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Calumet Lubricants 8 (1214), Shreveport

Releases in 2013

LDEQ Accident Number
Accident Date
Point Source/Release CauseNotes
152865

2013-12-15
Point Source(s):
Tank Farm

Pollutant(s):
Fuel - 420 gallons
Cause of Problem: Human Factors

A release of diesel fuel occurred at the refinery on December 15th. Failure of charge pump seal released diesel fluid. Spill of approximately 10 barrels of diesel fuel at 50tk when charge pump developed a seal leak. Product in containment basin and down drainage ditch to first storm water pond.
Shut down charge pump. Begin removing free product and digging up contaminated soil. A summary of remediation activity was submitted by Calumeto n 12/11/14. Fro that report: Following removal of free product, an initial soil excavation was performed at the site to removed contaminated soil. Samples were taken for total petroleum hydrocarbon (TPH) fractions. TPH sample results indicated one area with unacceptable concentrations. To address the remaining contaminated area (the southeast portion of the diked area), a plan was developed to bio-remediate the soil. This plan was forwarded to the Louisiana Department of Environmental Quality (LDEQ). The soil was removed from the site and treated with the bio-remediation product. An underground sewer line was found to be leaking into the area; the line was repaired to avoid continued contamination. Additional samples were pulled and tested from the treated soil and the area from which the soil was removed. The excavated soil will be returned to the site of contamination. The area will be returned to normal service.
152539

2013-11-22
Point Source(s):
No Information Given

Pollutant(s):
Slop Oil - 420 gallons
Cause of Problem: Power Failure

Spill of slop oil on east side of refinery on November 22. Loss of power due to heavy rain caused East sump pump in the tank farm area to back up of east sump separators and release oil to surrounding area.
Restore power. Use vac trucks to remove product in area and restart pumps when power restored.
152202

2013-11-06
Point Source(s):
No. 2 Flare

Pollutant(s):
Hydrogen - 0
Natural Gas - 0
Cause of Problem: Power Failure

Citizen complaint of flaring was received on 11/6/13. Flaring was a result of power failure which caused the No. 2 Hydrogen Plant to trip and lose power. The heavy flaring occurred from the No. 2 flare from 10:35 to 10:50 on 11/6/2013
151749

2013-10-20
Point Source(s):
Tank Farm, Tank #43

Pollutant(s):
Crude Paraffinic - 168 gallons
Cause of Problem: Corrosion

A pinhole leak in crude oil storage tank #43 was discovered on October 20, 2013. Approximately 4 barrels of crude oil was released to the ground inside the dirt dike wall containment. The release was caused due to corrosion on the 6-inch line. The release impacted an area of 40 yards by 3 feet.
Shut down and isolate line. Begin clean up of spilled material and contaminated soil. Repair piping as needed. Free liquids were removed via vacuum truck. Excavation of the impacted area started on 10/23/13 and should be complete by 10/28/13. Waste generated will be stored in the holding area at the solid waste slab inside the facility for landfill disposal. On November 8, 2013, sample results were available. The results revealed remediation was not complete due to elevated levels of TPH-D.
151676

2013-10-16
Point Source(s):
Tank Farm

Pollutant(s):
Crude Oil - 33,600 gallons
Cause of Problem: Process Upset

Overfill of Tank 82 during line up cause release of heavy wax crude oil into surrounding dike area.
Isolated tank and secured area. Planned clean up of free product and soil in the dike area.
151638

2013-10-16
Point Source(s):
Tank Farm

Pollutant(s):
Diesel Fuel - 210 gallons
Cause of Problem: No Information Given

Spill of diesel fuel to ground at salt drums by No. 4 Vacuum Unit. Caused by run down not opened on finish diesel to tank. Caused relief valve to open, overwhelmed sewer/ contaminated and caused loss of product to surrounding area
Opened valve to stop relieving of diesel fuel. Removing floating product via vacuum truck and clean surrounding area. Flowing product diverted to wastewater treatment.
151556

2013-10-09
Point Source(s):
Tank Farm

Pollutant(s):
Kerosene - 126 gallons
Cause of Problem: Human Factors

A release of 3 barrels of Kerosene to Oil due to and open Bleeder valve left open on kerosene line.
Removed free liquids, remediated contaminated soils.
150709

2013-08-29
Point Source(s):
Waste Water Treatment

Pollutant(s):
Crude Oil - 84 gallons
Cause of Problem: Piping or Tubing

Rupture in hose connection near skim pump. Spill of approximately 2 barrels of slop oil at the grit separator when a hose ruptured on the temp diesel skim oil pump. On September 6, 2013, a site inspection was conducted. The oil sprayed approximately 30 yards of soil near waste water treatment system.
Shutdown pump to prevent further leakage. The hose had been replaced and the affected soil excavated at the time of inspection. The contaminated soil is to be profiled and properly disposed of.
150721

2013-08-29
Point Source(s):
Tank Farm

Pollutant(s):
Crude Oil - 210 gallons
Cause of Problem: Human Factors

On August 29, 2013, there was a release of crude oil at the rail car unloading facility. The spill was approximately 5 barrels of crude oil.
Shut down unloading operations and valve off. Affected area excavated. Soil to be properly disposed of.
149948

2013-07-29
Point Source(s):


Pollutant(s):
Sulfur Dioxide - 89 pounds
Cause of Problem: Power Failure

On July 27, at approximately 9 AM, the plant sustained a power loss during inclement weather. Power was out for 2h 30m. The resultant startup caused the flares to exceed the maximum permitted pounds per hour release.
No information given on remedial actions. Flares exceed permits and are to be reported in deviation reports, but due to the incident being unavoidable, and not of reportable quantity, the permit exceedences are to be deferred to the next enforcement inspection. H2S fuel gas concentration was 1600 ppm following the event during startup, and the rolling average was approximately 360 ppm when the permitted limit is 160 ppm. There was approximately 87 pounds of SO2 from flare #2 and 2 pounds of SO2 from flare #3 in the 24 hour period.
149294

2013-06-18
Point Source(s):
Waste Water Treatment

Pollutant(s):
Crude Paraffinic - 210 gallons
Cause of Problem: Weather

On June 18, 2013 at approximately 3:30 PM there was a release from Calumet's waste water treatment unit. The release of crude oil in the refinery was from sewer overflows following a heavy rain event.
immediate corrective action was to begin containment of spilled material. Remedial action was utilizing a vacuum truck to remove spilled oil. Although the facility did not offer any information in their 7 day letter regarding the Reportable Quantities that were exceeded by this event, the RQ for crude oil (which is 42 gallons or 1 barrel) was exceeded since there was 5 barrels of crude released during this event.
148795

2013-05-20
Point Source(s):
crude distillation unit

Pollutant(s):
Crude Oil - BRQ
Cause of Problem: Seal or Gasket

On May 20th, Calumet Lubricants Shreveport Refinery self reported a seal fire from a crude oil leak. At approximately 0830 hours a charge pump seal was to the crude distillation unit reported to have started leaking and caught on fire. On May 29th, LDEQ spoke with Calumet's environmental engineer - he advised that the charge pump to the crude distillation unit developed a small leak, which caught on fire. The material was contained on the containment pad around the pump and was determined to be Below Reportable Quantity.
Material was contained on the containment pad around the pump. The seal was replaced and the unit was returned to service. Less than 1 gallon of oil discharged to containment pad around pump.
148504

2013-05-02
Point Source(s):
Flare #2

Pollutant(s):
Hydrogen - BRQ
Cause of Problem: Equipment Failure

At approximately 7 PM on May 2, a PSA compressor tripped, routing gas to Flare #2.
No remedial actions taken. No exceedances resulted from incident and no emissions of reportable quantity were released. Gas was estimated to be 70 to 80 percent hydrogen. LABB was unable to locate a corresponding seven-day refinery letter.
148460

2013-05-01
Point Source(s):
Tank Farm

Pollutant(s):
Lube Oil - 420 gallons
Cause of Problem: Human Factors

On May 1, 2013, 700 viscosity lube oil from a rail car on the east side of the refinery was spilled due to the overfilling of a tanker car during loading operations. Release impacted an area of 150 ft long and 40 ft wide. The release migrated to Calumet process drains which are treated at the waste water plant. The release stayed on-site and did not leave the facility or enter a waterbody.
Immediate corrective action was to isolate loading line to stop flow of oil into the tanker car. Specific remedial action was to clean up free oil and start soil remediation. Hill Services was on-site and contracted to perform the clean-up. Free standing liquid (oil) and affected gravel was removed via vacuum truck. From May 1, 2013 to May 14, 2013, the free liquids in the affected area was removed via vacuum truck twice. Final attempt for clean-up was to remove the affected gravel via bobcat equipment and replaced the area with new gravel. All waste generated from clean-up was stored on-site at the non-hazardous holding area that will be disposed at Woolworth Landfill.
148076

2013-04-12
Point Source(s):
Flare

Pollutant(s):
Sulfur Dioxide - BRQ
Cause of Problem: Equipment Failure

The facility flared for approximately 6 to 8 minutes around 2045 hours on April 12, 2013, releasing Sulfur Dioxide from the flare when the diesel hydrotreator compressor went down.
This report was prompted by a concerned citizen reporting a Hydrogen Sulfide and Sulfur Dioxide odor around the entire perimeter of the Calumet Lubricants Plant in Shreveport. LADEQ report indicates that Calumet representative James Desonier stated no major incidences occurred that evening. He stated that flaring occurred for about 6 to 8 minutes releasing Sulfur Dioxide because of diesel hydrotreator compressor going down.
148030

2013-04-10
Point Source(s):
Junction box

Pollutant(s):
Slop Oil - 1,050 gallons
Cause of Problem: Equipment Failure

On April 10, 2013 for approximately one hour, 25 barrels (or 1050 gallons) of slop oil was released in the refinery tank farm area. This accident resulted due to a restriction in the line downstream of the junction box from a clogged pipe.
Lab results from clean-up were received on May 7, 2013. The soil samples were tested for gasoline, diesel and oil. The diesel results were very high as noted in the LADEQ report dated May 14, 2013. Mr. Desonier Calumet Shreveport representative) stated that despite these high results, he did not plan on doing any more remediation.
147939

2013-04-08
Point Source(s):
Flare #2

Pollutant(s):
Sulfur Dioxide - 7 pounds
Cause of Problem: Process Upset

The compressor for the Pressure Swing Absorber (PSA) tripped for 35 seconds on April 8, 2013. The PSA is responsible for purifying low grade hydrogen into high grade hydrogen. As a result of the PSA tripping, a mixture of 80% hydrogen gas and light hydrocarbon gas routed to the Flare #2 for approximately 3 minutes between 12:29 PM to 12:32 PM on April 8, 2013. Later on the same day, the PSA tripped again and upset the Propane De-asphalt Unit. Propane, which is used to separate the asphalt ingredients in this Propane De-Asphalt Unit, in excess was sent to this unit creating an overabundance of propane gas to be routed to Flare #2. Approximately 6.5 pounds of Sulfur Dioxide emissions were released to the flare between 1421 and 1454 hours on April 8, 2013. This amount was below reportable quantity.
This investigation was prompted by a citizen complaint (Velma White) reporting on flaring black smoke was coming from Calumet refinery in Shreveport on April 8, 2013 at 12:34 PM. Air monitoring and an on-site investigation were conducted by LDEQ on 4/8/2013. Air monitoring report states that instrument "detected no harmful levels of CO, LEL, O2 or H2S".
147433

2013-03-20
Point Source(s):
Tank Farm

Pollutant(s):
Crude Oil - 84 gallons
Cause of Problem: Human Factors

Operator opened the dome lid while belly valve was open on rail car, causing the spill of about 2 barrels (84 US gallons) of Utah Yellow Crude Oil onto the ground. The duration of the spill lasted for approximately 4.25 hours between 3:00AM and 7:15AM.
The belly valve was closed to prevent any further loss.
146534

2013-02-11
Point Source(s):
Flare #2

Pollutant(s):
Sulfur Dioxide - 0 pounds
Cause of Problem: Process Upset

Flaring and black smoke was documented by a citizen complaint and visually observed by LADEQ report author on February 11, 2013. Calumet representative attributed the flaring to three different factors. 1) The flare gas compressor tripped due to a bump in the fuel gas system. 2) The MEK Unit was being started up, and vents propaline to the flare with start up. 3) Boiler #6 was down due to a problem with the pressure control valve on the fuel gas line. While no reportable quantity levels were exceeded, the sulfur dioxide permit limits were exceeded. A total of 0.47 pounds of sulfur dioxide were released in the 24 hour period from flare #2. Sulfur dioxide emissions permit was exceeded between 1200 and 1400 hours on February 8, 2013.
A citizen report voicemail was received on the date of the incident (February 11. 2013) at approximately 1339 hours documenting flaring and black smoke that had lasted about 32 minutes at the time of the phone call. The LADEQ report author also visibly confirmed flaring and black smoke from the Northwest Regional Office. Also, lower explosive level (LEL) recorded by LADEQ was recorded at 1-2 ppm after car idled. LABB could not locate refinery letter to LADEQ citing sulfur dioxide permit exceedance.
146493

2013-02-08
Point Source(s):
Flare #2

Pollutant(s):
Sulfur Dioxide - 8 pounds
Cause of Problem: Process Upset

A citizen reported flaring and black smoke at Calumet Lubricants Shreveport Refinery at approximately 1100 hours on February 8, 2013 to LADEQ. The flare was utilized due to the over-pressuring of the stripper tower downstream from the reactor during startup of the naphtha unifer. The LADEQ report author could also visibly see a black cloud of smoke from flare #2 from the LADEQ Northwest Regional Office. Communication between the LADEQ report author and plant provide flaring occurred around 0700 hours and 1100 hours on February 8, 2013. The event did not exceed reportable quantities, but the hourly permit limit of sulfur dioxide emissions (0.01 pounds per hour) were exceeded by a range of 0.08 to 3.34 pounds per hour (a total of 8.04 pounds SO2) on February 8, 2013.
LABB could not locate a refinery letter documenting this incident to LADEQ.
146440

2013-02-04
Point Source(s):
Flare #2

Pollutant(s):
Sulfur Dioxide - 455 pounds
Cause of Problem: Power Failure

Heavy flaring of sulfur dioxide resulted due to power failure on February 4, 2013. The heavy flaring began at approximately 2026 hours on February 4, 2013, and continued until 0730 hours on February 5, 2013. At 0949 hours on February 5, 2013, an email from Calumet documented that the flaring stopped at 0730 hours that morning. The plant lost a substation in the west side of the refinery that brought down the boiler systems due to loss of feed pumps and water softeners. This cascaded to loss of other units in the plant. Flaring continued until the flare gas compressor operation could be restored. Reportable quantities were not reported to Louisiana State Police. While reportable quantities were not exceeded, the permit limit for Flare 2 (the point source for this incident) of 0.01 lbs/hour of sulfur dioxide was exceeded by a rate of 41.1 lbs/hour. Also, the plant reported that the highest average three hour value to be 3325ppm SO2.
Even though email correspondence has been located between the refinery and LADEQ the day of the discovery and after heavy flaring had stopped, LABB COULD NOT LOCATE OFFICIAL REFINERY LETTER BEYOND EMAIL CORRESPONDENCE WITH LADEQ. A memoranda from LADEQ dated February 8, 2013 cites that this scenario has also occurred with an incident labeled by LADEQ on 12/25/2013 (a typo, but still mentions a repetitive incident). A complaint was reported to LADEQ by Ms. Velma White citing "extremely bad flaring" on February 4, 2013 at 1635 hours.
146329

2013-01-31
Point Source(s):
Tank 98 and 82

Pollutant(s):
Crude Paraffinic - 420 gallons
Cause of Problem: Seal or Gasket

Flange on pipe in the tank farm ruptured and released crude oil.
The line was isolated. The facility began removing oil with vac trucks and remediating soil. 10 barrels of crude oil paraffinic was released.