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Calumet Lubricants 8 (1214), Shreveport

Releases of Hydrogen Sulfide

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release

Flare Gas Compressor - FL 2001
Same as above
Cause: Broken valves in FGC were repaired during and emergency shutdown.

Followup: No

Notes: Valves were repaired upon shutdown.
126.0 pounds

Sulfur Recovery Unit
Same as above
Cause: SRU tripped due to weather conditions. Had to be restarted and release occurred at that point.

Followup: No

Notes: No Information Given
12.0 pounds

Tank Farm
Cause: : Sour water tank caught on fire while vac trucks were removing residual oil from an open manway. The truck engine ignited vapors which caused an explosion and fire. Calumet policy on truck entry into the dike wall was not followed.

Followup: No

Notes: Fire extinguished. Dark smoke from the refinery for two hours.
50.0 pounds

FL 2001 #3 Flare
vacuum truck loading area, flare line knock-out drum
Cause: Hurricane Ike blew down 2 power poles inside the refinery causing plant power failure. Both Sulfur Recovery Units (SRUs) were down and all acid gas was routed to the #3 flare. The boilers were also down and there was no steam on the flare. As a result the #3 flare opacity was greater than 20% for 2 hours. While in start-up, refinery operators noted that the flare pressure was higher than normal. The investigation revealed that the flare knock-out drums were full of liquid and the flare lines had liquid in them as well.

Followup: No

Notes: Power lines and poles were replaced In response to problems during start-up, contractors were immediately brought in to provide vacuum truck services, and the liquids removed from the knockout drums and flare lines was placed into Baker fractionation tanks. The Vacuum truck operations of removing the liquid from the flare line had the unfortunate result of creating odor problems within the refinery. Low levels of Hydrogen Sulfide were detected around the vacuum truck loading areas and at the three flare line knock-out drums. Calumet personnel monitored hydrogen sulfide levels within the refinery for industrial hygiene purposes. Liquids from the Sour Water Stripper were also found to be entering the flare lines, adn the sources of these liquids were identified and blinded off.

FL 2001 #3 Flare
Cause: Power outage on previous day caused motor windings to burn out on liquid pump on flare drum. The flare gas compressor shut down as a result.

Followup: No

Notes: This incident is linked to the previous day which is why the state police numbers are the same. The pump was replaced.

Hydrogen Plant
Cause: Piping Flange broke off recycle absorber on LOHT unit

Followup: No

Notes: Unit was depressurized and purged with nitrogen.
46.0 pounds

Cause: "Excess hydrogen gas and Flare Gas compressors not fully loaded". In other words, flare gas compressors not taking the load of the system. The hydrogen plant #1 was putting excess hydrogen in the flare line causing high flow issues a well. Reportable quantities of sulfur dioxide were exceeded from flare # 2.

Followup: No

Notes: Immediate corrective action taken was just to increase FGC pumping rates. No specific remedial action or plan to prevent recurrence. No LDEQ or SPOC report included
3.4 pounds

SRU Unit
Cause: 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 .

Followup: No

Notes: 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.