounds of slfur trioxide were released. | The CP plant was shut down. The oleum flow was stopped within 3 minutes and the liberation of sulfur trioxide within 15 to 20 minutes. | Initially a level 1 called into agencies. A level 2 was called at the close of the event. |
| Tesoro Golden Eagle Refinery January 12, 2005 |
Visible emissions of steam and coke dust from No. 5 Boiler Stack due to tube failure. | Boiler was shutdown. | Tesoro received 2 complaints from the community for the visible emission. Odor patrol indicated theat there were no odors in the surrounding communities (Concord, Vine Hill, Benicia Bridge, and Martinez areas) |
| ConocoPhillips October 31, 2004 |
Plant 19, F-1 flare gas knockout drum line 14 inch flange was opened while process gases were flowing, instead of another flare line flange that emptied and suppose to be opened. | Release of process gases and plant emergency called. | Hydrogen sulfide and reduced sulfur compounds were released that caused strong odors downwind. Complaints about strong odors came from as fay away as Bay Point. Sirens were sounded and the residents of Crockett and Rodeo were asked to shelter-in-place. |
| Tesoro Golden Eagle Refinery October 30, 2004 |
No 5 boiler pluming during start-up of the coker unit after the turnaround. | Operational upset during coker start-up and ultimate shutdown. | Visible black plume, signigicant pluming of coke dust. Tesoro rec'd one complaint, BAAQMD rec'd five compliants. |
| Tesoro Golden Eagle Refinery October 14, 2004 |
Fire at a naphtha transfer pump at 2:45 A.M. At 5:30, the fire is no longer visible and at 6:27 CCHS declares the incident to be "all clear." | Fire response personnel were able to isolate tank from the pump. | Visible black plume, no odor complaints received by BAAQMD or CCHS. IH detected no chemicals of concern off-site. |
| Tesoro Golden Eagle Refinery September 16, 2004 |
Explosion and fire within Tank 745 at 12:03 A.M. The Tank contains sulfuric acid and a floating layer of alkylate. Fire was out at 6:56. CO2 was introduced to tank at 6:42. | Sulfuric acid recycling unit was shutdown. | 50' to 100' flames, smoke plume straight up, no odor complaints received by BAAQMD or CCHS, one odor report received by Tesoro. IH detected no chemicals of concern off-site. |
| Tesoro Golden Eagle Refinery July 4, 2004 |
#5 boiler developed an internal water leak at app.1:42 p.m. and coker flue gas was then diverted directly to the stack. | #5 boiler shutdown, coker and crude rate reduced. | Visible black plume containing coke dust. |
| General Chemical Bay Point Works April 3, 2004 |
Fire at a storage hangar near packaging building. The fire involved several pallets of chemicals (hydrogen peroxide-30%, nitric acid-69%, ammonium hydroxide-29%, misc. etchants), cased in one-gallon bottles, several 55-gallon drums and 8-pallets of empty bottles. | Facility was evacuated. | A plume of smoke was visible for 1-2 hours. Community advisory notice was distributed but not shelter-in-place. |
| Tesoro Golden Eagle Refinery March 2, 2004 |
Odor complaints were received at the Golden Eagle Refinery and recognized in the Vine Hill area the evening of March 1. The refinery receive additional odor complaints on March 2. Hundreds of odor complaints were received from Bay Point, Pittsuburg, Concord, Pleasant Hill, Walnut Creek, Alamo, Danville, San Ramon, Dublin, and Pleasant. The odors seemed to have originated from the Golden Eagle Refinery. Tesoro was unable to locate the source of the odors. The odors could have originated from some of the areas doing special operations. Tesoro shut down the operations and odors were no longer noticeable. | No noticeable impact onsite. | Hundreds of odor complaints throughout Central and parts of East County from the north part of the County into Alameda County. The odors were consistent with reduced sulfur compounds. CCHS received information that people were feeling ill from the odors and at least case where a person past out. |
| Tesoro Golden Eagle Refinery February 20, 2004 |
Due to problems that occurred at the Foster Wheeler Cogeneration Facility, electrical power was lost at the Golden Eagle Refinery. The refinery shut down and depressured to the flare. This caused incomplete combustion of the flare and large amount of black smoke. | The refinery shut down due to the lack of power and sent large quantaties of hydrocarbons to the flares. | The flare smoking caused concerns to the community. The smoke in most part was going straight up with some smoke drifting over North Concord. |
| Chevron Richmond Technology Center September 16, 2003 |
Fire at the Tank field (Oronite Drum loading) at 12:41 p.m. While discharging gasoline from a tank truck to 55 gallon drums via a manifold system an ignition occurred in a partially filled drum. Flames quickly spread to the tops of adjacent drums and eventually caused the breach of several drums. It is reported that the Operator and Truck Driver activated the shutdown systems as they evacuated the area. | Heat blistered paint on one 60,000 gallon tank in the nearby tank farm area. $150,000 of product loss (400 gal) and equipment damage. | Black smoke until the fire was extinguished by CFD. |
| Chevron August 9, 2003 |
North Isomax plant hydrogen recycle compressor, K600 unexpectedly shut down resulted in flaring activity with visible smoke. | Shutdown N. Isomax. | Odor complaint, 26 persons sought medical attention at Richmond Kaiser. |
| Tesoro June 8, 2003 |
The #5 Boiler developed an internal water leak sufficient to compromise good boiler water level contro. #5 Boiler fuel (waste heat from coker) was then diverted directly to the stack, and #5 Boiler was shutdown. When this occurs coke fines go out the stack. Coke fines continued to go out of the stack from 2200 6/8 to 0600 hours 6/10. It is estimated that 3.4 tons of coke fines went to atmosphere. | The refinery is at reduced production, until the #5 boiler is brought back online or temporary boilers can come online. | Coke fines were sent to the atmosphere. Complaints of rotten egg and burnt match spells were received. |
| Shell Martinez Refinery January 11, 2003 |
The Flexicoker Unit had a small fire starting about 3pm on 1/11/03. The fire may have involved gas oil or a heavy oil stream. One of the Safety Supervisors thought the smoke was traveling off-site so the bumped it to a level 3, including sirens and a scroll across the TV. Wayne was told that the scroll did not work so well since it blacked out the football game, instead of just scrolling. Paul Andrews responded by telephone and was interviewed by the press. Wayne said that Paul informed the press that Shell conservatively went to a level 3. Shell started their incident investigation, including the RCA over the weekend. Art Kinney is leading the investigation. | Small fire, smoke. | Smoke potentially traveling offsite. Level 3. Sirens sounded. TV warning message scrolled. |
| General Chemical-Richmond September 26, 2002 |
SO3 release from CP unit, control valve problem, prompting Level 2. | Unit shutdown. | Plume toward Chevron. |
| Phillips (now ConocoPhillips) Rodeo, CA July 10, 2002 |
The steam boilers were tripped off, which led to a loss of steam for the refinery. The refinery was shutdown immediately with much of the offgas going to the flares. The flares were overwhelmed and created a lot of smoke and decreased the overall efficiency of the flares. | The refinery lost steam and had an emergency shutdown. | Smoke, partial burned hydrocarbons, and sulfur compounds impacted the communities downwind. Tormey and Crockett were asked to shelter-in-place. Sirens and the CAN were activated. |
| Shell Martinez, CA April 23, 2002 |
Sulfur Recovery Unit #3 was being shut down on the morning of 4/23/02 to address concerns about SO2 stack emissions, which were approaching the BAAQMD 250 ppm/hr limit. SRU#3 converts acid gas consisting of SO2 and H2S to elemental sulfur in a catalytic reactor utilizing the "Claus" process. The SRU#3 vent gas is routed through a Shell Claus Offgas Treatment (SCOT) plant for additional treatment. The SCOT-3 vent gas is routed through a catalytic oxidizer to convert remaining H2S to SO2. By 11am all acid gas feed had been removed from SRU#3. Approximately an hour later, at 12:15 p.m. the catalytic oxidizer experienced a temperature excursion (most likely resulting from burning sulfur), which led to a plume from the SCOT-3 stack by 12:30 p.m. At 12:30 p.m., Shell called the incident a Level 1. At 12:35am, the Shell IC upgraded the incident to a CWS Level 3 and sounded sirens. Steam and nitrogen were used to cool the catalytic oxidizer. CCHS field observations identified black plume, which dissipated very quickly and no plume was visible after about 10 or 15 minutes. Shell secured the unit at 12:57 p.m. CCHS called the official "All Clear" at 1:21 p.m. | Shutdown SRU#3 pending outcome of investigation and completion of RCA. | Smoke released. Level 3 was called with sirens activated. CCHS identified that visible smoke plume stayed elevated and dissipated quickly. Event was over very quickly. |
| Loctite Bay Point Pittsburg, CA February 21, 2002 |
Considerable smoke was released from a 55-gallon drum containing intermediate adhesive product (epoxy resin). The smoke was caused by an exothermic runaway reaction (Monkey) that occurred due to addition of excessive hardener to the drum. | Drum moved from manufacturing area to outside. | Smoke released. Level 3 was called with sirens activated. People living downwind were asked to shelter-in-place. |
| Chevron Richmond, CA January 31, 2002 |
Release of sulfur dioxide from the #3 SRU plant. A high vapor/liquid flow condition was created by the Isomax #4 H2S plant when a normal heat exchanger backwash was being performed, which caused an interlock plant shutdown at #3 SRU. The momentary release occurred while restarting the plant.(Level 3 initiated by CCHS.) | Shutdown Isomax and the #3 SRU. | A few calls were reported to the facility expressing concern or inquiring as to the activity taking place. People in Richmond were asked to shelter-in-place. |
| Ultramar (now Tesoro) Martinez, CA January 26, 2002 |
Release of sulfur trioxide from the acid plant was released. A malfunction of the sonic meter system to measure concentration of 99% H2SO4. The acid became super saturated with sulfur trioxide, and the sulfur trioxide was released out of the stack. | Shutdown their acid operations. | No measurable quantities of sulfur trioxide or sulfur dioxide were measured offsite. Sirens and CAN was activated. People in Clyde and North Concord were asked to shelter-in-place. |
| General Chemical Richmond, CA November 29, 2001 |
The 99.5% sulfuric acid concentration was super saturated, which caused a release of sulfur trioxide. | The plant was starting up. Shut down the plant. | Sulfur trioxide and sulfur dioxide went offsite and a Level 3 was called. Sirens were activated. People from the communities downwind were asked to shelter-in-place. |
| Equilon (Now Shell) Martinez, CA October 17, 2001 |
Cat cracker release of soot, catalyst, and hydrocarbons during another catalytic cracking unit upset (same unit as 10/14, 2001 incident). More than 50,000 lbs hydrocarbons emitted. | Cat cracker unit shutdown to do a full investigation. Unit was down for 2 months. | Mostly hydrocarbons were released. A Level 3 was called with sirens and CAN being activated. The people in the community downwind were asked to shelter-in-place. Interstate 680 was shutdown for most of the duration of the release. Numerous calls from community. |
| Equilon (Now Shell) Martinez, CA October 14, 2001 |
Cat cracker release of soot, catalyst, and hydrocarbons during catalytic cracking unit upset. More than 5,000 lbs hydrocarbons emitted. | Cat cracker was starting up and had to discontinue the startup. | Soot dusted the Martinez area that is north of the refinery. Odors were smelled over a mile north of the refinery. Level 3 was called with sirens being sounded. CAN was not used, since the incident was over before CAN could be used. |
| Equilon (Now Shell) Martinez, CA July 18, 2001 |
An upset occurred in the straight run hydrotreater unit in the light oil processing area. Subsequently, fires occurred in the vacuum flasher heater furnace and crude unit heater furnace. Hydrocarbons, H2S, and smoke released offsite. Level 3 under CWS, sirens activated. | Unit upset resulting in unit shutdown. One MRC emergency responder slightly injured when a fire truck fitting struck his leg. | Smoke and hydrocarbons released. Level 3 was called with sirens activated. |
| General Chemical Richmond, CA May 1, 2001 |
Truck hit a power line and GCC lost power. A release of sulfur dioxide occurred when the decomposition chamber went positive. | The plant shutdown and had problems when starting up. Another release occurred. | Sulfur dioxide went offsite and a Level 3 was called. Sirens and CAN were activated. People were asked to shelter-in-place downwind of the plant. |
| MBA Polymers Richmond, CA October 26, 2000 |
MBA Polymer recycles plastics from computer components. They cut the plastics and fines are collected in a vent system. The dust from the cutting operation is believed to have found an ignition point and a dust explosion and a fire occurred. | One worker was killed and four others injured. The initial concern was a fire, since there is very little hazardous materials handled at the site. The concern was that the by-products of the fire was toxic and when the wind shifted and was going in the direction of a residential area sirens were sounded and telephone calls were made. One employee was killed and there was major impact to the building. | Because smoke was impacting the community. Sirens and telephone calls were made after the wind shifted and there was a concern that the smoke was going into the neighborhood. |
| Tosco (now Tesoro) Avon, CA June 6, 2000 |
A fire at the coker unit. Naphtha was released from the flushing oil tank and caught on fire. | The #5 Boiler was shutdown. Two contractors had minor injuries. | Smoke from the fire was visible offsite. With the #5 boiler offline, particulates were released into the air from the stack. |
| Tosco (now Tesoro) Avon, CA March 22, 2000 |
A fire occurred at the alkylation unit. A contractor was welding in the alkylation unit with a fire watch spraying down any errant sparks. The firewater caught on fire because flammable hydrocarbons backed into the fire waterline. | Two contractors were injured. | None. |
| Tosco (now ConocoPhillips) Rodeo, CA February 7, 2000 |
Catacarb leak and hydrogen fire at the unicracking unit. The fire lasted approximately 10 minutes. Localized corrosion caused a pipe to fail and dumped the Catacarb from the unit and then hydrogen was released and ignited. | Unit shutdown loss of the supply of Catacarb. | Smoke visible offsite. |
| Tosco (now ConocoPhillips) Rodeo, CA January 15, 2000 |
Flaring from the MP-30 ground flare for approximately 2 hours. The low level point in the header caused the flaring. | Unit shutdown. | Black smoke visible offsite. |
| Tosco (now ConocoPhillips) Rodeo, CA December 16, 1999 |
Overpressure of the flare header system where the MP-30 ground flare was used. There was a low point in the flare header that accumulated liquids. | Unit shutdown. | Black smoke that could be seen as far away as Emeryville. People in Rodeo were asked to shelter-in-place. |
| Chevron Richmond, CA March 25, 1999 |
Isomax fire that required the sounding of sirens. A valve stem blew out that caused a release of hydrocarbons and hydrogen sulfide that ignited, resulting in a major fire. | Shutdown a major part of the refinery - two people slightly injured fighting the fire. | Smoke was visible over much of the North Bay Area - Disruption in traffic - Sirens sounded, people were asked to shelter-in-place. |
| Tosco (now (now Tesoro) Avon, CA February 23, 1999 |
50 crude unit flash fire killing 4 people and seriously injuring another. | The shutdown of 50 crude and then later the shutdown of the whole refinery. Four people died with another seriously injured. | None. |
| Tosco (now ConocoPhillips) Rodeo, CA April 23, 1997 |
An upset in the distillation unit sent hydrocarbons to the sulfur recovery units. The sulfur recovery units released hydrogen sulfide. | Shutdown parts of the refinery until the problem was found and the different units were stabilized. | People were asked to shelter-in-place in Tormey and Crockett. |
| Tosco (now Tesoro) Martinez, CA January 27, 1997 |
A hydrocracker had a run away reaction that raised the temperature and pressure of the outlet gases. An outlet pipe failed and caused an explosion and fire. One worker was killed and forty-six people sought medical attention. | One worker was killed and forty-six other sought medical attention. Many of the people seeking medical attention were injured while running away from the explosion and fire. The outlet piping and some of the equipment and instrumentation was damaged. The hydrocracker unit was shutdown until the unit could be repaired. | There was little of no offsite impact from this explosion and fire. People were not asked to take any protective action, such as sheltering place. |
| Unocal (now ConocoPhillips) Rodeo, CA May, 1996 |
A hot coke drum was dumped and a fire was initiated. | Fire damage to the coker unit. The coker unit was run at partial capacity until repairs could be made. | People were asked to shelter-in-place in Tormey and Crockett. A few people in Vallejo sought health care assistance complaining of the smoke and odors. |
| Shell Martinez, CA April 1, 1996 |
Fire at their cracked gas unit. The fire lasted for over 3 hours. | Fire damage was extensive onsite. The unit was shutdown until repairs could be made. | People were asked to shelter-in-place downwind of the refinery. The smoke from the fire impacted the area downwind. |
| Air Products Martinez, CA February 1, 1996 |
Piping failed because of corrosion and a release of hydrogen occurred with an explosion. The fire lasted approximately 10 minutes. | Shutdown of the hydrogen unit. | Noise of the explosion was heard offsite for well over a mile. Some minor damage offsite. |
| Unocal (now ConocoPhillips) Rodeo, CA June 16, 1995 |
Tank fire that continued to burn off and on for approximately 1 week. | Response from the facility along with the local fire departments. | Smoke impacted the communities of Crockett, Rodeo, CA and Tormey. The communities were asked to shelter-in-place. Odors lingered in the communities for a week after the fire. Unocal put up approximately 100 people in motels until the incident was 100% secure. |
| Unocal (now ConocoPhillips) Rodeo, CA August 22 - September 6, 1994 |
A column used to strip carbon dioxide developed a leak. The column continued to operate for a 16-day period. The hole in the column became larger where a solution of Catacarb® was atomized and released. Estimates of between 80-225 tons of Catacarb® was released. | The Catacarb® affected the health of many of the workers downwind of the column. At the end, the hydrocracker processing unit was shutdown. | The release impacted the communities of Crockett, Rodeo, CA and Tormey. Many homes and cars were cleaned to remove the Catacarb® solution. A health clinic setup by Unocal in Crockett treated over 1200 people over the next year. Some people are still complaining of health effects from the release. |
| General Chemical Richmond, CA July 26, 1993 |
Overheating of a tank car of 35% oleum that released between 4 and 8 tons of sulfur trioxide over a three hour and forty-five minute period. The sulfur trioxide formed a sulfuric acid cloud. | The loss of a tank car of 35% oleum and the shutting down of their processing. | Over 22,000 people sought medical assistance with 15-22 people staying in the hospital overnight. People were asked to shelter-in-place downwind of the release. |
| Rhône Poulenc (now Rhodia) Martinez, CA May, 1992 |
Sulfuric acid mixed with hydrocarbon spill and fire. The fire was difficult to put out because the sulfuric acid would break down the foam used by the fire fighters. One employee was killed and another was seriously injured. | Fire damaged some of the equipment onsite. The man who died and the one who was injured were Rhône Poulenc employees. | Smoke did go offsite and impacted the community. The smoke also included the degradation products of the sulfuric acid (e.g., sulfur trioxide, sulfur dioxide). Shelter-in-place was called for the community downwind of the fire. |
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