LA Bucket Brigade : Refinery Accident Database

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Calumet Lubricants 8 (1214), Shreveport

Releases in 2012

LDEQ Accident Number Accident Date	Point Source/Release	Cause	Notes
145587 2012-12-25	Point Source(s): Flare #2 Pollutant(s): Sulfur Dioxide - BRQ	Cause of Problem: Power Failure On 12/20/12, The voltage on the six 12.5 kV feeders supplying service to Calumet from the Midway Substation experienced a significant voltage sag. The voltage dropped down to 18.9 volts (16.4%) on the West 12.5 kV bus for 37.32 cycles, and 18.3 volts (15.9%) on the east bus for 37.31 cycles. This event caused all the incoming voltage to sag, which caused Calumet to lose production. At the same time, 12.5 kV OCB 5500 tripped and reclosed auto. At the time of the event, the area was in midst of a severe storm, including very strong wind gusts and lightning. A 12.5 kV knife-blade switched burned up, probably due to lightning, which caused 12.5 kV circuit breaker 5500 to open. Calumet personnel reported seeing a blue flash at the time of the incident, which was most likely the offending lightning strike. On 12/25/12, the west 69/12.5 kV transformer differentialed, causing both of the 69 kV Breakers (8310 and 10320) in the Midway Substation to lock out. Therefore, the voltage went to 0.0 volts (0.0%) on all six 12.5 circuits feeding the refinery. At the time of the event, the area was in midst of a severe storm, including strong wind gusts and lightning. 12.5 kV circuit breaker 5500 experience both external and internal damage. 12.5 kV circuit breaker #5500 failed which caused the west 69/12.5 transformer to differential, which triggered the operation of the 69 kV breakers. Also, lost on 12.5 kV middle phase metering PT when the neutral burned off. On 12/30/12, the incoming voltage to the six 12.5 kV feeders supplying service to Calumet from the Midway Substation dropped down to 59.3% of normal for approximately 3.84 cycles. At the time of the event, the 69 kV circuit breakers on the transmission line between SWEPCO's Arsenal Hill and Shed Road Substations tripped on time and reclosed automatically. The cause of the fault is unknown. The events that occurred on 12/20/12 and 12/25/12 were due to weather, but the cause of the event that occurred on 12/30/12 is unknown.	The 69 kV breakers (8310 and 10320) in both the Midway and Hardy substations operated one time and reclosed automatically, with no further problems. Circuit breaker 5500 was cleared, and then the rest of the station was restored to normal. The SWEPCO protection scheme worked as designed to prevent further damage to the system. Circuit breaker 5500 was later replaced, which should help to prevent a further outage like this one. SWEPCO is also looking at replacing 12.5 kV circuit breaker #4910. SWEPCO will also be replacing another 15 switches, bus PT's, station post insulators and adding transition plates where needed. On 12/25/12, a citizen reported flaring, black smoke, and a sulfur odor at the Calumet Lubricants Shreveport Refinery. The LDEQ contacted the facility who advised that the plant suffered a power failure during the bad weather when a circuit breaker failed at Southwester Electric and Power Company and caused a refinery circuit breaker to trip. Due to the incident, the flare increased, and an estimated 80 pounds of SO2 was released from Flare #2. This flare is permitted to emit a maximum of .01 pounds per hour of SO2. In a Power Disturbance/Interruption Analysis submitted by Calumet, the facility reported three separate incidences of power outages. The event reported by the concerned citizen occurred on 12/25/12. The following incidents are reported by Calumet: On 12/20/12, the 69kV breakers in both the Midway and Hardy substations operated one time and reclosed automatically, with no further problems. The 12.5 kV knife-blade switch was later bypassed by SWEPCO, thus temporarily eliminating the problem. The SWEPCO protection scheme worked as designed to prevent further damage to the system. All three phases on the switch with the burned blade were changed out the next morning, and the substation was returned to normal. On 12/25/12, the 69kV breakers in both the Midway and Hardy substations operated one time and reclosed automatically, with no further problems. Circuit breaker 5500 was cleared and then the rest of the station was restored to normal. The SWEPCO protection scheme worked as designed to prevent further damage to the system. Circuit breaker 5500 was later replaced, which should help to prevent further outage like this one. SWEPCO is also looking at replacing 12.5 kV circuit breaker #4910. SWEPCO will also be replacing another 15 switches, but PT's station post insulators and adding transition plates were needed. On 12/30/12, after the 69 kV breakers reclosed automatically, no further action was required. The RQ for sulfur dioxide is 500 pounds.
145355 2012-12-12	Point Source(s): NIG Pollutant(s): Propane - BRQ	Cause of Problem: Process Upset A Bucket Brigade representative contacted the LDEQ in reference to flaring and heavy black smoke at Calumet Waxes and Lubricant's Shreveport location. The LDEQ contacted Calumet who advised that the flaring was due to over pressure of the propane feed drum. The drum vents to the flare to reduce pressure, and did so intermittently a few times.	The unit was readjusted to resolve the issue. Sweet propane was released to the flare, and no sulfur compounds were emitted. Opacity was tracked during the event. LABB only has access to an LDEQ Field Interview Form and the LDEQ Incident Report.
145118 2012-12-05	Point Source(s): Tank Farm Pollutant(s): Lube Oil - 294 gallons	Cause of Problem: Human Factors While placing tank in service (circulating), operator left bleeder valve open on 700 viscosity lube stock line near tank that released the finished product to soil.	The facility immediately closed bleeder and began to vacuum spill and remediated soil. The RQ for lube oil is 1 barrel. This event released 7 barrels.
144820 2012-11-20	Point Source(s): NIG Pollutant(s): Calpro 60 - 15 gallons	Cause of Problem: Human Factors A 15 gallon spill of Calpro 60 occurred when a pump was not shut off in time while the company was loading, and the trailer overfilled.	Calpro 60 is 50% naphthenic hydrotreated distillates and 50% hydrotreated light parraffinic distillates. It is a nonhazardous substance. 15 gallons of Calpro were discharged to asphalt and did not impact a water body. The spill was cleaned with a sand absorbent. MSDS for Calpro is provided. LABB could not locate a letter from the refinery documenting the accident.
144647 2012-11-13	Point Source(s): Tank Farm Pollutant(s): Crude Paraffinic - 210 gallons	Cause of Problem: Equipment Failure Spill of 5 barrells (210 gallons) of oil from the frac tank near 201 tank. Bad check valve and ball valve caused material to backflow through frac tank releasing crude oil to secondary containment	The facility cleaned up oil with vac trucks and remediated the soil. They will replace faulty valves at equipment.
143200 2012-09-25	Point Source(s): Storage tank 10 Pollutant(s): Lube Oil - 756 gallons	Cause of Problem: Under Investigation Light lube oil Calpar 80 release of 18 barrels (from storage tank 10) was reported on 9/25/2012.	Contractors removed impacted materials outside of secondary containment and vacuumed fluids inside of secondary containment. The facility has been doing weekly inspections of the secondary containment structure and has noted planned discharges of stormwater.
143229 2012-09-01	Point Source(s): Tank 44 Pollutant(s): Gasoline - 3,150 gallons Benzene - BRQ Toluene - BRQ Ethylbenzene - BRQ m&p-xylene - BRQ o-Xylene - BRQ Arsenic - BRQ	Cause of Problem: Human Factors Tank 44 was filled beyond emergency high alarm level causing gasoline to overflow. SPOC states there were two overflow spills, from Tank 44 and Tank 61.	Tank flows were shut down. Foam was spread over the spilled area. Called emergency response contractors. SPOC report states 100 bbl of gasoline was released, verbal report states 50-75 bbl, field interview form states approximately 50.75 bbl, refinery written report states 75 bbl. LABB has reported the refinery's stated 75 bbl. Written report has a discrepancy on the date started/ended, stating the incident date was 9/4/2012. Gulf States Environmental Laboratories analytical results attached. Lab report states that a benzene total of 0.41 mg/kg was in the soil sample and that 0.10 mg/kg is the reportable quantity for this pollutant. Similar circumstances with other VOCs in the soil sample lab report. Also reports arsenic, barium, cadmium, chromium, lead, selenium, mercury, silver, and zinc as mg/L.
142418 2012-08-28	Point Source(s): Tank 61 Pollutant(s): Gasoline - 126 gallons	Cause of Problem: Piping or Tubing A plugged in sewer line caused a substance to be released. Substance did not escape the confines of the dike wall containment around Tank 61. Material leaked off-site and LEL was detected.	Fresh water was used to flush the gasoline to prevent the flammability properties. Free liquids were being removed via vacuum truck., Impacted soil will be excavated and confirmatory soil sampling will be preformed and forwarded to NWRO. Air monitoring was conducted around the facility perimeter prior to the inspection. LEL was not detected and 20ppm of benzene was detected downwind of the spill. A LDEQ representative drove the perimeter of the facility to conduct air monitoring with Crowcon 4-Gas #1. On 8/28/12 LEL was detected at 3-4% on Jewella Ave and Clarke Blvd. Confirmatory sample results were received on 9/28/12. the results for both TPH and BTEX were below RECAP standards. Based on the analytical, the site was determined remediated. It should be noted that the reportable quantity for oil is 1 barrel. Three barrels of oil were leaked at Calument on 8/28/2012.
139058 2012-04-22	Point Source(s): SRU Unit Pollutant(s): Sulfur Dioxide - 1,696 pounds Hydrogen Sulfide - BRQ	Cause of Problem: Power Failure On 4/22/12 both Sulfur Recovery Units (SRUs) tripped and sent acid gas to flare gas recovery system. This increased the hydrogen sulfide concentration of the fuel gas and caused an exceedance of the 500 lb RQ limit for sulfur dioxide. Emission point v-f .	Attempt to restart SRUs and reduce DHT/LOHT charge rate. Specific remedial actions and plans to prevent recurrence are to be determined. 2 copies of written report were included in this document. Written report says that the release started on 4/23/12 at 12 pm and ended on 4/23/12 at 11 pm. The duration says 11 hours. Then it says that the event occurred on 4/22/12. They reported the release on 4/23/12. A memorandum is included in this document dated 4/25/12. It states that the permit levels for hydrogen sulfide gas released through a flare with exceeded several times during this incident. There were no complaints and no follow ups related to this incident.
138675 2012-04-07	Point Source(s): crude drop out/slop oil line Pollutant(s): Sour Crude - 420 gallons	Cause of Problem: Piping or Tubing Crude oil leak discovered in multiple locations in the plant. Leaking from ground at road south of Tank 43. Product in dike wall at Tank 45. Product in dike wall at Tank 39. Failure of underground line. Estimated total of 10 bbl released at the leak locations. The crude drop out/slop oil line was inadvertently blocked in at the tank and caused leaks in the line. Two main areas found with petroleum having reached surface. Leakage mitigated on 4/7/12.	Opened valve to tank to relieve pressure. Excavation to locate line failure locations to ensue between 4/13 and 4/16. No soil remediation done at all yet. Recommended immediate removal of contaminated soil and confirmatory sampling. Some clean soil has been applied to asphalt in area 2. Storm water controls are in place for contingency if upcoming storm displaced hydrocarbons. Lyndon Johnson, safety manager, on site and interviewed. He agreed to send applicable SPOC portions to NWRO via email.
138122 2012-03-21	Point Source(s): #2 Flare Pollutant(s): Sulfur Dioxide - 1,000 pounds	Cause of Problem: Power Failure Electricity to the flare gas compressors failed, returned, and failed again, causing sulfur dioxide to be released to the #2 flare on two occasions. The power failure was attributed to a bad solenoid valve, which cauased a primary fuse to blow in the breaker.	The bad valve has been replaced, and the compressor began running well again as of 15:30 on 3/22/12.
137502 & 137503 2012-02-27	Point Source(s): No Information Given Pollutant(s): Sulfur Dioxide - 11,583 pounds	Cause of Problem: Start Up, Shut Down On 2/27/12 Calumet self reported a sulfur dioxide release around 5:00 am. A site visit was conducted on 2/28/12 with report of release of sulfur dioxide on 2/28/12. SRU, Dinowave, and Thermoxidixer units down. An estimated 1100 lbs of sulfur dioxide was released. Calculations pending. Air monitoring conducted on 2/28/12 with no hazardous detection of sulfur dioxide. The fuel gas system's H2S contents had increased to a point where the refinery exceeded 500 lb/day limit for SO2 through the heaters and boilers systems from February 27-29. Caused by emergency shutdown in the No. 1 Hydrogen Unit for safety concerns.	The total emissions of SO2 for the three days were as follows: 1775, 6169, and 3639. These estimates are based on the operator samples and flow meter data.
137471 2012-02-26	Point Source(s): barrels at the rail car unloading station Pollutant(s): Crude Oil - 84 gallons	Cause of Problem: Human Factors A tank at the rail car unloading station was pressurized and the hatch was not secure. 2 barrels of yellow crude oil was released.	The crude oil and impacted rock were removed. The impacted rock was placed in a container to be disposed with other waste. It was determined that the crude oil did not leave the site and did not impact any water source. There are photos attached to the file. There is no Incident Report or SPOC report attached to the file. The refinery letter included is not the correct letter.
137435 2012-02-23	Point Source(s): Boiler #5 Pollutant(s): Fuel - BRQ	Cause of Problem: Under Investigation A fuel gas explosion destroyed boiler #5 and caused an evacuation. The cause of the explosion is unknown and under investigation.	Air monitoring was conducted and no harmful emissions were detected. A root cause analysis will take place and findings will be sent to NWRO. There is no incident report and no SPOC report attached to the file. The monitoring report form is attached to this file.
No LDEQ Number Available 2012-02-22	Point Source(s): Pollutant(s): Smoke - 0 Liquid Hydrocarbons - 0	Cause of Problem: Other - See text Over pressurization of #5 Boiler. High BTU liquid hydrocarbon present at boiler #5 lead to an explosive mixture in the boiler. Fire and smoke were witnessed during boiler start-up.	Systems stopped and re-started several times. Instrument technician was called in to perform repairs.
137545 2012-02-20	Point Source(s): Pump at the lift station from the API unit Pollutant(s): Wastewater - 0	Cause of Problem: Equipment Failure There were mechanical issues and seal failure with the main lift pump, which pumps to the waste water holding tank (T-79). The pump was taken out of service, during which time untreated process waste water from the grit separator flowed directly into the Aerated surface impoundments.	Maintenance craftsmen made necessary repairs. There were failed attempts to start the backup belt-driven pump, but it cycled 3 times and lost prime, and operations was unable to re-prime it. As of 02/21/12, maintenance craftsmen were working with the repairs and were expected to complete them. The refinery letter advises that the bypass was not expected to cause any additional problems with effluent limits.
137126 2012-02-11	Point Source(s): FLARE: Flare #2 Pollutant(s): Sulfur Dioxide - 1,462 pounds	Cause of Problem: Human Factors Workers were purging hot air treater with gas and the compressor could not handle the amount. SO2 was released from flare #2.	There are no remedial actions listed in the report. This file does not contain an Incident report, LDEQ report, or SPOC report. The only form is the field interview form. Release over 500lbs not reported within 24 hours. Investigation occurred on 2/14/12 LDEQ report as of 2/14/2012. Facility representaive state he didnt know it was over 500 lb RQ until Monday.